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Life-cycle Analysis on Acid-gases Emissions of the Lightweight to Passenger Cars Using Aluminum Alloy and Advanced High Strength Steel

Li-sa Zhu 1 1School of Applied Science, JiLin teacher's Institute of Engineering and Technology, Changchun, China

Abstract – Nowadays, in order to reduce fuel With the research progress of lightweight (LW) to consumption and tail gas emissions, the lightweight has been passenger cars/vehicles, environmental, energy and adopted in passenger cars. However, whether the fuel economic issues aroused by LW have been studied. Kim consumption and tail gas emissions including acid-gas can be Hyung-Ju et al. (2011) provided an assessment of vehicle reduced must be calculated from life-cycle. In this paper, LW with aluminum and high strength steel (HSS), and the acid-gas emission of normal and modified passenger cars has been calculated in life-cycle and more detailed stages on assessment results show greater GHG savings derived acid-gas emission have been analyzed. from greater LW and added manufacturing costs as expected [3]. Kim Hyung-Ju et al. (2010) compared the Keywords –passenger cars, the lightweight, acid-gas, life- increase in greenhouse gas (GHG) emissions associated cycle with producing LW vehicles with the saved emissions during vehicle use, and calculated that how many years of vehicle use are required to offset the added GHG I. INTRODUCTION emissions from production stage, and the result show payback periods for HSS are shorter than for aluminum [4]. In China, the population of passenger cars (PPC) has Kang, Yong-Lin et al. (2008) pointed out that the been increasing with drastic speed. In 1960, the PPC was development and application of advanced high-strength only 230,000; and in 2000, the PPC has been reached steels (AHSS) for automobile LW not only brings about 11,270,000 and almost has been increased by 50 in 40 significant emissions reduction and energy-saving, but years. Five years later, the PPC were nearly double and also has advances of improved safety as well as recycling arrived at 20,500,000. In 2010, the PPC hit a new high and reutilization [5]. Waurzyniak and Patrick (2009) have and arrived at 62,040,300. It was estimated that the PPC given the result that advanced materials for automotive will exceed 100 million in 2020. manufacturing are helping automakers build lighter, more With the wide use of passenger cars and the fuel-efficient vehicles, and related advanced materials tremendous PPC, much acid-gas emissions have been property, including AHSS, HSS and aluminum, has been emitted during the using of passenger cars. Supposing that given [6][7]. Masataka Hakamada et al. (2007) have given a passenger car has been drive 10,000(km/year) and drive these conclusions that magnesium substitution can save 100 thousand kilometers before scrapping; and the more life cycle energy consumption than the Al amount of SO2 are 0.295(kg) in one year and 2.95(kg) substitution, although magnesium ingot production before scrapping. So In 2010, the SO2 emissions by the consumes more energy than aluminum and steel PPC were 1802 (ton). SO2 is a main acidification gases, it productions; The use of recycled magnesium ingot in a can form acid rain and destroy building, forest and crops. high weight ratio is needed in keeping the life cycle Besides SO2, there are also a lot of acid gases in passenger energy consumption and CO2 emissions low; Strength cars tail gases such as NO2 and NOx. improvement in the magnesium alloy decrease total Based on mentioned above, the acidification caused by energy consumption and CO2 emissions; if the body and the PPC was very critical. So in order to reduce hood are made of magnesium alloy and the ratio of acidification gases, the lightweight to passenger cars has recycled ingot is sufficiently high, the total energy been adopted. The lightweight can reduce curb mass, oil consumption and CO2 emissions will be markedly consumption and acid-gases emissions of using stage, but reduced [8]. acid-gases also have been emitted during other stages From related articles mentioned above, the deeper such as mineral mining, materials producing, and studies upon LW to passenger cars/vehicles of energy and products manufacturing stages. So the analysis on acid- environment have been made. But acid-gas emissions gases emissions must be considered from life-cycle, were few studied. which will give the proper conclusions. III. METHODOLOGY II. LITERATURE REVIEW The proposed analysis method consist three steps: They are goal and scope definition, calculation model establishment, data collection. Particulars of each step are Acid  Acid shown below. total  i A. Step 1: goal and scope definition (1) In this step, a life cycle assessment application has Where Acid is acidification of the lightweight to been used to study acidification of the lightweight to passenger cars in life-cycle; passenger cars. The scope of this step is to calculate i is from mineral stage to using stage. acidification of the lightweight to passenger cars in life C. Step 3: data collection cycle; and scope definition is divided into five stages: In this paper, four evaluating projects were 1. Mineral mining stage; constructed. They main parameters and acidification data 2. Materials producing stage; are calculated by equation (1) and shown as table 5 [13- 15]. 3. Products manufacturing stage; For the paper limited, only the detailed input and output 4. Transporting stage; data of project 1 and project2 were listed in this paper. 5. Using stage. In this paper, transporting stages only included Table II materials transporting stage between different enterprises. Main technologic and economic parameters of H passenger cars So the acidification produced in internal enterprises was Curb Crew Oil Material [9] Model mass size consumption structure neglected . (kg) (person) (L/100km) Steel Iron B. Step 2: calculation model establishment 4×2 1300. In this paper, acidification calculation model has Frontengine 5.00 13.00 70 30 00 been established as below [11][12]: Frontdrive

TABLE II PROJECT 1 INPUT/OUTPUT (695KG PRIMARY HIGH STRENGTE STEEL BODY)

Stages in life cycle Regular Unit Materials Product Mineral mining Transporting Using producing manufacturing Iron ore kg 16503 Scrap kg 196 Manganese kg 113 Limestone kg 384 Dolomite kg 666 Input Fluorite kg 5 Iron mud kg 219 Water kg 241 281625.58 123956.15 Diesel fuel kg 9.4 7 8.20 Gasoline kg 1.87 0.94 21497.16 Nature gas m3 4.27 263 76.71

CO2 kg 615.07 3958.65 1829.98 454 68835.4 CO kg 301.21 35.08 0.15 0.02 5011.06

SO2 kg 41.08 35.08 0.15 0.02 5011.06

NOx kg 19.63 3369.68 30.32 2.47 625.64

Output CxHy kg 499.20 0.08 0.04 987.39 HC kg 13.85 11.30 Dust kg 198.76 266.24 9.77

H2S kg 1.10

N2O kg

TABLE III PROJECT 2 INPUT/OUTPUT (375.3KG PRIMARY ALUMINUM BODY)

Stages in life cycle Unit Materials Product Mineral mining Transporting Using producing manufacturing Input Bauxite kg 6831 Soda ash kg 195 Limestone kg 891 Anthracite kg 128.50 Stages in life cycle Unit Materials Product Mineral mining Transporting Using producing manufacturing Baking soda kg 41 Bay red mud kg 2680.88 Carbon pole kg 759 Cryolite kg 22.10 Aluminum fluoride kg 35 Calcium fluoride kg 4.10 Magnesium fluoride kg 5.50 Nacl kg 27 KCl kg 27 Water kg 41068 Diesel fuel kg 6.33 Anthracite kg 53.5 Datong system of coal kg 896.80 Matellurgical coke kg 75 Heavy oil kg 561.69 Nature gas m3 201.25 Electricity KW.H 74.22 20027.81 434.48 Gasoline kg 16775.74

CO2 kg 95.09 5923.66 407.56 344.72 53717.07 CO kg 0.12 490.12 0.02 0.015 3910.48

SO2 kg 0.12 108.78 0.48 0.41 6.88

NOx kg 0.48 54.06 2.21 1.87 488.23

Output CxHy kg 0.01 0.22 0.06 0.03 770.53 HC kg 0.02 PM kg 0.02 HF kg 17.30 Dust kg 42

Table V ACIDIFICATION（SO2.EQ KG） DATA of EVALUATING PROJECTS* Total MM MP PM T U Total Using Project 1 54.82 2417.94 24.57 2.27 446.70 2946.30 s

Project 2 0.46 146.62 2.03 1.72 348.64 499.70 t Transporting c e j

Project 3 5.98 2.03 0.42 348.64 357.07 o Production r Project 4 42.41 129.19 1.01 405.64 988.25 P manufacturing Materials *MM is mineral mining stage; producing

MP is materials producing stage; Mineral mining PM is product manufacturing stage; T is transporting stage; 0 500 1000 1500 2000 2500 3000 3500 Acid-gass emissions(SO2.eq) U is using stage. In table.2, project 1 is basic passenger car, which body Project 1 Project 2 Project 3 Project 4 in white (BIW) was made by high strength steel (HSS) Fig.1 Acid-gas emissions of projects and curb mass is 1300.00 (kg). Project 2, 3, 4 are modified passenger cars, whose IV. DISCUSSIONS: EFFECTS OF DIFFERENT BIW were replaced with primary aluminum alloy, MATERIALS AND USING DISTANCE recycled aluminum alloy and advanced high strength steel This part included three contents: Effects of primary and curb mass were 980.3(kg), 980.3(kg) and 1166.40(kg) aluminum; Effects of recycled aluminum; Effects of respectively. Oil consumption of using stage is calculated advanced high strength steel (AHHS). by equation (2). A. Effects of primary aluminum Gasoline  M  (L/100km) Compared with normal project1, project2'BIW were replaced with primary aluminum and its life-cycle acid- (2) gases emissions were reduced from 2946.30(SO .eq kg) to Where 2 499.70(SO2.eq kg). That mainly because that acid-gases   8.072 ; emissions of project2 were extremely reduced in materials   1.019 . producing stage. Concrete details were shown as fig.2. using stage;

450 3000 400

2500 350

2000 300

250 acid-gases amonut 1500 200 1000 150 500 100

0 50 MM MP PM T U Total Life-cycle Stages 0 Project 1 Project 2 Project 3 Project 4

PM 24.57 2.03 2.03 129.19 U 446.7 348.64 348.64 405.64 Project 1 Project 2

Fig.2 Acid-gases amount between project1 and project2 Fig.4 The amount of acid-gases in product manufacturing and using stages of all projects B. Effects of recycled aluminum and the amount of acid-gases emissions in product Compared to primary aluminum, at materials producing manufacturing is the highest in all projects. The specific stage, recycled aluminum can extremely reduce acid- results were shown as Fig.4. gases emissions. But recycled aluminum has less effect on D. Effects of USING DISTANCE total acid-gases emissions in life-cycle of passenger cars. As to the most acid-gases emissions are emitted during That mainly because the acid-gases emissions of using using stage, it is essential to consider the effects of using stage dominates the life-cycle acid-gases emissions. distance. In this paper, the using distance is 200,000(km), As in developed countries, the ratio of recycled and the sensitivity analysis of per 10,000 (km) must be aluminum has surpassed 50%. So in this paper, six calculated. recycled ratio of aluminum have been considered, they were 50%, 60%, 70%, 80%, 90%, 100% and details data 3500 700 were shown as Fig.3. 3000 600

2500 500 80

g 2000 400 k

70 2 O 1500 300 S

60 1000 200

50 500 100

0 0 40 5 10 15 20 1E+4km 30 Project 1 Project 2 Project 3 Project 4 20 Fig.5 Sensitivity analysis of Acid-gases emissions

10 From Fig.5, the sensitivity analysis results are as same 0 50% 60% 70% 80% 90% 100% as the life-cycle, that only because compared to using 76.3 62.24 48.17 34.11 20.04 5.98 stage, the acid-gases emissions, in mineral mining, materials producing, product manufacturing and Fig.3 Effects on acid-gases emissions of recycled aluminum ratio transporting stage, are very few.

From Fig.3 that if the ratio of recycled aluminum can V. CONCLUSIONS be reached 70%, the amount of acid-gases emissions in From these studies, main conclusions have been materials producing stage can be reduced 98.45(SO2.eq achieved from life cycle as follows: kg) and if the ratio is reached 100%, in materials 1. The acidification emissions of project 1 is the most producing, amount of acid-gases also can be arrived at in all projects, that means basic passenger cars emit acid- “zero”. gas amount is bigger than modified passenger cars. That C. Effects of AHHS mainly due to basic passenger cars emitted more acid-gas

From table.5, due to adopted AHHS, the amount of in materials producing stages and should be given ample acid-gases on project2 was second in all projects. That attention; mainly due to the density of AHHS is higher than neither 2. Applying recycled aluminum alloy can extremely primary aluminum nor recycled aluminum alloy, which reduce acid-gas emissions than primary aluminum alloy. led to the amount of acid-gases emission is higher in That mainly due to acid-gas emissions can be reduced in materials producing stages by using recycled aluminum steel (Periodical style),” Journal of industrial ecology. alloy. So in order to reduce acid-gas emissions, the ratio ENG., PP:929-946, Vol.,14(1), 2010. of recycled aluminum alloy must be height. [5] Kang Yong-Lin, “Lightweight vehicle, advanced high Nowadays, the ratio of recycled aluminum alloy has strength steel and energy-saving and emission reduction (Periodical style),” Kang Tieh/Iron and Steel. ENG., been arrived at 50% to 60% in developed countries, and Vol.,14(1),2008. the ratio is very poor in developing countries. So the [6] Waurzyniak, Patrick, “Advanced materials in automotive: potential of improving recycled ratio of aluminum is very Newer steels, aluminum, magnesium, and other materials tremendous in the word. If the conditions are permitted, lead to more lightweight, economical vehicles (Periodical the mechanism of recovering scrap aluminum should be style),” Manufacturing engineering. ENG., Vol.,143(3), built. 2009. 3. The acid-gas emissions of using AHHS is higher [7] Li an, Chao Zan-Yi, “Advanced materials in automotive: than using neither primary or recycled aluminum alloy, Newer steels, aluminum, magnesium, and other materials and that due to acid-gas emissions is higher in production lead to more lightweight, economical vehicles (Periodical style),” Manufacturing engineering. ENG., Vol.,143(3), manufacturing and using stages. 2009. Detailed results and conclusions have been shown as [8] Masataka Hakamada, Tesuharu Furuta, “Life cycle Figure 1. inventory study on magnesium alloy substitution in vehicles VI. ACKNOWLEDGEMENT (Periodical style),” Energy. ENG., pp:1352-1360, 2007. This paper was supported by the outline of the eleventh [9] JianXu, XiaomingBu, FengLiZheng, “Manufacturing five-year scientific and technological plan of Jilin industry green product appraisal system based on product province education department [No.2009 (279)]. life cycle (Published Conference Proceedings style),” in Proc. The sixth wuhan international conference on E- business-innovation management, pp.3258–3261, 2008. VII. APPENDIX [10] Tonn B.E, Schexnayder S.M Peretz J.H, Das S, “An A. Ingredient of tail gas assessment of waste issues associated with the production of new, lightweight, fuel-efficient vehicles (Periodical Table VI Main ingredient of tail gas (g/L) style),” Journal of cleaner production. ENG., pp:753-765, Ingredient Weight Vol.,11(7), 2009. CO2 2321.5 [11] Pingtao Yan, Mengchu Zhou, Donald Seatian, “Multi-lfie SO2 0.295 CO 169.0 cycle product and process development: selection of optimal production, usage, and recovery process (Published NOx 21.1

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