Life-Cycle Assessment of Energy and Environmental Impacts of LED Lighting Products
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BUILDING TECHNOLOGIES PROGRAM Life-Cycle Assessment of Energy and Environmental Impacts of LED Lighting Products Part I: Review of the Life-Cycle Energy Consumption of Incandescent, Compact Fluorescent, and LED Lamps February 2012 Updated August 2012 Prepared for: Solid-State Lighting Program Building Technologies Program Office of Energy Efficiency and Renewable Energy U.S. Department of Energy Prepared by: Navigant Consulting, Inc. DISCLAIMER This report was prepared as an account of work sponsored by an agency of the United States Government. Neither the United States Government, nor any agency thereof, nor any of their employees, nor any of their contractors, subcontractors, or their employees, makes any warranty, express or implied, or assumes any legal liability or responsibility for the accuracy, completeness, or usefulness of any information, apparatus, product, or process disclosed, or represents that its use would not infringe privately owned rights. Reference herein to any specific commercial product, process, or service by trade name, trademark, manufacturer, or otherwise, does not necessarily constitute or imply its endorsement, recommendation, or favoring by the United States Government or any agency, contractor or subcontractor thereof. The views and opinions of authors expressed herein do not necessarily state or reflect those of the United States Government or any agency thereof. Page i ACKNOWLEDGEMENTS The authors would like to acknowledge the valuable guidance and input provided during the preparation of this report. Dr. James R. Brodrick of the U.S. Department of Energy, Building Technologies Program offered oversight of this assignment, helping to shape the approach, execution, and documentation. The authors would also like to express their appreciation to members of the technical review committee who participated in a review of the reports, methods and results, which added to the integrity of the estimates. These members include: Steve Bland SB Consulting Makarand Chipalkatti Osram Sylvania Heather Dillon Pacific Northwest National Laboratory Monica Hansen Cree Brad Hollomon Compa Industries, Inc. Noah Horowitz National Research Defense Council Michael Scholand N14 Energy Leena Tahkamo Aalto University & Université Paul Sabatier (Toulouse III) Fred Welsh Radcliffe Advisors COMMENTS DOE is interested in feedback or comments on the materials presented in this document. Please write to James Brodrick, Lighting Program Manager: James R. Brodrick, Ph.D. Lighting Program Manager EE-2J U.S. Department of Energy 1000 Independence Avenue SW Washington D.C. 20585-0121 Page ii ERRATA August 31, 2012 Readers of the original report identified several typographical errors. The changes made in response to the comments improve the clarity of the report and do not result in any changes of calculations, graphs, findings or conclusions to the body of work as originally published. The following text, highlighted in red, indicates corrections made to the original report: 1. In Acknowledgements, p. ii: The affiliations of report contributors Brad Hollomon and Leena Tahkamo were corrected. Steve Bland SB Consulting Makarand Chipalkatti Osram Sylvania Heather Dillon Pacific Northwest National Laboratory Monica Hansen Cree Brad Hollomon IDHS at the Center for Innovative Technology Compa Industries, Inc. Noah Horowitz National Research Defense Council Michael Scholand N14 Energy Leena Tahkamo Aalto University & Université Paul Sabatier (Toulouse III) Fred Welsh Radcliffe Advisors 2. In section 4.2.5, p. 30: The ‘Total’ row values for both incandescent lamps and CFLs were corrected. Table 4.5 Manufacturing Phase Primary Energy (MJ/20 million lumen-hours) 2011 LED Future 2015 LED Incandescent CFL Manufacturing (16 LED Packages) (5 LED Packages) Process Min. Avg. Max. Min. Avg. Max. Min. Avg. Max. Min. Avg. Max. Bulk Lamp 10.1 42.2 106 11.3 170 521 38 87.3 154 25.4 58.5 103 Material 1 LED N/A N/A N/A N/A N/A N/A 0.12 16 83.5 0.11 14.6 76.2 Package1 Total LED Packages N/A N/A N/A N/A N/A N/A 1.9 256 1,336 0.54 73 381 contribution 11.8 42.9 134 20.7 183 638 Total 39.9 343 1,490 25.9 132 484 10.1 42.2 106 11.3 170 521 1. This value is not included in the total sum, but is presented to show the manufacturing energy contribution from one LED package. Page iii 3. In section 4.4, p. 35: The use phase energy consumption equation was corrected. The conversions from kWh to MJ and from secondary to primary energy consumption were added. 20 = = 22.2 1,000 × 900 푚푖푙푙푖표푛 푙푢푚푒푛 − ℎ푟푠 퐼푛푐푎푛푑푒푠푐푒푛푡 푙푎푚푝 푒푞푢푖푣푎푙푒푛푡 푙푎푚푝푠 ℎ푟푠 푙푢푚푒푛푠 60 × 1,000 = × 3.6 × 3.15 × 22.2 1000 / 푊 ℎ푟푠 푀퐽 퐿푖푓푒 − 푐푦푐푙푒 푢푠푒= 15푝ℎ,푎푠푒100 푒푛푒푟푔푦 푙푎푚푝푠 푊 푘푊 푘푊ℎ Note: In order to convert to primary electricity푘푊ℎ consumption푀퐽 the EIA U.S. electricity mix conversion factor of 3.15 is used (U.S. EIA, 2011). 4. In section 4.4, p. 36: The CFL lifetime in Table 4.7 was corrected. Table 4.7 Use Phase Primary Energy (MJ/20 million lumen-hours) Energy Use LED Packages Lamp Type Watts Lumens Lifetime (MJ/20 million per Lamp lumen-hrs) Incandescent 60 900 N/A 1,000 15,100 Halogen 43 750 N/A 1,000 13,000 12,000 CFL 15 900 N/A 3,780 8,500 LED 12.5 800 16 25,000 3,540 LED - future (2015) 5.8 800 5 40,000 1,630 Page iv Table of Contents Executive Summary ........................................................................................................................ 1 1. Introduction ............................................................................................................................. 4 2. Life-Cycle Assessment Background ....................................................................................... 7 2.1 Goal, Scope, and Boundary Definition ............................................................................ 7 2.1.1 Life-Cycle Inventory Analysis .................................................................................. 9 2.1.2 Life-Cycle Impact Assessment ............................................................................... 11 2.1.3 Life-Cycle Interpretation ........................................................................................ 11 3. Literature Review.................................................................................................................. 13 4. Life-Cycle Energy Analysis .................................................................................................. 18 4.1 Lamp Performance and Functional Unit ........................................................................ 19 4.2 Manufacturing Phase ...................................................................................................... 21 4.2.1 Method .................................................................................................................... 21 4.2.2 LED Manufacturing Data Sources .......................................................................... 25 4.2.3 LED Package Manufacturing and Process Steps .................................................... 26 4.2.4 LED Package Energy Estimates ............................................................................. 27 4.2.5 Manufacturing Phase Energy Consumption ........................................................... 29 4.3 Transportation Phase ...................................................................................................... 32 4.3.1 Method .................................................................................................................... 32 4.3.2 Transportation Phase Energy Consumption............................................................ 33 4.4 Use Phase Energy Consumption .................................................................................... 34 4.5 Total Life-Cycle Energy Consumption Results ............................................................. 36 5. Conclusion ............................................................................................................................ 40 Appendix A Complete List of LCA Studies Considered ......................................................... 41 Appendix B List of Studies Utilized for Life-Cycle Energy Consumption Comparison ........ 42 Appendix C Calculation Assumptions and Conversion Factors.............................................. 43 Works Cited .................................................................................................................................. 45 Page v List of Tables Table 3.1 List of Studies Utilized for Life-cycle Energy Consumption Comparison .................. 14 Table 4.1 Performance of Conventional and LED Lighting Technologies .................................. 20 Table 4.2 Example of LED Lamp Components............................................................................ 24 Table 4.3 General Components and Associated Materials by Lamp Type................................... 25 Table 4.4 Summary of the Types of Data Provided Within the LED Focused Studies ................ 26 Table 4.5 Manufacturing Phase Primary Energy (MJ/20 million lumen-hours) .......................... 30 Table 4.6 Transportation Phase Primary Energy (MJ/20 million lumen-hours) .......................... 34 Table 4.7 Use Phase Primary Energy (MJ/20 million lumen-hours) ............................................ 36 Table 4.8 Total Life-Cycle Primary Energy (MJ/20 million lumen-hours).................................. 39 Page vi List of Figures Figure 2.1 LCA Framework Schematic Based on ISO Standards .................................................. 7 Figure 2.2 General Life-Cycle