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Last Ned Publikasjon Authors: Ingunn Saur Modahl and Ellen Soldal Report no.: OR 11.15 og Andreas Brekke ISBN:Navn 82 -7520-736-3 ISBN:Navn 978-82-7520-736-2 The 2015 LCA of products from the wood-based biorefinery at Borregaard, Sarpsborg. Results for cellulose, ethanols, lignosulfonates, vanillin, sodium hypochlorite, sodium hydroxide and hydrochloric acid. © Østfoldforskning The 2015 LCA of products from the wood-based biorefinery at Borregaard, Sarpsborg. Results for cellulose, ethanols, lignosulfonates, vanillin, sodium hypochlorite, sodium hydroxide and hydrochloric acid. Report no.: OR.11.15 ISBN no.: 82-7520-736-3 Type of report: ISBN no.: 978-82-7520-736-2 Commissioned report ISSN no.: 0803-6659 Report title: The 2015 LCA of products from the wood-based biorefinery at Borregaard, Sarpsborg. Results for cellulose, ethanols, lignosulfonates, vanillin, sodium hypochlorite, sodium hydroxide and hydrochloric acid. Authors: Ingunn Saur Modahl and Ellen Soldal Project no: 1721 Project title: LCA av Borregaard sine produkt Commissioner: Commissioners reference: Borregaard Industries Limited, Kjersti Garseg Gyllensten Norway Keywords: Availability: Number of pages incl. appendixes: LCA Open 95 Biorefinery Wood conversion Lignocellulose Approved: Date: 19th of May, 2016 Project leader Research leader (Sign) (Sign) © Copying with reference allowed © Østfoldforskning The 2015 LCA of products from the wood-based biorefinery at Borregaard, Sarpsborg. Results for cellulose, ethanols, lignosulfonates, vanillin, sodium hypochlorite, sodium hydroxide and hydrochloric acid. CONTENTS 1 INTRODUCTION .................................................................................................................................. 3 1.1 BACKGROUND ............................................................................................................................. 3 1.2 METHODOLOGY ........................................................................................................................... 5 1.3 GENERAL LIMITATIONS OF LCA ................................................................................................... 7 1.4 MANAGEMENT OF THE PROJECT .................................................................................................... 7 2 GOAL, SYSTEM BOUNDARIES AND DATA ..................................................................................... 9 2.1 GOAL OF THE ANALYSIS ............................................................................................................... 9 2.2 DECLARED UNIT........................................................................................................................... 9 2.3 SYSTEM DESCRIPTION AND SYSTEM BOUNDARIES ........................................................................ 10 2.4 DATASET AND CONDITIONS ........................................................................................................ 12 2.4.1 About the datasets ........................................................................................................... 12 2.4.2 Collection of specific data for raw materials and chemicals .............................................. 13 2.4.3 Infrastructure at Borregaard ............................................................................................. 15 2.4.4 Electricity model ............................................................................................................. 17 2.4.5 Transport to customer ..................................................................................................... 17 2.5 ALLOCATION ............................................................................................................................. 18 2.5.1 Allocation principles ....................................................................................................... 18 2.5.2 Allocation on energy outflows ......................................................................................... 20 2.5.3 Allocation of energy to mutual functions ......................................................................... 20 2.5.4 Adaptations in the lignin plant ......................................................................................... 20 2.5.5 Adaptations in the ethanol plant....................................................................................... 21 2.5.6 Allocation is affected by mass balances ........................................................................... 21 2.6 QUALITY CONTROL .................................................................................................................... 21 3 RESULTS ............................................................................................................................................ 22 3.1 GLOBAL WARMING POTENTIAL (GWP) ...................................................................................... 22 3.2 ACIDIFICATION POTENTIAL (AP) ................................................................................................. 26 3.3 EUTROPHICATION POTENTIAL (EP) ............................................................................................. 29 3.4 PHOTOCHEMICAL OZONE CREATION POTENTIAL (POCP)................................................................ 33 © Østfoldforskning 1 The 2015 LCA of products from the wood-based biorefinery at Borregaard, Sarpsborg. Results for cellulose, ethanols, lignosulfonates, vanillin, sodium hypochlorite, sodium hydroxide and hydrochloric acid. 3.5 OZONE DEPLETION POTENTIAL (ODP) ........................................................................................ 37 3.6 CUMULATIVE ENERGY DEMAND (CED) ...................................................................................... 40 3.7 WASTE ...................................................................................................................................... 44 4 SUMMARY AND CONCLUSIONS..................................................................................................... 49 5 REFERENCES ..................................................................................................................................... 54 Appendix 1 Process model, energy- and mass balance Appendix 2 Aggregated results Appendix 3 Emissions and water consumption Borregaard Appendix 4 Masses and treatment of waste from Borregaard Appendix 5 How to read the LCA network figure? Appendix 5 LCA – what, why and how? Appendix 7 Environmental impact categories and potential effects Appendix 8 LCI/LCA report (for EPD verification purposes) © Østfoldforskning 2 The 2015 LCA of products from the wood-based biorefinery at Borregaard, Sarpsborg. Results for cellulose, ethanols, lignosulfonates, vanillin, sodium hypochlorite, sodium hydroxide and hydrochloric acid. 1 INTRODUCTION 1.1 BACKGROUND During the spring 2008, a life cycle assessment of greenhouse gas emissions was performed for Borregaard’s products; cellulose, ethanol, lignin and vanillin (Modahl and Raadal, 2008). The analysis was based on data for 2007. Thereafter, Borregaard wanted to expand the analysis (phase II) in order to consider multiple environmental impact categories. It was hence decided to perform a complete LCA1, and develop EPDs2 for the products. The main improvements in phase II were that other emissions than those affecting climate change were included, in addition to waste treatment, Borregaard’s infrastructure and specific data for the most important raw materials and chemicals. The lignin plant was divided in two, meaning that liquid lignin and lignin powder were separated, and the accounting of energy was changed in order to envisage energy use and energy content of the products. Phase II is documented in Modahl, Brekke and Raadal (2009a, b, c). EPDs were developed for cellulose, liquid lignin, lignin powder and vanillin, and these can be found at the Norwegian EPD foundation website (EPD-Norway, 2015). In 2010/11 Borregaard wanted to develop EPDs also for ethanol (both 96% and 99%). Connected to this, the LCA model and datasets were updated with 2010 data. From 2007 to 2010 three major changes had taken place; a new waste incineration plant had been built, the aerobic part of the biological effluent plant had stopped due to legionella problems, and use and emissions of copper in the vanillin plant had been reduced due to a new recycling process. In addition, the LCA model of Borregaard was developed to include parameters representing specific values regarding energy and production data. This would make it possible to analyse future situations without changing the historical values. The 2010 results are documented in Modahl and Vold (2011). In 2015 the model has been updated once again in order to be able to distinguish between two types dry lignin, to reflect the improvements that have been made in the biorefinery, and by using updated energy and production data. The aim of this study is to document the environmental profile of Borregaard’s products and to serve as a basis for revising the EPDs. The analysis has been based on the latest available specific data (2014). These are the main changes since last update (OR 32.10 by Modahl and Vold, 2011): 1 LCA = Life Cycle Assessment. Wikipedia: http://en.wikipedia.org/wiki/Life_cycle_assessment . An introduction to LCA is presented in appendixes. 2 EPD = Environmental Product Declaration. Standardised (ISO 14025) method for presentation of LCA results. www.environdec.com © Østfoldforskning 3 The 2015 LCA of products from the wood-based biorefinery
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