LC A P T- 2 0 0 | 1

PT-200
Recycled rigid PUR foam

L i f e C y cl e A s s e s s m e n t
C ra d l e - to - G rav e 2012

Summary
Greenhouse gas Acidification Ecosystem Toxicity Eutrophication Human Toxicity Ozone Depletion Energy Demand Smog Formation

P r e pa r e d b y M s c . r o m a i n s a c c h i r e v i e w e d b y M s c . m o rt e n b i d strup

verified for ISO 14040 and ISO 14044 compliance

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About SUNBY
FOUNDED IN 2011, SUNBY operates originally as a consulting engineering company,
FOLLOWING A RAPID and poorly controlled industrial development since the nineteenth century in most developed countries, a growing concern among the scientific community has been expressed in regards to a non-sustainable consumption of resources and the consequent pollution affecting our daily life quality. In our opinion, helding industries for responsible is also highlighting a part of the solution as they will be key actors if we are to step up towards a more sustainable world. In fact, SUNBY believes that offering alternative solutions to substitute inefficient and polluting technologies to industries could deliver demultiplied benefits to the society as a whole.

specialised in low ecological footprint composite and insulation materials. Hence, the core activity of SUNBY resides in offering engineered solutions for different industrials and architects. Strong of several years of experience in servicing the building and the industry sectors, SUNBY was developed with the aim of providing the industry with resource-efficient material solutions. Indeed, growing demand from industrials facing waste overflow and material scarcity problems led SUNBY to develop innovative materials with outstanding mechanical and evironmental performances.
SUNBY has its headquarters based in Nrresundby, in northern Jutland, since 2011. Composed of 4 highly-qualified engineers and salesmen, SUNBY managed to grow an international profile, operating in Scandinavia and Europe, with agencies in Norway, Finland, the United Kingdom and France. Additionally, SUNBY operates large-scale projects in China and the United States. SUNBY develops alternative materials and energy conservation techniques to enhance industrial resource-efficiency. SUNBYs solutions aims at limiting the industries exposure to Earths resources finite availability and increase the overall sustainability of their operations techniques and research studies, including environmental assessment, market studies, etc. Sustainability is a key value to SUNBY as most of our added value comes from delivering thermally efficient panels and providing with a smart material design characterized by a minimal environmental footprint. Considering the predominant role of the building and industry sectors vis--vis global environmental impacts, SUNBYs products are thought to have assessing and quantifying the actual material and energy requirements, as well as the pollution-generating processes involved in the manufacturing of these materials. In this respect, this document provides with an in-depth description of the material and energy flows involved in the Production, Distribution, Use and Disposal of SUNBYs recycled insulating polyurethane (PUR)-made PT-200 panels. It is the result of a thorough analysis

80 %

increase in GHG emissions since 1970 *

19,4% 28 %

of the total GHG emissions are directly related to industrial operations *

through reduced material consumption and reduced environmental footprint. Therefore, SUNBY activities revolve around the development of recyclatesmade solutions, energy conservation the potential of bringing significant benefits in terms of, for example, greenhouse gases reduction or ozone layer depletion. However, conscious of the limitations of an undocumented qualitative assessment of our products, SUNBY takes a step ahead in that direction and start from the upstream Supply Chain actors down to the waste treatment step.

of the world energy serves industrial purposes, 81% of it is fossil-based **

* IPCC, 2007 fourth assessment report ** International Energy Agency, 2012

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Business overview
FROM AN ORGANISATION viewpoint, SUNBY ApS belongs to Barsmark A/S, a public limited company operating since 1999, in Nrresundby, Denmark. Barsmark A/S is originally an engineering company, that now provides on-measure building solutions for architects. Yet, over the years, requests from industries in terms of waste reutilization solutions and alternative greener materials led Barsmark A/S to develop SUNBY ApS in 2011. SUNBY ApS is a company that focuses on developing solutions for industries with production waste overflow problems on one hand, while designing special alternative materials from these production surpluses for companies that wish to reduce their environmental footprint and increase their resource-efficiency on the other hand. However, SUNBY reuse technology is not completely solutions-based, as it also distributes re-engineered materials for a greener procurement and advanced window framing techniques and insulation materials for energy conservation.

We use a vast amount of resources on guiding customers, developing and adjusting products, planning, manufacturing prototypes, testing and documentation.

Paul-Erik Andersen
Chairman and Founder
From an educational background focused on international trade and import/export management, attended at Hamburg Business School, Paul-Erik has a strong and eclectic international profile in terms of professional achievements. From Division Manager in Singapore to Sales Director in Denmark, Paul-Erik has a broad experience in the industry and food sectors. In 1999, Paul-Erik founded Barsmark, which has now become a leading partner for Scandinavians top architects and entrepreneurs in providing niche products for insulation, acoustic and facade uses.

Romain Sacchi
With an environmental engineering background from Aalborg University, Romain has specialized into Environmental Assessment techniques, such as Life Cycle Assessment and Environmental Product Declaration. Additionally, Romain developed a strong interest for Environmental Management and issues regarding corporate responsabilities vis--vis the environment, the waste treatment and clean production techniques. Finally, Romain holds a bachelor degree in Production and Logistics management.

R&D Manager

SUNBY ApS Voerbjergvej 40 9400 Nrresundby Denmark Office: +45 9632 3500 Fax: +45 9632 3501 Web: www.sunby.dk

Mikkel Andersen
Working Board Member
Responsible for setting the strategic direction of SUNBY in collaboration with other members of the board and providing high level strategic operational guidance to all employees of SUNBY. Responsible for developing and executing on a business plan for a region or business unit in collaboration with other members of the board to lay the foundation for SUNBY to become a profitable growing business in 2013.

We believe that a greener industry is possible if environmentally-preferable solutions are adopted and resources consumption is reduced. In this regard, we offer our customers alternative materials and energy conservation techniques to enhance their resourceefficiency.

Peter Olesen
Paul-Erik Andersen, Chairman and Founder

Logistics and Sales Manager

Finance and Logistics manager at Barsmark building solutions, Peter holds a master degree in Communication and Globalization from Aalborg University. With a strong international profile, Peter manages the value chain of our operations, linking Barsmark to its suppliers and customers, while adding value to our services by delivering solutions precisely when and where needed.

Team

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LC A P T- 2 0 0 | 7

density (compared to rock wool and glass fiber). Therefore, it is believed that rigid plastic foams, such as SUNBYs PT-200, belong to a specific market segment and are rarely the object of comparison with e.g. wood-based natural materials, aerogels, glassbased materials. Today, rigid foam panels are most often found: in contact with the ground and against foundation walls, against foundation walls exposed directly to the outside environment in this case, an UV coating is usually required, against exterior walls between the roof and the foundation, under and above the roof cladding, within the interior walls during construction or as pre-cut mats or panels cut to fit inside the walls, where the overall volume is limited and a high insulation capacity in a small space is needed. Table 1 lists some of the most commonly marketed plastic insulating foams. Of course, natural insulating foams also exist, such
Table 1 Material PUR (Polyurethane) PIR (Polyisocyanurate) Density 30-200 kgm-3 30-300 kgm-3 Description

as cork and expanded clay grains. These solutions, based on renewable sources of material, are believed to be environmentally respectful. However, because of a high price and a lack of presence in European construction traditions, they do not stand as common insulating solutions and will not be represented in this study.

Insulation

Yet, preferring environmentally-detrimental options to insulate a construction may cancel-out the benefits drawn from energy conservation especially in regards to potential blowing agents, such as HCFCs and CFCs emissions during cutting, installation and service time. SUNBYs PT-200 is compared to a generic PVC foam. The choice of comparing PT-200 with a generic PVC foam is not representative of all plastic foam insulating options, but it gives the reader an idea of the environmental benefits that are drawn from using recycled rigid PUR foam panels over (virgin) PVC foam. Although not documented, it is equally believed that PUR foam observes roughly similar environmental performances with PVC foam, as the production process based on the polymerization of monomers issued from crude oil remain somewhat similar.

Preferring environmentally-detrimental options to insulate a construction may cancel-out the benefits drawn from energy conservation over time. Hence, the underlying purpose of this LCA study is to provide with an environmental comparison between two equivalent-in-function insulating plastic foam solutions.

The first oil crisis in 1973 resulted in the apparition, in cold and temperate climates, of a new type of construction, making intensive use of thermal insulation materials. Yet, its implementation imposes such constraints during the building construction that its use has not always been done rigorously. Studies agree on the importance of a good insulation, notably in the building sector, where up to 30-40% of the heat losses are believed to be potentially avoided through a good insulation, and where emitting 1 kg of COeq. in the manufacture of rigid insulating solutions would save up to 48 kg of COeq. over the building service time (50 years)(). Hence, properly insulated habitats, warehouses and other constructions may lead to tremendous benefits in terms of conservation of energy, dependence on fossil fuels, noise pollution,...

Diverse solutions for insulation exist nowadays: spray foams, concrete forms, rigid foam panels, fiberglass batts, natural fiber and aerogels.

Insulating foams
This study chooses to focus on rigid plastic foams, which remain one of the most preferred insulating solutions because of their good thermal conductivity (compared to natural fiber and other natural-based options) allowing to keep the wall thickness low, their affordable price (compared to aerogels) and their low

Thermal conductivity

Can be used as solid plates and as a foam spray. 0,027 W/mK Mainly used in cavity walls. Plastic produced under the addition of catalysts 0,023 - 0,026 W/mK and propellants with isocyanides. Used in floors and flat roofs, but also in cavity walls. Used for signs moulding but also in cavity walls. 0,0399 W/mK Produced by suspension polymerization of styrene. 0,038 W/mK

30-40% of the heat losses are believed to be potentially avoided through a good insulation

PVC (Polyvinyl Chloride)

763 kgm-3

EPS (Expanded Polystyrene) 430 kgm-3

( )

Michael H. Mazor, John D. Mutton, David A. M. Russell, and Gregory A. Keoleian. Emissions reduction from rigid thermal insulation

use in buildings. Journal of Industrial Ecology, 15(2), 2011

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LC A P T- 2 0 0 | 9

The reference flows are base don their respective thermal conductivity values, see Table 2. 1. 1m, 95mm thick 47,5 kg PT-200 board 2. 1m, 49,8mm thick 38 kg PVC foam board

this analysis is the year 2012. The assumption that technologies operating in the 2000s for the production of PVC are similar to 2012s is held. A Use phase of 50 years for the two products is set. Current waste treatment technologies are used.

Data collection method

An extensive analysis within SUNBYs Supply Chain facilities and direct partners has been carried out. Data has been collected consistently, cross-checked and when possible, backed up with proof materials. The main method for data collection consisted in the collection of direct on-site measurements, surveys and consultation of material supply invoices. SUNBY and its direct partners (transport companies, direct suppliers and waste treatment entities) refers to the primary data area. The use of the EcoInvent v.2.2 database has been prioritized, when primary data was missing in regards to the PT-200, but also for the PVC foam product system.

Table 2 Material Density Thermal conductivity

Goal and Scope

ture of SUNBYs recycled PUR insulating panels.

PT-200

500-550 kgm-3 0,027 W/mK 0,0399 W/mK

PVC foam(2) 763 kgm-3

(2)

MatWeb, Overview of materials for PVC, Foam Grade, 2012

This document intends to give clear and understandable information to an external non-specialist audience about the environmental burden associated with the manufacHence, this document and the outcomes of the study are not exclusive to an internal use but more of a response to customers demand for transparency of the above manufacturing processes, associated environmental burdens and the supply of necessary data to extend the study further down in the Supply Chain.

In accordance with these specifications, the Scope of this study will be set as a Cradle-to-Grave analysis. It encompasses the early stages of a product life cycle, such as the energy capture and transformation, the raw materials excavation, but also the packaging and palletizing operations of the boards and all other necessary in-house processes before the delivery (including the material loading in the truck), down to the use of the product as an insulating panel and its disposal, as shown in Figure 1.

Peer-review
This work has been revised by Morten Bidstrup, postgraduate in environmental sciences from Aalborg University, currently sitting the position of Teaching Assistant. The interest-free and independent third party reviewer has had the task of certifying the compliance of this study with the international ISO 14040 series standards. This critical and independent review of the work consists into verifying that: the methods used to carry out the Life Cycle Assessment are consistent with the ISO 14040 series international standards, the methods used to carry out the Life Cycle Assessment are scientifi- cally and technically valid, the data used are appropriate and reasonable in relation to the goal of the study, the interpretations reflect the limitations identified and the goal of the study, and the study report is transparent and consistent. The critical review report states that this study manages to comply in large with the requirements contained in the ISO 14040 norms series, in terms of validity and reliability. Although, the study fails to meet the following requirement: the involvment and the review of this study by a interested panel of professionals from the PVC foam industry.

Aim of the study

The present document reports the results obtained through this comparative Life Cycle Assessment of one of SUNBY s most innovative products: the rigid PUR foam PT-200 panel. The reasons of such initiative is to provide SUNBYs decision-makers, customers, suppliers and the more general public with: the identification of environmental hotspots in the value chain of the reuse of rigid PUR foam panel manufacture, to support and guide future product design and engineering initiatives, to help making a selection of appropriate and relevant environmental indicators for future monitoring surveys within the company, and to promote the environmental performances of SUNBYs PT-200, in comparison to a similar standard foam insulating panel.

Scope of the study

This study will quantify and characterize the environmental burden behind the realization of equivalent reference flows that satisfy a same functional unit. 1m of thermally insulated vertical and weatherexposed surface (window frame), reaching a thermal transmittance as low as U = 0, 8W/mK, with a service time of 50 years, in Denmark.

Temporal product system boundaries

Reliable and valid data related to the whole product system for PT-200 have been gathered within SUNBYs Supply Chain from the year 2010 up to 2012. For the PVC foam, a secondary set of data is used, compiled by Roland Hischier based on EuropePlastics studies and made available in the EcoInvent v2.2 database. The data are based on observations made during the years 2005-2007, from 26 European plastics manufacturing sites, considering an average production of PVC by suspension. Although this dataset concerns only rigid PVC, and not PVC foam, it is considered to be a fairly accurate approximation. The reference year for

Reference flows
Two equivalent-in-function materials and their respective reference flows are studied in this Life Cycle Assessment, to fulfil the funcitonal unit.

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LC A P T- 2 0 0 | 1 1

This study reveals 3 116 and 3 040 industrial processes interacting with the environment within the PT-200 and PVC foam product systems boundaries, respectively.

Inventory Analysis
PVC foam PT-200
PUR off-cuts, falls

Industrial surplus

Procurement

Crude oil extraction

26,68 tKm

Production

Polymerization of monomers

Shredding, mixing, pressing

Distribution

42,86 tKm

31,21 tKm

Use

50 years 1 m U = 0,8W/mK

50 years 1 m U = 0,8W/mK

Disposal

3,12 tKm

3,9 tKm

Figure 1 Simplified view of a Cradle-to-Grave product system.

Treatment

Thermal waste treamtment Energy recovery

Thermal waste treatment Energy recovery

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SUNBY
life cycle of the two reference flows: 1 m of PT-200 and PVC foam.

Impact Assessment is the only method in this study to set indicators that help evaluating the magnitude of damage inflicted upon

Impact Assessment
Indicator
Increase of the Earths radiative budget

LC A P T- 2 0 0 | 1 3

the ecosystem, the humans and the living organisms, in regards to the impact categories selected, induced by the Cradle-to-Grave

Selection

Global Warming Eco Toxicity

Classification
Greenhouse gas (CO, CH, NO, ...) Benzene, Cumene, Formaldehyde, ...

Characterization
IPPC GWP 100a UseTOX UseTOX

kg of CO2 eq. CTUe

Toxic chemicals impacting aquatic species

Toxic chemicals ingestion leading to acute and chronic morbidity

er of the Barsmark group

Eutrophication Ozone Depletion Smog Formation

use technology
Human Toxicity
Acrolein, Benzene, Methanol, Phenol, ... Fossil-fuels, biomass, nuclear, wind, ...

CTUh
MJ

Energy Demand Acidification

Cumulative Energy Demand

Energy intensity

NOx, SO2, HCl, NH3, ...

EDIP03 EDIP03 EDIP03 EDIP03

m uES

Area becoming exposed to exceeding concentration of acidic substances

Land area becoming exposed to eutrophicaiton damage, release of eutrophication-enhancing substances in marine and fresh waters

NOx, NH3, ...

kg of N- eq., m UES

Halon 1301, CFC-10, CFC-114, HCFC-22, ... NOx, NMVOC, VH4, Ethene, ...

kg of CFC-11 eq.
m/ppm/h, person/ppm/h

Release of substances leading to the detruction of ozone molecules in the stratosphere Persons and vegetation affected by the photochemical formation of ozone in the tropposhere

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LC A P T- 2 0 0 | 1 5

Global Warming
125,05

On a total emissions basis, PT-200 scores clearly lower: -87 kg in comparison to PVC foam. Greenhouse gas emissions for the PT-200 are mostly associated to the incineration process at the Disposal phase, the production of isocyanates and the energy required for the transport to the Production site and to the Use location. On a gas emissions basis, PVC foam emissions are characterized by a strong CO dominance. An in-depth analysis shows that this is mainly due to the PVC polymerization by suspension process, which accounts for 57% of all greenhouse gas emissions. The thermal waste treatment of the product by incineration also accounts for a significant share of the emissions.
The avoided incineration of the PUR off-cuts at the Procurement phase, as well as the co-generation of electricity at the Disposal phase, save a total of 162,6 kg of CO eq. for PT-200. MJ

Energy Demand
2192,8

PT-200 relies significantly on fossil fuels, notably hard coal and nat- ural gas, for the production of electricity used during the Production phase, which totals an energy quantity of 56,98kWh/functional unit. The production of isocyanates, by phosgene-based reaction, requires high temperatures and energy expenditures. But, compared to the PVC foam reference flow, the PT-200 has a significantly lower energy demand. The large share in nuclear power is also to be noticed, in both product systems the share of nuclear power in the PVC foam manufacturing dedicated to the polymerization process is of 481MJ out of a total of 2 192,8 MJ. Some embodied energy contained in biomass hard coal, lignite is saved due to the co-generation of electricity in both product systems.
Wind, solar, geo
1635,6

kg CO eq.

38,07

680

PT-200

Generic PVC foam

PT-200
Fossil fuel
1800,0 1600,0 1400,0 1200,0 1000,0

Generic PVC foam

Nuclear Hydropower

Biomass

Ecosystem Toxicity
0,018

CTUe.

MJ

In regards to Ecosystem Toxicity, the PT- 200 product system performs poorly in regards to impacts inflicted to Aquatic species, compared to the PVC foam, because of high emissions of Phenol, originating the production of isocyanates there is also a non-negligible quantity of Phenol released in the PVC foam product system, during the treatment and discharge of used water.
0,015

800,0 600,0 400,0 200,0 15,8 0,0 -54,0 PT-200 510,4 314,3 594,8

50,9 -38,0 PVC foam -51,0

PT-200

Generic PVC foam

-200,0

-89,0

Human Toxicity

3,24E-08

PT-200 scores significantly lower than PVC foam in terms of Human Carcinogenic and Non-Carcinogenic morbidity. Non-Carcinogenic human impacts are mostly stemming from Carbon Disulfide and Tetrachloroethene emissions from the manufacturing of steel (bolts and nuts) and the incineration process. In regards to Human Carcinogenic morbidity, Tetrachlorodibenzo-p-dioxin emissions occupy a significant share, mostly due to the combustion of lignite and the disposal of ashes and slags from the incineration process in landfills. The PVC foam scores particularly high in Human Carcinogenic morbidity because of its emissions of Chloroethene originating the polymerization process of the PVC. Over and above, PT-200 scores very well in terms of toxic chemical compounds emissions.

Acidification

3,5

The PT-200 product system scores better than PVC foam. PT-200s emissions contributing to Acidification are represented mostly by nitrogen oxides originating the produc- tion of isocyanates, but also emissions resulting from the combustion of the PT-200 panel during incineration. These emissions are compensated by the avoided emissions resulting from the co-generation of electricity. The PVC foam impacts are mostly represented by the emissions of nitrogen oxides but also sulphur oxides. Without much surprise, both types of emissions originate the polymerization process of PVC.

m UES

CTUh

0,84

6,67E-10 PT-200 Generic PVC foam

PT-200

Generic PVC foam

Interpretation

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Eutrophication (marin.)
20 16 kg N-eq.

Eutrophication (terr.)

4,6

m UES

The PT-200 product system performs better in regards to Eutrophication impacts in Terrestrial and Marine environments than the PVC foam product system. This is due to lower emissions of nitrogen oxides to the soil (2,11m UES against 4,47 for the PVC foam), with a large share of the emissions for the PVC foam attributed to the PVC polymerization process which represents 80% of the impacts in Terrestrial environments. In Marine waters environments, the PT-200 product system releases slightly lower emissions of nitrogen oxides and nitrates than the PVC foam product system. However, it is to notice that the incineration process is by far the process responsible for most emissions 31,76 g of N-eq. while the heaviest process in that regard in the PVC foam product system only releases 15,02 g of N-eq. the polymerization of PVC.

2,14

PT-200

Generic PVC foam

PT-200

Generic PVC foam

Smog Formation (veg.)

492,7

The PT-200 reference flow scores lower both in terms of Photochemical Ozone Formation impacts on vegetation and humans, with 216m of unprotected land and 0,0153 persons exposed to dangerous ozone concentration per square meter, against 492,7m and 0,0353 persons for the PVC foam board.
person/ppm/h

Smog Formation (human)

0,035

m/ppm/h

Similarly to some other impact categories already studied, most of the impacting emissions stem from the production of type isocyanates and the polymerization of PVC by suspension, for the PT-200 and the PVC foam respectively.
215,8

Besides this, the humans and vegetation are mostly impacted by the incineration process as well as the combustion of fuel and other transport operations in the PT-200 product system. In the PVC foam product system, it mostly originates the transport operations and the combustion of hard coal for electricity production. This is probably due to the fact that higher quantities of coal are burned in the PVC product system due to a higher energy demand. Substances-wise, the same emissions are identified in both product systems. Nitrogen oxides emissions are about twice as much in the PVC foam product system. Methane emissions are higher in the PT-200 product system and NMVOC emissions are the second most impacting substances in the PVC foam and seven times higher compared to the PT-200 product system while it is only ranking third, in the PT-200 product system.

0,015

PT-200

Generic PVC foam

PT-200

Generic PVC foam

Ozone Depletion
1,26E-06

The PVC foam scores lower with 7,410-7kg of CFC-11eq., against 1,6110-6 for PT-200. While both product systems release ozone-depleting substances, such as Halon 1301, the PVC foam product system manages to compensate them by saving additional emissions of Halon 1211, thanks to the avoided processing, sweetening and distribution of natural gas, where the PT-200 product system has too high emissions of CFC-114 in comparison to zero out. Most of ozone-depleting substances, in both product systems, are linked to the handling and refining of uranium, crude oil and natural gas for electricity production.

kg CFC-11 eq.

7,40E-07

1m of thermally insulated vertical and weatherexposed surface (window frame), reaching a thermal transmittance as low as U = 0,8W/mK, with a service time of 50 years, in Denmark.

Interpretation

PT-200

Generic PVC foam

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It is our definition of material and energy-efficient insulating solutions for an increasingly sustainable industry.
Nevertheless, its performances in terms of impacts to Aquatic Ecosystems and impacts on life quality through Ozone depletion need to be mentioned and balanced in the overall conclusion on the product system. environmental benefits. Table 3 shows the environmental benefits of using PT-200 when an equivalent PVC foam panel would have been used otherwise. Compared to the PVC foam, Table 3 shows that preferring the PT-200 option would deliver great impacts saving: in terms of greenhouse gas (-69,5%), with an almost disappearance of emissions linked to Human morbidity (-99,9 and -99,7% for chronic and acute diseases, respectively), by halving impacts on vegetation and humans through troposphere formation of ozone (-56 and -57%, respectively). The PT-200 product system shows however a downside in regards impacts on Aquatic ecosystems and eutrophication in inland waters compartments, where, compared to the PVC foam performances, the impacts are increased by 18,9 and 290%, respectively. Finally, one must remember the direct reliance of the PVC foam option on the polymerization of crude oil, a very useful resource going scarce. The PT-200 option also relies on the polymerization of urethane monomers, but on a farther degree. From a sustainability perspective, this makes recycled materials preferable, as it is likely to reduce in time the polymerization pace of crude oil.

Because an increase in insulation and energy-efficiency in buildings has the potential of significantly curving human systems impacts on the environment, it is important to know exactly how detrimental it is to produce such solutions, in order to avoid a situation where remedying to the energy-efficiency problem brings about additional environmental issues.
The PVC foam board is a very good solution for insulating, given its unmatched thermal properties. Nevertheless, from an environmental viewpoint, its performances can be discussed. Indeed, strong emissions of CO during the polymerization process and the incineration of the product at its end-of-life, strong emissions of Chloroethene during the polymerization of the monomers makes it relatively undesirable for its effects in regards to human morbidity, potentially contributing to the development of acute but also chronic (carcinogenic) diseases, the geographical locations of production has the consequences of making the PVC foam product system very much relying on fossil fuels (mostly oil, hard coal, brown coal and gas), with industrial processes very demanding in energy, important releases of nitrogen oxides through the soil compartments impact significantly land areas, by overdosing the soils with limiting nitrate-based nutrients, leading to an unprotected area, which expo- sure to an overload of limiting nutrients is exceeded, of 4,47m. and similarly, these same emissions of nitrogen oxides, along with none the less important emissions of sulphur oxides, through heavy industrial processes proper to the polymerization of monomers in general, have lead to expose an Ecosystem area of 3,5m beyond acceptable concentration of acidificationenhancing substances.

Conclusions

But as a general trend, the PT-200 insulation outperforms largely its PVC counterpart by minimizing the use of non-renewable sources of energy, and therefore, the consequent emissions of compounds responsible for human morbidity, acidification of waters and others. But most importantly, the PT-200 material provides with an equivalent output in terms of insulation while allowing a reduced use of inputs: (virgin) materials and energy.

Environmental benefits
Hence, potential for environmental preservation are worth mentioning. Preferring environmentally-friendly products, such as PT-200, to more commonplace materials can deliver
Table 3 Impact Global Warming Ecotoxicity Human Toxicity Energy Demand Acidification
Eutrophication (terr.) Eutrophication (marin.)

PVC foam board

But besides these above-listed issues, one of the main drawbacks of the PVC foam board is its complete reliance on scarce resources, notably crude oil. In a technosphere where the industry needs to decouple its economic growth from the use of fossil-fuels, the manufacture and use of PVC foam for insulation is advocating an opposite and unsustainable policy.

PT-200
38,07 kg of CO eq.

... instead of PVC foam

% variation

-87 +0,003 -7,910-8 -1 512,8 -2,66 -2,46 -4 +8,810-7 -277 -0,02

-69,5% +20% -99,9% -69% -76% -53,5% -20% +18,9% -56% -57%

0,018 CTUe 6,6710-10 CTUh 680 MJ 0,84 m UES 2,14 m UES 16 g N-eq.
1,6210-6 kg CFC-11 eq.

SUNBYs PT-200
The alternative recycled solution seems to present lower thermal performances. Still, it shows comparatively very interesting environmental benefits. Although made from unused industrial surpluses, the PT-200 product system still relies significantly on the combustion of hydrocarbon- based fuels: the transport of PUR off-cuts, the distribution of the finished board and its own combustion at disposal, to a non-negligible 38,07 kg of COeq. This is still a great improvement compared to the PVC foam panels 125,05 kg. The difference in terms of Global Warming Potential is remarkable. The PT-200 product system benefits largely from the avoided incineration of PUR off-cuts later used as primary component of the panel. It allows good performances in terms of greenhouse gas releases, in reduced toxic chemical compounds spreading to soil and air compartments, in a reduced energy footprint and in minimized impacts in terms of acidification,

Ozone Depletion
Smog Form. (veg.)

216 m/ppm/h

Smog Form. (hum.) 0,015 person/ppm/h

r e -

0,076
ductivity certified by Danske Vindues Certificering sustainable water-resistant fungus-resistant easy-to-machine high compressive strength wear-resistant approved by the Danish Technological Institute

cycled low thermal con-

W/mK

20 | SUNBY

LC A P T- 2 0 0 | 2 1 quantify the annual energy saved thanks to reducing the heat loss. Indeed, The emission factor, EF, is based on the energy split in Denmark, weighed by their respective COeq. factors. Hence, Therefore, the annual greenhouse gas emissions saved through the application of 95mm of PT-200 over 1m of concrete wall is believed to be around:

Pay-back time
Although existing, the benefits drawm from a well insulated enveloppe are not always obvious and difficult to quantify. The following case study tries to roughly assess the energy savings allowed by the insulation of 1 m concrete wall in Northern Europe, using the PT-200 reference flow of the LCA study. Environmental benefits, in regards to greenhouse gas emissions are derived and presented.

Environmental pay-back time

The greenhouse emissions saved by the avoided consumption of energy by the HVAC system to compensate for the heat loss can be estimated. Compared to the environmental burden associated to the Cradle-to-Grave life cycle of the PT-200 foam, it is possible to determine the Global Warming pay-back time of the foam: the point in time where the emissions required to manufacture the foam are cancelled-out by the emissions saved through insulation. Table 4 presents the energy split in Denmark, used for heating purpose through HVAC systems(2).

Over 50 years of service time:

Assumptions
This Case Study presents a simplified model to assess the energy savings drawn from insluating 1 m surface enveloppe by comparison to a reference concrete wall in Northern Europe. The model assumptions are the following: the building enveloppe is located in northern Europe, the reference building enveloppe is a basic concrete wall, the service time of the building is 50 years, the reference temperature, from which Heating Degree Days are derived, of 17C, is considered valid in northern Europe, the thermal conductivity of PT-200 does not decrease over time. the HVAC heating rate in the bulding enveloppe equals the heat loss rate, so as to keep a stable inside temperature.

3. the annual Heating Degree Days (HDD), with the unit of day degrees Kelvin [dayK], is the relative temperature to a reference confortable temperature in a building, previously defined as 17C. The weather station of Aalborg, a city of North Jutland, Denmark, indicates an average HDD, from March 2012 to February 2013, set as

Table 4
Electricity 23% Nat. gas 16% Fuel oil 14% Coal 0%
Dist. heat

Considering the Global Warming Potential of the PT-200 foam, (1m, 95mm thick, reaching U= 0,8W/ mK), of 38 kg of COeq., the pay-back time in terms of greenhouse emissions is:

Biomass 7%

40%

Brought back to a per m of PT-200 basis, the greenhouse emissions saved during 50 years is:

Fuel type split in Denmark. Source: Kemna R. et al., 2007

Calculations
The heat flux reduction due to the addition of the PT-200 foam on the concrete wall is defined as

Parameters
The following model parameters are set: 1. the thermal resistance value (Rwall) of the reference concrete wall is set as

which represents the decrease in thermal transmittance after the application of the PT-200 foam on the reference concrete wall on an enclosure of 1m, given the average heating need observed in northern Europe. Therefore,

The district heating and biomass sources will not be associated to any environmental burden in this study, since: 1. the primary function of incinceration (from which originates the district heating) is waste reduction (and not heating), 2. for the biomass, the biogenic emissions of greenhouse gas during its combustion are considered balanced by its carbon uptake during the growth. A study by Mazor et al.(3) has been used to obtain an approximation of the COeq. per energy unit of delivered fuel in Denmark, based on the scientifically renowned Boustead Model. The estimates are shown in Table 5.
Table 5
GHG emissions CO2-eq. [g/MJ] Electricity Denmark 218,011 Nat. gas 64,96 Fuel oil 83,035 Coal 101,998

This gives a service-time-emissions-saved-to-foamemissions ratio of:

Hence, every kilogram of COeq. emitted the lifecycle of the PT-200 foam will later on help avoiding 338 kg of COeq. during its service time.

This results from a thermal conductivity () for concrete of () = 1 [W/mK] and a thickness m = 282 [mm]. 2. the thermal resistance value (RPT-200) of the PT-200 foam is set as the thickness of the foam (m) divided by its thermal conductivity value (), such as Given the assumption that the HVAC system will compensate for the heat loss and given that it has an energy efficiency proper to northern Europe of 0,64(1) - meaning, 1 input of energy delivers 0,64 output of useful heat in the building - it is therefore possible to

CO2-eq. emissions in Denmark. Source: Mazor et al., 2011

based on an study on boilers efficiency for heating buildings in northern Europe. Source: Kemna, R.; van Elburg, M.; Li, W.; van Holsteijn, R.; Preparatory Study on Eco-design of Boilers Task 3 Report (Draft final) Consumer Behaviour and Local Infrastructure; prepared for European Commission DG TRENN by VHK Delft, NL, 2007. (2) based on the same study (Kemna R. et al., 2007) (3) M. Mazor, J. Mutton, D. Russell, and G. Keoleian. 2011. Life Cycle GHG Emissions Reduction from Rigid Thermal Insulation Use in Buildings. Journal of Industrial Ecology, 2011.
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22 | SUNBY

LC A P T- 2 0 0 | 2 3

1m insulated surface (window frame), U = 0,8W/mK, service time of 50 years, in Denmark.

moisture-resistant inorganic

38 kg CO eq.
will save 338 times as much greenhouse gas emissions

processed like wood

high compressive strength

born from inter-industrial collaboration

diverts thousands of tons of foam from incineration

0,076 W/mK

Voerbjergvej 40 Nrresundby, DK-9400 Office: +45 9632 3500 Fax: +45 9632 3501 Web: www.sunby.dk

PT-200-made Habi-Sabi Bat Box. Design by 51% Studios.