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Abstract
The life cycle analysis method was used to determine the environmental impacts associated
with the production of an electrochromic (EC) glazing (called ECD). This paper describes the
inventory analysis for all the basic materials used during the manufacture of the ECD, i.e. K-
Glass, tungsten oxide (WO3), poly-methyl methacrylate (PMMA), propylene carbonate (PC),
lithium perchlorate (LiClO4) and acetic silicone sealant. K-Glass, PC and PMMA account for
the 98% of the total device mass and the CO2 emissions during their production processes are
810 g. The total embodied energy was estimated to be 49 MJ/ECD, with 32.1 MJ/unit of them
derived from the K-Glass. The comparison of the total embodied energies of the ECD and
various insulating glass units concluded that mass-produced EC glazings could easily compete
with them in terms of environmental performance, anticipating cost attenuation and overall
thermal and optical behavior. The above analysis could be implemented for the reduction of
the embodied energy of the ECD life cycle, since it is proposed as an energy saving device.
r 2004 Elsevier B.V. All rights reserved.
1. Introduction
Research for advanced glazing materials has focused so far to the realization of
systems that ensure acceptable visual transmittance, reduced glare and low thermal
0927-0248/$ - see front matter r 2004 Elsevier B.V. All rights reserved.
doi:10.1016/j.solmat.2004.03.005
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206 E. Syrrakou et al. / Solar Energy Materials & Solar Cells 85 (2005) 205240
performance static solar control insulated glass units (IGUs) is about 80 h/m2, while
the corresponding value for the EC glazing is estimated at 1000 h/m2 [2]. The retail
price of Pilkington E-ControlTM, a combined EC-IGU product, was about 1080 h/
m2. Increased sales will require pricing to be much more aggressive. For signicant
market penetration to occur, EC glazing prices will need to be reduced by one order
of magnitude to around 100150 h/m2, which is less than prices for low-e IGUs
incorporating mechanical blind systems for light and energy control [2]. Meeting this
aggressive market-driven price can be achieved in the long term, by efcient in line,
large volume manufacturing [3].
Greenhouse gas (GHG) emissions in the European Union (EU) were 4046 Tg in
1998. About 82% of EU GHG emissions are CO2 while CH3 and N2O emissions
amount to 9% each. CO2 emissions have been stabilized between 1990 and 1998 with
a 0.2% increase, while CH3 and N2O emissions have been reduced by 16.5% and
9.9%, respectively. However, actually achieving the Kyoto targets for 2012 will still
be difcult and require large efforts, as GHG emissions and energy consumption are
expected to grow in the next decade [4]. The adoption of new window technologies
has been estimated, by the year 2025, to provide the United Kingdom with an annual
saving in primary energy equivalent of about 0.2 million tonnes of coal with a CO2
saving of 5.2 million tonnes [5]. In the USA, with the adoption of the Green Seal
environmental standards for windows,2 it is estimated that 350 million barrels of oil
per year will be saved.
EC windows can reduce the peak electricity demand for cooling during summer
and heating during winter, thus contributing toward the further reduction of GHG
emissions. They can lead to the reduction of annual electricity consumption by 30%
and peak demand by 23% in large area buildings [1]. The use of EC windows as
active elements in a building envelope can also save up to about 50% of the primary
energy used for air-conditioning.3 Better thermal insulation provided will also reduce
the amount of space heating required during winter.
Given that 40% of the energy consumed each year is used in buildings and that
electricity consumption in buildings is about 20% of the total energy used [6], we can
estimate that the widespread use of EC windows will cause a net reduction of
electricity consumption by 2.4%. The reduction of GHG is expected to be three
times this amount (e.g. 7.2%), given that electricity production has an efciency of
about 30%. Furthermore, the incorporation of the EC part in an advanced window
(e.g. by the possible utilization of an evacuated component or by use of inert gas)
would improve the thermal insulation and reduce thermal losses during winter.
Considering that 60% of the thermal losses in buildings take place through windows
and that 60% of the energy in buildings is used for space heating, a reduction of 46%
2
Green Seal Proposed Environmental standards for windows (GS 13) and Retrottable window
frames (GS 14).
3
Pilkington Presseinformation PR/15/00, 16/02/00.
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208 E. Syrrakou et al. / Solar Energy Materials & Solar Cells 85 (2005) 205240
in the glazing U-value (possible by use of advanced materials), can cause a 17%
reduction of the energy for heating of buildings, or a 6.8% reduction of the net
energy consumption. This can be translated to an equal reduction of GHG emissions
by 14%.
These savings are expected to increase further, due to the reduction of energy for
cooling and lighting during daytime. Indeed, the eighty EC panels of the
Stadsparkasse building in Dresden were found to reduce the energy required for
cooling by 30% as compared to conventional heat protection glazing (see footnote 3).
The Fraunhofer Institute for Building Physics has estimated that the Pilkington E-
ControlTM glazing saves about 50% of the primary energy used for air-conditioning.
Furthermore, such a glazing will facilitate better daylighting of buildings and
ofces. A standard EC window will allow a continuous modulation of the
illuminance between two extreme values during daytime (almost 944 and 316 lx in
the bleached and colored state, respectively, while the International Commission on
Illumination recommends 500 lx as natural limit for normal vision) [7]. This can also
lead to signicant cost savings due to the improvement of workers productivity [1].
In order to estimate the potential energy savings of the EC windows
implementation and the environmental impacts of their production, life cycle
assessment (LCA) is undertaken. The results of the Inventory Analysis of the main
raw materials used during all the production processes are presented in this study.
The production route, the raw and auxiliary materials used, the energy requirements
and all emissions per produced kilogram of each material are reported. Health
effects, toxicology data, working safety, exposure issues and environmental impact
of the intermediate and the end products are also presented. Finally, the contribution
of each material to the embodied energy of the ECD is discussed.
LCA is a technique for assessing the environmental aspects and potential impacts
associated with a product through its whole life cycle. LCA is used in the building
sector for environmental improvement of the building materials and comparative
studies of the total energy demand and material used, considering the entire building
life cycle [8]. LCA studies of advanced windows aim to assess their environmental
benets compared to the conventional glazing or to explore the relationship between
the embodied and operating energy in buildings. The LCA study in advanced
windows conducted by Lawson [9] aimed to examine the life cycle of materials used,
the resultant environmental impacts and to assess the efcacy of advanced glazing
systems in terms of environmental, energy and comfort criteria. In Ref. [10] LCA
was implemented in the analysis of the production and the maintenance phase of a
glazing system and also for the evaluation of the thermal balance of its utilization
phase. Weir and Muneer [11] estimated the embodied energy for the manufacture of
the main components used in the construction of an inert gas lled, double-glazed
window, while the environmental consequences of the manufacture, application,
disposal, reuse and recycling of advanced windows are being discussed in Ref. [12].
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E. Syrrakou et al. / Solar Energy Materials & Solar Cells 85 (2005) 205240 209
LCA methodology is being implemented in the ECD according to the ISO 14040
guidelines, thus four phases are distinguished: goal and scope denition, inventory
analysis (LCI), impact assessment (LCIA) and interpretation [1316]. In LCI, an
integrated analysis of the entire manufacture procedure of the device is carried out in
order to collect the life cycle inventory data. Thus, all inputs used (raw materials and
energy) and outputs produced (air, liquid and solid emissions) during the device life
cycle (fabrication, use and disposal) are quantied.
With this analysis, the environmental burden and the embodied energy of the nal
product are allocated to the life cycle stages of the materials used for its production.
More specically, the contribution of each material (used in the production stage) to
the environmental input and output analysis is a signicant information for the
decision-making about the devices improvement and further re-design. Moreover,
the capabilities for reduction of the embodied energy of the nal product life cycle
can be examined, since it is proposed as an energy saving device. The obtained data
can be used to explore new possibilities, to plan, monitor and represent
environmental issues in R&D of the product.
The studied system is a 40 cm 40 cm ECD which comprises of four layers (Fig. 1)
[17,18]. Pilkington K-Glass serves as the transparent conductor, coated with a
350 nm thick WO3 lm (the active EC material which optical properties are
modulated). Polymer electrolyte (with 1.5 mm layer thickness in order to compensate
the lack of an ion storage layer) is prepared using a solution of a lithium salt mixed
with a polymer: lithium perchlorate diluted in propylene carbonate and poly-methyl
methacrylate (LiClO4PCPMMA). A second K-Glass is used to create the
necessary cavity for the infusion of the electrolyte. The whole device is sealed via
a silicone sealant. The total mass of the fabricated ECD was 3.33 kg: K-Glass
material [g]/ECD
represents 89.9% of this weight while PC, LiClO4 and PMMA 7.5%, 0.7% and
0.6%, respectively. Silicone used for the fabrication accounts for 1.1% of the total
weight, while the WO3 weight contribution is very low (0.4 g/ECD).
The ow chart for the ECD fabrication stage is depicted in Fig. 2. WO3 layer is
evaporated on K-Glass (Fig. 2, process 1). The two K-Glass sheets form the
electrolyte cavity, which is being peripherally sealed with the silicone sealant (Fig. 2,
process 2). The polymer electrolyte is produced (Fig. 2, process 3) and is inserted in
the cavity (Fig. 2, process 4). The assembled ECD is nally sealed (Fig. 2, process 5).
The system boundaries include the raw materials production processes (Fig. 2,
processes 1a, 1b, 2a, 3a, 3b and 3c). Therefore, we estimate the inputs and outputs
for resource extraction and mining processes, procurement of auxiliary materials and
all manufacturing processes for each material used.
In this study, we present the LCI for each of the six basic raw materials used in the
fabrication of the ECD: (1) K-Glass, (2) tungsten oxide (WO3), (3) PMMA, (4) PC,
(5) lithium perchlorate (LiClO4) and (6) acetic silicone sealant. Most of these
materials are complex chemicals requiring several steps for their production. The
inventory analysis is based on ow charts for each production process, showing the
inputs and outputs allocated in each phase. Thus, each production process is
described, the raw and auxiliary materials used are quantied and the energy
requirements are registered. As far as the outputs of each production process are
concerned, the air, water and solid emissions per manufactured kilogram of each
product are reported.
WO3
production 1a
see Fig. 4
WO3 WO3 layer
K-Glass evaporation 1
K-Glass
production 1b PMMA
see Fig. 3 production 3a
see Fig. 5
K-Glass PMMA
polymer electrolyte PC
peripheral sealing PC production 3b
silicone silicone 2 production 3 LiClO4
see Fig. 6
production 2a
see Fig. 8 LiClO4
production 3c
see Fig. 7
electrolyte
insertion 4
final sealing
5
ELECTROCHROMIC
DEVICE
3.1. K-Glass
1500C
alumina Melting and
refining precursor's vaporization
1 1100C
600C
Annealing halides topcoat pyrolytic tin
(HF, HCl) reaction compounds
4 60C
packed bed high
chemical temperature
fluorine doped
scrubber tin oxide reactor
Inspection 38C
5 electrostatic
precipitator
cullet
coated glass
precipitation
Cutting to order
6
stresses. The lehr is divided in sections in which there is heating and indirect or direct
cooling by forced and natural convection.
Automated online inspection (Fig. 3, process 5) is carried out at every production
stage in order to reveal process faults and minimize wastage. Finally, the cooled glass
ribbon is cut to size (Fig. 3, process 6) by a computer controlled travelling cutter,
while the ribbon selvedges (named cullet) are trimmed off and then recycled to the
furnace [21,22].
dust recycling and cullet recycling is considered of high priority for reducing SOx
emissions. Also, CO is emitted as product of incomplete combustion, particularly in
hot blast cupolas. However, in the cross-red regenerative furnaces the low energy
use per tonne of glass melted leads to reductions in many of the combustion
pollutants. Furnace emissions also contain traces of chlorides, uorides and heavy
metals (e.g. V, Ni, Cr, Se, Pb, Co, Sb, As, Cd) present also and in secondary
processing (e.g. cutting, polishing, etc.).
If the oat bath (Fig. 3, process 2) is correctly operated, the emission of tin vapor
has been found to be very low and it is generally monitored only to ensure low
workplace exposure levels. Emissions during CVD coating (Fig. 3, process 3) that
typically contain acid gases (HF, HCl) and ne particulate matter (e.g. oxides of
silicon and tin) can be controlled using a combination of techniques (dust abatement
equipment, bag lter or EC, dry/wet-chemical scrubbing, high temperature oxidation
and thermal incineration). Emissions from the undercoat stage pass through a
thermal incinerator to destroy any organic remains, the waste gas is cooled and a bag
lter removes the solids (amorphous silica). The collected material is recycled to the
furnace. During the top coating stage, the waste gases, which contain halides and tin
compounds, are passed through a high temperature reactor to oxidize the tin
compounds. The solid tin oxide is removed with electrostatic precipitator and the
halides in a packed bed chemical scrubber [19,2225].
During the annealing process in the lehr (Fig. 3, process 4), SO2 is sprayed on
both sides of the ribbon, providing a surface treatment to protect the glass
against the contact of the rollers. If the process is properly operated, SO2
emissions are insignicant. The only potential emissions are combustion products
from natural gas heaters in the lehr. In K-Glass production, water is used for
cooling, cleaning and batch humidication. Water used for cooling and washing the
hot glass ribbon, which is the greater part of water used, is not contaminated except
that it may contain some Na2SO4. Water emissions contain glass solids, oil
contamination and chemicals from cooling water system treatment that can be
controlled with simple abatement techniques (e.g. settlement, screening, oil
separators, neutralizing) [22].
Tungsten has the highest melting point of all metals, exhibits high hardness and
corrosion resistance and its thermal expansion is almost equal as for glass. Pure
tungsten can be forced, drawn and extruded and is extensively used in lighting
laments, television sets, magnetrons for microwave ovens, wire, rods and other
electrical consumer products. Other applications include chemical uses (mainly in the
form of catalysts) and use in the ammunition industries [26,27]. Tungsten oxide
(WO3) is the most widely studied EC material. It is incorporated in ECDs as the
active material, due to its favorable properties: reversible transmittance modulation
under applied voltage, prolonged durability, cycling reversibility and relative ease of
production by various physical vapor deposition techniques (thermal evaporation,
electron gun, sputtering). Another important feature is the stability of WO3 lms
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E. Syrrakou et al. / Solar Energy Materials & Solar Cells 85 (2005) 205240 215
turnings, ingots pieces composed of CuW, FeW, NiW, AgW, etc., (iii) the rejects
or by-products of manufacturing hard metals as well as worn tools (cutting and
drilling tools, wire drawing stones) composed of WCCo, WCTa(Nb), CTiCCo,
etc. Other scrap materials are steel products that are reprocessed with pyrome-
tallurgical steel-making technologies and used catalysts that require very careful
selection and testing [28]. Contaminated cemented carbide scrap, turnings, grindings
and powder scrap are oxidized and chemically processed to APT in a way similar to
that used for the processing of tungsten ores. Clean cemented carbide inserts and
compacts are converted to powder by the zinc process (treatment with molten zinc,
which is dissolved in the cobalt phase and is then distilled off, leaving a spongy
material that is easily crushed). This powder is added back to the manufacture of
ready-to-press powder. Great part of tungsten is being recycled industrially in high-
speed steel plants, and a typical melt contains 6070% scrap, including internally
generated scrap. On the other hand, recycling in such applications as lamp laments,
welding electrodes and chemical uses is low [26].
The main auxiliary materials used during WO3 production are Na2CO3 and
H2SO4 which is used during APT purication (Fig. 4, process 3a), while NaOH,
Al2(SO4)3 18H2O, Mg(SO4) 7H2O, Na2S and NH4OH are also used [28].
acetone HCN
acetone cyanohydrin
production 1
acetone
cyanohydrin
methacrylamide sulphate
production 2
methacrylamide
sulphate
methyl methacrylate
MMA polymerisation
4
POLY METHYL
METHACRYLATE
industry for a replacement process. The greatest part of energy required to produce
PMMA is provided from fuels; condensate gas and crude oil are the primary fuels
used [32].
Hydrogen cyanide and acetone are used in the ACH process, which also requires
handling of large amounts of sulfuric acid. Acetone can be produced by a number of
different routes, but the most commonly used is the manufacture of phenol (Fig. 5,
process 1a) which gives acetone as by-product. Hydrogen cyanide is mainly
produced by the reaction of methane (natural gas) with ammonia over a catalyst (the
Blausaure Methane Anlage process) or by reaction of methane and ammonia in the
presence of oxygen over a catalyst (the Andrussow process) (Fig. 5, process 1b). A
small proportion of hydrogen cyanide, however, is obtained as a by-product from
acrylonitrile production process (the Sohio production process) [34]. The required
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220 E. Syrrakou et al. / Solar Energy Materials & Solar Cells 85 (2005) 205240
water resources for cooling processes exceed 72% of the total, while the rest is used
during processing.
than 100 and is not expected to signicantly bio-accumulate. When MMA is released
into the air, it is expected to degrade by reaction with photochemically produced
hydroxyl radicals [37,38].
PMMAs chemical, physical and toxicological properties have not been
thoroughly tested [39]. It may be harmful by inhalation, ingestion or skin absorption
and may cause eye and skin irritation and irritation to mucous membranes and
upper respiratory tract. In case of chronic exposure target organ are found to be
lungs, thorax or respiration. Heat should be avoided, as during combustion toxic
fumes of carbon monoxide and carbon dioxide are produced. PMMA is
incompatible with strong oxidizing agents and strong acids. Disposal considerations
suggest to dissolve or mix the material with a combustible solvent and burn in a
chemical incinerator equipped with an afterburner and scrubber [39].
isobutane oxygen
crude oil procesing natural gas processing
1 2
4
PROPYLENE
CARBONATE
introduced. The efuent from the reformers is fed into carbon monoxide shift
converters, where the carbon monoxide reacts with water to form hydrogen and
carbon dioxide. The product of the shift converters is cooled and condensed water is
removed. The carbon dioxide and some excess hydrogen are then removed from the
synthesis gas as co-products [40].
NaCl
cell construction
1
2a
Sodium Sodium
chloride chloride solution
Stainless
RuO2, TiO2 steel saturation
LITHIUM electrolyte
PERCHLORATE solution
formation (Fig. 7, process 6) and (7) purication (Fig. 7, process 7). The conditions
in the cell are usually optimized to increase the reaction rate (pH is kept around 6
and temperature between 60 C and 80 C). The manufacture of perchlorate salts
begins with the electrolysis of brine (sodium chloride), rstly to form sodium
chlorate (NaClO3) and then sodium perchlorate (NaClO4). The sodium perchlorate
reacts with lithium chloride to form lithium perchlorate (LiClO4) and sodium
chloride (NaCl). The NaCl is taken out rst, then the crop of lithium perchlorate is
separated by cooling, the crystals are dried in an oven at 100 C and nally they are
packaged.
perchlorate, 50 Ah are required if the cell operates at an ideal 100% efciency, but in
real conditions more electricity is needed.
The principal raw materials used in the manufacture of lithium perchlorate are salt
(sodium chloride), lithium chloride and hydrochloric acid. Stainless steel is a suitable
cathode material, while mild steel may also be used (Fig. 7, process 1). Anode
materials suitable for perchlorate synthesis are: platinum, lead oxide and
dimensionally stable anode (DSA). The obvious disadvantage of platinum is its
high price, although it provides an almost ideal anode material, since it corrodes only
at a very slow rate and thus high efciency can be reached. Using platinum,
processing of the electrolyte is greatly simplied due to the absence of insoluble
anode erosion products. Lead dioxide provides an economical alternative to
platinum, but it usually has a slightly lower efciency. The DSA consists of a layer of
noble metal oxides (usually RuO2 and TiO2) coated onto a substrate, usually
titanium. Although, the required chemicals for the manufacture of these anodes are
expensive and difcult to handle, they nd increased use in industrial cells because
their cost remains lower than platinum and they resist to corrosion.
Sodium chloride is used to prepare sodium chlorate (Fig. 7, process 3), as it is very
soluble in water and can therefore be easily separated from existing insoluble
impurities. The amount of NaCl is usually recycled by 50%. In case of preparing
fresh electrolyte (Fig. 7, process 2a) a saturated solution of sodium chloride is made,
which is brought to a boil and then it is cooled back to room temperature. Some
sodium chloride will crystallize as the solution cools, while ltering follows.
Optionally, 24 g/l of potassium dichromate, potassium chromate, sodium chromate
or sodium dichromate may be added to improve efciency. These compounds are
suspected carcinogens. If lead dioxide anodes are used, potassium dichromate will
reduce efciency, thus instead 24 g/l of sodium or potassium uoride may be used
(not carcinogenic). The pH of the solution should be kept around 6 and can be
adjusted by addition of dilute solutions (2% w/v) of sodium hydroxide or
hydrochloric acid. When old electrolyte is available from previous batch of
perchlorate, it can be recycled (Fig. 7, process 2b). First, the solid particles in the
electrolyte should be removed by ltering. Any impure chlorate from the purication
and extraction steps should also be dissolved. Sodium chloride is used to re-saturate
the solution following the procedure mentioned above with the fresh electrolyte.
During sodium perchlorate formation (Fig. 7, process 4) small amounts of
chromates or dichromates are added in order to prevent the products of the
electrolysis from being reduced at the cathode again. A layer of hydrated oxides of
chromium will then form around the cathode effectively preventing hypochlorite and
chlorate ions from reaching the cathode surface. The nal product of the electrolysis,
sodium perchlorate, is conveniently converted in high yield to lithium perchlorate by
double decomposition reactions (Fig. 7, process 6). Lithium chloride is dissolved in
the smallest volume of water possible and when this solution is mixed with the
electrolyte (solution of sodium perchlorate) a white precipitate of the corresponding
perchlorate should be formed. The solution is boiled and small amounts of water are
added until all the perchlorate has dissolved. The pH of the solution should be
neutral or slightly alkaline (above 7) and can be adjusted with dilute sodium
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226 E. Syrrakou et al. / Solar Energy Materials & Solar Cells 85 (2005) 205240
hydroxide solution or hydrochloric acid. Then the solution is cooled slowly to room
temperature and the perchlorate will crystallize. The solution is further cooled to 0 C
and ltered. The crystals are rinsed in the lter with some ice-cold water and may be
further puried [44].
current technologies (ion exchange, reverse osmosis and electrodialysis), thus bio-
and/or phytoremediation technologies are attempted (acetate-oxidizing and per-
chloratechlorate-reducing bacteria) [4550].
Acetic silicone sealant is a clear, durable and exible rubber paste, specically
intended for use as a sealant for bonding to non-porous surfaces such as glass, metal,
ceramic, etc. It forms a long lasting seal that is resistant to the effects of sunlight,
rain, snow, ozone, ultraviolet radiation and temperature extremes. Acetic silicone
sealants are based on poly-dimethyl siloxanes (PDMSs), they typically contain a
cross-linker, methyl triacetoxy silane, and are cured by atmospheric moisture. Their
name is derived from the acetic acid, which is generated during the curing reaction
and accounts for the distinctive smell derived from these products. Acetoxy, or acetic
acid cured silicones are the most widely used (instead of alkaline or neutral) in the
glass and sanitary industries and can be exposed to maximum service temperature of
120180 C. They are used for the peripheral sealing of some ECDs [51,52].
quartz processing
1a
chlorosilane synthesis
1
dimethyl
dichlorosilane
chlorosilane
HCl
hydrolysis 2
acid/basic acid/basic
condensation polymerisation
catalysts 3a 3b catalysts
acetic acid
ACETOXY SILICONE
SEALANT
In the following sentences, the necessary raw materials for the three steps synthesis
processes of PDMS are presented [53]:
The other two basic raw materials used in silicone production silica and quartz are
substances primarily composed of silicon dioxide (SiO2) [57]. Silica is a general term
for silicon dioxide, both natural and man-made, while quartz refers to certain
crystalline forms of silica and is very abundant. Quartz used to produce silicon metal
must satisfy moderate requirements in terms of particle size and purity. Feed chip
sizes ranging from 10 to 100 mm insure appropriate gas permeability in the electric
furnaces used for silicon reduction. In terms of purity, a typical composition for
quartz used for silicon metal production is SiO2 content >98.0%, Al2O3 1.0% max,
Fe2O3 1.5% max, CaO 0.2% max and MgO 0.2% max.
4. Discussion
The results of the inventory analysis for the production phases of the constituents
of an ECD are depicted in Tables 1 and 2. The raw data used were obtained from EU
and EPA reports, product-specic LCAs and bibliographic sources. The rst table
summarizes the input data (raw materials and energy consumption), while analyses
of the air, water emissions and solid waste are presented in Table 2. Tungsten oxide
energy contribution (Table 1) has not been estimated, but it is expected to be
negligible because of its low mass contribution to the ECD (E0.1%). The emissions
data in Table 2 refer only to K-Glass, PC and PMMA, which all together represent
the 98% of the total ECD mass.
Some basic remarks regarding the K-Glass data incorporated in this study are:
* The nal product represents 70% in weight of the raw materials input, while the
cullet used replaces 20% of virgin raw materials. The packed product to melted
glass ratio used was 0.9.
Table 1
E. Syrrakou et al. / Solar Energy Materials & Solar Cells 85 (2005) 205240
Inventory table, input analysis
K-Glass Tungsten oxide Poly-methyl methacrylate Propylene Carbonate Lithium perchlorate Acetoxy silicone sealant
Substance (kg/kg Substance (kg/kg Substance (kg /kg Substance (kg /kg PC) Substance (kg /kg Substance (kg /kg
K-Glass) WO3) PMMA) LiClO4) silicone)
Raw materials
4
Silica sand 0.788 Sulfuric acid 1.40 Bauxite 7.3 10 Sodium 1.18 Sodium 0.212 Hydroxyl-terminated 0.6
ARTICLE IN PRESS
chloride chloride PDMS
Soda ash 1.37
5 2
Soda ash 0.286 Sodium hydroxide 1.03 Barytes 7.5 10 Crude oil 7.51 10 Lithium 0.308 Amorphous Silica 0.25
chloride
5 4
Limestone 0.141 Ammonium 0.12 Clay 1.1 10 Natural gas 3.17 10 PDMS 0.1
hydroxide
6
Dolomite 0.091 Al2(SO4)3 18H2O 0.08 Dolomite 6.0 10 Ethyl triacetoxy 0.026
silane
6
Alumina 0.043 Sodium sulde 0.05 Bentonite 2.0 10 Methyl triacetoxy 0.017
silane
Cullet 0.011 Mg(SO4) 7H2O 0.03 Calcium sulfate o5 10 7
Specic additives 0.007
Others 0.011 Chalk o5 10 7
Energy consumption
(MJ/kg K-Glass) (MJ/kg WO3) (MJ/kg PMMA) (MJ/kg PC) (MJ/kg LiClO4) (MJ/kg silicone)
231
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232 E. Syrrakou et al. / Solar Energy Materials & Solar Cells 85 (2005) 205240
Table 2
Inventory table, output analysis
Air emissions
CO2 1.28 10 1 CO2 1.24 CO2 5.6
NOx 3 10 3 Hydrocarbons 2.45 10 2
SOx 2.8 10 2
organics
7 4 4
Nickel 5.56 10 Propylene 2.58 10 HCl 1.5 10
4 4
Propylene 1.29 10 Aldehydes 1.0 10
oxide
Aldehydes 2.27 10 5 Metals 1.3 10 5
chlorine, HCl,
kerosene
6
H2S 4.0 10
6
HCN 3.0 10
6
Aromatic-HC 1.0 10
N2O, Cl2, lead, F2, o5 10 7
mercaptans,
organo-Cl,
polycyclic-HC, Hg,
CFC/HCFC,
H2SO4, CS2, DCE,
VCM
Water emissions
4
Chloride 0.082 Sulfuric acid 1.69 10 SO4 2 2.7 10 2
4 4
COD 2.31 10 Dissolved 1.43 10 Na+ 1.9 10 2
solids
Sulfate 1.8 10 4 Iron 4.20 10 5
Cl 1.0 10 2
(Kjeldahl)
6
Boric acid 7.11 10 BOD 2.18 10 6 Phosphate (P2O5) 1.0 10 3
6
Barium 5.33 10 Susp. solids 1.94 10 6 Dissolved solids 6.3 10 4
Phenols 1.78 10 6
Phenol, zinc, o5 10 7 BOD 5.1 10 4
chromium,
acid, lead
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Table 2 (continued)
Pb
Ni+2, Cu+/Cu+2, 1.0 10 6
sulfur/sulde, other
organics
Arsenic, DCE, o5 10 7
Solid waste
* The water quantity used and wastewater emissions data (assumed to be 1.6 m3/
tonne glass melted) were taken from inputoutput analysis referring to container
glass production [22].
* Data from at glass industry [59], referring to fully recycled (by use of cullet) and
virgin glass, have been used to extrapolate the values presented in Table 2: 20%
use of cullet has been assumed.
* It is assumed that a cross-red regenerative furnace (code name FG3 [22]), which
uses gas or oil (1% in Sulfur), is incorporated in the K-Glass production line. Its
capacity is 650 tonne/day and primary NOx abatement techniques are used, while
100% of the dust is recycled with electrostatic precipitators and dry scrubbers.
This furnace is also equipped with waste heat boiler.
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* The generally accepted value for the energy required per kilogram of oat glass
melted and kilogram of glass produced are 8 and 10.7 MJ, respectively. On the
other hand, the lowest corresponding values were reported to be 6.2 and 8.3 MJ
for FG3 plant furnace [22].
K-Glass accounts for 90% of the total ECD mass (see Fig. 1). Subsequently, the
raw materials used for its production are the major contributors to the whole input
analysis. These are mainly natural materials, which are mined, crushed and graded.
Thus, the abundant silica sand (SiO2) representing 72% of the total K-Glass mass,
accounts for 65% w.w. in the ECD composition. Tin tetrachloride (SnCl4),
hydrouoric acid (HF), methanol (CH3OH) and silane (SiH4) used during the K-
Glass coating process (CVD) are environmentally signicant, even if their quantities
are not reported in Table 1. Silane is a spontaneously combustible (pyrophoric) gas
and its existence may result to a subsequent re or explosion hazard. The lower limit
for spontaneous ignition of SiH4 in air ranges 23%, depending on the carrier
gas [60].
Tungsten oxide production demands many auxiliary materials, with sulfuric acid
and sodium carbonate (soda ash) being used in larger quantities. Raw materials for
the tungsten and PMMA production are mined by ores and then they are processed
to the nal product, while salt (NaCl) taken from brines is the main constituent for
PC and LiClO4 production. Furthermore, fossil fuels (crude oil and natural gas) are
used as energy sources and raw materials during PC production process. On the
contrary, acetoxy silicone sealant synthesis requires more complex chemical
substances apart from silica, namely siloxanes and silanes that are also produced
from quartz among others.
The contribution of each material to the embodied energy of the ECD is presented
in Fig. 9. K-Glass corresponds to almost 66%, PC to below 25%, while PMMA,
LiClO4 and silicone account for less than 10% in total. The production of WO3 is
not characterized as high energy demanding and due to its negligible mass presence
its energy contribution to the ECD is considered insignicant. As presented in Table
1, the most energy demanding procedure is the manufacture of PMMA (110 MJ/kg
material produced). On the other hand, there is signicant difference between the
required energy for the production of 1 kg of K-Glass and PC: 10.7 and 47.7 MJ,
respectively. Due to this and although the PC mass ratio in ECD is quite small
(almost 8%, see Fig. 1) its nal contribution to the total embodied energy is
important and comparable to that of the K-Glass: 24.5% and 65.6%, respectively.
In Table 3 the embodied energies of an ECD and other insulating glass units
(IGUs) with the same dimensions (40 cm 40 cm) are compared. The data used [11],
refer to argon, krypton and xenon cavity lled double-glazed windows, which
represent a signicant percentage of the IGUs market worldwide. The values for the
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PMMA
PC
4.7%
Material MJ/ECD 24.5%
K-Glass 32.13
WO3 -
PMMA 2.31
Propylene Carbonate 12.00 LiClO4
4.4%
Lithium Perchlorate 2.18
Silicone 0.37
Silicone
Total 48.98 K-Glass 0.8%
65.6%
Table 3
Embodied energy of raw materials and manufacturing processes
ECD and the argon lled IGU are similar, while the energy required in the case of
krypton is more than double compared to ECD. On the other hand, xenon lled
IGUs demand extreme energy consumption, which could make them rather
unadvisable for real applications.
The frames are not included in the calculation of the above values, but in the case
of a typical timber frame suitable to t the EC window, 220250 MJ [11] should be
added to the embodied energy of each unit. In this frame we have incorporated some
aluminum components as the glazing unit spacer, frame ventilation, outer timber
protection and window mechanism. The energy requirements for the manufacturing
process of each of the IGU window systems (including frame and sealed glass unit
construction, aluminum processing, lighting and factory services) are 137 MJ/unit.
Corresponding values for an ECD are not commercially available, but taking into
account that no complex fabrication procedures will be included [3], an estimate of
130170 MJ/ECD is logical.
Thus, the values for the total embodied energies for the ECD and the argon lled
IGU are 431471 and 431 MJ/unit, respectively. The energy payback time for the EC
glazing is estimated to be less than 2 years [1,62]. On the other hand, given that the
added rst cost for installed, mass manufactured EC glazing will be almost 160 h/m2
of glazing, we can estimate a simple payback period of 3.2 years [1]. This analysis
depicts the promising future that advanced window systems such as ECDs could face
when they come to market, as they can combine favorable thermal and optical
properties with low energy demanding production procedures.
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A public health goal (PHG) in the range of 26 mg/l is proposed for perchlorate
percentage in drinking water, while a safe exposure limit is 0.03 mg anion of
perchlorate/kg of weight per day [4550].
PMMA and PC health impacts are discussed in Sections 3.3.3 and 3.4.3,
respectively, but their chemical, physical and toxicological properties have not been
thoroughly analyzed yet. MMA is a harmful and ammable chemical which should
be handled as hazardous waste, and the permissible exposure limit of OSHA and
ACGIH is 100 ppm time weighted average (TWA) [37,38]. The exposure limit for
methyl triacetoxy silane and ethyl triacetoxy silane, chemicals used during silicone
sealant production, is for both 10 ppm TWA and 15 ppm short-term exposure limit
(STEL) as denoted by ACGIH [52,55,58]. As far as tungsten is concerned, the lower
impacts among all the above-mentioned materials are recorded. The ACGIH has
recommended 5 mg/l for insoluble and 1 mg/l for soluble tungsten compounds [27,30].
5. Conclusions
with LCIA, where the contribution of the above results to specic impact categories
will be estimated. Finally, with the interpretation of these results the total
environmental assessment of the ECD lifecycle will be carried out.
Acknowledgements
The authors would like to acknowledge the EU for nancially supporting this
work within the frames of the EESD program (project name ELEVAG, Contract
No. ENK6-CT-2001-00547).
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