Download Carbon footprint for Enervent Family air handlers and heat

Carbon footprint for Enervent Family
air handlers and heat exchangers
Project summary report September 23rd, 2011
Proprietary & Confidential
Your partner for sustainable performance
1. What is product carbon footprint and how is it calculated
2. Scope of the air handler & heat exchanger product system
3. Inventory analysis and manufacturing carbon footprint
4. Use phase scenario description
5. Carbon footprint over product lifecycle
6. Conclusions and recommendations
Annex: calculation data and additional information
2
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Goals of the study
The study aims to quantify the lifecycle carbon footprint for selected
products from the Enervent Family portfolio
The goals Ensto has set for the study are:
–
–
–
To understand the greenhouse gas impact of the products and the key
drives of the greenhouse gas impact
To gain marketable proof of the greenhouse gas impact of the products
that can be utilized in marketing and communication, including
comparative assertions vs. similar products on the market
To identify ways for R&D to reduce the CO2 emissions from products
Ensto has a large and a diverse product portfolio, and the approach for
conducting the lifecycle analysis should be suitable for portfolios
3
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Product carbon footprint
Product carbon footprint means the lifecycle impact of a product or a
service, in all locations and every part of supply chain. Greenhouse gas
emissions are generated during the manufacturing, assembly, shipping,
use and disposal phases of the product. For energy saving products,
emissions may also be avoided during the operation of the product.
Calculating carbon footprint allows Enervent to demonstrate the lifecycle
climate impact of Enervent products in an widely recognized way.
Lifecycle from cradle to grave
Raw
materials
production
Manufacturing &
Assembly
Packaging &
Shipping
Installation
4
Operation
Final
disposal /
recycling
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How life cycle assessment is done
The life cycle assessment usually always follows below stages,
indifferently of standards and scope that are applied. The steps are not
strictly chronological, but they also interact with each other. Various
standards exist and may be used to govern the process.
Setting goals and
the scope of the
calculation
What is the goal?
What is included?
What info is needed?
Inventory analysis:
material and utilities
flows & byproducts
Impact
assessment: the
calculations
Gathering data.
Defining process and
material flows.
Calculating impact
using also research
and databases.
Results and
conclusions
Conclusions and
evaluation of the results
Utilising the results: planning activity, designing products, marketing and sales, and so forth
According to ISO 14040
5
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How the study was conducted
The carbon footprint was calculated by Bionova Consulting during the spring
and summer 2011.
Ensto selected two products from the Enervent Family series to be analyzed:
Pingvin and LTR-6. Of these, Pingvin has a VTT certificate for heat recovery
and energy efficiency.
Eleven component and part suppliers were contacted to gather lifecycle
inventory data. Suppliers responses were partially incomplete, and missing
information was completed with secondary data.
Use scenario was built based on the assumption of a typical residential use
scenario in Southern Finland with a historical weather pattern.
The study follows the principles and guidelines ISO 14040 and ISO 14044 life
cycle assessment standards, but does not comply with all of the requirements.
6
Your partner for sustainable performance
1. What is product carbon footprint and how is it calculated
2. Scope of the air handler & heat exchanger product system
3. Inventory analysis and manufacturing carbon footprint
4. Use phase scenario description
5. Carbon footprint over product lifecycle
6. Conclusions and recommendations
Annex: calculation data and additional information
7
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Product system: manufacturing and assembly
Life cycle cradle to grave
Raw material
production
Manufacture
& assembly
Steel plate
production
Bending,
drilling, etc.
Other metals
Other
materials
Packaging
materials
Transport
Component
production
Shipping parts
and materials
Assembly
(Enervent)
Transport to
the end user
8
End of life
treatment
Use phase
Use phase
(see next slide)
Recycling
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Product system: use phase
The air handler and heat exchanger unit is installed in a residential building. The heat
exchange is partial, and the lost heat is produced with a ground source heat pump. The
air flow is controlled based on temperature, time and possibly the air CO2 concentration.
Product system
inputs
Product system
heat flows
Electricity for
the heat pump
Cold air in
(needs heating)
Heat
exchanger
(energy
recovery)
Electricity for
the air handler
Filters for
the air handler
Warm air out
(energy loss)
Exclusions from the system: ground source heat pump and related systems manufacturing is excluded. The installation process and required
piping and works for the air handler system are excluded, business trips and employee commuting are excluded.
9
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Functional unit
The purpose of the functional unit is to measure the performance that
matters in the intended use of the product and avoid comparison
based on measures such as weight etc, which are a consequence
rather than the intended outcome.
The functional unit for air handlers and heat exchangers used here is
–
–
Providing one cubic meter (m3) of volume with the air volume required by
the Finnish regulation during one year (i.e. exchange the entire air volume
once every two hours).
For information purposes, data is also shown for one square meter (m2)
for a given house.
10
Your partner for sustainable performance
1. What is product carbon footprint and how is it calculated
2. Scope of the air handler & heat exchanger product system
3. Inventory analysis and manufacturing carbon footprint
4. Use phase scenario description
5. Carbon footprint over product lifecycle
6. Conclusions and recommendations
Annex: calculation data and additional information
11
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Finished product material balance
Some 80 % of the mass of the finished product is made up of metals, mostly casing, the
heat exchanger and the fans. The rock wool insulation is a major component in the LTR-6.
The ready to ship LTR-6 weighs 106 kg, while the Pingvin weighs 53 kg.
100 %
Other materials
90 %
80 %
Filter, PET + Alu
70 %
Packaging, Cardboard
60 %
50 %
Insulation, Rock wool
40 %
Fans, Metals
30 %
20 %
Heat exchanger,
Aluminium
10 %
Casing, Steel plate
0%
LTR 6
Pingvin
Does not account for scrappage etc.
12
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Manufacturing emissions are driven by
the emissions from metal parts
Steel plate and the aluminium heat exchanger are the most significant
components for the carbon emissions. Together, they account for
roughly the half of the total emissions for LTR-6, less for Pingvin.
Manufacturing phase carbon emissions, kg CO2e
450
400
350
Transport
300
Assembly
250
Other materials
200
150
Heat exchanger
100
Steel plate
50
0
LTR-6
Pingvin
13
Your partner for sustainable performance
1. What is product carbon footprint and how is it calculated
2. Scope of the air handler & heat exchanger product system
3. Inventory analysis and manufacturing carbon footprint
4. Use phase scenario description
5. Carbon footprint over product lifecycle
6. Conclusions and recommendations
Annex: calculation data and additional information
14
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General description of the use scenario
The use scenario assumes a newly built home, heated with a ground
source heat pump situated in the Uusimaa region in southern Finland
–
The scenarios are calculated with a 150 m2 single family house
–
–
Average single family house : 150 m2 (room height 2,5 meters)
Volume is 375 m3, approximately 70% of the Pingvin maximum volume
Relative emissions from LTR-6 are calculated with a larger house
–
The heat pump efficiency (COP) is assumed to be 3, i.e. the heat pump
consumes 1 kWh of electricity to produce 3 kWh of heat
This house is not used in comparative calculations
The use phase is assumed to last for 20 years and filters are replaced
as per the manufacturer instructions
15
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Air flow and heat loss calculations
Air flow calculations
–
–
Heat loss calculations
–
–
The air handler is assumed to run at the legally required volume (i.e.
exchanging the entire air volume every two hours) the whole year
The residents are absent 1 550 hours per annum, and if a home/away
switch is used, during this time air is exchanged once every three hours.
Historical temperature data is used to calculate average temperatures
The heat loss is calculated by multiplying intake air heating need with (1
minus the heat exchanger recovery rate)
Air handler electricity consumption calculations
–
Air handler electricity consumption is calculated with air exchange volume
multiplied by the total electricity consumption of the product PesU
16
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Benchmark against competing products
VTT has a valid energy efficiency certificate for 20 air handling units. Of these,
seven were selected randomly. Two did not pass most recent requirements. The
average of the remaining five was benchmarked against Enervent Pingvin.
Annual heat recovery rate, Southern Finland
75 %
Enervent LTR-3
Enervent Pingvin
70 %
65 %
60 %
Average of 5 competitors
that pass requirements
55 %
Excluded from average
(PesU is above 2,0)
50 %
45 %
0
0,5
1
1,5
2
2,5
Characteristic electricity consumption kW / ( m3 / s)
Source: VTT listing July 22, 2011 and VTT certificates
17
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Comparison and scenario variations
Variations were developed to highlight the impact of the use of an average
competing product and the impact of use of Home/Away switch. Other
parameters remain unchanged. Source for the parameters are VTT certificates.
The competitive comparisons are done with Enervent Pingvin. For purposes of
internal comparison, LTR-6 energy efficiency figures are taken from LTR-3. It
should be noted that the best competitor is very close to Enervent Pingvin.
Scenario variation
Annual heat recovery
Electricity consumption PesU
A. Average competitor
60 %
1,6 kW / (m3 / s)
B. Enervent Pingvin
71 %
1,3 kW / (m3 / s)
C. Enervent Pingvin
with Home/Away
71 %
1,3 kW / (m3 / s)
18
Your partner for sustainable performance
1. What is product carbon footprint and how is it calculated
2. Scope of the air handler & heat exchanger product system
3. Inventory analysis and manufacturing carbon footprint
4. Use phase scenario description
5. Carbon footprint over product lifecycle
6. Conclusions and recommendations
Annex: calculation data and additional information
19
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Carbon footprint for first year use is
substantially higher than manufacturing
After the first year of use, the greenhouse gas emissions for Pingvin
consist of equal thirds from manufacturing, electricity for the ground
heat pump to replace lost heat and electricity for the air handling unit.
Pingvin manufacturing and first year carbon footprint
Electricity - ground heat
pump
32%
Manufacturing
36 %
Materials
28%
Assembly
8%
Transportation
2%
Electricity - air handler
29%
20
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LTR-6 and Pingvin show similar results
When both products results are shown in relation to the air volume they
handle, the emissions are similar in the use phase. Manufacturing
shows a minor economy of scale in emissions for the larger LTR-6.
Carbon footprint kg CO2e / m3 volume
1,00
0,80
0,60
0,40
0,20
0,00
LTR-6
Ma nufa cturi ng
Pingvin
Use i n fi rs t yea r
21
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The use phase: CO2 emissions (ground heat pump)
Enervent achieves approximately one fourth lower carbon emissions, when used in a
150 m2 Southern Finland single family house with a ground heat pump.
Lifecycle carbon footprint, kg CO2e / year
500
On an absolute basis, Enervent saves
over 100 kg CO2 emissions per year.
435
400
332
312
Enervent Pingvin
Enervent Pingvin with
Home/Away
300
200
100
0
Average product
On a relative basis, Enervent achieves
emissions lower than 1 kg CO2e / m3
3,5
3,0
2,5
2,0
1,5
1,0
0,5
0,0
Relative carbon footprint, kg CO2e / year
2,9
2,2
1,2
Average product
0,9
0,8
Enervent Pingvin
kg CO2e / m3
22
2,1
Enervent Pingvin with
Home/Away
kg CO2e / m2
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The use phase: electricity (ground heat pump)
Enervent achieves approximately one fourth lower electricity consumption when used in a
150 m2 Southern Finland single family house with a ground heat pump.
Electricity consumption, kWh / year
On an absolute basis, Enervent saves
450-550 kWh electricity per year.
2 500
2 000
1 500
721
593
556
861
808
Enervent Pingvin
Enervent Pingvin with
Home/Away
1 000
500
1 200
0
Average product
Heat pump
Relative electricity use, kWh / year
Air handler
On a relative basis, Enervent achieves
consumption lower than 4 kWhe / m3
14,0
12,0
10,0
8,0
6,0
4,0
2,0
0,0
12,8
9,7
5,1
Average product
3,9
23
3,6
Enervent Pingvin
kWh / m3
9,1
Enervent Pingvin with
Home/Away
kWh / m2
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The use phase: CO2 emissions (district heating)
Enervent achieves approximately one fourth lower carbon emissions, when used in a
150 m2 Southern Finland single family house with average district heating.
Lifecycle carbon footprint, kg CO2e / year
1000
On an absolute basis, Enervent saves
circa 250 kg CO2 emissions per year.
926
800
684
642
Enervent Pingvin
Enervent Pingvin with
Home/Away
600
400
200
0
Average product
On a relative basis, Enervent achieves
emissions lower than 2 kg CO2e / m3
7,0
6,0
5,0
4,0
3,0
2,0
1,0
0,0
Relative carbon footprint, kg CO2e / year
6,2
4,6
2,5
Average product
1,8
1,7
Enervent Pingvin
kg CO2e / m3
24
4,3
Enervent Pingvin wi th
Home/Away
kg CO2e / m2
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The use phase: energy (district heating)
Enervent achieves approximately one fourth lower energy consumption when used in a
150 m2 Southern Finland single family house with average district heating.
Energy consumption, kWh / year
On an absolute basis, Enervent saves
circa 1 200 kWh energy per year.
5 000
4 000
3 000
3 600
2 000
2 584
2 424
721
593
556
Average product
Enervent Pingvin
Enervent Pingvin with
Home/Away
1 000
0
Electricity
District heat
Relative energy use, kWh / year
35,0
30,0
25,0
20,0
15,0
10,0
5,0
0,0
On a relative basis, Enervent achieves
consumption lower than 9 kWh / m3.
28,8
21,2
11,5
Average product
8,5
25
7,9
Enervent Pingvin
kWh / m3
19,9
Enervent Pingvin with
Home/Away
kWh / m2
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Over the lifecycle, the difference matters
Over the 20 years lifecycle in a 150 m2 home heated with ground heat pump in Southern
Finland, the saved electricity is approximately 10 000 kWh and the avoided emissions are
over 2 300 kg CO2 equivalent. The savings vary based on the use of Home/Away feature.
Carbon footprint over the entire lifecycle, kg CO2e
10 000
9 000
Emissions, kg CO2e
8 000
24-28 % lower emissions
and electricity use
7 000
6 000
5 000
4 000
3 000
2 000
Average product
Enervent Pingvin
Enervent Pingvin with Home/Away
1 000
0
1
2
3
4
5
6
7
8
9
10 11 12 13 14 15 16 17 18 19 20 21 22
Time, years
26
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Enervent achieves positive climate impact
Enervent’s higher efficiency starts reducing global CO2 emissions in two years.
Carbon payback time = CO2 from investment / annual operating CO2 savings.
Carbon payback time in years when compared to
an average air handling unit
3
2,2
1,8
2
1
0
Enervent Pingvin
Enervent Pingvin with Home/Away
27
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1. What is product carbon footprint and how is it calculated
2. Scope of the air handler & heat exchanger product system
3. Inventory analysis and manufacturing carbon footprint
4. Use phase scenario description
5. Carbon footprint over product lifecycle
6. Conclusions and recommendations
Annex: calculation data and additional information
28
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Conclusions 1/2 - takeaway figures
For a family house situated in Southern Finland and heated with a ground heat
pump, Enervent Pingvin achieves 24-28% lower CO2 emissions than an
average competitor.
Life cycle emissions for Enervent Pingvin in a 150 m2 house in Finland is:
–
–
Energy consumption for Enervent Pingvin in a 150 m2 house in Finland is:
–
–
Less than 1 kg CO2e / m3 air volume / year, when heated with a ground heat pump
Less than 2 kg CO2e / m3 air volume / year, when heated with average district heat
Less than 4 kWh electricity / m3 air volume / year, when using a ground heat pump
Less than 9 kWh energy / m3 air volume / year, when using average district heat
Use phase accounts for over 95 % of life cycle emissions over 20 years period.
29
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Conclusions 2/2 – generic notes
There are substantial variations between competing products, and the result
can not be generalized to concern any and all competitors; indeed, the best
competitor comes very close to Enervent Pingvin. In the sample however 4 out
of 5 are close to the average.
The CO2 emissions of heat and electricity determine the absolute emissions
figures, for example when product is sold to markets outside Finland or with
other heating systems.
30
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Recommendations
Managing the air volume with Home/Away switch or comparable
automation is a very efficient way to reduce CO2 emissions.
–
In the manufacturing phase, materials have the highest contribution.
Reducing the use of materials has the highest potential yield.
–
–
Any opportunities to adjust the air volume based on the real need and to
avoid over-ventilation have the highest contribution towards reducing
lifecycle emissions (for example, because of wrong settings).
For example, reducing the use of metal in casing, or to make the casing
from single piece to reduce the loss (up to 20%) in plate processing
Utilizing Norwegian or Icelandic aluminium would also improve the result
Reducing the assembly energy consumption has significant potential.
–
–
If materials could be stored in lower temperature storage with on demand
lighting before assembly, this could reduce energy consumption
Porvoon Energia plans to supply carbon free district heat around 2015.
31
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Product development suggestion: from CO2
ppm boost to CO2 ppm management
CO2 sensor could be used to deliver fresh air as needed, not just to boost, but also to
downgrade the air exchange volume in similar manner as a Home/Away switch does.
Below chart shows two hypothetical ppm based air exchange control models.
Using CO2 ppm for need based air exchange
Air exchange as share of total m3
0,700
Boosted 0,5 1 / h + 30 %
0,650
0,600
0,550
Normal 0,5 1 / h
0,500
0,450
0,400
0,350
Minimum (Away) 0,325 1 /h
0,300
400
Fresh outdoor air
500
600
700
800
Quality indoor
air (S1 class)
750 ppm
900
Quality indoor
air (S2 class)
900 ppm
32
1 000
1 100
1 200
Maximum allowed
(normal conditions)
S3 class 1200 ppm
Your partner for sustainable performance
1. What is product carbon footprint and how is it calculated
2. Scope of the air handler & heat exchanger product system
3. Inventory analysis and manufacturing carbon footprint
4. Use phase scenario description
5. Carbon footprint over product lifecycle
6. Conclusions and recommendations
Annex: calculation data and additional information
33
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Use phase duration and maintenance
System is assumed to be in use for 20 years. Air handlers and heat
exchangers are very robust technology and have a long lifespan.
The system probably would require some maintenance during this
lifespan. However, as this has only a negligible impact on the carbon
footprint, it was not accounted for.
To keep the heat exchanger clean and the system operational periodic
replacement of air filters is imperative.
–
–
LTR-6 and LTR-7 use bag filters, which need replacement annually and
where the metallic frame is disposed together with the filter
Pingvin and LTR-3 use horizontal filters, which need replacement quarterly
and where the metallic frame is not disposed
34
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Uncertainties and possible errors
Uncertainty due to the energy emissions and choice of heating system
–
–
Uncertainty due to the partial sample in the competitor benchmark
–
Heating solution determines the absolute emissions more than other
choices, therefore the absolute results are valid for ground heat pump only.
Over the 20 years period, electricity CO2 emissions will likely be lower
than today, however this development is not accounted for in this study
The sample size for competing products is 7, out of the total possible 18
VTT certified competing air handlers. The average of the sample should
provide an appropriate benchmark. However, from the sample it can be
seen that the best competitors approach Enervent.
Uncertainty due to lacking or misinterpreted data
–
–
Some of the supply chain could not provide full or any life cycle data
Where necessary, secondary sources, empirical values and estimates
have been used to complete the information gaps
35
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Case: renovating a 1950’s veteran house
The 1950’s veteran houses have natural ventilation. The air tightness varies a lot, but here we consider
a typical veteran house to exchange 0,4 of its air volume in one hour. The air flow is assumed to be
constant around the year, although cold normally increases it. Heating works with district heating.
The veteran house is insulated and it becomes airtight, naturally ventilating only 0,05 of its air volume
in one hour. Because the insulation material consumption for the renovation is undefined, the net
savings over project lifecycle are not considered here and only CO2 from energy use is shown. The
achieved savings can not be attributed to Enervent alone, as also insulation materials are utilized.
Veteran house energy renovation impact
Pre renovati on
Pos t renovati on
Energy renovation with Enervent
reduces heat loss via air by 50 %.
3 992
At the same time, heat loss through
walls and roof is also reduced (not
considered here)
1 919
840
407
Energy kWh
Use phase CO2e kg
Source: Laskelmat rakennusten energiataloudessa ja sisäilmaston hallinnassa
36
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Veteran house energy renovation, scenarios
Below chart from a final year thesis considering veteran house energy renovation shows various
scenarios for the overall impact of a veteran house energy renovation in different heat loss categories.
Source: Mirka Poikelin: Rintamamiestalon energiatehokkuuden parantaminen
37
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Emissions from various heating choices
Below chart shows kWhheat CO2 emissions for selected energy sources. These
figures exclude the fuel supply chain and capital investments and consider only the
combustion emissions, hence renewable heating emissions are considered as nil.
Furthermore, efficiency factor is not considered (excepting the ground heat pump).
For electricity and heat, long term average values have been chosen to reflect
periodical variations such as cold winters and high and low rainfall years.
Heating CO2 emissions per kWh
300
267
250
210
222
200
150
100
74
50
0
0
Ground heat Finnish district
Finnish
pump (COP 3)
heating avg
electricity use
2004-2008
avg 2004-2008
Oil heating
38
Renewable
heating
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Electricity consumption in scenarios
Electricity consumption for the use phase in scenarios is shown below.
To convert heat pump electricity to heat, multiply by 3 (COP=3).
Scenario
Ground heat pump
electricity kWh
Air handler
electricity kWh
Electricity
total kWh
Average product
1 200
721
1 921
Enervent Pingvin
861
593
1 454
Enervent Pingvin
with Home/Away
808
556
1 364
39
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Data from suppliers
The supplier processes have been accounted for as shown below. All suppliers except PakkausÖhman (a trader) provided answers, however in some cases the data quality or completeness did
not provide sufficient assurance and in these cases other data sources have been used.
Vendor
Materials
Status
Ruukki
Steel, Al line
Data received
Lankapaja
Steel
Partial data received
Brione
Painted steel
Data received
Seamotion, OEM
Motor
Data received
Onninen
Copper parts
Secondary data used (partial data
received)
Noisetek
Insulation
Partial data received
Paroc
Insulation
Data received
Pakkaus-Öhman
Packaging
Secondary data used
Ebm-Papst
Fans
Data received
Dimico
Heat exchanger
Data received
40
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Emission factor data
Below table lists the most important secondary data sources used in the study.
Emission factors
Data point, CO2e
Source of information
Grid electricity
222 g / kWh Finnish average 2004-2008
District heat, Porvoo
115 g / kWh Porvoon Energia
District heat, Finland
210 g / kWh Finnish average 2004-2008
Insulation materials
Paroc
Steel plate
Ruukki
Transport
VTT Lipasto
Copper
Kupfer institut
Various
ICE, Ecoinvent
41
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FASTER GROWTH
WITH ENVIRONMENTAL EFFICIENCY
Bionova Consulting develops performance and
competitive edge from environmental efficiency.
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Contact person:
Mr. Panu Pasanen
+358 44 2871 722
[email protected]
42
www.bionova.fi
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