EGG 2004+ New Materials: Flame Retardants · Dipl.-Ing. K. Lichtenvort Institute for Environmental Engineering EGG 2004+, 6-8 September 2004 in Berlin, Germany EGG 2004+ New Materials:

Dipl.-Ing. K. Lichtenvort

Institute for Environmental Engineering

EGG 2004+, 6-8 September 2004 in Berlin, Germany

EGG 2004+ New Materials: Flame RetardantsEnvironmental and economic implications of a shift to

halogen-free printed wiring boards

Kerstin Lichtenvort, Technical University Berlin, GermanyCarl Gunnar Bergendahl, IVF, Sweden

Glenn Johansson, IVF, SwedenMats Zackrisson, Aspocomp Oy, FinlandJonna Nyysönen, Aspocomp Oy, Finland

www.grEEEn.it

September 7, 2004, 12:30-13:00




grEEEn consortium

Funded by the EuropeanCommission grEEEn is partner of theCARE network

10 Partners representing 5 European countries(Germany, Spain, Sweden, United Kingdom, Italy)

2 University institutes:

2 Research institutes:

4 Industrial partners:

2 Service providers:




grEEEn cost management system

grEEEn target groupEnvironmental experts supporting the product design team

grEEEn method and toolprovideCalculation of resultsl Economic profilel Legal compliance with

WEEE, RoHS, EoLVl Environmental profile

Scenario definition andrecalculation

Design recommendations




Method: grEEEn method

Product andits Life Cycle

Economicprofile

Environmentalprofile

Legalcompliance

End ofLife

Produc-tion Use

Scenarios

Support for DesignDecisions




Method: Process Model

Use

Production

End of life

Research & development

Pre-manufacturing

Manufacturing

Distribution

Operation

Maintenance

Takeback

Life cycle structure Processes within the life cycle

Sorting

Disassembly

Pre-Treatment

Recycling

Disposal

Pre-production

Component production

Material production




Method: Product Model

Pre-production Production Use End of life

Com

pone

nts

Mat

eria

ls

Rawmaterials

usedproduct

Wastenewproduct

Productmodel:

- Components

- Structure

- Materials

Process model

Product Model definitionl Material definition

l Product hierarchy

l Connections/ disassembly operations




Method: Economic Profile

pre-production

pre-production production

production useuse EOLEOL

direct cost direct cost direct cost direct cost

indirect cost indirect cost indirect cost indirect cost

productionproduction

material cost

energy cost

personnel cost

transport cost

machinery cost

revenues, end of life value

disposal cost

…

e.g.

pre-production

pre-production production

production useuse EOLEOL

direct cost direct cost direct cost direct cost

indirect cost indirect cost indirect cost indirect cost


material cost

energy cost

personnel cost

transport cost

machinery cost


disposal cost

…

e.g.


material cost

energy cost

personnel cost

transport cost

machinery cost


disposal cost

…

e.g.

Main costelementsmaterialsenergypersonneltransportmachinery

Supplementarycost elementsservicetoolingstoragetaxes...




Simplified IndicatorsNumber of materialsMassToxicity index

Inventory IndicatorsEnergy consumptionTotal waste generated

Design for RecyclingRate of recoveryRate of re-use and recyclingRate of energy recoveryRecycling efficiency rate

Impact Assessment IndicatorsRaw material consumptionGreenhouse indexOzone depletion indexAggregated single score

Method: Environmental Profile

Eco-indicator 99




Method: Eco-indicator 99 (1/2)

l Consolidation of an LCA Inventory to a single score

l Aggregation based on damage analysis for three damagecategories:

− human health

− ecosystem

− mineral and fossil resources

l Marginal damages concept

l Integration of cultural theory, calculation based on differentperspectives possible (egalitarian, individualist, hierarchist)

l Weighting based on results of a panel procedure among SwissLCA interest group




Method: Eco-indicator 99 (2/2)

NOxSOxNH3PesticidesHeavy metalsCO2HCFCNuclides (Bq)SPMVOC’sPAH’s

Land-use:occupation andtransformation

Extraction of mineralsand fossil fuels

Concentration minerals

Fossil fuel availability (p. type)

Change in habitat size

Changed pH and nutrient avail.

Concentr. Urban, agri, nat. soil

Concentration greenh. gases

Concentr. ozone depl. gases

Concentration radionuclides

Concentration SPM and VOC’s

Concentration in air water, food

Surplus energy for future extraction

Surplus energy for future extraction

Regional effect on vascular plant species

Local effect on vascular plant species

Acidif./eutr. (occurrence target species)

Ecotoxicity: toxic stress (PAF)

Climate change (disease and displacem.)

Ozone layer depl. (cancer and cataract)

Ioniz. Radiation (cancer cases and types)

Respiratory effects (cases and type)

Carcinogenesis (cancer cases and type)

Damage tomineral andfossil resources[MJ surplus energy]

Damage to ecosystem quality [% vacx.plant species*km² * yr]

Damage tohuman health[disability adjusted lifeyears (DALY)]

Indicator

Resource analysisLand-use analysisFate analysis

Exposure andEffect analysis

Damageanalysis

Normalisationand weighting

Source: The Eco-indicator 99 Methodology Report 3rd Edition, Goedkoop & Spriensma, 2001, electronic version downloaded from www.pre.nl




Method: Legal Compliance

100

500

100 60 100 80 100

20

900

600

9001000

0

100

200

300

400

500

600

700

800

900

1000

mas

s in

[p

pm

]

lead mercury cadmium hexavalentchromium

PBB PBDE

restricted substances

Arbitrary background level:

Fulfilled:

Not fulfilled:

No Yes qCompliance with RoHS:




Case Study: Product

ProductTraditional PWBs containing a halogenatedflame retardant vs. PWBs containing a halogen-free flame retardant

Functional unitA PWB production panel containing 54 repeated4-layer laser drilled PWBs for mobile phones

FocusTwo life cycle phasesl The design phasel The manufacturing phase (including pre- production)

Research design




Case Study: Modelling

X = 555 mmY = 610 mmZ = 0,9 mm

Product model

Product consists of copper-foiled laminate, prepreg and copper-foil

Process model

Pressing

Cleaning and hole

metalisation

Desmear-ing

Drilling

Copper and tinplating

Solder Mask

CleaningOxide

protection

Machining Electrical testingFinal inspection

Design

Design Production

EtchingStripping

Depositionof bond oroxide layer

Photo resistExposeDevelop

Photo resistExposeDevelop




Case Study: Scenarios

Process step TraditionalPWB

Design Original process Increased designcycle time

No increase indesign cycle time

Pressing Original process Increased cycletime

Increased cycletime

Drilling Original process Reduction innumber of panelsthat can be drilledat the same time

No reduction innumber of panelsthat can be drilledat the same time

Desmearing Original process Increased cycletime

No increase incycle time

Solder mask Original process Increased cycletime

Increased cycletime

Halogen-free PWB

Worst case Best case




Cost increase in percentage per cost element

Case Study: Economic Profile (1/2)

(a)

0

10

20

30

40

50%

Personnel (Design) Materials Aggregated Personnel/...

(b)

0

10

20

30

40%

Personnel (Design) Materials Aggregated Personnel/...

Worst case (a) and best case (b)




Comparison of cost effects in % between worst case and best case

Desig

nDr

illing

Pressi

ng

Desm

earing

Solde

r mas

k

Lami

nate

Prepre

g

Entry

board

Back

up bo

ard

"Total

cost"

0

10

20

30

40

50

60%

Worst caseBest case

Case Study: Economic Profile (2/2)




Case Study: Environmental Profile (1/2)

Analysis of the environmental profileWorst case (a) and best case (b)

(a)

0

500

1000

1500

2000

2500

3000

0

500

1000

1500

2000

2500

3000

Eco

indi

cato

r 99

(m

Pt)

Traditionalmaterial

Halogen-freematerial

(b)

0

500

1000

1500

2000

2500

3000

0

500

1000

1500

2000

2500

3000

Eco

indi

cato

r 99

(m

Pt)

Traditionalmaterial

Halogen-freematerial

PWBPWB productionMaterial production




Increase in environmental impact. Worst case (a) and best case (b)

Case Study: Environmental Profile (2/2)

(a)

0

510

15

20

2530

35

40

Eco

-indi

cato

r 99

(mP

t)

Copper Laminate Prepreg Drilling Pressing Desmearing Solder mask

(b)

0123456789

Eco

-indi

cato

r 99

(mP

t)

Copper Laminate Prepreg Drilling Pressing Desmearing Solder mask




Conclusions

l The shift to halogen-free material should mean that toxic substancesare eliminated or decreased (the positive effect of this has not beenquantified in the case study due to lack of data).

l This elimination does however lead to slight increases inenvironmental burden in the pre-production and production phases.

l In the ‘worst case’: increase in environmental burden in the productionphase primarily due to the increased energy use during drilling.

l In the ‘best case’: increase in environmental burden is mainly relatedto pre-production phase (material production).

l With increasing manufacturing volumes the materials cost for halogen-free laminates is expected to decrease.

l Cost ranging between nearly zero and 10 € per panel.

Documents

EGG 2004+ New Materials: Flame Retardants · Dipl.-Ing. K. Lichtenvort Institute for Environmental Engineering EGG 2004+, 6-8 September 2004 in Berlin, Germany EGG 2004+ New Materials: