Tutorial Umberto Nxt

Transcript

Umberto® NXT (v7.1) Tutorial 1 ifu Hamburg GmbH Max-Brauer-Allee 50 22765 Hamburg / Germany www.ifu.com DocVersion: 2.5 Date: October 2014 Publisher: ifu Hamburg GmbH http://www.umberto.de ifu Hamburg GmbH Umberto NXT ® Umberto is a registered trademark of ifu Hamburg GmbH Microsoft and MS are registered trademarks. Windows and Excel are trademarks of Microsoft Corp. Other brand and product names are trademarks or registered trademarks of their respective holders. Information in this manual is subject to change without notice. No liability for the correctness of the information in this manual. All figures are for demonstration purposes only and contain fictitious data. Reproduction or translation of any part of this manual in any form (electronic or mechanic) without prior written permission of the copyright owner is unlawful. Requests for permission should be addressed to ifu Hamburg GmbH, Hamburg, Germany. ifu Hamburg GmbH Umberto NXT Tutorial 1:Umberto NXT Simple Example Time: 1 h Pages: 20 Level: New User Requirements: none What you will learn: • • • • • • • Umberto NXT work area and window handling Create a project, a model and a first process Specify a process Calculate a small model View the calculation results Create Sankey diagrams Use the Module Gallery Tutorial 2a: U NXT LCA/UNIV Tutorial 2b: U NXT EFF/UNIV Time: 1-2 h Pages: 40 Level: Beginner Time: 3-4 h Pages 40 Requirements: Tutorial 1 or experience with Umberto 5 for Life Cycle Assessment and general knowledge about LCA Requirements: Tutorial 1 or experience with Umberto 5 Level: Beginner What you will learn: • Working with activity datasets • Product life cycle phases • LCA calculation and results • Disposal and transport activities • Function and parameters • Group-By Box • Material type • Calculation log What you will learn: • User defined process specification • Create subnets • Analysis of input/output inventory • Function and parameters • Cost accounting for MFA • Allocations • Generic materials • Co-products • Sankey diagrams • Advanced Features Tutorial 3: U NXT LCA/UNIV Tutorial 4: U NXT UNIV Time: 1-2 h Pages: 48 Level: Advanced Time: 1-2 h Pages: 15 Level: Advanced Requirements: Tutorial 1 and 2 or experience with Umberto 5 for Life Cycle Assessment and knowledge about LCA Requirements: Tutorial 1 and 2 for LCA and Efficiency and 3 or experience with Umberto 5 for Life Cycle Assessment and knowledge about LCA What you will learn: • Allocations • Generic materials • Set multiple virtual reference flows • Co-products • Working with functional units • Sankey diagrams • Results by products • Print and export results • Advanced Features Tutorial 1 What you will learn: • Integrate costs LCA • Material Mapping • Calculate Selection Page 1 ifu Hamburg GmbH Umberto NXT Introduction Welcome to the tutorial section of Umberto NXT. It is divided into five independent tutorials of increasing complexity. Each tutorial has its focus on a different topic. The first tutorial introduces the basic features of Umberto NXT. The four following tutorials provide more complex modeling and information about advanced features. The first tutorial gives an introduction on how to create a basic model as well as the handling of general settings. This is done by using a simple example. In the second tutorial for LCA the focus is set on the creation of a model for a Life Cycle Assessment. It is shown how to work with a database and how to use different impact assessment methods. In the second tutorial for Efficiency the focus is set on cost accounting and efficiency analysis. Part of both second tutorials is also to visualize the results via Sankey diagrams. The third tutorial for LCA has its main focus on more advanced topics of Life Cycle Assessment. It provides additional information about useful features of Umberto NXT LCA and gives further modeling hints. The fourth tutorial for Universal has the main focus on the integration of costs into LCA and therefore required material mapping. For further information about the functions covered in this tutorial have a look at the Umberto NXT LCA User Manual. The user manual can be accessed directly in the software via the Help menu. Page 2 Tutorial 1 ifu Hamburg GmbH Umberto NXT Tutorial 1: Simple Network Model This tutorial covers th he basic handling of Umberto NXT. It is s also shown how to create a first simplle model. Therefore, the tutorial sta arts with a simple example which is n not exemplary for a typical LCA orr MFA calculation. Nevertheless it succe essfully demonstrates the basics of how w to work with the software Umberto NX XT. Content • • • • • • Umberto NXT worrk area and windows Create, rename orr delete a project, a model, a module and a material Create, rename orr delete a net element Building up a grap phical network model Calculate a network model Analyzing calculattion results Getting Started The first thing that appears after opening Umberto NXT is tthe start page. This page offers some iinformation about the software and provides links to commands for creatiing a new Umberto project file as well ll as to opening the example project files of this tutorial. In Umberto NXT the topmost data structure is a project file e. A project file is a database where the models and materials are stored in. Several S models can be created in one p project file. A model typically contains one network for calculation. Every ma aterial defined in a project can be use ed for every model within one project. All change es made while working on a project arre instantly written in the pro oject database. Therefore, it is not nec cessary to actively save the working w progress. Before a model can b be created a new Umberto project file needs to be opened. There are three ways s to do that. Either, follow the link 'Ne ew Umberto Project File' on the start pag ge, or navigate to 'File' in the menu bar b and choose the entry 'New'. The third d possibility is to click on the 'New Proje ject File' button in the main toolbar at th he top. A file save dialog will ll be shown asking whether to save the e project file on the hard disk. Please find d an adequate name for the Umberto project p file, such as 'Tutorial 1'. Now that a new projject file has been opened, the graphical user interface of Umberto NXT shows the workspace: There are four windows s on the screen. Tutorial 1 Page 3 Umberto NXT ifu Hamburg GmbH Figure 1: Graphical User Interface of Umberto NXT LCA The largest window is called 'Net Editor'. The net editor allows for creating a graphical model. The window pane on the top left is the so called 'Project Explorer'. It shows all models and materials which are contained in the respective Umberto project file. At the bottom left there is the 'Property Editor' window pane. The first information on the top of this window shows the type and name of the selected element. Further properties of this element are also displayed and can be edited here. Below the net editor the 'Specification Editor' is located. It allows for specifying the elements of the model. This pane is also used to show the calculation results. Since no network has been created yet, the specification editor is empty. A model can be renamed by selecting it within the Project Explorer. Navigate to the property editor, type a new name into the name field and confirm by pressing the return key or by simply leaving the field. Page 4 Tutorial 1 ifu Hamburg GmbH Umberto NXT To create a new model within the current projec ct, select the folder 'Models' in the Project Explorer and choose 'Ne ew Model' from the context menu, m which can be opened by the right mouse click. Otherwise e press the 'New Model' button in th he Project Explorer toolbar. Creating a Network Model After having created a new project and a new model, pleas se start to build the first network model. In this example processes that supply a system reference flow in a simple pro oduction chain will be developed. Therre will be an input material which will be e processed in two production steps. Start by clicking on the t process symbol in the toolbar of the net editor. The cursor changes to a cross, indicating that the design mode is active. Next, click in the middle off the net editor to draw the first process s. To draw several elements in a row without e exiting the editing mode, do ouble-click on the desired element in the toolbar. After double-cli licking on an element a small pin is sh hown in the button icon indicating that multiple elements can be crreated → . To exit the multi-draw mode, use the right mouse b button. Name the process by y clicking the process's text label locatted right below the process. Navigate to the property editor and enter the name 'Process 1' in the field 'Text'. It is also o possible to change a text label by clicking on its text while it is selected. Apply the change by hitting the tab key or by clicking elsewhere in the net editor. Figure 2: A first process The process will need an input place and an output place. Choose the input place (symbol with h a green line and a vertical trace on th he left) and place it left of the process b by clicking there. Then, select the outtput place from the toolbar (symbol wiith a red line and a vertical trace on the e right) and place it on the right side off the process. Name the elements 'In nput' and 'Output', respectively. Tutorial 1 Page 5 Umberto NXT ifu Ha amburg GmbH Another way to c create elements is to use the 'Draw' menu and to select the desired d element. Alternatively, choose 'Draw w' from the context menu wh hich pops up by right clicking on the area a of the model editor. The next step is to connectt the three elements with arrows, on n which the materials or substances flow w into the process and out of the pro ocess. As a general rule, places always s connect to a process, and proces sses always connect to a place. Never does an arrow connect a place directly to another place, or a process directly to o another process. To connect the input place to o the process with an arrow, click the arrow button in the toolbar. Place the cursor over the input place. When a grey filling appears, drag the cursor on nto the process symbol (keeping the left mouse button pressed). Watch the e arrow emerging from the element.. When the cursor comes close to a con nnectable target element, the arrow sn naps to this element automatically as the e mouse button is released: the two ellements are now connected with an arrow w leading from the input place to the prrocess. In the same way, draw an arrow from the process to the outputt place. The first very simple network model should now look like Figure 3 below. Figure 3: A process with inputs and d outputs, the start of a process chain The process shows a small rred warning sign. This means, that the e process is unspecified. The function 'Sna ap to Grid' in the net editor's toolb lbar can be used to easily ali lign elements. By default, this feature is enabled which is indicated d by a blue square around the symbol.. To disable this feature, clic ick on the symbol and the blue s square will disappear. The grrid to which the elements are aligned can c also be enabled and disab bled by using the 'Show Grid' button . Page 6 Tutorial 1 ifu Hamburg GmbH Umberto NXT Defining Materials ls To specify a process,, it is necessary to add materials to the e process as inputs or outputs, and to specify their quantitative relationship. Depending on the Ve ersion Umberto NXT may come with a large database of materials (master material data from ecoinvent v3) whic ich can be used to create LCA models. However, H in this example it is demonstrrated how to create new materials. Materrials are categorized into material groups. Material groups are shown as folders in the Project Explorer. The material group 'Project Materials' contains all materrials used within a project. In the Projec ct Explorer select the folder 'Project Matterials'. Press the 'New Materrial' button in the Project Explorer's s toolbar or use the context menu to crea ate a new material. Figure 4: Project Explorerr The properties of the e material are managed in the Propertties editor (situated below the Project Ex xplorer). Rename the material to 'inpu ut material'. At this stage of the tutorial tthere is no need to change other materrial properties. Create a second mate erial entry named 'product'. Tutorial 1 Page 7 Umberto NXT ifu Ha amburg GmbH Figure 5: Property Editor Material groups and sub groups can be created by s selecting a directory for the group within the Project Explorer an nd pressing the 'New Materiial Group' symbol on the Projectt Explorer's toolbar. Another option is using the context menu to crreate a new material group by pressing the right mouse button n. Material groups are usefull for large projects with a variety of materials. A material group can be named and renamed by selec cting it and editing the name field within the Property Editor. Page 8 Tutorial 1 ifu Hamburg GmbH Umberto NXT Specifying Proces ss To specify the proces ss with input and output material entrie es, click the process in the net editor. When a process is selected, the Specificattion pane below the net editor shows two o sections: the left section for the inp puts of the process and the right section for its outputs (see Figure 6). Materials from the material's list can easily be added to the t input or output side using drag&drop p. Click and hold the left mouse butto ton on the material 'input material' in the e 'Project Materials' group and drag it tto the input section of the specification e editor. When a little square with a plus s sign appears near the cursor, release th he mouse button. Then, the material is s added to the input section of the process s. Proceed the same way with the material 'product' and ad dd it to the output section of the process s. Materials can also be added to a process by usin ng the button at the bo ottom of the Specification editor belo ow the table. This button prrompts a dialog which allows searching for materials by group, name, display unit and source. As there is still a warning marker on the process element,, the process is still not fully specified. It is necessary to determine the ratio between the input and output materials. This can be done by adding coefficien nts to the materials in the specification pa ane for this process. In this first illustratiive example the quantity of the input material and the quantity of the outpu ut material (product) are defined equa al. This means that there are no addition nal inputs or outputs (e.g. losses, reje ect). It is, however, not required to spec cifically enter a coefficient "1", becau use the actual flow quantity is determin ned in each calculation by the actua al process level or quantity of the prod duct being produced. Hence, the proc cess specification is nothing more than a "recipe" that is linearly scaled up or down. For the sake of simplicity, enter a coefficient of '1.00' for f both, the input material and the prod duct. The unit is 'kg' for both entries, so that no material is lost, and the process is mass-balanced. Figure 6: Process specifica ations Tutorial 1 Page 9 Umberto NXT ifu Ha amburg GmbH After entering the coefficients the process is specified and the warning sign disappears. Alternatively a co oefficient of '100' could be entered on both sides to obtain a ratio of 1:1. The possibility to enter any coe efficients is very helpful in c case of unknown values of a proces ss. E.g.: a process requires 70 kg of input material to produce 120 0 kg output material. Both values can be written in the specifica ation editor instead of calculating the ratio. Note that adding the materi rial on the output side results in a cha ange of the respective font to bold and of the 'Material Type' to 'Reference Fllow'. This is because the product is con nnected to a system output place and therefore leaves the system. Any prroduct that leaves the system is co onsidered a reference flow and is assum med to be (one of) the functional unit(s) of the network. For further inforrmation about the topics of reference flows and functional units in i Umberto NXT have a look at the Um mberto NXT User Manual. Th he user manual can be accessed dire ectly in the software via the Help menu. Expanding the Model In this example the process labeled 'Process 1' needs electricity to process the input material to the (intermediate) product. Enter a new input place ab bove the process and connect it to the th process. Name the new input place 'E Energy'. To avoid the arrow crossing through t the name label of the input plac ce simply drag the label to another po osition, e.g. above the place. Figure 7: The expanded model with h an energy input to Process 1 A material entry for the inc coming energy has to be added to th the process. Insert a new material entry called “electricity, high voltage” and make sure to choose “Energy” as unit type e. Page 10 Tutorial 1 ifu Hamburg GmbH Umberto NXT The field 'Place' in the specification editor now shows three question marks for the newly added material. The reason for that is that there are now two input places for the process. Click the field 'Place' and choose the right input place for the newly inserted flow. Next, add a coefficient for the entry 'electricity, high voltage'. Let us say the process requires 0.5 MJ of electricity to produce 1 kg of product. Change the unit of the electricity in the specification editor to MJ and enter a coefficient of '0,5'. A comma (',') is used as the decimal point. Type '0,5' not '0.5' for the coefficients in the process specification window. Otherwise a message will be prompted to confirm the right value. Figure 8: Specification of 'Process 1' with electric energy input The first process of the exemplary production network is complete by now and will be the basis for the first network calculation. Calculating the Flows of the Model The network is specified and almost ready to be calculated. In order to calculate the network a starting point for the calculation has to be defined. In Umberto this is the so-called 'manual flow'. A manual flow determines the process level, or, in other words, how much of a product is actually produced. This can be one unit of the product (e.g. with a weight of 500 grams), but also, for example, the yearly production output of a process (e.g. 250 tons). Such a manual flow is entered in an arrow. In most cases it is the output flow at the end of the process chain, but a manual flow can also be placed as an internal flow anywhere else within the network. To set the manual flow in the network, select the arrow between Process 1 and the output place: From the list of materials in the Project Explorer drag Tutorial 1 Page 11 Umberto NXT ifu Ha amburg GmbH the entry 'product' to the Specification S pane (make sure the arrrow is still selected!). Next, the quantity of the ma anual flow has to be defined. Enter 100 kg as the quantity of the manual flow, for example. Watch the arrow turn purple indicating that this is where the manu ual flow that triggers the model calculation has been entered. The network is no ow ready to be calculated. Figure 9: Arrow specification for a manual m flow To calculate the flows of th he model open the dropdown menu n next to the 'Calculate' button in the ne et editor toolbar and choose 'Calculate Total Flows' from this menu. Alternative ely, choose the command 'Calculate T Total Flows' from the 'Calculation' menu in i the main toolbar. After a successful calculation n all arrows change their color from grrey to black (except for the manual flow, which stays purple). Additionally a n new tab will open up in the Specification pane at the bottom. It lists all materia ials entering the processes of the mode el with their quantity on the left sid de, and the exchanges leaving the system m on the right side. Figure 10: Input/Output Inventory Note that at this stage of the tutorial and with a very basic model, this inventory only contains a fe ew entries. But the same procedure is applied for models that are much more c complex.. Expanding the Model The model will now be expan nded. First, change the type of the e output place to connection. This can be done by activating the output place a and choosing the type 'Connection' in tthe Property Editor. Page 12 Tutorial 1 ifu Hamburg GmbH Umberto NXT Figure 11: Property Editorr for the place Now add another pro rocess to the right of the new connecttion place. Activate the label of this proce ess and rename it to 'Packaging'. Add an output place e to its right and connect the 'Packag ging' process to it. Apart from the conn nection to 'Process 1', the packaging g process needs a further input place from where the packing material, namely boxes, is delivered. The modell should now look similar to Figure 12. Figure 12: Expanded proc cess model Tutorial 1 Page 13 Umberto NXT ifu Hamburg GmbH Note, that the former output place (P2) is not a system boundary any more, but lies in the middle of the model. If desired, rename the place P4 to 'Box of 12 units' and remove the label 'P2 Output' by unchecking 'Display ID' and 'Display Text Label' from the Properties pane of the connection place (compare to Figure 11). The packaging process is still not specified. To do so, some additional flows (materials) are required: Add two new materials to the 'Project Materials' group named 'packaged product' and 'corrugated board box'. Both materials have the unit type Mass (kg), and both do have the material type 'Good'. Next, add the material 'product' to the input side of the packaging process. Add the material 'packaged product' to the respective output side. The 'corrugated board box' is another input material. Imagine that the weight of the carton board box for 12 units of product amounts to 600 grams. One product has a weight of 250 grams. Hence, the total weight of 12 units of product adds up to 3 kg. The filled box including the packaged products has a total weight of 3,6 kg. There are two ways of specifying the packaging process. The first way is to work with the total weight of 12 units that are packaged in one box. Figure 13: Alternative process specification for the packaging: per 12 units… Alternatively, the weight of the 'corrugated board box' input can be scaled to one unit (600 grams weight divided by 12 units = 50 grams per unit). The field 'Function' can be used to type in a formula, and to determine the coefficient value. Type 0.25+0.6/12 in the 'Function' field, which will convert to '0,30' kg. Page 14 Tutorial 1 ifu Hamburg GmbH Umberto NXT Figure 14: …or per one unit Note that it is not important which way the process is specified, as long as the relation between the flows remains the same. The actual flow quantities are determined during the calculation of the full model only, and depend on the quantity of the manual flow entered for the model calculation. Analyzing the Results After specifying the packaging process, calculate the model once again. For the calculation to work usually only one manual flow in the network has to be defined. This manual flow does not have to be located in an arrow that leads to an output place, but can also be placed elsewhere within the model. Only the 'Total Flows' (SHIFT+F9) need to be calculated. At this stage only the actual physical flows (material and energy flows) related to the process system are considered. Figure 15: Inventory of the process model, including a production and a packaging process Sankey Diagrams Next to the calculation button in the network editor toolbar there is the button for the Sankey diagram mode. With this button the Sankey visualization can be switched on or off. Once a network has been calculated it is possible to visualize all material flows with Sankey arrows. Sankey diagrams have been invented by Cpt. Sankey in the late 19th century. He used them to visualize the energy (in-)efficiency of steam engines. Each arrow width corresponds to the flow quantity, so that an increase of a quantity by 50% leads to a Sankey arrow with a 50% wider arrow magnitude. If the Sankey mode is not enabled use the Sankey button to switch it on. The model in the Sankey diagram mode should now look similar to the figureFigure 16 below. Tutorial 1 Page 15 Umberto NXT ifu Ha amburg GmbH Figure 16: Sankey diagram of the model m with arrows displaying the flow quantity In the Properties pane a ttab called 'Scaling of Sankey Diagram ms' is now available. Bring the respectiv ive tab to front and scale the Sankey arrows up or down. Each unit type (here: Mass and Energy) can be scaled se eparately or even switched off so that im important information can be highlighted without overloading the image. Figure 17: Scaling of Sankey Diagra am Please notice that the arrow representing the flow of 'corrugated board box' from the place 'Packaging Materials' to the 'Packaging' process doe es not show a spike. Hence, it is not expli licitly clear in which direction the flow ru uns. To visualize even small arrow w spikes, turn on the option 'Spikes for arrows up to:' with a value of 5 px. Orr, activate the option 'Always draw arrrow spikes'. Both options are available in n the Properties pane of the net diagram m. To bring it to front, click on an emp pty area of the Net Editor, or use the e command 'Properties' from the contextt menu of the net editor area. Page 16 Tutorial 1 ifu Hamburg GmbH Umberto NXT Figure 18: Setting arrow spikes s Once the arrangemen nt of the model and the scaling of the e arrows is done, it can be copied (CTRL L+A to select all, CTRL+C to copy) to o the clipboard and pasted to other appli lications. This way, actual representatio ions of a model can quickly be added to a PowerPoint presentation or a report. Using the Module Gallery In the next step a process will be copied to the 'Mo odule Gallery' and afterwards be pasted to the same or another model. The Modu ule Gallery in Umberto allows storing a model or a part of a model as a a module. Stored modules can be us sed in every model of any pro oject by dragging it from the Module Gallery onto the net editor dire ectly. Go to the Project Exp plorer and bring the tab Module Gallery y to front (tabs are located at the bottom m of this pane). Select the Folder 'Modules' and press the 'Create Module Group' button in the Module Gallery too olbar. Alternatively, use the context menu u. Rename the module group to 'Tutorial' by using the 'Rena ame Module Group' button from the to oolbar or the associated command from the context menu. Tutorial 1 Page 17 Umberto NXT ifu Ha amburg GmbH Select the process 'Process 1 1' in the net editor and click the copy b button on the main toolbar. Note that when w copying a process all adjacent pllaces will be selected and copied, too. Instead of using g 'Copy', 'Cut' and 'Paste' commands s the wellknown shortcuts 'CTRL+C', 'CTRL+X' and 'CTRL+V' ca an also be applied. Mark the module group 'Tutorial' in the Module Gallery and use e the 'Paste Clipboard Data to Module G Group' button in the Module Gall llery toolbar (alternatively use the context menu). Notice a preview thumbnail a and the name of the module in the botttom section of the Module Gallery. To cha ange the name of the module select it a and use the 'Rename selected Module' bu utton (compare to Figure 19). Rename the module to 'Simp ple Process'. Figure 19: Module Gallery Now, that there is a basic p process with adjacent places stored in the Module Gallery that module can be c copied into the existing model. Select the module and copy y it to the net by using the 'Copy mod dule to net' button . Or simply add it to the model by using drag&drop. Clic ick and hold the left mouse button on the module and drag it to the net editor arrea. Page 18 Tutorial 1 ifu Hamburg GmbH Umberto NXT The comm mand copy&paste can also be used within a model. For didacticall purposes the copied net model section has been copied to the Module Gallery at first. Figure 20: Copying a mod del section to the Module Gallery, and retrieving it again. The newly inserted model section can now be connecte ted to the existing structure. The proce ess specification may of course have to be adapted to account for the additi tional input of product from the other prrocess chain. Merge the connection n place with the connector plug symboll by dragging it onto the existing connectio ion place. Note that the manua al flow that had been entered on the o output arrow of the process section befo ore it was stored to the Module Galllery has not been maintained. To make e the newly inserted process section calculate properly, enter a manual flow ''product' with a quantity (e.g. "100 kg"") in the arrow that leaves the copied pro ocess and is linked to the connection pla lace. The small tutorial mo odel has two production lines now, wh hich each deliver a certain product quan ntity. The outputs of both are going g to the packaging process. Tutorial 1 Page 19 Umberto NXT ifu Ha amburg GmbH Figure 21: The newly inserted model section has been connected by merging the places p It is possible to return to the e previous stage of the model (without the t inserted second supply chain) by click king the 'Undo' button as often as neces ssary. For further inform mation about the functions covered in tthis tutorial have a look at tthe Umberto NXT User Manual. The us ser manual can be accessed directly in the software via the Help me enu. Thank you for completing Tutorial 1. Please continue with Tu utorial 2 to discover more practical featu ures of Umberto NXT. Page 20 Tutorial 1 Umberto® NXT (v7.1) Tutorial 2a LCA ifu Hamburg GmbH Max-Brauer-Allee 50 22765 Hamburg / Germany www.ifu.com DocVersion: 1.50 Date: October 2014 Publisher: ifu Hamburg GmbH http://www.umberto.de Umberto® is a registered trademark of ifu Hamburg GmbH Microsoft and MS are registered trademarks. Windows and Excel are trademarks of Microsoft Corp. Other brand and product names are trademarks or registered trademarks of their respective holders. Information in this manual is subject to change without notice. No liability for the correctness of the information in this manual. All figures are for demonstration purposes only and contain fictitious data. Reproduction or translation of any part of this manual in any form (electronic or mechanic) without prior written permission of the copyright owner is unlawful. Requests for permission should be addressed to ifu Hamburg GmbH, Hamburg, Germany . ifu Hamburg GmbH Umberto NXT Tutorial 1: Umberto NXT Simple Example Time: 1 h Pages: 20 Level: New User Requirements: none What you will learn: • • • • • • • Umberto NXT work area and window handling Create a project, a model and a first process Specify a process Calculate a small model View the calculation results Create Sankey diagrams Use the Module Gallery Tutorial 2a: U NXT LCA/UNIV Tutorial 2b: U NXT EFF/UNIV Time: 1-2 h Pages: 40 Level: Beginner Time: 3-4 h Pages 40 Requirements: Tutorial 1 or experience with Umberto 5 for Life Cycle Assessment and general knowledge about LCA Requirements: Tutorial 1 or experience with Umberto 5 Level: Beginner What you will learn: • Working with activity datasets • Product life cycle phases • LCA calculation and results • Disposal and transport activities • Function and parameters • Group-By Box • Material type • Calculation log What you will learn: • User defined process specification • Create subnets • Analysis of input/output inventory • Function and parameters • Cost accounting for MFA • Allocations • Generic materials • Co-products • Sankey diagrams • Advanced Features Tutorial 3: U NXT LCA/UNIV Tutorial 4: U NXT UNIV Time: 1-2 h Pages: 48 Level: Advanced Time: 1-2 h Pages: 15 Level: Advanced Requirements: Tutorial 1 and 2 or experience with Umberto 5 for Life Cycle Assessment and knowledge about LCA Requirements: Tutorial 1 and 2 for LCA and Efficiency and 3 or experience with Umberto 5 for Life Cycle Assessment and knowledge about LCA What you will learn: • Allocations • Generic materials • Set multiple virtual reference flows • Co-products • Working with functional units • Sankey diagrams • Results by products • Print and export results • Advanced Features Tutorial 2a What you will learn: • Integrate costs LCA • Material Mapping • Calculate Selection Page 1 Umberto NXT ifu Hamburg GmbH Introduction Welcome to the tutorial section of Umberto NXT. It is divided into three independent tutorials of increasing complexity. Each tutorial has its focus on a different topic. The first two tutorials introduce the basic features of Umberto NXT. The third tutorial provides more complex modeling and information about advanced features. The first tutorial gives an introduction on how to create a basic model as well as the handling of general settings. This is done by using a simple example. In the second tutorial the focus is set on the creation of a model for a Life Cycle Assessment. It is shown how to work with a database and how to use different impact assessment methods. Part of the second tutorial is also to visualize the results via Sankey diagrams. The third tutorial has its main focus on more advanced topics of Life Cycle Assessment. It provides additional information about useful features of Umberto NXT and gives further modeling hints. To be able to learn how to use Umberto NXT, the examples presented in the three tutorials are designed to be independent of LCI databases that require a license. Hence, the activity datasets used in the tutorials 2 and 3 are sample datasets with fictitious values that can be used even without having access to ecoinvent data. For more information about the functions covered in this tutorial have a look at the Umberto NXT User Manual. The user manual can be accessed directly in the software via the Help menu. Page 2 Tutorial 2a ifu Hamburg GmbH Umberto NXT Tutorial 2: Whiteboard Marker This tutorial is based on the experience already gained in accomplishing tutorial 1 of Umberto NXT. In this second tutorial a more complex network for a real life product – a whiteboard marker will be created. Working on this example further functionalities of Umberto NXT will be introduced that support Life Cycle Assessment studies. In the course of the example it will be demonstrated how to work with life cycle inventory (LCI) databases, and how to use them to find life cycle inventory data for upstream chains of raw materials. The "whiteboard marker" example is based on trial datasets which contain fictitious values only. Hence, the results of the LCA conducted in this tutorial are not applicable. Please note, that the number of available datasets in the trial version of Umberto NXT is limited to suit the examples of the tutorials. The complete ecoinvent database is merely part of a full license of Umberto NXT. Contents • • • • • • • • • Project overview Working with activity datasets Modeling a life cycle network Integrating product life cycle phases Calculation options for the LCI Using different LCIA factors Visualisation of material flows with Sankey diagrams Export of results Modeling of scenarios Preparation In order to work on this tutorial, tutorial 1 should have been completed. Users who are working on this tutorial without holding an ecoinvent license (such as the users of the 30-day trial version) will find all required datasets in a separate database called "Tutorial Example" with a group "Tutorial Activities". These datasets have fictitious values only. Please do not use the trial version datasets for operative, actual LCA studies. When working with a licensed version of Umberto NXT including the ecoinvent database, all activity datasets needed, can be found in the master databases shipped with the software. The following table lists the free trial datasets and their corresponding actual datasets from the ecoinvent database. Users holding an ecoinvent database Tutorial 2a Page 3 Umberto NXT ifu Hamburg GmbH license may use ecoinvent data instead of trial data. However, please be aware that the screenshots and results of the whiteboard marker example always refer to the trial datasets. Table 1: Trial datasets used in example of tutorial 2 and corresponding ecoinvent 3 activities. tutorial/trial dataset name ecoinvent activity dataset name starch biopolymer production (ifu tutorial dataset) [RER] polyester-complexed starch biopolymer, production [RER] ethanol production from maize (ifu tutorial dataset) [GLO] ethanol, 95 % solution state, from fermentation [GLO] polypropylene production, granulate (ifu tutorial dataset) [RER] polypropylene production, granulate [RER] injection moulding (ifu tutorial dataset) [RER] injection moulding [RER] extrusion, plastic pipes (ifu tutorial dataset) [RER] extrusion production, plastic pipes [RER] electricity, medium voltage (ifu tutorial dataset) [NL] market for electricity, medium voltage [NL] transport, lorry 16-32 ton, EURO5 (ifu tutorial dataset) [RER] transport, freight, lorry 16-32 metric ton, EURO5 [RER] treatment of waste polypropylene, MSWI (ifu tutorial dataset) [CH] treatment of waste polypropylene, municipal incineration [CH] treatment of waste plastic mix, sanitary landfill (ifu tutorial dataset) [CH] treatment of waste plastic, mixture, sanitary landfill [CH] Note: the suffix in square brackets indicates the geography: GLO = global, RER = Region Europe, CH = Switzerland, NL = Netherlands Page 4 Tutorial 2a ifu Hamburg GmbH Umberto NXT Project Overview This tutorial's example focuses on the life cycle of a whiteboard marker. The example has been simplified for the purpose of this tutorial. Figure 1: Picture of the whiteboard marker The whiteboard marker is mainly made of a polypropylene tube with a cap made of the same plastic (PP). The marker has a felt tip made of a biopolymer and uses ethanol based ink1. In the manufacturing process the whiteboard marker is assembled by using preproduced plastic pipes made of polypropylene. For the sake of simplicity, tube and cap are not distinguished at first but handled as one component of the whiteboard marker. One whiteboard marker has a total weight of 20.75 g: it consists of 13.55 g of plastic, 4.0 g of felt tip made of biopolymer and 3.2 g of ethanol. After the assembly four whiteboard markers are packaged together in a polypropylene box and shipped to the retail locations. In the use phase – as the user writes a certain amount of text – the whiteboard marker is emptied and the ethanol of the ink is released into the atmosphere. After the use the whiteboard marker is disposed of, disassembled and incinerated (see Figure 2). 1 The example in this tutorial is fictitious and has been simplified for training purposes. It does not resemble the real production chain of a whiteboard marker. The example is used to illustrate the workflow of a life cycle assessment and to introduce the features of the software. Tutorial 2a Page 5 Umberto NXT ifu Hamburg GmbH Figure 2: Simplified life cycle model Using the Activity Database In tutorial 1 the 'Project Explorer' has already been used to create and change materials and to add them to the process specification. One branch of the project tree is called 'tutorial example'. In addition to creating new project materials, in this example, material data from the included database will be used. Even without holding a valid license for the ecoinvent database, there are still two branches of the project tree called ecoinvent 2.2 and ecoinvent 3. In the course of this tutorial free materials from the ecoinvent 3 database will be used. The respective data can be found in the project tree under ecoinvent3/Exchanges/Intermediate Exchanges. A short introduction to the structure and content of databases in Umberto NXT will be given at this point. For more detailed information please have a look at the Umberto NXT User Manual. Users holding a licensed version, including the ecoinvent database, can also obtain further information on the ecoinvent web page2. Data(sets) of the tutorial example branch are subdivided in two main categories: 'Activities', which are clustered in groups by their production processes or processes of origin and 'Exchanges' (flows). 2 ecoinvent is the most comprehensive database for LCI available. All data derive from scientific LCAs reviewed by the ecoinvent centre http://www.ecoinvent.org/database/ Page 6 Tutorial 2a ifu Hamburg GmbH Umberto NXT Figure 3: Grouping of datasets in the Project Explorer and sample of properties for one tutorial dataset (activity), e.g. 'aluminium primary, cast alloy (ifu tutorial dataset) [GLO]' Tutorial 2a Page 7 Umberto NXT ifu Ha amburg GmbH When choosing an activity from the project tree, the 'Propertie es' explorer shows the 'Available Activity Sets' as well as some general informa ation on the activity. 'Exchanges' can be either 'Elementary Exchanges' or 'In ntermediate Exchanges'. Elementary exch hanges are materials typically crossing the system boundaries. Therefore, they appear in the Input/Output inventorie es, after the process model is calculate ed. Examples for Elementary Excha anges are: unprocessed inputs from natu ture or emissions to air, water and soil. Intermediate materials, are generally only used within the system boundaries and do not have associated d impact assessment factors. These in intermediate materials are the outputs of a technical activity, i.e. reference flow,, input flow. In Umberto NXT all materials have a 'Material Type'. This property classifies the matterials. Materials with the material type e are expenditures of raw materials, intermediate products or auxiliary materials. The prroducts of any process also have the m material type . Direct e emissions as well as wastes caus sing indirect emissions (like w waste being transported to the landfilll) obtain the material type . Materials which should not contrribute to the life cycle inventorries are marked with the material type . Page 8 Tutorial 2a ifu Hamburg GmbH Umberto NXT Getting Started Start this tutorial with the creation of a new project using the 'New Project' icon on the menu bar. Give the project an adequate name, for example 'Tutorial 2 – Whiteboard Marker'. A first model template named 'Model' with a drawing editor is already open. After selecting the model in the Project Explorer, it can be renamed in the 'Properties' window. Call the first model, for example, 'Whiteboard Marker 1'. Assembly Process The processes of the manufacturing phase are usually best known in detail and most data is available for this life cycle phase from primary sources. Therefore, the modeling of this example will start with the manufacturing phase of the whiteboard marker. The whiteboard marker is not sold individually, but four whiteboard markers are packed together in a plastic box. On these grounds, the manufacturing process consists of the following main steps: the assembly of the marker, the production of the plastic box and the packaging of the markers. The whiteboard markers are made of plastic tubes; in this example they are called 'marker shells'. Apart from the marker shell, each whiteboard marker is protected with a cap which is also made of plastic. The production of the marker shells takes place in an extrusion process; whereas the marker cap and the plastic box are shaped in an injection moulding process. For all three parts, polypropylene (PP) granules are used. The ink of the whiteboard marker is based on ethanol and its felt tip is made of biopolymer. Tutorial 2a Page 9 Umberto NXT ifu Hamburg GmbH Table 2: Materials used for the production of the whiteboard marker Materials used in the Whiteboard Marker Production Material name Source of material Use of material Ethanol, without water, in 95% solution state, from fermentation Polyester-complexed starch biopolymer Electricity, medium voltage Whiteboard marker Ecoinvent Intermediates Assembly Ecoinvent Intermediates Assembly Ecoinvent Intermediates Project Material, defined by user Project Material, defined by user Project Material, defined by user Ecoinvent Intermediates Ecoinvent Intermediates Assembly Assembly / Packaging Marker shell Marker cap Extrusion, plastic pipes Polypropylene, granulate Injection moulding Plastic box Packaged markers Ecoinvent Intermediates Project Material, defined by user Project Material, defined by user Assembly / Extrusion marker shell Assembly / Cap moulding Extrusion Marker Shell Extrusion Marker Shell / Box Production Box production Box production / Packaging Packaging Begin by dragging a process symbol onto the editor area. Name the process 'Assembly', add a connection place to the left hand side of the process and another one to its right hand side. Connect the symbols with each other by drawing arrows. Since the assembly process is not specified yet, a red circle with a white cross shows up in the process symbol (see Figure 4). Figure 4: First process of the whiteboard marker model Start to specify the assembly process: Create the material 'whiteboard marker' (display unit: 'kg', material type: 'Good'). Once created, add the material to the output side of the assembly process using drag&drop. This is the main product being studied in this LCA. Furthermore, create the materials 'marker shell' and 'marker cap' (display unit: 'kg', material type: 'Good') and add them to the input side of the 'Assembly'. For the additional materials on the input side, we will be using predefined flow names (exchanges) from the ecoinvent 3 material master data shown in the Project Explorer. Page 10 Tutorial 2a ifu Hamburg GmbH Umberto NXT In order to find the material 'polyester-complexed starch biopolymer', type the string 'polyester-' into the search field, then choose the 'Filter' button and start the search by clicking the 'Find' button . Both, the activities that have the search string in their name (here: grey process symbol) as well as the exchanges (red and green triangle symbol) are shown. Select the intermediate exchange 'polyester-complexed starch biopolymer' from the intermediate flows group of the ecoinvent 3 master data and drag it onto the input side of the assembly process in the 'Specification Editor' area. Repeat this step for the materials 'ethanol, without water, in 95% solution state from fermentation' and 'electricity, medium voltage'. To find a specific material within the material list, use the project explorer's search functions. There are two ways of finding a material. One is to use the 'Incremental Find' button . This feature shows the result of a search while the keyword is typed. The incremental find feature marks a matching result yellow without hiding the structure of the directory tree. Another way is to use the 'Filter' button .The filter feature only shows entries with an exact match of the search string. All other entries are hidden. The filter function also works for parts of the material name, for example the string '95% solution state' for ethanol. The process 'Assembly' is now complete regarding the input and output flows. The next step is to specify the process by assigning coefficients to the input and output materials. One whiteboard marker has a total weight of 20.75 g. It consists of 11.55 g marker shell, 2 g cap, 4.0 g biopolymer felt tip and 3.2 g ethanol-based ink. Please mind the units! Either enter the values in 'kg', or switch to grams 'g' first to enter the coefficient value in grams. The assembly process needs on average 0.02 kWh of electricity for one whiteboard marker. The specified 'Assembly' process should look like Figure 5. All flow entries have been selected from the exchanges listed under the ecoinvent v3 master material data. Figure 5: Specification of the Assembly process Tutorial 2a Page 11 Umberto NXT ifu Hamburg GmbH The number format can be changed by navigating to 'Tools'
'Options' in the menu bar. Now, add another process to the model. Name it 'Extrusion Marker Shell' and connect it to the connection place that serves as input place of the 'Assembly' process. Add the material ‘marker shell’ on the output side. The plastic tubes for the marker shell are molded in an extrusion process using polypropylene granulate. The intermediate exchange providing this service or work is called 'extrusion, plastic pipes' (most likely used for larger pipes than the plastic tubes of the whiteboard marker, however, for this example it is fine to use this extrusion process as an approximation). Add the exchanges 'polypropylene, granulate' and 'extrusion, plastic pipes' to the input side of the process. Then, add another process to the model again and name it 'Cap Moulding'. Add the material ‘marker cap’ on the output side and the materials 'polypropylene, granulate' and the service input 'injection moulding' on the input side. The specification of the 'Extrusion Marker Shell' process and the 'Cap Moulding' process will be done in the next chapter. Packaging Process Add a process named 'Packaging' to the right of the assembly process and connect the process to the connection place that serves as output of the assembly. Create an output place and connect it to the 'Packaging' process. The small model should now look like Figure 6: Figure 6: The first four processes of the whiteboard marker model The whiteboard markers are shipped in packages of 4 markers of 20.75 g each in a transparent polypropylene casing (in this example called 'plastic box') of 45 g. The total weight of the package is 128 g. Page 12 Tutorial 2a ifu Hamburg GmbH Umberto NXT Figure 7: Picture of the set of whiteboard marker Add the materials 'packaged markers' and 'plastic box' to the project materials list (both have the display unit: 'kg' and the material type: 'Good'). Goods are products that have a value and are either purchased from or sold. All expenses to produce typically have the green material type (Good) while emissions and wastes (which are undesired "side-effects" of producing typically have the red material type (Bad). For more information on the role of the material type, please refer to the Umberto User Manual. Specify the 'Packaging' process with the materials 'whiteboard marker' and 'plastic box' on the input side and 'packaged markers' on the output side. The flow 'packaged markers' on the output side is identified as the product of the process (reference flow) Add the corresponding coefficients according to Figure 8. Figure 8: Specification of the packaging process Tutorial 2a Page 13 Umberto NXT ifu Hamburg GmbH It is possible to use the column "Function" to calculate the coefficient value. Try typing 4*20.75 as a function for the ‘white board marker’ to determine the coefficient of '83'. Mind the units: Either set to 'g' before entering the values, or use 'kg' for all coefficient entries. Remember that it is only the mass relation of the coefficients on the input and output side that matters, not the absolute figures. Add another process to the network, connect it to the input side of the 'Packaging' process and name it 'Box Production'. Please add the material 'plastic box' to the output side of this process. In the intermediate exchanges of the ecoinvent tree search for the entries 'injection moulding' and 'polypropylene, granulate' and add them to the input side of the process 'Box Production'. Note that since 'polypropylene, granulate' has already been used in this project it also appears in the 'Project Material' group. The plastic boxes are also produced in an injection moulding process using polypropylene granulate. The work process for the injection moulding should have the same coefficient as the amount of polypropylene granulate, indicating that for moulding 1 kg of PP, we also have to consider the work process 'injection moulding' with the same amount (1 kg). The work or service process 'injection moulding' also accounts for losses. Therefore, it should be used with the coefficient 1 for both inputs (material input and work process input) but the coefficient 0.997 for the injection moulded material on the output side (an explanation can also be found in the description of the activity in the properties dialog). Figure 9: Specification of the box production process Page 14 Tutorial 2a ifu Hamburg GmbH Umberto NXT Expanding the Model In this step, we add all of the activities which deliver the specified flows or intermediate exchanges to the model. We can manually choose and place the delivering process in the model, or we can let Umberto search and add an appropriate process from the list of activities of the tutorial database. Let us start with the 'Box production' process. It has two entries on the input side 'injection moulding' and 'polypropylene, granulate'. Browse for the activity 'injection moulding (ifu tutorial dataset) [RER]' in the tutorial master data, either by opening the hierarchical group, or by using the string search with a filter. Then, drag&drop the respective activity from the 'Project Explorer' onto the editor, to the left hand side of the box production process. Figure 10: List of activities for injection moulding, geography 'Europe' The selection dialog shown in Figure 10 pops up. Please choose the 'Result' (i.e. 'System Terminated') process and confirm by pressing 'ok'. Result activities include all upstream activities and therefore also include the system boundaries. The respective in- and outputs are elementary flows. Unit activities, however, resemble the direct production process. The respective inputs are intermediate products; the outputs are only direct emissions from this process. For more information on unit and result activities as well as elementary and intermediate flows, please refer to the user manual. To replace a Result process by a Unit process (or vice versa) use the function 'Replace result process with unit process' (respectively, 'Replace unit process with result process'), which can be found in the context menu of the process to-be-changed. A model stub will be added in the model editor with an input and an output place and a connection place, where the reference flow (or product) of the process is delivered (compare to Figure 11). Connect the connection place as a delivering input of the box production. Please check, if in the 'Specification Editor' of the 'Box Production' the delivering place for the inputs is correctly set. Tutorial 2a Page 15 Umberto NXT ifu Hamburg GmbH Figure 11: Model stub of the selected activity, here: injection moulding, geography 'Europe' In contrast to the processes which have been added to the model so far, additionally a small lock symbol appears in the blue process box. This lock indicates that a predefined process from a database is being used here. Such processes can only be modified after unlocking. This can be done via the context menu of the process. Before the process can be modified a further inquiry is displayed (see Figure 12). Figure 12: Further inquiry before unlocking an activity dataset Manually adding the activities is the one option. If it is already known which process delivers a certain product or service, then choosing the activity from the master data will be another possibility. In some cases, however, the user may want to research the different activities that can possibly deliver an input. Therefore, please try the automatic 'Expand' feature next. To add the production of 'polypropylene, granulate' use the 'Expand' button at the bottom of the specification window. First, highlight the polypropylene, granulate input and then press the 'Expand' button. Umberto will search for activities that deliver this intermediate material. Pick the corresponding 'Result' activity from the list (shown in Figure 13). Page 16 Tutorial 2a ifu Hamburg GmbH Umberto NXT Figure 13: List of activities which deliver the material polypropylene granulate, geography 'Europe' After clicking 'OK', the complete activity will automatically be added to the network. Arrange the places in the model editor so that there are no overlapping elements. The model should now look similar to this: Figure 14: The expanded box production Next, we will specify the extrusion process of the marker shell: Similar to the injection moulding process used above, the extrusion production is also a work process, using polypropylene granulate. Expand the material 'extrusion, plastic pipes' on the input side of the 'Extrusion Marker Shell' process with the result Tutorial 2a Page 17 Umberto NXT ifu Hamburg GmbH process 'extrusion, plastic pipes (ifu tutorial dataset) [RER]' and the material 'polypropylene production, granulate (ifu tutorial dataset) [RER]' with the result process. The work process for the extrusion production should have the same coefficient as the polypropylene granulate. This means that for extruding 1 kg of PP, we also have to consider the work process 'extrusion, plastic pipes (ifu tutorial dataset) [RER]' with the same amount (1 kg). In contrast to the service process 'injection moulding' no material losses occur. This is why the extrusion process should be used with the coefficient 1 for both inputs (material input and work process the input side) as well as for the extruded material on the output side. And finally, we will add the delivering activities to the 'Assembly' process. Please always use the respective result (system terminated) process. Start with the expansion of the material 'electricity, medium voltage'. Please use the 'Expand' feature again to see the delivering processes contained in the database. Select 'electricity, medium voltage (ifu tutorial dataset) [NL]' from the available activities, or drag the respective activity onto the editor and connect it to the 'Assembly' process. It is assumed that the assembly process takes place in the Netherlands. In a full LCI library (e.g. ecoinvent v2.2 or ecoinvent v3) there would be numerous activities (from all different kinds of countries) for the production of 'electricity, medium voltage'. As delivering process for the production of 'ethanol, without water, in 95% solution state from fermentation' choose the activity 'ethanol production from maize (ifu tutorial dataset) [GLO]'. Also, expand the polyester-complexed starch biopolymer with the activity 'starch biopolymer production (ifu tutorial dataset) [RER]'. The current network should look similar to Figure 15, now. Regard, whether all materials from the just added production processes enter the assembly process at the right place. Page 18 Tutorial 2a ifu Hamburg GmbH Umberto NXT Figure 15: Model of the whiteboard markers manufacturing processes Adding Life Cycle Phases Life cycle assessment deals with all potential environmental impacts along the life cycle of a product or service. To allow an analysis of the contribution of each single process to the overall environmental impact, add phase frames for each life cycle stage. Tutorial 2a Page 19 Umberto NXT ifu Ha amburg GmbH Choose the command 'Life Cycle Phases' from the 'Draw' menu to add life cycle phase frames. The diallog allows choosing from a list of prede efined study types, or a certain number o of phases. Select the first entry 'Cradlle-to-Grave' with 5 phases from the dropd down list and click 'OK'. Figure 16: Life Cycle Phases selectiion dialog The structuring of the life cyc cle model helps to arrange not only the e model, but also the results later on. If necessary, rearrange the processes and phase frames as follow ws: the box production, the assembly including the extrusion marker she ell and cap moulding processes as welll as the packaging of the whiteboard markers belong to the 'Manufacture phase'; p all upstream processes belong to the 'Raw Materials phase'. The produc ction and the supply of electricity belong to the life cycle phase in which the elec ctricity is used. To enlarge the life cycle phas se frame in vertical direction click near the edge of the frame to select the w whole life cycle phase frame. Now its vertical dimensions can be changed by b using the small squares on the selec ction frame. Figure 17: Change phase size and phase p frame size Page 20 Tutorial 2a ifu Hamburg GmbH Umberto NXT An element belongs to the phase in which most of the elements structure is located. In case that an element is exactly centered between two phases, it will be assigned to the phase on its left. Figure 18: First part of the model for the whiteboard marker with Life Cycle Phase frame Tutorial 2a Page 21 Umberto NXT ifu Hamburg GmbH Modeling the Downstream Life Cycle Phases To get a complete life cycle model for the product the phases 'Distribution/Retail' as well as 'Consumer Use' and 'Disposal/Recycling' still have to be modeled in detail. After its packaging the whiteboard marker has to be shipped to the retail stores. In this example, use a freight lorry for transportation. During its utilisation the whiteboard marker is emptied and the ethanol of the ink is released into the atmosphere. Finally, at the end of its life the empty whiteboard marker is being disposed of. Start to expand the network by adding one process to each of the life cycle phases 'Distribution/Retail' and Consumer Use'. Name each process accordingly e.g. 'Distribution' and 'Use'. In order to connect the new process of the 'Distribution/Retail' phase to the output of the packaging process, change the type of this place from 'output' to 'connection'. As a connection place it links two processes while before, as an output place it was part of the system boundary. Use the 'Type' panel in the properties editor of the place to change the type. Figure 19: Properties Editor of a Place Distribution: Next, the distribution process will be specified. In this example let us assume the whiteboard markers will be transported to the point of sales by a freight truck. (The actual logistics might be more complicated including i.e. long-haul shipping to a distribution center and short-haul regional distribution. Also, the delivery, or customer shopping trip, from the point of sales to the office building where the marker is used, is not included in this first modeling approach.) Open the specification window of the process 'Distribution' and add the material 'packaged markers' to both sides of the process. Furthermore, add the intermediate exchange 'transport, freight, lorry 1632 metric ton, EURO5' as service input to the input side of the distribution process. Expand this service upstream by using the 'Expand' button on the bottom of the 'Specification' window or by choosing 'Expand delivering activity' from the context menu of the service input) with the adequate 'Result' process (system terminated process 'transport, lorry 16-32 ton, EURO5 (ifu tutorial dataset) [RER]'. Page 22 Tutorial 2a ifu Hamburg GmbH Umberto NXT Figure 20: The transport service is an input to the distribution process of the whiteboard marker. It is an immaterial freight service input with the basic unit 'metric ton*km' The transportation distance for the whiteboard markers from the packaging location to the consumer is assumed to be 550 km, which is about the average distance for a transport across Germany. The unit of the intermediate exchange that represents the freight service input is 'metric ton*km'. Since the whiteboard markers transported as cargo do not change their weight, their input and output coefficients are the same. Choose any weight for the transported markers, but make sure to calculate the value for the transportation service input in relation to it: When choosing 1000 kg as coefficient for the whiteboard markers for example, 550 metric ton*km have to be used as coefficient for the transportation process. Alternatively the process can be specified using any other representation of the same linear ratio such as 1 kg for the whiteboard markers and 0.55 metric ton*km for the transportation service input for example. Umberto will always scale the specifications according to the reference flow leaving the production system. Figure 21: Specification of 'Distribution' process Tutorial 2a Page 23 Umberto NXT ifu Hamburg GmbH In tutorial 3 the distribution phase will be further improved and the impact of different distribution routes will be discussed. Use Phase: In the use phase the whiteboard marker is used to write on a whiteboard in an office. After some time (or to be more precise: after writing script of a certain length) the whiteboard marker will by empty (dry). The ethanol used as a solvent of the ink will be emitted during this process. Part of the use phase is also the removal of the plastic box. It can be assumed, that the plastic box is thrown away, since it is no longer needed. Specify the 'Use' process by adding the material 'packaged markers' (128 g) to the input side and the materials 'whiteboard marker' (4*20,75 g) and 'plastic box' (45 g) to the output side. Add two output places to the 'Disposal/Recycling' phase and send one of the two output materials to one of them. Further, add the emission 'Ethanol [air/urban air close to ground]' to the output side of the 'Use process'. Use the predefined elementary exchange from the ecoinvent 3 master database. Please add an output place for the emission and lead the ethanol to this place. Figure 22: Specification of 'Use' process, defined for the box of four markers Page 24 Tutorial 2a ifu Hamburg GmbH Umberto NXT Observe in the specification of the 'Use' process, that the two output flows are identified as reference flows of the process. This is due to the fact that they have the material type "Good" and leave the system to an output place. Hence, they are considered as "products", which at this stage (after use) is not fully correct. In fact, both the 'whiteboard marker' and the 'plastic box' are now a waste that must be disposed of. The waste treatment is an additional expense that also contributes to the whiteboard markers life cycle and still has to be accounted for. Start by changing the material type of the 'whiteboard marker' and the 'plastic box' to red (Bad)! Figure 23: Specification of 'Use' process, with material type of the (waste) whiteboard marker and the (waste) plastic box changed to red (Bad). In doing so, a red marker symbol will appear on the 'Use' process, indicating that the system cannot be calculated as there is no system reference flow available. That is true: in the whole life cycle model there is no more flow of the green material type (Good) crossing the system boundary. Which one shall the system reference flow be assigned to, now? The whiteboard marker has fulfilled its function, when its material type turned from 'Good' to 'Bad'. Therefore, it makes sense to assign the system reference flow to the service that the whiteboard marker has fulfilled. This can be indicated by adding an additional 'whiteboard marker' to the output side of the process with its default material type green (Good). Then comes the important part: choose the command 'Set Virtual Reference Flow Property' from the context menu of the newly created whiteboard marker (right mouse click on this entry in the table on the output side). The coefficient of the whiteboard marker should be identical to the one on the input side (namely 83.0 g). Please mind that the whiteboard markers on the input side of the 'Use' process arrive packaged in a plastic box (45 g). Figure 24: Specification of 'Use' process, with a virtual reference flow (material type green) that represents the system reference flow. Tutorial 2a Page 25 Umberto NXT ifu Hamburg GmbH A hidden output place (labeled "RF") will be added to the model and the virtual reference flow will be sent there (see the respective arrow leaving the use process in Figure 26). This will play an important role in the LCIA Sankey diagrams later on. In tutorial 3 the topic of the system reference flow will be addressed once again when the topic of the functional unit is being discussed. End of Life: After its use, the whiteboard marker has to be disposed of. The treatment of different waste fractions takes place at the site of disposal directly. Since the behavior of the consumer can only be guessed, the end-oflife treatment routes of the whiteboard marker will be split: We assume that half of the markers will be sent to a municipal waste incineration; the other half to a sanitary landfill. The assumption of the distribution of the whiteboard markers on the market as well as their disposal at municipal waste incineration and sanitary landfill may not be realistic. Both life cycle phases depend on consumer behavior and on the end-of-life treatment options available in the respective country. To this end, the splitter process for the two treatment routes will be parameterized and the parameters used for a sensitivity analysis in tutorial 3. Add a new process to the 'Disposal/Recycling' phase, name it 'End-of-Life Route' and specify as follows: Add the material 'whiteboard marker' on the input side. On the output side add the material flows, 'waste polypropylene' and 'waste plastic, mixture' (both intermediate exchanges from the ecoinvent 3 database). 1 kg of 'whiteboard marker' on the input side is transformed to 0.5 kg 'waste polypropylene' and 0.5 kg 'waste plastic, mixture' on the output side. Make sure the material type of the 'whiteboard marker' on the input side (to be more precise: the empty, used whiteboard marker, now considered to be waste) is set to red (Bad), since this is the material type of the corresponding flow out of the use phase. Change the output place of the whiteboard marker leaving the 'Use' process to a connection place and connect it to the 'End-of-Life Route' process. Next, add the activity 'treatment of waste plastic mix, sanitary landfill (ifu tutorial dataset) [CH]' from the tutorial activities group. Choose the result version of the activity and connect the model stub to the 'End-of-Life Route' process on the output side. Observe that the treatment process has the reference flow on the input side: The intermediate exchange 'waste plastic, Page 26 Tutorial 2a ifu Hamburg GmbH Umberto NXT mixture' with the material type red (Bad) appears on the input side. On the output side there are only emissions (elementary exchanges) listed. In addition to the flows that have a green material type (Good) on the output side, also the exchanges that have a red material type on the input side are identified as reference flows. Then, go back to the 'End of Life route' process and expand the material 'waste polypropylene' with the result dataset for 'treatment of waste polypropylene, MSWI (ifu tutorial dataset) [CH]'. Finally, please check if all of the flows are properly assigned to their respective in/ and output places. The 'End-of-Life Route' process should look like Figure 25. Figure 25: Specification of 'End-of-Life Route' Figure 26: Specified 'Disposal/Recycling' phase Tutorial 2a Page 27 Umberto NXT ifu Hamburg GmbH The 'Disposal/Recycling' phase should now be completely specified and look similar to Figure 26. Preparation for Calculation of the Model Before the model can be calculated, specify a manual flow (compare to tutorial 1). First, open the arrow that contains the virtual reference flow. That is the one leaving the 'Use' process vertically to the top. If it is not visible highlight the elements around the 'Use' process, an arrow leading 'nowhere' should appear. In the specification editor for this arrow add the material whiteboard marker with a quantity of 0.02075 kg. When closing the arrow specification, observe that the arrow has turned its color from grey to purple, indicating that a manual flow has been defined here. At this stage of the tutorial we calculate the model for one unit of whiteboard marker with a weight of 20.75 g. One might argue that a weight-based reference flow is not appropriate. In tutorial 3 the topics of the system reference flow and the functional unit will be discussed further. The current life cycle model should look similar to the one in Figure 27 below. Figure 27: Model of the whiteboard marker Page 28 Tutorial 2a ifu Hamburg GmbH Umberto NXT Life Cycle Model Calculation and Inventory The life cycle model is now ready to be calculated. In the section above have the reference flow has already be defined. Calculate the model by clicking on the button with the calculator icon in the toolbar. If the model is fully specified and no problems occur all arrows will turn their color from light grey to black. If errors occur during the calculation a warning will be displayed asking whether the calculation log shall be opened. This log allows identifying the causes of errors. The calculation log is accessible in the main toolbar under 'Calculation' → 'Show Calculation Log' at any time. After the calculation has finished two new tabs will appear in the 'Specification' window at the bottom. These windows display the calculation results and the inventory results (named 'Results – Whiteboard marker' and 'Inventories – Whiteboard marker'). Let us start by looking at the inventory results. Open the inventories window, to display the overall physical flows associated with the product life cycle of the whiteboard marker: On the left hand side there are the inputs from the surrounding system (biosphere/nature) into the modeled system, and on the right hand side there are the respective outputs from the system (into nature). Figure 28: Inventory of Input/Output Flows The input/output places serve as the boundary of the life cycle model. The flows listed in the inventories table are the flows that run on the arrows from the input places (input flows) and to the output places (output flows). All flows are based on the quantity of the manual flow for which the life cycle model has been calculated (in this case one whiteboard marker of 20.75 g). Tutorial 2a Page 29 Umberto NXT ifu Ha amburg GmbH The manual flow could also o be one unit of whiteboard marker, fulfilling its service, or any other proporttionate quantity that was entered as ma anual flow. The inventory table can be so orted and grouped: Sort by clicking on the column header, e.g. to see the large est flows in the inventory; group by dragging the column header to the area ab bove the input or output side of the tab ble grid. For example, try grouping by the e column 'Unit'. Figure 29: Grouping results in the inventory i In the grouped view the secttions can be expanded by clicking on th he plus sign on the group header. Figure 30: Grouping by unit Page 30 Tutorial 2a ifu Hamburg GmbH Umberto NXT Life Cycle Impact Assessment In the previous step, the life cycle model with its associated physical flows (the inputs into and the outputs from the processes along the product life cycle) has been calculated. In this section it will be demonstrated how to assess the environmental impacts of the whiteboard marker by applying one or more LCIA impact assessment factors. Umberto supplies some twenty or more LCIA methods to choose from (compare to Figure 31). Figure 31: List of available LCIA Factors in Umberto NXT For the assessment of a life cycle analysis it is necessary to select either an LCIA Method or individual LCIA Factors. Please choose an impact assessment Tutorial 2a Page 31 Umberto NXT ifu Hamburg GmbH method by navigating to the 'Menu' and selecting 'Tools'
'LCIA factors'. All available impact assessment methods are listed. A method can be activated by right-clicking and choosing 'Activate Group'. It is possible to select or deselect individual impact categories and combine different impact assessment methods in order to meet the specific demands of the study. Note: The impact assessment method ReCiPe Midpoint (H) w/o LT is activated by default (compare to Figure 32). When opening the context menu on an elementary exchange in the 'Project Explorer', e.g. dinitrogen monoxide, choose 'View Impact Assessment Factors'. Uncheck the box 'Show only activated' to view all available impact assessment factors of the respective material. Figure 32: Activated impact categories of a LCIA Method Since one LCIA Impact assessment factor group (ReCiPe Midpoint (H) w/o LT) is activated by default, Umberto already calculated the impact assessment based on the inventory flows. Page 32 Tutorial 2a ifu Hamburg GmbH Umberto NXT Now, open the window 'Results – Whiteboard marker' to see the aggregated results for the selected LCIA factors with the respective data and the contribution of the different life cycle phases. There are two different views of the LCIA summary – watch the results as absolute values or scaled to 100% as shown Figure 33. Note that some categories remain empty here due to data gaps of the fictitious values. Figure 33: 'Results' tab (results by phases) Tutorial 2a Page 33 Umberto NXT ifu Ha amburg GmbH Details of the impact assess sment results can be viewed on the 'LC CIA Details' page. Select 'LCIA Details' fr from the selection list on the left hand side of the 'Results' page. Figure 34 sho ows the detailed LCIA results sorted by y phases. It is also possible to sort by processes or by materials, or display raw data without grouping. Figure 34: 'LCIA Details' The LCIA details can be arran nged custom-made by using the Group-By Box. To make the group by box visiblle click the 'Toggle Group-By Box'-butto on . The grouping is done by dra agging&dropping one or more column headers to the dark grey area above the e column. To remove a grouping criterria just drag it back to the result table. Page 34 Tutorial 2a ifu Hamburg GmbH Umberto NXT Sankey Diagrams After calculating the network a Sankey diagram will show the physical flows of the life cycle model. Sankey diagrams are also a very good way of verifying the consistency of the life cycle model. Click the button 'Show Sankey Diagram' to turn on the Sankey diagram mode for a calculated model. Figure 35: Exemplary Sankey Diagram of mass and energy flows of the LCA model Since 'Result' activities are likely to have many different unit types (e.g. area, radioactivity, and freight transport), it is recommended to limit the Sankey display to 'Mass' and 'Energy' at first. To do so, switch to the 'Scaling of Sankey Diagram' tab (left hand bottom side of the Umberto window) and remove the check marks for all unit types except these two. Figure 36: Scaling of Sankey diagram Tutorial 2a Page 35 Umberto NXT ifu Hamburg GmbH In addition to the view of the physical flows a Sankey diagram of the environmental impacts chosen for the life cycle assessment can be displayed also. To see it, open the dropdown menu next to the button 'Show Sankey Diagram' and select one of the LCIA impact categories shown here. Figure 37: Sankey Diagram for one chosen LCIA factor, e.g. GWP It can be observed that the Sankey arrows of the environmental burdens of the end of life phase are displayed with an inverted flow direction (see Figure 38). The environmental burdens of every impact category are aggregated along the production chain of the life cycle model. The environmental impacts of waste disposal are visually "added". The overall LCIA impact is displayed as the flow from the 'Use' phase to the top (to an invisible place; this resembles the reference flow "RF") Figure 38: Sankey Diagram for one chosen LCIA factor, e.g. GWP – inverted Sankey arrows Page 36 Tutorial 2a ifu Hamburg GmbH Umberto NXT In a network with more than one product, the cascading menu allows choosing one reference flow (product) for which the associated flows will be shown. After choosing a product there will be a more detailed view of the available Sankey diagrams by clicking on the entry 'More…'. A new window will then open in the properties pane displaying all activated impact categories of the impact assessment method. When clicking on one category, e.g. eutrophication, a Sankey diagram will show the contribution of all flows to the eutrophication potential. Try out different impact categories and see how the processes differently contribute to the selected impact categories. This enables to visually understand how environmental burdens are associated with the production process and that optimization in one impact category may have offsetting results for another impact category. Figure 39: Select Source of Sankey Diagram Tutorial 2a Page 37 Umberto NXT ifu Hamburg GmbH Exporting Results All data on the 'LCIA Details' page can be exported to Excel, in order to create diagrams and graphs for selected topics. The data will be exported according to the current view of the results. A window appears, asking for a name of the Excel file. The exported tables will be shown immediately after saving. In tutorial 3 the use of a raw data export and Pivot tables for the creation of virtually any diagram to support material tracing and contribution of substances to the environmental impacts is being explained. For further information about the functions covered in this tutorial have a look at the Umberto NXT User Manual. Thank you for completing tutorial 2. Please continue with tutorial 3 to discover more practical features of Umberto NXT. Notes: Page 38 Tutorial 2a Umberto® NXT (v7.1) Tutorial 3 LCA ifu Hamburg GmbH Max-Brauer-Allee 50 22765 Hamburg / Germany www.ifu.com DocVersion: 1.5 Date: October 2014 Publisher: ifu Hamburg GmbH http://www.umberto.de ® Umberto is a registered trademark of ifu Hamburg GmbH Microsoft and MS are registered trademarks. Windows and Excel are trademarks of Microsoft Corp. Other brand and product names are trademarks or registered trademarks of their respective holders. Information in this manual is subject to change without notice. No liability for the correctness of the information in this manual. All figures are for demonstration purposes only and contain fictitious data. Reproduction or translation of any part of this manual in any form (electronic or mechanic) without prior written permission of the copyright owner is unlawful. Requests for permission should be addressed to ifu Hamburg GmbH, Hamburg, Germany. ifu Hamburg GmbH Umberto NXT Tutorial 1: Umberto NXT Simple Example Time: 1 h Pages: 20 Level: New User Requirements: none What you will learn: • • • • • • • Umberto NXT work area and window handling Create a project, a model and a first process Specify a process Calculate a small model View the calculation results Create Sankey diagrams Use the Module Gallery Tutorial 2a: U NXT LCA/UNIV Tutorial 2b: U NXT EFF/UNIV Time: 1-2 h Pages: 40 Level: Beginner Time: 3-4 h Pages 40 Requirements: Tutorial 1 or experience with Umberto 5 for Life Cycle Assessment and general knowledge about LCA Requirements: Tutorial 1 or experience with Umberto 5 Level: Beginner What you will learn: • Working with activity datasets • Product life cycle phases • LCA calculation and results • Disposal and transport activities • Function and parameters • Group-By Box • Material type • Calculation log What you will learn: • User defined process specification • Create subnets • Analysis of input/output inventory • Function and parameters • Cost accounting for MFA • Allocations • Generic materials • Co-products • Sankey diagrams • Advanced Features Tutorial 3: U NXT LCA/UNIV Tutorial 4: U NXT UNIV Time: 1-2 h Pages: 48 Level: Advanced Time: 1-2 h Pages: 15 Level: Advanced Requirements: Tutorial 1 and 2 or experience with Umberto 5 for Life Cycle Assessment and knowledge about LCA Requirements: Tutorial 1 and 2 for LCA and Efficiency and 3 or experience with Umberto 5 for Life Cycle Assessment and knowledge about LCA What you will learn: • Allocations • Generic materials • Set multiple virtual reference flows • Co-products • Working with functional units • Sankey diagrams • Results by products • Print and export results • Advanced Features Tutorial 3 What you will learn: • Integrate costs LCA • Material Mapping • Calculate Selection Page 1 Umberto NXT ifu Hamburg GmbH Introduction Welcome to the tutorial section of Umberto NXT. It is divided into three independent tutorials of increasing complexity. Each tutorial has its focus on a different topic. The first two tutorials introduce the basic features of Umberto NXT. The third tutorial provides more complex modeling and information about advanced features. The first tutorial gives an introduction on how to create a basic model as well as the handling of general settings. This is done by using a simple example. In the second tutorial the focus is set on the creation of a model for a Life Cycle Assessment. You will learn how to work with a database and how to use different impact assessment methods. Part of the second tutorial is also to visualize your results via Sankey diagrams. The third tutorial has its main focus on more advanced topics of Life Cycle Assessment. It provides additional information about useful features of Umberto NXT and gives further modeling hints. To be able to learn how to use Umberto NXT, the examples presented in the three tutorials are designed to be independent of LCI databases that require a license. Hence, the activity datasets used in the tutorials 2 and 3 are sample datasets with fictitious values that can be used even without having access to ecoinvent data. For further information about the functions covered in this tutorial have a look at the Umberto NXT User Manual. The user manual can be accessed directly in the software via the Help menu. Page 2 Tutorial 3 ifu Hamburg GmbH Umberto NXT Tutorial 3: Whiteboard Marker (cont.) In this third tutorial the whiteboard marker example previously modeled in tutorial 2 will be continued. The existing model will be amplified and refined; thereby, more features of Umberto NXT, which support the analysis of life cycle models, can be explored. Preparation Tutorial 3 can easier be followed after having finished Tutorial 2. Users, who are working with a licensed version of Umberto NXT with ecoinvent v3 database, will find all activity datasets needed in the master database shipped with the software. Users, who are working on this tutorial without holding an ecoinvent license (e.g. users of the 14-day trial version) will find a group "Trial Version Datasets" in the Project Explorer, where datasets with a similar name but fictitious values can be found. Trial version users can deal with all three models of tutorial 3 using the trial version datasets. An overview of the trial datasets used is shown in Table 1 and Table 2 below. Do not use the trial version datasets for operative, real-world LCA studies, since they contain fictitious values only. Contents • • • • • • • Creating subnets Using net parameters Specifying processes with user defined functions Copying models Sensitivity analysis Advanced exporting options Data analysis Tutorial 3 Page 3 Umberto NXT ifu Hamburg GmbH Table 1: ecoinvent activities and corresponding tutorial datasets used in tutorial 2 tutorial/trial dataset name ecoinvent activity dataset name starch biopolymer production (ifu tutorial dataset) [RER] ethanol production from maize (ifu tutorial dataset) [GLO] polypropylene production, granulate (ifu tutorial dataset) [RER] injection moulding (ifu tutorial dataset) [RER] extrusion, plastic pipes (ifu tutorial dataset) [RER] electricity, medium voltage (ifu tutorial dataset) [NL] transport, lorry 16-32 ton, EURO5 (ifu tutorial dataset) [RER] polyester-complexed starch biopolymer, production [RER] ethanol, 95 % solution state, from fermentation [GLO] polypropylene production, granulate [RER] injection moulding [RER] extrusion production, plastic pipes [RER] electricity, medium voltage [NL] transport, freight, lorry 16-32 metric ton, EURO5 [RER] Table 2: ecoinvent activities and corresponding tutorial datasets additionally used in tutorial 3 tutorial/trial dataset name aluminium primary, cast alloy (ifu tutorial dataset) [GLO] treatment of aluminium scrap (ifu tutorial dataset) [GLO] extrusion of aluminium (ifu tutorial dataset) [RER] treatment of waste polypropylene, MSWI (ifu tutorial dataset) [CH] treatment of waste paper and board (ifu tutorial dataset) [RER] treatment of waste plastic mix, sanitary landfill (ifu tutorial dataset) [CH] transport, freight, inland waterways, barge (ifu tutorial data) [RER] transport, freight train (ifu tutorial dataset) [GLO] ecoinvent activity dataset name aluminium cast alloy [RER] treatment of aluminium scrap, postconsumer, prepared for recycling, at remelter [RER] impact extrusion of aluminium, 2 strokes [RER] treatment of waste polypropylene, municipal incineration [CH] treatment of waste paper and board [RER] treatment of waste plastic, mixture, sanitary landfill [CH] transport, freight, inland waterways, barge [RER] transport, freight train [RoW] Note: the suffix in square brackets indicates the geography: GLO = Global, RER = Region Europe, CH = Switzerland, NL = Netherlands, RoW = Rest of World Page 4 Tutorial 3 ifu Hamburg GmbH Umberto NXT Introduction When carrying out a life cycle assessment results sometimes need to be refined in order to ensure the quality of the report. This tutorial covers different approaches to refine your model as well as to prepare your life cycle assessment report. In addition, further modeling hints are explained. Tutorial 3 bases on the example created in tutorial 2. The LCA model for the whiteboard marker that has been developed is now refined and used as a basis for variants. At first, a sub-module of the transportation process is created to examine the distribution processes more closely. In the next step (3.1) an alternative use case will be developed as a means to improve the environmental performance of the product. In this alternative use case, the whiteboard marker is refilled with ink, rather than throwing it away at the end of its first use. Another part of this tutorial (3.2) looks at the choice of raw materials. What if the body of the whiteboard marker were made of aluminium instead of PP? This product design decision is compared in regard to the selected impact categories. Net parameters are explained in 3.3 and an example of a process specification with user defined functions rather than with coefficients is shown in 3.4. Finally, it is explained how to create any type of diagram supporting an LCA analysis and the respective interpretation. In order to do so, the LCIA results can be exported to an Excel sheet where the PivotChart feature can be used. Tutorial 3 Page 5 Umberto NXT ifu Hamburg GmbH Subnets (Hierarchical Modeling) In some cases a refinement of the model is needed while keeping the initial graphical layout intact. In other cases the analysis of results of one part of the model shall be separated from the overall results. In either case the use of subnets is indicated. Start by opening an existing whiteboard marker model (either the one you created in Tutorial 2 or the one linked on the Umberto start page). Copying the Model: The first step is to add a new model within the project. To do this, press the 'Create a New Model' button in the top right corner of the 'Project Explorer'. When asked for it, do not add life cycle phases, as the phase frames from your existing model will be copied as well. Name the model 'Tutorial 3.0', for example. Create a copy of the existing model by selecting all elements (Ctrl-A) and saving them to the clipboard (Ctrl-C). Next, paste the selected elements into the newly created empty model (CTRL-V). This should now be a copy of the original whiteboard marker model, where modifications can be made. Creating a Subnet: In this chapter a subnet will be added to refine the distribution phase of the whiteboard marker model designed in Tutorial 2. In this subnet three different distribution routes with varying parameters will be created. They will be analyzed in relation to each other. Each transportation route makes use of a different combination of means: Table 3: Overview of transportation routes and means of transportation Route 1 2 3 Share 30% 30% 40% km by lorry 550 50 150 km by train 50 400 50 km by boat 50 100 400 km total 650 550 600 The current transportation process ('transport lorry 16-32 ton, EURO5' of the 'Distribution/Retail' phase) will be replaced by a subnet that has more detail and transportation variants. Page 6 Tutorial 3 ifu Hamburg GmbH Umberto NXT Figure 1: Creating a subne et (via context-menu) Use the context menu of the distribution process to convertt the process into a subnet (see figure above). The subnet will automatically open in a new tab next to the main tab.. Please notice that the e subnet is also displayed in the projectt tree of the project explorer as a branc ch of the current model. Using mu ultiple subnets the hierarchical tree will ll display to which of model each sub bnet belongs. It is possible to create a s subnet within a subnet and there is currrently no limitation of depth in the hierarrchy. Figure 2: Display of subne et in the project explorer If you want, you can n drag the subnet window from its position and attach it side-by-side to the rig ight of the main net. Tutorial 3 Page 7 Umberto NXT ifu Hamburg GmbH Figure 3: The newly created subnet with the neighboring places of the subnet process as connection places The synchronization between the nets allows identifying each connection place – called ports in subnets – in both nets. Activate a port place on the subnet and observe how the corresponding connection is highlighted in the main net (see Figure 4). Figure 4: Synchronization of nets – corresponding places are marked The subnet will be calculated upstream because the manual flow of the main net is located further downstream. An upstream calculation generally means that the product output of a process is known, whereas its input(s) and the respective emissions are calculated according to the input/output specification or the user defined functions of the process. Please remember, we defined the manual flow as part of the use phase process of the main net in Tutorial 2. Therefore, the output flows of the subnet are known; hence, it will be modeled upstream. Specifying the Subnet: Start to devise the subnet now. The transportation process will be modified, resulting in three different routes expressed as shares of the total mass transported. Add a process to the subnet and connect it to the port place supplying the use phase in the main net. Name this process 'Splitter' and add the material 'packaged markers' to the output side once and three times to the input side (compare to Figure 5). Page 8 Tutorial 3 ifu Hamburg GmbH Umberto NXT Figure 5: Splitter process for calculating the share of each transportation route Please notice that the font of the packaged markers on the output side changed to red and bold. This is to show that the packaged markers are a reference flow with regard to the whole subnet. For more information on reference flows relating to processes and nets please refer to the Umberto NXT user manual. Change to the 'Parameter' tab of the 'Specification' window of the 'Splitter' process. Add three parameters by clicking on the button 'Add'. Identifiers will be assigned automatically (here 'C01', 'C02' and 'C03'). Rename the variables to R01, R02 and R03, respectively. Then, allot to the three parameters the proportional share according to the data given in Table 3. Figure 6: Parameter specification of the 'Splitter' process Next, return to the 'Input/Output' tab and type the variable for the first parameter ("R01") in the 'Function' field of the first entry. This is to reference the parameter value. Repeat this procedure for the remaining two parameters with the identifiers 'R02' and 'R03', respectively. Change the coefficients for and second entry to '0,3 kg' and the one for the third entry to respectively. Then, add a coefficient of '1 kg' on the output side so process specification is balanced. Tutorial 3 variable the first '0,4 kg', that the Page 9 Umberto NXT ifu Hamburg GmbH The specification of the 'Splitter' process should look like Figure 7, now. Figure 7: Input/Output tab in specification window of the 'Splitter' process Next, create a new process to the left of the 'Splitter' process and connect them with each other. Therefore, simply draw an arrow from an empty place in the model to the 'Splitter' process. The process and the connection place will be automatically added to the model. Call the new process 'Route 1' and connect it to the port place that receives the packaged markers from the main net. If the connection from the initial transportation activity to the subnet has not been deleted there is a third port place in your subnet. As all transports will be entirely modeled within the subnet, please delete this transport process and/or its remaining places of the main net. They will also be deleted in the subnet then. Figure 8 shows the current subnet with its two port places (connections to the main net). Figure 8: Route 1 in the distribution subnet For the specification of the 'Route 1' process, please add the material 'packaged markers' on the input and on the output side. Moreover, search for the following intermediate exchanges (in the ecoinvent 3 branch of the Project Explorer) and also add them to the process specification on the input side: 'transport, freight, lorry 16-32 metric ton, EURO 5', 'transport, freight train' and 'transport, freight, inland waterways, barge'. The units of all selected means of transportation are defined as 'metric ton * km'. Therefore, both the weight and the distance must form a part of the material specification. We will allow for this by defining the weight Page 10 Tutorial 3 ifu Hamburg GmbH Umberto NXT of the packaged markers and the distance of each means of transportation for the selected route. First, change to the 'Parameters' tab of the process 'Route 1', and add a parameter called 'LDIST' for the distance of lorry transportation with the value of 550 km. Then, return to the 'Input/Output' tab and type the function 'LDIST/1000' in the 'Functions' column behind the material 'transport, freight, lorry 16-32 metric ton, EURO 5'. Enter with return and observe how the coefficient of the 'Material' 'transport, freight, lorry 16-32 metric ton, EURO 5' is updated. Please, repeat these steps for the two remaining means of transportation (barge and train) with a distance of 50 km, respectively (compare to figure below). Figure 9: Parameter tab of the first route For a complete specification of the 'Route 1' process, finally insert a coefficient of 1 kg of the material 'packaged markers' on the input side as well as on the output side (see Figure 10). Make sure to assign the same coefficient for the transported good on both, the input and the output side. The first transportation route can easily be modified now, by merely changing the parameters for the distance of each transportation means. Figure 10: Specification of the first distribution route of the whiteboard markers Go on, using the expand function to add the three activities that provide the respective transportation processes. In all three cases, use the respective 'Result' (i.e. 'System Terminated') process. Tutorial 3 Page 11 Umberto NXT ifu Hamburg GmbH Users of the trial version without access to the ecoinvent database, please use the activities in the group "Tutorial Activities" of the database "Tutorial Example" instead. See the tables at the beginning of this document for a list of corresponding datasets. Result activities include all upstream activities and therefore also include system boundaries. The respective in- and outputs are elementary flows. Unit activities, however, resemble direct production processes. The respective inputs are intermediate products; the outputs are only direct emissions from this process. For more information on unit and result activities as well as elementary and intermediate flows, please refer to the user manual. If you wish to replace a Result process by a Unit process (or vice versa) you can use the function 'Replace result process with unit process' (respectively, 'Replace unit process with result process'), which can be found in the context menu of the process to-bechanged. The subnet should now look similar to this: Figure 11: Distribution subnet with expanded ecoinvent activities connected to the first route In the next step, add the other two transportation routes: In order to save time, simply copy and paste the first route and connect it to the appropriate places. Therefore, select the 'Route 1' process and choose 'Copy' from the Page 12 Tutorial 3 ifu Hamburg GmbH Umberto NXT context menu. Observe that not only the process, but also all of the connected places are selected and copied. Paste the entire process twice below the 'Route 1' process. Arrange the connection places so, that they use less space than the original layout (compare to Figure 12). The arrangement of the elements does not influence the calculation of the model, however, the model will be more clearly laid out and easier to comprehend as it gets larger. Rename the new processes to 'Route 2' and 'Route 3', respectively. Additionally, merge the produced 'Packaging' connection places, which deliver the packaged markers with the existing port place (supplying 'Route 1'): In order to do so, simply drag and drop the respective connection places onto the port place until they are highlighted. The new part of the subnet should now look similar to Figure 12 below. Figure 12: Subnet with copied routes Connect the places on the output side of the newly created routes to the splitter process. Another option to keep the model well-arranged is the usage of duplicates. In this case, duplicates of the connection places of 'Route 2' and 'Route 3' to the three transport processes, namely transport freight lorry, transport freight barge and transport freight train, will support clarity. In order to do so, choose 'Duplicate' from the context menu of the connection place between the transport activity for the lorry transport and the 'Route 1' process. A duplicate of the respective place appears right next to it in the model. Both counterparts are highlighted, when the other one is chosen. This holds true also, when Tutorial 3 Page 13 Umberto NXT ifu Hamburg GmbH more than two copies exist. Thus, you can easily control which connection you are handling at the moment. Figure 13: Creating a duplicate of a connection place Move the duplicate onto the connection with the similar ID of Route 2. When both places are highlighted, they will merge to one place. Please notice that each copy of the original element receives the same ID with a consecutive index. In case of the example the ID of the original connection is P9. Then, the copies of this place are called P9(2) and P9(3). Additionally, the specifications of the copied processes are automatically updated to the IDs of the copied places and are therefore easy to find. Repeat the duplication and merging steps for the remaining five connection places to connect each means of transportation with the respective delivering activity. Please check, if the different inputs are being delivered by the right connection place and the weight of the transported packaged markers is assigned a coefficient of 1 kg on all input and output sides of the three route processes (see Figure 14). Page 14 Tutorial 3 ifu Hamburg GmbH Umberto NXT Figure 14: Copies of 'Route 1' with duplicate connections The next step is to specify 'Route 2' and 'Route 3'. As a copy of the fully specified 'Route 1' was used, the parameter values in the 'Parameters' tab of the process specification of each means of transportation only need to be updated. Therefore, please use the values displayed in Table 4. Table 4: Overview of transportation routes and means of transportation Route 1 2 3 Share 30% 30% 40% km by lorry 550 50 150 km by train 50 400 50 km by boat 50 100 400 km total 650 550 600 Finally, the splitter process needs to be specified. This process still shows a red warning sign, because the input places for the packaged markers have not been assigned yet. Once more, select the Input/Output tab of the respective process specification and assign the correct places to each route on the input side. Tutorial 3 Page 15 Umberto NXT ifu Hamburg GmbH Figure 15: Final specification of the splitter process dividing the distribution routes Before the model can be calculated there is still one last alteration left to do: The input and output places of the transportation processes are not connected to the main net so far. Please switch to the main net, add an input and an output place to the 'Distribution' process and connect them accordingly. As already observed, these two places also appear in the subnet. Go back to the subnet, duplicate each of the new places twice and merge them with the respective input and output places of the transportation means (compare to Figure 16). Figure 16: Input and Output port places with their respective places in the main net The entire created subnet should look like Figure 17 below. When copying an entire model, manual flows are not automatically transferred as well. Therefore, please add the following manual flow to the virtual reference flow arrow leaving the 'Use' process in the main network: 'whiteboard marker', 0,02075 kg. Page 16 Tutorial 3 ifu Hamburg GmbH Umberto NXT Figure 17: Final subnet model of the whiteboard marker distribution The model is now ready to be recalculated. To do so, use the calculate icon of the main net editor. There should be no calculation warnings. After calculating the main net, the results of the subnet will be displayed like any ordinary process. Analyzing the Results: The new model has a more refined transport section. What was originally represented by a single process is now represented as a subnet with three different routes and has been parameterized (e.g. for studying the impacts or consequences of transport variations). After calculation the tab 'LCIA Summaries – By Phases, scaled to 100%' has an overview of impact assessment results with all selected impact categories. Tutorial 3 Page 17 Umberto NXT ifu Hamburg GmbH Figure 18: LCIA results by phases scaled to 100% Looking at Figure 18 (results may vary from user to user depending on the respective database used) one can see that the impact category results are now different from the LCIA results that were calculated with the previous model created in Tutorial 2. Remember that in Tutorial 2 the distribution of the whiteboard markers was assumed to be carried out by a lorry over a distance of 550 km. However, be aware, that the results scaled to 100% do not represent absolute values. The absolute contribution of the distribution phases to selected impact categories might be even lower in Tutorial 3 than in Tutorial 2 (compare to the LCIA summaries – by phases, absoltue values, e.g. impact category 'fossil depletion'). Please also keep in mind, that the whiteboard marker example uses fictitious values only. For this reason, the calculated results might not make sense concerning their quantity or the relation of the quantities among the different impact categories. Some of the impact categories may not even be considered at all. In one impact category, the overall contribution of the distribution phases has risen significantly: metal depletion. The total amount of Fe-equivalents rose from 4.3 kg in Tutorial 2 to 6.1 kg in Tutorial 3, which accounts for a relative share of the metal depletion of 41% and 50%, respectively. Hence, this impact category should be examined closer in the subnet. Start the examination by selecting the subnet and activating the Sankey Diagram. Then, select the small black arrow next to the Sankey button to see the drop down list and choose 'More…'. Page 18 Tutorial 3 ifu Hamburg GmbH Umberto NXT In the property editor on the left hand bottom side a new tab is shown called 'Source of Sankey diagram'. Select the impact category 'metal depletion' (compare to Figure 19). The analysis of the subnet will also work for any other selected impact category. Now switch to the tab 'Scaling of Sankey Diagram' (also located on the left hand bottom side) to adapt the width of the slider to 20 pixels (Figure 19). When you look back at the model of your subnet, you will see the contribution to the impact category metal depletion of each transportation mean and for each route (shown in Figure 20). In the results tab, switch to the section 'LCIA details – by processes' to check the results for the distribution more closely. Which means of transportation contributes the most to the selected impact category of metal depletion? Please notice that the subnet will be shown just like a process when the main model is activated. When you switch to the subnet only the data for the processes of the subnet will be displayed. Figure 19: Source and scaling of Sankey Diagram in the distribution subnet Tutorial 3 Page 19 Umberto NXT ifu Hamburg GmbH Figure 20: Sankey diagram showing the contribution of the distribution routes to the impact category metal depletion Page 20 Tutorial 3 ifu Hamburg GmbH Umberto NXT A Different Use Scenario: Refill (Tutorial 3.1) Consumer decisions are not solely based on economic effects but also depend on the environmental performance of certain goods and services. A prime example of ecological behavior is the reuse of goods. In this part of the tutorial a reuse model for the whiteboard marker will be created. Therefore, a refill station for the ink of the whiteboard marker will be added to the model. The following use case will be assumed: The whiteboard marker will be refilled in a refill station provided by the same supplier as the whiteboard marker itself. The refill station holds 16 ml of ink and allows for 5 refills (compare to Table 5). To model this use case the product chain will be expanded further downstream, like it was already done in Tutorial 2. Table 5: Characteristics of one refill station refill station 1 capacity 16 ml refills possible 5 Again, the first step is to add a new model to the project tree. When asked for it, do not add life cycle phases. Name the model: 'Tutorial 3.1 Use Case'. Create a copy of 'Tutorial 3.0' in the exact same way as done earlier in this chapter. Expanding the Model: To expand the existing model at the refill station, a whole process chain has to be added. Keep in mind to consider the necessary space, when adding processes and places. Start by adding a process to the raw material phase and call it 'refill station extrusion'. Next, create the material 'refill station' to your list of project materials and drag it to the output side of the newly created process. Furthermore, add the materials 'polypropylene, granulate' and 'extrusion, plastic pipes' to the input side (both materials are intermediate exchanges of ecoinvent 3). Assign a coefficient of 1 kg to each material on the input as well as on the output side of the process. Expand both materials on the input side with the respective result process and arrange the net elements clearly. Then, create a new process in the manufacture phase and call it 'Refill station filling'. Connect this process to the process 'Refill station extrusion' and add the material 'refill station' on the input side. Another way of adding materials to a process is to drag it over the process in the model editor and drop it there. You will be asked whether to put it on the input or output side of your process specification. This way you do not have to select a process in Tutorial 3 Page 21 Umberto NXT ifu Hamburg GmbH order to add materials to it. Continue the specification of the 'Refill Station Filling' process by adding the following three materials to the input side: 'ethanol, without water, in 95 % solution state, from fermentation', 'electricity, medium voltage' and 'carton board box production, with offset printing' (all materials are intermediate exchanges of ecoinvent 3). Next, create the material 'refill station, full' to your material list and add it to the output side of the last modified process. Please amend the weight of the refill station (consisting of corpus and lid) according to the table below The respective table also lists the single parts of the refill station with the according weights for additional information. Please take care of the units! Expand the materials 'ethanol…', 'electricity…', and 'carton box board…' with the respective result processes of the same name. Please use 'electricity, medium voltage' with the geography 'Netherlands', as we already used electricity produced in the Netherlands for the production of the whiteboard marker. Afterwards, move the net elements of the ethanol production to the 'Raw Materials' phase. The net elements belonging to the electricity supply and the carton box board production should remain in the 'Manufacture' phase. Do not forget to arrange the net elements nicely to keep a clear and simple structure. Table 6: Specification data for the refill station part corpus lid ink material polypropylene polypropylene ethanol quantity 15 6 16 unit g g g Additionally, the process needs 0,01 kWh of electricity for the assembly of the materials and 3,8 g of carton board box per refill station. The weight of the full refill station on the output side adds up to 40,8 g. The complete specification of the 'Refill station filling' should look like Figure 21 below. Figure 21: Specification of the 'Refill station filling' Furthermore, an additional distribution process is needed to deliver the refill station to its point of usage. Add another process, this time to the distribution Page 22 Tutorial 3 ifu Hamburg GmbH Umberto NXT phase. Call it 'Distribution refill station' and drag the material 'refill station, full' to the input and to the output side of the distribution process. Then add the material 'transport, freight, lorry 16-32 metric ton, EURO5' to the input side of the process. Create a new parameter called 'DIST' in the parameter tab of the distribution process and assign to it a coefficient of '550 km'. Switch back to the specification tab of the distribution process, type the function 'DIST/1000' in the function column of the transport and add a coefficient of 1 kg for the refill station on the input and on the output side (compare to Figure 22). Expand the material 'transport, freight lorry 16-32 metric ton, EURO 5' with the respective result process. At last, connect the 'Refill station filling' process to the 'Distribution refill station' and the latter one to the 'Use' process of the existing whiteboard marker model. Figure 22: Process specification of distribution process Finally check, if all the newly created processes have the right in- and output places assigned to them. The added model parts of the 'Refill Station' model should look similar to Figure 23. Figure 23: Current model of the refill process The next step is the specification of the 'Consumer Use' phase. In Tutorial 2 the 'Use' process has been specified according to the use of a package of 4 whiteboard markers. For this purpose the coefficients of the existing 'Use' process also have to be changed to reflect the use of one whiteboard marker refilled from a refill station. Tutorial 3 Page 23 Umberto NXT ifu Hamburg GmbH Firstly, open the specification of the 'Use' process. Change the mass of the packaged markers on the input side to 32 g which represents the weight of one marker including the allocated weight of a quarter plastic packages. Then, add the material 'refill station full' to the input side of the 'Use' process with a coefficient of 40,8 g. Add the material 'refill station' to the output side with a coefficient of 21 g and change its material type to 'Bad'. Since the refill station it is made of plastic just like the empty whiteboard marker it could be send to the same output place. However, the life cycle of the refill station shall be analyzed in detail. Thus, its end of life processes need to be separately included. Therefore, copy the existing end of life processes and also connect them to the 'Use' process. Rename the connection place leading from the 'Use' phase to the newly added 'End-of-Life Route to 'Refill station to disposal'. In the specification of the latter process, replace the material 'whiteboard marker' on the input side by the material 'refill station'. Do not forget to change the material type to 'Bad', as it is considered a waste now. Switch back to the 'Use' process again: Lead the refill station to the respective output place and update the material 'ethanol [air/urban or close to ground]'. It should now only contain the ink of one whiteboard marker (3,2 g) plus the ink of the refill station (16 g). Also, amend the coefficient of the plastic box, which weighs only the allocated quarter of the whole plastic box, now. Finally, change the weight of the whiteboard marker with the material type bad to 17,55 g and delete the whiteboard marker entry representing the reference flow. The 'Use' process should typically look like this. In the net editor, the 'Use' process shows a red warning sign now, since its specification does not contain a reference flow anymore. A new reference flow will be defined in the next steps. Figure 24: Current specification of the 'Use' process Go on, by creating a new material: 'writing' with the 'Unit Type' 'Amount [unit]', the 'Display Unit' 'unit' and the 'Material Type' 'Good'. In the properties editor for this material, check the box 'Material represents functional unit' and name the functional unit 'writing 500 meters' with a quantity of 1. This means that one unit of writing represents the functional unit of writing 500 meters. Add the material 'writing' to the output side of the 'Use' process. As the whiteboard marker can be refilled 5 times the coefficient of the material must Page 24 Tutorial 3 ifu Hamburg GmbH Umberto NXT be 6 units (first use and five refills). Left click on the material 'writing' and choose 'Set virtual reference flow property'. A new virtual reference flow will be created, leaving the 'Use' process. The arrow next to it, holding the old manual flow still has to be deleted. Lastly, the carton board box of the refill station needs to be disposed of. To do so, add the material 'waste packaging paper and paperboard' to the output side of the 'Use' process. Create an output process and lead the 'Use' process to it. Place this output place in the 'Disposal/Recycling' phase next to the one for the 'Plastic box to disposal' and name it 'Carton box to disposal'. Make sure the respective material of the 'Use' process goes to this output place. The completely specified 'Use' process should now look like Figure 25 below. Figure 25: Specification of the 'Use' process with five refills The 'Consumer Use' and 'Disposal/Recycling' phase should now look like Figure 26 below. Tutorial 3 Page 25 Umberto NXT ifu Hamburg GmbH Figure 26: Overview of the currently modified phases of the LCA model As final step of the specification of the alternative use case please update the manual flow. Choose the arrow that holds the virtual reference flow, leaving the 'Use' process. Add the entry 'writing' to the arrow specification. The chosen quantity will determine the scale of the calculation. Choosing 6 units of writing would mean a life cycle of one whiteboard marker and one refill station equal to writing 3000 meters. As we want to compare the results of the refilled whiteboard marker to the original one, we must choose a quantity of 1 unit, also reflecting a 'writing of 500 meters'. The results of the two use cases are than comparable to each other. Page 26 Tutorial 3 ifu Hamburg GmbH Umberto NXT For more information on the choice of functional units and system reference flows please refer to the Umberto NXT user manual as well as literature on LCA in general. A selection of published sources can be found in chapter three of the Umberto NXT user manual. It is now time to recalculate the model: Please, press the 'calculate' button. There should be no calculation warnings. As you recalculate the model you will notice that the results per functional unit have, of course, changed. Use the 'LCIA Details' tab to analyze your results more closely. Calculate a Selection of Processes: Taking a look at the whiteboard marker model, it stands out, that there are two production branches leading to the 'Use' process: one for the whiteboard marker and one for the refill station. However, both parts are produced by the same manufacturer even using some of the same processes. Take the electricity production, for example. Electricity is needed for the assembly of the whiteboard marker and for the assembly of the refill station as well. Both electricity production processes use the same tutorial activity and are located in the 'Manufacture' phase. To specifically compare the impact of the two electricity production processes, Umberto NXT enables to display an aggregation of any selected processes; how to do so, will be explained now. To calculate a selection of processes, press the shift key on your keyboard to select both electricity processes of your model. Then, use the drop down menu of the calculate button to choose 'Calculate Selection' (compare to Figure 27). Now, the model will be recalculated but only the inventories and results of the selected processes will be shown. The 'Inventories' tab and the 'LCIA Details' show the sums of either electricity processes or respectively the distinct results depending on the chosen processes. Figure 27: Calculating a selection of processes By using the method 'Calculate Selection' you can choose different system boundaries for your calculation without having to edit your model. Tutorial 3 Page 27 Umberto NXT ifu Hamburg GmbH It will also be interesting, to reopen and recalculate the original model. Afterwards, the results of the two use cases can be compared with each other in detail. With the 'Calculate Selection' method you can choose the same processes in both models. Therefore, arrange the two models side by side to easily switch between the models and the respective 'Inventories' and 'Result' tabs. Compare how the material flows of the whiteboard marker production change when assessing the two different use cases. In the section 'exporting results' at the end of this tutorial an even a better way to compare two separate scenarios will be showed. Page 28 Tutorial 3 ifu Hamburg GmbH Umberto NXT Alternative Material Use (Tutorial 3.2) One major concern of LCAs is decision support of the phase of production as well as of consumption behavior. In this context, it is interesting to examine the differences of whiteboard markers made of plastic to whiteboard markers made of aluminum. Just like in the previous sections fictitious data will be used and the example will be kept simple. A whiteboard marker made of aluminum basically has the same life cycle as the one made of plastic. The differences concern the extraction of raw materials and the use of different recycling paths. As done before, add a new model to the project tree. When asked for it, do not add life cycle phases. This time, name the new model: 'Tutorial 3.2 Alternative Production' and create a copy of the existing model 'Tutorial 3.1 Use Case'. The aluminum marker has only one essential part consisting of aluminum, namely the marker shell. In this fictitious example, it is assumed that the replacement of aluminum for plastic leads to a decrease in shell weight of 18%. Start by opening the specification of the process 'Extrusion marker shell'. Then, replace the materials on the input side with the materials 'aluminium, cast alloy' and 'impact extrusion of aluminium, 2 strokes' (both intermediate exchanges of ecoinvent 3). To do this, add the two new entries on the input side, assign the place identifier and enter the coefficients. The coefficients remain the same (1 kg each, treating 1 kg of aluminium requires a work process extrusion with the same amount). Finally remove the old entries. Figure 28: Process 'Extrusion Marker Shell' Next, delete the old delivering processes (including the connected places and arrows) to the left of the process 'Extrusion marker shell', so that new activities can be added. Use the 'Expand' function to add the respective result activities: 'aluminium primary, cast alloy (ifu tutorial dataset) [GLO]' and 'extrusion of aluminium (ifu tutorial dataset) [RER]'. Now you have to update the affected coefficients to the new weight of the marker shell: Open the specification of the 'Assembly' process and change the coefficient of the marker shell on the input side to 9,471 g and the coefficient of the whiteboard marker on the output side to 18,671 g (less 18% weight of the marker shell). Tutorial 3 Page 29 Umberto NXT ifu Hamburg GmbH Afterwards, select the 'Packaging' process. Still, four markers are packaged in a plastic box that weights 45 g. Change the coefficient of the whiteboard marker on the input side from 83 g to 74,684 g and the one of the packaged markers on the output side from 128 g to 119,684 g. As the 'Distribution' process is simply scaled to the transported weight it does not need to be updated. Instead, select the 'Use' process and change the coefficient of the packaged markers on the input side to 29,921 g. This equals the weight of one fourth of the entire package (119,684/4) or of one marker plus the allocated package weight (18,671 g + 11,25 g). On the output side, the coefficient of the whiteboard marker needs to be adjusted as well. Only the marker shell of aluminum is to remain to enter the recycling process. Therefore, delete the material 'whiteboard marker' and replace it with the material 'marker shell' weighting 9,471 g. Also, add the material 'marker cap' with a coefficient of 2 g to the output side. Create a new material named 'felt tip' and also add it to the output side of the 'Use' process. Lastly, add a new output place and lead the marker cap and the biopolymer felt tip (with a weight of 4,0 g), there. Both materials were formerly included in the weight of the whiteboard marker. Their end-of-life treatment will be neglected at this point. All added waste materials on the output side need to have the material type 'Bad'. Figure 29: Specification of the 'Use' process in Tutorial 3.2 The table below sums up all of the processes with coefficients that have been updated or added. Table 7: Coefficients to be changed for the aluminium marker shell in the production scenario Process Assembly Assembly Packaging Packaging Use phase Use phase Use phase Use phase Page 30 Material Marker shell Whiteboard marker Whiteboard marker Packaged markers Packaged markers Marker shell Marker cap Felt tip Old coefficient 11,55 20,75 83 128 32 11,55 2 4 New coefficient 9,471 18,671 74,684 119,684 29,921 9,471 2 4 Tutorial 3 ifu Hamburg GmbH Umberto NXT But turn back to the new production case now, since not all phases have been specified, yet. After its use, the aluminum shell of the whiteboard marker will be disposed of. In contrast to the plastic shell, all of the aluminum will receive the same end-of-life treatment. Therefore, open the 'End-of-life route' process of the whiteboard marker and delete all materials on the in- and output side (namely, the whiteboard marker on the input and the two waste materials on the output side). Also, delete the attached two waste treatment processes, including their connected places and arrows. Next, specify the 'End-of-life route' process for the aluminum shell: Add the material 'marker shell' (material type: 'Bad') on the input side and the material 'aluminium scrap, post consumer, prepared for melting' from the ecoinvent 3 intermediate materials on the output side. Use a coefficient of '1.00' on each side of the process. Expand the material 'aluminium scrap, post consumer, prepared for melting' on the output side (downstream) using the respective 'Expand' button. Choose the system terminated process 'treatment of aluminium scrap (ifu tutorial dataset) [GLO]' from the tutorial activities. The specification of the 'End-of-life route' process is also shown in Figure 30. Check, if all the materials are connected to the right in- and output places. Note: The 'End-of-life route' processes for the refill station as well as the attached treatment processes remain unchanged. The 'Consumer Use' and 'Disposal/Recycling' phases of 'Tutorial 3.2 Alternative Production' should look similar to Figure 31, now. Figure 30: Specification of the end-of-life route process of Tutorial 3.2 Tutorial 3 Page 31 Umberto NXT ifu Hamburg GmbH Figure 31: Model of the 'Consumer Use' and 'Disposal/Recycling' phases of Tutorial 3.2 Before you can recalculate the model to see if all changes have been made correctly, please insert the manual flow again. The material 'writing' of the reference flow, leaving use process, is assigned a coefficient of 1 unit again. Now, press the 'Calculate' button. There should be no calculation warnings. Compare the LCIA results of the two different whiteboard markers – one made of plastic and the other one made of aluminum. In the following section on net parameters a more simple way to change the weight of the marker shell throughout the model will be demonstrated. Page 32 Tutorial 3 ifu Hamburg GmbH Umberto NXT Using Net Parameters (Tutorial 3.3) As already demonstrated, the use of process parameters supports the analysis of life cycle models. In addition, process parameters can also be used to create different scenarios for an existing production chain. When it comes to improving or changing parts of the production chain affecting the entire model, however, the use of process parameters is not very helpful. In the last chapter, the weight of the whiteboard marker had to be modified manually in all of the affected processes. Depending on the complexity of the model such changes may be hard to trace and forgetting changes may lead to unexpected or wrong results. When you want to create a model alternative that affects more than one process in the same way, the use of net parameters is indicated. Net parameters can be used in all processes in one net-level. In this example a net parameter called 'MatEff' (short for material efficiency) will be used to change the material weight of the whiteboard marker. Let us assume that it was possible to reduce the material consumption of the whiteboard marker by 10%. What will be the effects on the entire model? To work on this part of Tutorial 3, please reopen the model named 'Tutorial 3.0'. Make a copy of the respective model and call it 'Tutorial 3.3 Net Parameters'. Defining Net Parameters: Net parameters can be created easily: Use a blank space of your model (no process, arrow or place is selected) and simply left-click. The tab 'Net Parameters' opens at the place of the specifications editor below the main net. Add a net parameter called 'MatEff' and assign a quantity of 0,9 (or 90 %) to it (compare to Figure 32). The parameter 'MatEff' can be used in any function of the entire model now, and even in all subnets of the respective main model. Figure 32: Net Parameters There are, however, two limitations concerning the use of net parameters. Firstly, a net parameter created in a subnet will only be applicable in the respective subnet and all subnets of this subnet (and not in the respective main net). In other words net parameters can be handed down to subnets but not vice versa. The second limitation concerns the name of the net parameter. If a parameter with the same name exists in a process specification, the net parameter will not be applied in the respective process. That means, if you use a process Tutorial 3 Page 33 Umberto NXT ifu Hamburg GmbH parameter with the name 'MatEff' and the value '6,0' in a process of your model, this process will use the value '6' for the calculation instead the coefficient of the net parameter. This holds also true for subnet net parameters of the same name. All parameters in Umberto NXT are not case-sensitive. That means capital (upper-case) or lower-case letters may be used likewise. Updating Process Specifications: In the next step the net parameters will be included in the process specifications. Start by selecting the 'Assembly' process and apply the net parameter 'MatEff' to the material marker shell' by multiplying it with the original value. Type: '11.55*MatEff' in the Function column. Please note, that within the Function column a decimal point is used instead of a comma. In order to balance out the process specification the material 'whiteboard marker' on the output side has to be adjusted as well. Use the function column to simply add up the inputs while maintaining intact the formula of the marker shell. The specification of the 'Assembly' process should now look like Figure 33 below. Figure 33: Process Specification with net parameter based function to determine coefficient value Go on to the packaging process and update the coefficients according to the new weight of the marker shell. The easiest way is to copy the formula used on the output side of the 'Assembly' process. Copy the respective formula and paste it to the Function column on the input side of the Packaging process. Do not forget to multiply it times four, since in this process four markers are put together in a plastic box. Continue similarly on the output side: Paste the formula to the Function column again but furthermore, add the weight of the plastic box. For ease of understanding the formulas, brackets may be used. The updated specification of the 'Packaging' process should now look like Figure 34. Page 34 Tutorial 3 ifu Hamburg GmbH Umberto NXT Figure 34: Use of formulas in 'Function' column As before, the coefficients of the respective process specifications are automatically calculated according to the functions now including the net parameters. If a parameter is used before it was assigned, or if it is simply mistyped, an error message will appear that the formula cannot be updated. Try changing the value of the model parameter and watch how the coefficients are automatically updated. The processes of the 'Distribution' subnet do not need to be updated. All processes therein are solely based on total mass inputs. Proceed with the 'Use' process in the same way as before with the 'Assembly' and the 'Packaging' process. However, the function of the whiteboard marker used as reference flow must not be changed! In this case the coefficient for the reference flow would also be changed according to the change of the net parameter; thus, altering the scaling of the entire model by a small fraction without given a further warning. For your reference, the process specification is shown in Figure 35 below. Figure 35: Updated 'Use' process Lastly, insert the manual flow on the arrow leaving the use process again. The quantity of the material 'whiteboard marker' accounts for 19,595 g (equal to 20,75 g*MatEff), like shown in Figure 36. Figure 36: Updated manual flow. The 'End-of-life route' process does not need to be updated at this point as it only represents a splitter function dividing the share of each treatment activity of the disposal phase. Tutorial 3 Page 35 Umberto NXT ifu Hamburg GmbH Recalculate the model, now. There should be no calculation warnings. Afterwards, please compare the LCIA results for the two different whiteboard markers. Does a reduction of 10% of the marker shell weight have the respective effect on the LCIA results? Page 36 Tutorial 3 ifu Hamburg GmbH Umberto NXT Process Specification with User Defined Functions (Tutorial 3.4) Start this chapter by copying the existing 'Tutorial 3' once again. Name the new model 'Tutorial 3.4 User Defined Functions'. Looking at the 'Disposal/Recycling' phase it stands out, that the plastic box of the whiteboard markers leaves the system without end-of-life treatment. Since the box consists of the same material as the whiteboard marker shell, namely plastic, the existing end-of-life treatment for the whiteboard marker could be copied and applied to it, also. However, yet another way to specify processes will be introduced in the following. Therefore, open the specification of the 'Use' process and change the destination (place) of the plastic box on the output side to the place of the used whiteboard marker with the material type 'Bad'. Figure 37: Use phase Now add the plastic box to the input side of the adjacent 'End-of-life Route' process, dividing the whiteboard marker in a stream of 'waste polypropylene' and 'waste plastic, mixture'. Do not forget to change the material type. One option to specify the process would be to use coefficients describing the ratio of whiteboard marker and plastic box. To use a constant ratio, however, means that a modification of weight of any of the respective materials, would also change the ratio of these materials; thus, probably resulting in a false calculation. But there is a more elegant way of specifying a process, namely the specification with mathematical formulas, called 'User Defined Functions'. To change the process type of the 'End-of-life Route' open the context menu of the process and choose 'Convert To' > 'User Defined'. The look of the table in the specification editor of the process changes: The columns for coefficients and functions are replaced but the new column 'Var' and identifiers are shown for each material entry. These variables identify each flow on the input side (named X00, X01, …) and on the output side, respectively (named Y00, Y01, …). These variables are used in the mathematical formulas to reference the flow entries. Tutorial 3 Page 37 Umberto NXT ifu Hamburg GmbH Figure 38: User defined process specification Next, use the context menu of the process again and select 'Edit User Defined Functions'. A new window opens that serves as editor for defining the inputoutput relation of the process. In the process specification of the 'End-of-life Route', open the parameter tab and add a new variable called 'RATIO' with a default quantity of 0,5. It does not need a unit. This parameter describes the share in waste plastic of the underlying process. It might be changed later in order to try out differently weighted plastic treatment options. Figure 39: Parameter 'RATIO' Figure 40: Writing a specification as 'User Defined Functions' Please type the assignments for Y00 and Y01 in the editor. The amount of waste plastic mixture (Y00) consists of the sum of both inputs multiplied with the defined ratio of waste separation (RATIO). The amount of waste polypropylene (Y01) yields the remaining proportion (1-RATIO). Y00 = (X00 + X01) * RATIO Y01 = (X00 + X01) * (1-RATIO) The amount of a specific material flow can be assigned to its variable identifier (Y00, Y01) and is defined by a term on the right hand side of the equal sign. Page 38 Tutorial 3 ifu Hamburg GmbH Umberto NXT As shown in the screenshot of the editor above, characters written after a semicolon appear in a different shade of green. They are considered as comments and are not included in the calculation. In the given example, it is assumed that the flows X00 and X01 are known flows because they are calculated in the use phase and handed further downstream to the 'End-of-life Route' process. Y00 and Y01 are then determined by the calculation of the 'User Defined Functions' based on the given values for X00 and X01 and the use of a parameter. Variables can also be used to define other variables, provided that the former ones are calculated beforehand. To give an example of an alternative to calculating 'Y01'. Y01 = X00 + X01 – Y00 Here, "Y00" can be used in the expression on the right hand side of the equal sign, because it has another expression that allows calculating its value. It is important to understand that each variable must have an expression that can be evaluated and calculated, in order to successfully complete the calculation of a process specified with user defined function. Of course, at least one flow must be known in order to start the calculation of the process. Although the syntax of the user defined functions can be very simple, their use is very effective. Many real processes are subject to restrictions, which can best be expressed using individually tailored user defined functions. For more information on user defined functions in general and the application of mathematical terms and functions please refer to the Umberto NXT User Manual. Next, close the Functions editor of the End-of-life Route process, using the close symbol located at the top of the Functions editor window. The process symbol for the End-of-life Route appears in a lighter blue, now, indicating the user defined functions (compare to Figure 41). Also, delete the redundant output place for the plastic box disposal. Before the model can be recalculated, please insert the manual flow again. Therefore, open the flow without output place leaving the 'Use' process and add the material 'whiteboard marker' with a quantity of 20,75 g. Afterwards, click the 'Calculate' button. There should be no calculation warnings. Tutorial 3 Page 39 Umberto NXT ifu Hamburg GmbH Figure 41: End-of-life Route as 'User Defined Functions' process Page 40 Tutorial 3 ifu Hamburg GmbH Umberto NXT Exporting Results With the possibility to use Sankey Diagrams Umberto NXT offers one of the best visualization techniques in terms of material flows and contribution analysis. Nevertheless, it is sometimes necessary to export data and create other result diagrams commonly used. In addition, further special (statistical) analysis might best be performed with other software such as Microsoft Excel. Umberto NXT supports the export of data into Microsoft Excel spreadsheets for further data handling. Two exports are described in this section of the tutorial. Excel Export of the Current Table View: All data will be exported to Excel according to the specific current view of the 'Results' tab, when clicking the 'Export Results' button. The content of the Excel output will have the same sorting, grouping and column arrangement that have been set for the table on the 'Results' tab. A 'Save File' dialog will be opened where the name of the Excel file and the location where to save the file to have to be entered. The exported Excel file can be shown immediately after saving. First, select the whiteboard marker model named 'Tutorial 3.1 Use Case' and make sure it is calculated. Then, open the 'Results' tab and switch to the 'LCIA Details – Raw Data' entry. Now click the icon in the top left corner of the results table to display the column 'Field Chooser': Figure 42: Field Chooser In this example the columns 'LCIA Method', 'Material', 'Material Type', 'Phase', 'Process', 'Product', 'Quantity' and 'Unit' are active and will be exported. Choose the desired columns, if they are not activated by default. Tutorial 3 Page 41 Umberto NXT ifu Hamburg GmbH Figure 43: Preparation for Excel export An Excel diagram with the selected content and layout will be created. It can be used to further work on the data, e.g. run detailed analysis, sort the items, and copy them to reports. The following section exemplary shows how a comparison of the LCIA results for two use cases can be performed using Pivot Charts of Excel. Please note that you need to have Microsoft Excel 2007 or higher installed to use the raw data export. This is due to the restriction of lines in older versions of Excel. Raw Data Export for Pivot Graphs: In contrast to the simple Export to Excel described above, the export of raw data and creation of Pivot graphs provides additional possibilities. Use 'Export LCIA Raw Data' to export all data, and create Pivot Tables and Pivot Charts in Excel. This will allow creating virtually any type of diagram for life cycle impact assessment results. After having calculated a LCA model, click the 'Export LCIA Raw Data' button in the 'Results' tab. This is independent of the current column layout. Choose a file name and select a folder where to save the Excel file to. After a successful export a dialog is shown asking whether the Excel file shall be opened. The export uses a template file that has the required settings and options for Pivot Tables and Pivot Graphs. The Excel file opens with the 'Charts' tab in front and four different (sample) diagrams based on the exported LCIA results raw data. A help text is shown on the first tab ('Description'). The raw data itself can be checked on the second tab ('LCIA RawData'). The Pivot Tables that are used to create the diagrams are taken from the fourth tab ('PivotTable 1', 'PivotTable 2', 'PivotTable 3', …). Page 42 Tutorial 3 ifu Hamburg GmbH Umberto NXT Figure 44: Raw Data exported to Excel For an analysis of the results the model can also be calculated with fewer impact categories, if necessary or desired. To adapt the diagrams or create own diagrams use the tabs 'Pivot Table': Figure 45: Pivot in Excel with Field List for selection of elements Tutorial 3 Page 43 Umberto NXT ifu Hamburg GmbH Remember: Impact categories (or groups) can be activated and deactivated under Tools
LCIA factors. The data series and data fields can be chosen individually to create virtually any type of diagram. To this end drag the entry 'Quantity' of the field list into the 'Values' section at the bottom right of the field list (compare to Figure 45) In some cases the field shows 'Amount'. Click on the field and change the view to 'Sum'. Next, drag&drop the entry 'LCIA Methods' to the 'Report Filter' field at the upper left field and filter the methods to display just one single impact category. Choose, for example, the impact category 'metal depletion' (or another LCIA category that was activated when you performed the export of raw data. Then, drag&drop the entry 'Model' to the 'Column Labels' field and the entry 'Phase' to the 'Row Labels' field. Please experiment freely by creating other diagrams. Comparison of LCIA Results using Raw Data Export: For a comparison of LCIA results with other LCIA results we need to gather them in one file and then use this as basis for a Pivot Graph. To this end the Excel export of raw data also contains the name of the project, the model, the net and a timestamp for the export. If the LCIA results are for two different model calculations within the same model, use the 'Timestamp' column to differentiate the two exports. Should you have different names for the system reference flow (the product), this is also a possibility to differentiate the two exports in the column 'Product'. Figure 46: Raw Data exported to Excel Combine both Excel files into one by copying and pasting one table below the other. Now click inside the data and choose the tab 'Insert' and 'PivotChart'. You are asked to choose the data while Excel will select the entire table by default. Choose the option 'New Worksheet' to copy the chart into a new sheet. Page 44 Tutorial 3 ifu Hamburg GmbH Umberto NXT Figure 47: Selecting the area for Pivot data In the Pivot Table Field List (see Figure 45) select the columns 'LCIA Method', 'Quantity', 'Phase' and 'Model' (or 'Timestamp'). Drag the entry 'LCIA Method' to the Report Filter field. Drag the entry 'Model' to the Legend Filter field. Drag the entries 'Phase' to the Axis Filter field. Make sure that for 'Values' the entry is 'Quantity' and the setting is 'Sum'. Then, choose the tab 'Insert' and 'Column'. Finally, select a diagram from the dropdown list. The PivotTable field list and the diagram will look similar to Figure 48 below. The contribution of each life cycle phase is shown for both use scenarios. 1,80E-03 1,60E-03 1,40E-03 1,20E-03 1,00E-03 8,00E-04 6,00E-04 One Marker 4,00E-04 Refill Station 2,00E-04 0,00E+00 Figure 48: Comparison diagram for one impact category based Pivot in Excel A more detailed diagram showing a comparison of the two models for the selected impact category can be created this way: Tutorial 3 Page 45 Umberto NXT ifu Hamburg GmbH In the Pivot Table Field List (compare to Figure 45) select the columns 'LCIA Method', 'Process', 'Quantity', 'Phase' and 'Model' (or 'Timestamp'). Drag the entry 'LCIA Method' to the Report Filter field. Drag the entry 'Process' to the Legend Filter field. Drag the entries 'Phase' and 'Model' to the Axis Filter field. Make sure that for 'Values' the entry is 'Quantity' and the setting is 'Sum'. Finally filter to one impact category only (e.g. metal depletion). Therefore, select 'LCIA Method' in the Pivot Chart and open the dropdown menu and choose a category from the list. Another possibility to display both of the scenarios more detailed has a similar field order. This time, use stacked columns for the layout of the diagram. Figure 49: Comparison with contribution from individual processes for one impact category You can see the results for the selected impact category, broken down to contributions from each life cycle phase. In order to change the impact category simply change the filter value of the LCIA Method. The last option presented in this tutorial is making use of a filter function within the column field. Change the Report Filter to the impact category 'Climate Change' and replace the field 'Process' with the field 'Exchange' (representing all materials used in the model and shown in the inventory). As these are typically many different elementary exchanges (which don't make much sense to display them all in one diagram) it is recommended to use the filter function and display certain specific exchanges only (e.g. display 'Methane, …" only). Alternatively, click the small black arrow next to the legend title and choose the option 'Value Filters' and 'Top 10…'. Page 46 Tutorial 3 ifu Hamburg GmbH Umberto NXT Figure 50: Choosing only the top 10 substances The dialog box allows for making additional choices. After clicking 'OK' the pivot chart should look like the one in the diagram below. The top ten materials contributing to the impact category climate change are shown in alphabetical order. Figure 51: Choosing only the top 10 substances Using pivot charts gives you the opportunity to create virtually any desired diagram without having to copy and paste within the Excel data. It is therefore a powerful tool for the visualization of LCA results. Tutorial 3 Page 47 Umberto NXT ifu Hamburg GmbH Thank you for completing tutorial 3. If there are still pending questions you should consult the Umberto NXT User Manual or have a look at the Umberto User Forum (my.umberto.de). Page 48 Tutorial 3 Umberto® NXT (v7.1) Tutorial 2b Efficiency ifu Hamburg GmbH Max-Brauer-Allee 50 22765 Hamburg / Germany www.ifu.com DocVersion: 1.5 Date: October 2014 Publisher: ifu Hamburg GmbH http://www.umberto.de ® Umberto is a registered trademark of ifu Hamburg GmbH Microsoft and MS are registered trademarks. Windows and Excel are trademarks of Microsoft Corp. Other brand and product names are trademarks or registered trademarks of their respective holders. While every precaution has been taken in the preparation of this tutorial, no responsibility for errors or omissions can be assumed. The information in this manual is subject to change without notice. All figures are for demonstration purposes only and contain fictitious data. Reproduction or translation of any part of this manual in any form (electronic or mechanic) without prior written permission of the copyright owner is unlawful. Requests for permission should be addressed to ifu Hamburg GmbH, Hamburg, Germany . ifu Hamburg GmbH Umberto NXT Tutorial 1:Umberto NXT Simple Example Time: 1 h Pages: 20 Level: New User Requirements: none What you will learn:        Umberto NXT work area and window handling Create a project, a model and a first process Specify a process Calculate a small model View the calculation results Create Sankey diagrams Use the Module Gallery Tutorial 2a: U NXT LCA/UNIV Tutorial 2b: U NXT EFF/UNIV Time: 1-2 h Pages: 40 Level: Beginner Time: 3-4 h Pages 40 Requirements: Tutorial 1 or experience with Umberto 5 for Life Cycle Assessment and general knowledge about LCA Requirements: Tutorial 1 or experience with Umberto 5 Level: Beginner What you will learn:  Working with activity datasets  Product life cycle phases  LCA calculation and results  Disposal and transport activities  Function and parameters  Group-By Box  Material type  Calculation log What you will learn:  User defined process specification  Create subnets  Analysis of input/output inventory  Function and parameters  Cost accounting for MFA  Allocations  Generic materials  Co-products  Sankey diagrams  Advanced Features Tutorial 3: U NXT LCA/UNIV Tutorial 4: U NXT UNIV Time: 1-2 h Pages: 48 Level: Advanced Time: 1-2 h Pages: 15 Level: Advanced Requirements: Tutorial 1 and 2 or experience with Umberto 5 for Life Cycle Assessment and knowledge about LCA Requirements: Tutorial 1 and 2 for LCA and Efficiency and 3 or experience with Umberto 5 for Life Cycle Assessment and knowledge about LCA What you will learn:  Allocations  Generic materials  Set multiple virtual reference flows  Co-products  Working with functional units  Sankey diagrams  Results by products  Print and export results  Advanced Features Tutorial 2b Efficiency What you will learn:  Integrate costs LCA  Material Mapping  Calculate Selection Page 3 Umberto NXT ifu Hamburg GmbH Introduction Welcome to the tutorial section of Umberto NXT. It is divided into five independent tutorials of increasing complexity. Each tutorial focuses on a different topic. The first tutorial introduces the basic features of Umberto NXT. The four following tutorials describe more complex modelling tasks and inform about advanced features. The first tutorial shows how to create a basic model and how to handle general settings. This is done by using a simple example. The second tutorial for LCA focuses on the creation of a model for a Life Cycle Assessment. The aim is to show how to work with a database and how to use different impact assessment methods. The second tutorial for Efficiency focuses on cost accounting and efficiency analysis. A section in each of the two second tutorials also demonstrates how to visualize the results via Sankey diagrams. The third tutorial for LCA focuses on more advanced topics of Life Cycle Assessment. It provides more information about useful features of Umberto NXT LCA and gives further modelling hints. The fourth tutorial for Universal focuses on the integration of costs into LCA and on the prerequisite material mapping. For more information about the functions covered in this tutorial have a look at the Umberto NXT User Manual. The user manual can be accessed directly in the software via the Help menu. Page 4 Tutorial 2b Efficiency ifu Hamburg GmbH Umberto NXT Tutorial 2: Whiteboard Marker Production This tutorial is based on the experience gained while working through Tutorial 1 of Umberto NXT. In this second tutorial a more complex network for a real life product – a whiteboard marker – will be created. While working on this example, special functions of Umberto NXT will be introduced that support an economic analysis. A cost accounting component has been implemented in Umberto. It is based on the mass and energy flows level and allows the handling of material direct costs as well as variable and fixed process costs. Contents  Modeling a more complex network  User defined functions  Analysis of input/output inventory  Creation of subnets  Using generic materials  Setting of Allocations  Cost accounting for material flow analysis  Scenario comparison Preparation In order to work on this tutorial, Tutorial 1 should have been completed. Tutorial 2b Efficiency Page 5 Umberto NXT ifu Hamburg GmbH Project Overview This example for this tutorial focuses on the production line of a whiteboard marker. The example has been simplified for the purpose of this tutorial. Figure 1: A whiteboard marker A marker shell with a cap made of plastic are the main components of a whiteboard marker. The marker has a felt tip made of a biopolymer and uses ethanol-based ink1. In the manufacturing process the whiteboard marker is assembled by using pre-produced marker shells and caps. This example focuses on the production of the colour ink for the markers in four different colours (black, blue, green and red). In the assembly process, the plastic shell and cap are combined with the ink cartridges. Each whiteboard marker weighs a total of 20.75 g. Getting Started Start this tutorial by creating a new project using the 'New Project' icon on the menu bar. Give the project an appropriate name, for example 'Tutorial 2 – Production Whiteboard Marker'. A first model template, named 'Model', is already open. After selecting the model in the Project Explorer, it can be renamed in the 'Properties' window. Call the first model, for example, 'Whiteboard Marker Production'. Production Line The "net editor" will be used to build a graphical model for the production line of the whiteboard marker. The first process is the "Pressing", which receives materials and energy from two sources as input and delivers pressed biopolymer as output to a connection place. Draw two input places and one transition and connect all the places and the transition with arrows. Change the label in order to name the two sources "electricity" and "Starch, 1 The example in this tutorial is fictitious and has been simplified for training purposes. It does not resemble the real production chain of a whiteboard marker. The example is used to illustrate the workflow of a life cycle assessment and to introduce the features of the software. Page 6 Tutorial 2b Efficiency ifu Hamburg GmbH Umberto NXT biopolymer". Click onto the label and edit the name in the "properties window" in the text field. The next process is called "Cutting" and receives electricity from the same source as the "Pressing". This time, there is "rejection" going to an output place and the cut biopolymer is sent to a subsequent process. Create the necessary transition and places, connect and name them according to their description. Remember, in order to connect two transitions there has to be a connection place between them. Create a connection place or draw an arrow directly from one transition to another and the connection appears automatically. The last process, called "Rolling", uses the cut biopolymer to produce the final "ink shape biopolymer". Again, connect the new process with the previous process, the electricity source and a new output for the "Production line Colours". In order to keep the network clean and structured it might make sense to use one source for several processes (e.g., electricity, operating materials, etc.). The network should look something like this: Figure 2: Unspecified production line colours So far, the processes have not yet been specified (see the red marker in the process symbol).To specify a process, it is necessary to add materials to the process as inputs or outputs, and to specify their quantitative relationships. Tutorial 2b Efficiency Page 7 Umberto NXT ifu Hamburg GmbH To specify the processes, new materials need to be created. For this model create the following materials: biopolymer (yard good, pressed); biopolymer (yard good, unpressed); biopolymer, cut; biopolymer, ink-shape; electricity; rejection biopolymer. Figure 3: Process materials The display unit will automatically be set to "kg" and material type "good". Remember to set the material type for the rejected biopolymer to "bad". Set the unit type for "electricity" to "Energy [MJ]" and the display unit to "kWh". Materials are categorized into material groups. Material groups are shown as folders in the Project Explorer. Using material groups is essential for keeping big projects clearly structured and to allow one to find materials easily. Create the following five material groups in your project explorer: Energy & Auxiliaries; Incoming goods; Intermediates; Products and Residues. The project explorer lists the different material groups and materials. The materials can be assigned to its corresponding material group. Select a material and drag and drop it into the right material group. Figure 4: Assignment of materials and material groups Linear Specification The definition of the processes plays an important role when building a material flow network. The first process will be specified by stating coefficients, which describe the linear relation between the input and output Page 8 Tutorial 2b Efficiency ifu Hamburg GmbH Umberto NXT flows of the process. With such a coefficient as the process definition, only one input or output flow (e.g., the production amount of pressed biopolymer) has to be known to be able to determine all other mass and energy flows. For the process "Pressing" 1 kg of unpressed biopolymer and 1.5 kWh of electricity are necessary to produce 1 kg of pressed biopolymer. Double click to open the process specification and insert the materials either per drag&drop from the project explorer or per "Add" button. Also remember to specify where the material is coming from. The process 'Pressing' is now complete in respect to the input and output. Figure 5: Process specification "pressing" Parameterized Specification Processes cannot always be defined by describing the linear interrelation of input and output flows simply with coefficients. In many cases the activity of the process depends on parameters (e.g., throughput, waste ratio, etc.). Parameters can be used in functions for the calculation of coefficients on the 'Input/ Output' tab. The process "Cutting" will be specified with a parameter that allows adjusting the amount of "cutting waste per input material". The value is "10", the unit can be set to "%". Figure 6: Parameterization "cutting" To define the parameter in the process specification, click on the "Parameters" tab and then the button 'Add'. A default entry will be created in the table on the 'Parameters' tab, which can subsequently be edited: enter the name, in this case "Cutting Waste as % of Input material" and set the unit to per cent. The value should be set to 10 % for the beginning. The default variable name (C00, C01, etc.) can be edited as well to allow a better identification of a parameter. The parameters are referenced in the functions with the variable Tutorial 2b Efficiency Page 9 Umberto NXT ifu Hamburg GmbH name given for an entry in the column 'Var'. In the above example, the default parameter names should be replaced with "CW" for better understanding. These parameter names can be used in the functions for coefficients and in the user defined functions for the process specification In contrast to the first process specification, where coefficients for input and output flows were used, functions will now be entered. Umberto NXT makes it possible to define processes using mathematical functions and operators. This is a a very helpful feature when the relationship between the input and output of a process is best described in terms of a mathematical function. To turn the process specification from a simple linear specification to the 'User Defined Function' mode, choose 'Convert' from the context menu right clicking on the process "Cutting" and then on "User defined". Converting a process defined with mathematical operators and functions back to a simple linear process specification and maintaining the functional relationship is, in most cases, not possible. However, should you wish to abandon the user defined function mode and prefer to specify a process with a coefficient once again, you can do so by using the command 'Convert' from the context menu of the process, and 'Linear'. A process that has been converted to the 'User Defined Functions' type, will not show the coefficient column any more. Instead, an additional column 'Var' on the input and output side now sports the variable identifier with which the flow entries can be referenced in the mathematical formulas and function terms. Open the specification of the "Cutting" process and insert "electricity" and "biopolymer, pressed" on the input side. On the output side specify the process with "biopolymer, cut". Figure 7: Process specification "cutting" Page 10 Tutorial 2b Efficiency ifu Hamburg GmbH Umberto NXT To be able to specify the relations between the input and output side, the functions have to be entered in the "Functions" window. Open the context menu again and choose "Edit User Defined Functions". In the main area (where the editor is located) a tab 'Functions' will be opened, which provides a text editor. In each line of the editing field a definition for one of the flows can be entered. The name of the variable ("Var") is on the left of the equals sign and makes reference to the flow entries on the "Input/ Output" tab. The term of the function is to the right of the equal sign. In this term other variables, transition parameter and net parameter identifiers, and all valid expressions for functions can be used. The valid expressions for mathematical formulae are listed in the user manual. This rather simple process definition consists of only three lines. Lines with a leading semicolon are comment lines, which explain the calculation steps (and might be important, if the process module has to be understood by others). Figure 8: User defined functions "cutting" Enter the functions shown above in the "Functions" window. Try to understand the functions and how the material flows are calculated from the known flows. In any case make sure to use the actual variable identifiers (X00, Y00, etc.) from your example. They might differ from the ones shown above if the materials were inserted into the specification in a different order. Set the specification for the last process "Rolling" according to this process specification. Tutorial 2b Efficiency Page 11 Umberto NXT ifu Hamburg GmbH Figure 9: Process specification "rolling" Calculation and Visualization The network is specified and almost ready to be calculated. In order to calculate the network a starting point for the calculation, the so-called 'manual flow', has to be defined. To set the manual flow in the network, select the arrow between "Rolling" and the output place: From the list of materials in the Project Explorer, drag the entry 'biopolymer, ink-shape' to the Specification pane (make sure the arrow is still selected!). Next, the quantity of the manual flow has to be defined. Enter 100 kg as the quantity of the manual flow, for example. Choose the command 'Calculate Total Flows' from the 'Calculation' menu in the main toolbar. After a successful calculation the "Inventory" tab will open up in the Specification pane at the bottom. Figure 10: Inventory - whiteboard marker production To have a closer look at the overall flows within the model use the Sankey button to switch on the Sankey mode. The model in Sankey diagram mode should now look similar to the figure below. Page 12 Tutorial 2b Efficiency ifu Hamburg GmbH Umberto NXT Figure 11: Sankey of production line colours Using the Module Gallery In the next step a process will be copied to the 'Module Gallery'. However, the manual flow between the "Rolling" and the output place has to be deleted first. Then go to the Project Explorer and bring the tab 'Module Gallery' to the front. Select the Folder 'Modules' and press the 'Create Module Group' button in the Module Gallery toolbar. Rename the module group to 'Tutorial'. Select the whole model in the net editor and click the copy button on the main toolbar. Mark the module group 'Tutorial' in the Module Gallery and use the 'Paste Clipboard Data to Module Group' button in the Module Gallery toolbar. Figure 12: Module Gallery Tutorial 2b Efficiency Page 13 Umberto NXT ifu Hamburg GmbH Rename the module to 'whiteboard marker production'. The module should now be available in the module gallery. Upload Physical Company Layout The company not only produces the ink but, for example, it also fills the whiteboard markers, assembles them and implements quality assurance measures. Please create a new project and model and call it "whiteboard marker production". The exact production steps are shown on the physical layout. To upload the layout open the module gallery next to the project explorer tab and select 'Tutorial Examples' > 'Tutorial Efficiency' and use the drag&drop function to pull the "image ground plan" onto the editor window. The next step is to create new places and processes as depicted in the model below: Figure 13: Physical layout of the main model Most of the processes consume electricity. In order to avoid a lot of arrows and different places that all deliver electricity, it makes sense to use duplicates of one source. In the figure above there are two places "P6: electricity". Use the context menu of a place to generate a duplicate. To use process symbols that better fit into the physical layout, use pictures from the clipart gallery and adjust the size of the processes to the physical layout. Use the "Load Image" button in the "Properties" window to load the predefined picture "simple process" out of the "tutorials" folder in your clipart directory for the processes "Incoming Goods", "Quality Assurance" and "Assembly". For the Page 14 Tutorial 2b Efficiency ifu Hamburg GmbH Umberto NXT Processes "Production Line Biopolymer, ink-shape" and the "Production Line Colour Filling" load the picture "simple subnet". Figure 14: Adjusted physical layout of main model To obtain a working model, the processes have to be specified and some new materials need to be created in the "Project Explorer". Generic Materials The first process "Incoming good" simply serves to distribute the incoming goods to the different working areas. The materials will not be treated in any way. Thus, generic materials can be used. They allow the transferrals of materials in specified quantities no matter what the material it represents. Create the necessary materials and specify "Incoming goods" according to the figure below. For the "Cargo" materials select the "Generic Materials" Tab in the "Specification" Window. Click the Add button to generate "Generic Materials". Make certain that the place definition is suitable for your model. Per default, a newly created generic material will be called " Cargo, Cargo(1)...". Change the names as indicated below. Figure 15: Process specification "incoming goods" Tutorial 2b Efficiency Page 15 Umberto NXT ifu Hamburg GmbH You can imagine a generic material as a "place holder" for one or more specific materials. When the calculation is started, the generic material entry is substituted by the specific material. However, the calculation does not depend on the actual type of goods transported. This process can be used flexibly and remains adaptable to various modelling situations. Subnets When modelling process systems with a higher complexity, or when the networks exceed a certain size, comprehensibility diminishes. The possibility of modelling hierarchies in networks allows the "hiding" of parts of a network mode as a subnet on a subordinate level. Refining a network and describing one process as a subnet model is a "natural" way to proceed in a material flow study. On the other hand, subnets permit the modelling, for example, of the various sites of a company and make it possible to consolidate them on one level higher. The overall material and energy flows of a group or holding can thus be assessed. Network sections containing typical process systems can be stored to the module gallery. In the course of the tutorial example, the "Filling production hall" process will be modelled with a subnet. To create a subnet, select the process. Then select 'Convert To' from the context menu and 'Subnet' from the cascading menu. The Subnet window will immediately be opened in the editor tab. Insert the physical layout for this process from the module gallery. The model for the Filling Production Hall was already created at the beginning of this tutorial and then stored in the module gallery. Use the drag&drop function to put the "whiteboard marker production" module into the existing subnet. Page 16 Tutorial 2b Efficiency ifu Hamburg GmbH Umberto NXT Take the transition templates for the processes again, fit the processes to the physical layout and match the module places with the correct subnet places. The model should look like the following model. It might happen that the layout image covers the rest of the editor tab. In that case use the context menu to bring the image to the back of the editor layer. Figure 16: Physical layout "production line biopolymer" The next process to specify will be the "Production line colour". Convert the process to a subnet and load the corresponding physical layout "layout production line colour" from the module gallery. Insert two processes "Mixer (black)" and "Filler (black) and arrange the layout, the labelling and the connections as shown below. Tutorial 2b Efficiency Page 17 Umberto NXT ifu Hamburg GmbH Figure 17: Physical layout "production line filling" The linear specification of the "Mixing" and the "Filling" process can be gathered from the two following graphics. The specification coefficients are based on measurements. Remember to create the new materials in the "Project Explorer" first. Figure 18: Process specification "mixer" Figure 19: Process specification "filler" Page 18 Tutorial 2b Efficiency ifu Hamburg GmbH Umberto NXT As can be seen in the layout of the subnet, the whole process takes place four times. Each pair of processes will produce another colour. Select the two processes and copy them. The copy process automatically selects all connected arrows and places as well. Paste it again in the editor field and connect places that belong together. Repeat this another two times. Bring the arrows into their correct order until your model resembles the diagram below. The newly generated open connection places can all be merged with the corresponding existing subnet connections on the right, left and top of the layout. The subnet source for electricity has to be duplicated three times and each duplicate has to be merged with the copied electricity sources. The specifications of the copied processes also need to be adjusted. Change the names of the three new process pairs to Mixer (blue) and Filler (blue), Mixer (green) and Filler (green) and Mixer (red) and Filler (red). The Material "colour solution...", "ink,..." and "ink cartridge..." have to be defined for all three colours. Select the corresponding processes for each colour and add the new materials. Take the same coefficients and delete the "black" materials out of the specification for the blue, green and red processes. The purpose of this is to create new materials for the new colours and replace the old "black" related materials with the appropriate colour. Figure 20: Subnet for "production line colour filling" Tutorial 2b Efficiency Page 19 Umberto NXT ifu Hamburg GmbH Advanced Specification The process "Quality Assessment" will be specified by a user defined function. Select the process and convert to "user defined". Add the same materials as in following figure into the process input and output specifications. Remember that this process uses "g". Furthermore, create a new material called "rejection cartridge" in the project explorer. Change the display unit to "g" before you create the process in order to get the same unit in the process specification. If you have already created the process and the specification, then convert it back to "Linear", change the units and convert it to "User Defined" again. Figure 21: Process specification "quality assessment" Next, create a parameter to describe the rejection rate of cartridges during the quality check. The parameter should be called RR for rejection rate to facilitate referencing the parameter in the function. Set the value to 10 %. Enter the assignments (mathematical formulas) shown in the next figure in the "Functions" window. Try to understand the functions and how the material flows are calculated from the known flows. In any case, make sure to use the actual variable identifiers (X00, Y00, etc.) from your example. They might differ from the ones shown above if the materials were inserted into the specification in another order. Depending on the location of the manual flow it is important to enable the calculation from both sides, input and output side. In this example, the output material "Y00" can be determined by the parameter and the input material "X00". This function enables the calculation in case the manual flow was set somewhere before the process. The function in line 4, however, determines the input material "X00" by using the parameter and the output material "Y00" in case the manual flow is located somewhere after the process. Page 20 Tutorial 2b Efficiency ifu Hamburg GmbH Umberto NXT Figure 22: User defined function for "quality assessment" In nearly the same way, create the specification for the process "Assembly". Take the necessary data from the following figures. Figure 23: Process specification "assembly" Tutorial 2b Efficiency Page 21 Umberto NXT ifu Hamburg GmbH Figure 24: User defined functions "assembly" The last step before the model can be calculated is to set the manual flows. In this case the markers are always sold in a package containing four whiteboard markers, one of each colour. Select the arrow after the "Assembly" and set a manual flow for each colour of 2075 kg per. That represents 1,000,000 markers. Figure 25: Setting of manual flows Page 22 Tutorial 2b Efficiency ifu Hamburg GmbH Umberto NXT Run the calculation and have a closer look at the result tab. Results can be listed in a disaggregated or aggregated view. In the view 'Materials A-Z, disaggregated' every input/output flow is shown as a separate entry with the processes that take an input and the processes that output the flow listed in the column 'Process'. If you switch to the view 'Materials A-Z, disaggregated' in the selection list on the left of the table, only one flow entry will be shown, aggregating them without showing the individual processes. The hint 'Multiple Processes' is displayed in the column field instead. Sankey Diagram The material and energy flows in the network can be visualized using the socalled Sankey diagrams2. Sankey diagrams are flow charts, where the flow quantities are represented proportional to their mass by the width of the arrow. To switch to the Sankey diagram mode, click on the button 'Show Sankey Diagram' in the model editor toolbar. The diagram can still be edited, even when in the Sankey diagram mode: elements can be moved, or can be doubleclicked to see the properties and values. The Sankey diagram mode can be switched off by clicking on the button 'Show Sankey Diagram' again. The Sankey visualization of the network after the calculations of the total flows is shown in the figure below: Figure 26: Sankey diagram of the main model 2 named after the Irish engineer Captain Henry P. R. Sankey (1853-1925) Tutorial 2b Efficiency Page 23 Umberto NXT ifu Hamburg GmbH The material flows are displayed as a Sankey diagram in the "editor" window. However, the image does not yet satisfy all expectations, and can be improved. As a first step, the colours of the different materials will be changed. Select a material the colour settings of which have to be changed. The colour for each flow is defined in the properties of a material and can be adjusted by clicking on the "set colour" button. A new window appears to select colours from either existing "named colours", colour circle" or a "colour set". Click on the tab "colour set" and load a predefined colour set. The colour set can be found in: "c:\...\documents\Umberto NXT Efficiency\Colour sets" Change the electricity to yellow, the whiteboard marker and the ink to its actual ink colour, the biopolymer to grey and the rejection materials to red. Figure 27: Usage of colour set for Sankey of main model In a second step, the diagram options will be changed. Check the 'Sankey Options and Style' panel in the Arrow properties window. For this example uncheck "Border" and tick "Rounded", "Arrow Head" and "Arrow Tail". Apply these settings for all arrows. Apply changes to the Sankey arrow for individual selected arrow, or for several arrows. The keyboard shortcut CTRL+A marks the whole carbon footprint model, and when 'Arrows' is selected from the dropdown list in the Properties window, the changed will be applied to all arrows. The new appearance of the Sankey diagram can be viewed below. Page 24 Tutorial 2b Efficiency ifu Hamburg GmbH Umberto NXT Figure 28: Optimized Sankey of main model Sankey Diagram Scaling By default, the flows in the Sankey diagram are created with a standard width calculated from the largest flow in the diagram. The scale of the Sankey arrow width can be adapted on the tab 'Scaling of Sankey Diagram' in the Properties window area. Should this tab be invisible, open it using the command 'Scaling of Sankey Diagram' from the Tools menu. One slider is shown for every unit type that exists in the model. In this case these are mass (kg) and energy (MJ). Change the setting for both units to 20 px. Be aware that showing different unit types in one diagram can be confusing and misleading as it is generally not possible to compare quantities with different units. Figure 29: Scaling of Sankey diagram Tutorial 2b Efficiency Page 25 Umberto NXT ifu Hamburg GmbH The scaling ratio is shown as px per basic unit. It can be adapted by dragging the slider. Removing the check mark in front of the unit type name will hide flows of that type. The settings will not directly apply to the subnets to allow an individual design for each model and subnet. The following three figures show the Sankey diagram visualization for the main net and the two subnets. After all the settings have been adjusted as explained above, the different models should resemble the following Sankey diagrams: Figure 30: Sankey diagram of main model scaled Figure 31: Sankey diagram of subnet "production line biopolymer" scaled Page 26 Tutorial 2b Efficiency ifu Hamburg GmbH Umberto NXT Figure 32: Sankey diagram of subnet "production line colour filling" scaled Sankey Diagram Options Further options for Sankey diagrams relate to the way arrows connect to the process. These options (e.g., connectivity) can be set individually for each process in the 'Sankey Arrow' panel of the Process Properties dialog when the process is marked. The connectivity setting for a process describes how arrows can attach to the process. As a default setting, the arrows are "free", and connect to the top, left, right or bottom of the process symbol. To force the connecting arrows to leave a process in a certain way, use the "Connectivity" dropdown list to restrict the general directions of the arrows. Another way to adapt the routing of arrows in the best possible manner to the given requirements is to change the position of the bending points and the lug points. Any number of grey bending points can be added onto the arrow segment between the yellow lug points. These grey points can be moved in the X- and Y-direction. Tutorial 2b Efficiency Page 27 Umberto NXT ifu Hamburg GmbH Select the arrow segment on which you wish to add a bending point. Then choose 'Add Point' from the context menu. Drag the grey point to the desired place. The yellow lug points are created by default at the end of the first segment after a horizontal or vertical offset from the process, and at the beginning of the last segment of an arrow that is linked to the process. These yellow points can only be moved horizontally or vertically, depending on the orientation of the base segment or head segment of the arrow to the process. They cannot be removed. Play with the different sankey options and settings until the Sankey visualization satisfies your expectations. Allocation This section describes how allocation on the process level can be done in Umberto. Allocation factors need to be set, when a process specification has more than one reference flow. For example, there are four whiteboard markers of different colour in this example. A precondition for the successful establishment of product-related inventories is that the network has been calculated on the material and energy flow level. Furthermore, it is required that the material types have been set. This enables the algorithm to determine which material or energy flow is an expense for a process and which flow is revenue of the process. In Umberto NXT all materials have a 'Material Type'. This property classifies the materials. Materials with the material type are expenditures of raw materials, intermediate products or auxiliary materials. The products of any process also have the material type . Wastes and emissions obtain the material type . Materials which should not have any effect are marked with the material type . Calculate the product related material and energy flows using the "Calculate Product Flows and Cost" from the calculation menu. The "Inventory" window opens again. Select "By Compartments" in the "Input/Output per Product" section and then "Select product". Page 28 Tutorial 2b Efficiency ifu Hamburg GmbH Umberto NXT Figure 33: Selection product related inventory The algorithm determines four "products" of the overall system because they are of the material type "Good" and appear on the output side of the system. From the dropdown list of the field "Selected product" select one of the products for display. For example, whiteboard marker black. The inventory data for only this product are shown: The input materials (marker cap, energy, etc.) and the rejection related to the manufacture of this product. Have a look at the input flows. Something is not correct in this inventory for this product. There are colour solutions of all the different colours in the list. However, this is the product related inventory for a black whiteboard marker. This leads to the problem of allocations in coupled processes. Figure 34: Allocation problem in inventory The question as to how to handle allocations in co-product processes, i.e., how to assign the expenses of a process to the various products, is a general one and has been discussed widely. In Umberto there are ways to make allocations by stating allocation rules. The allocation parameter can be defined process specifications. This has to be done allocation modifications, which is to say product specific materials used for different Tutorial 2b Efficiency using the "Allocation" tab in the for all the processes which require all the processes that work with products. Page 29 Umberto NXT ifu Hamburg GmbH In this example, these are the generic materials in "Incoming Goods", the ink cartridges in the "Quality Assurance" and the ink cartridges in the "Assembly". Switch to the allocation tab in the specification for "Incoming Goods". Three reference flows are listed there. They are the products of this process. For each reference flow the expenses (here: input flows) are shown. For all three different expenses, their contribution to the creation of the product (=revenue) must be defined by coefficients. The coefficients represent the relation of the different expenses to each other. Some values are already contained in the column "Coefficient". The default setting for allocation when creating a process specification will be "User Defined" and the coefficient "1" will be entered. As a consequence, the expenses are allocated equally to the products that stem from the process (two reference flows: 1:1 or 50% each, three reference flows: 1:1:1 or 33.33% of the expenses are allocated to each reference flow). Figure 35: Default allocation setting "incoming goods" In the "Transition Specifications" window on the "Allocation" tab enter the following values in the "Coefficient" column for each reference flow" of the cargo expense Figure 36: Adjusted allocation settings "incoming goods" Page 30 Tutorial 2b Efficiency ifu Hamburg GmbH Umberto NXT In other words: The whole input flow (100%) of the generic material "bipolymer" is used for the distribution of "biopolymer", but not for the production of the other two other generic materials "ethanol & colour" and "marker caps & shell" in this process (0%). The coefficients for the two other groups of expenses have to be set in the same manner. Figure 37: Finished allocation settings "incoming goods" Open the Allocation tab for the Quality Assurance and proceed in the same way. The rejection material can stay as it is. After all, the rejection consists of the four different ink cartridges. Figure 38: Adjusted allocation setting "quality assurance" Finally open the Allocation tab for the Assembly and proceed in the same way once again. The rejection material can stay as it is as the rejection consists of the four different ink cartridges. Tutorial 2b Efficiency Page 31 Umberto NXT ifu Hamburg GmbH Figure 39: Adjusted allocation setting "assembly" Again, as the manual flows for the four different whiteboard markers are equal, it is correct that 25 % of the expenses for electricity, marker caps and marker shells can be assigned to each colour. The Sankey option can now be used to show the product flows within the model. Turn on the Sankey mode, select "product flow" and then the black whiteboard marker. Page 32 Tutorial 2b Efficiency ifu Hamburg GmbH Umberto NXT Figure 40: Selection steps for product flow Sankey The Sankey visualization of the main model should show the product flow of the black whiteboard marker in black colour. Figure 41: Sankey of product flow whiteboard marker black Tutorial 2b Efficiency Page 33 Umberto NXT ifu Hamburg GmbH Material Flow Based Cost Accounting So far in this training example, we have only worked on the mass and energy flow level. Of course, it would be very helpful to be able to integrate cost data into such an assessment. A cost accounting component has been implemented in Umberto. It is based on the mass and energy flows level and allows direct material costs as well as variable and fixed process costs to be processed. Decisions can now be made taking economic and technical aspects into consideration. Open the input/output inventory that was calculated last. One might consider using the material flow quantities listed here as the basis for cost accounting, e.g., multiplying them with the material prices. Why does this approach not go far enough? Give some thought to the unit of cost, the product! Close the "Balance Sheet" window again. Calculate the product-related flow values of the system by performing the "Calculate Product Flows and Costs" Mark an entry from the Input/Output per Product section and select an entry from the "Reference Flows" dropdown list. This inventory is much more useful because it lists the material and energy flow contributions for the creation of one product, along with the rejections caused in its production process. In the following, the steps involved in cost accounting will be explained. The material and energy flow quantities shown in the LCI can be used to calculate the material direct costs. So far no prices have been assigned. Highlight the material electricity in the material group "Energy & Auxiliaries". Change to the "Material properties" window. Click in the field Market Price, enter the value 0.073 (the price for one unit in the basic unit 'kWh', i.e. 0.073 € / kWh). These costs will be considered expenses for the cost accounting. In the same way define prices for the following materials: Biopolymer (yard good, unpressed) Colour solution, black Colour solution, blue Colour solution, green Colour solution, red Ethanol Marker cap Marker shell Whiteboard marker, black Whiteboard marker, blue Whiteboard marker, green Whiteboard marker, red Page 34 0.8 €/kg 10 €/kg 9 €/kg 12 €/kg 7 €/kg 1 €/kg 0.5 €/kg 1 €/kg 3 €/kg 3 €/kg 3 €/kg 3 €/kg Tutorial 2b Efficiency ifu Hamburg GmbH Rejection biopolymer Rejection cartridges Umberto NXT 0.02 €/kg 0.05 €/kg Please note: The rejection is disposed of as waste. The amount entered would be the cost for its disposal. Perform the calculation again and a new result window for costs will open. Remember that you need to "calculate the total flows" for the input/output inventory and then to "calculate product flows and costs". The result window should show the same results as in the figure below. Figure 42: Result for cost calculation The result window shows the revenue, the expenses and thereafter the marginal income. As there were no variable costs so far, the corresponding field is empty. The revenue obtained for the sales of the whiteboard markers is shown on the line to the right. It is calculated from the quantity of products (reference flows) and the market price entered for each product. The costs for the materials listed in the table are summed up and deducted from the revenues. The difference is the marginal income. Please note that a market price has not been assigned for all materials. For example, there is no entry for "biopolymer, cut". The reason for this is that at the moment we are looking at the inventory for the whole system. The biopolymer is only produced within the system (in the "cutting" process). It is an internal flow and therefore does not affect the accounting here. Select the costs per product in the left window and compare the different products. Tutorial 2b Efficiency Page 35 Umberto NXT ifu Hamburg GmbH Figure 43: Cost per whiteboard marker Due to the different material costs for the colour solutions, the different whiteboard markers have different material direct costs. The next figure shows the Sankey for material direct costs of all reference flows. This mode can be activated by selecting "Only Material Direct Costs" out of the Sankey diagram button menu. Figure 44: Sankey for the material direct costs of all flows Cost Types Cost types are administered in the Project Explorer. A root folder 'Cost Types' is shown below the folder 'Project Materials'. The cost type groups can be organized in a hierarchical structure exactly like the material groups. Page 36 Tutorial 2b Efficiency ifu Hamburg GmbH Umberto NXT To create a new cost type group, mark one folder under which the cost type group is to be inserted, then click on the button 'New Cost Type Group'. Alternatively right mouse-click on the cost type group, and choose the command 'New Cost Type Group' from the context menu. Properties of a cost type group, such as its name or a description can be edited in the Properties Editor when the group is selected. Create a new cost type group for the fixed costs and call it 'Fixed Costs' Figure 45: Cost type groups Fixed Costs Fixed process costs describe costs for wages, tax write-offs, rents, etc.. These are costs that will always apply no matter what the production rate or throughput. To prepare for the calculation of the fixed costs, create two fixed cost types. Call them "Depreciation" and "Fixed Wages" Make sure that the box for "Fixed Costs" in the properties window is ticked. To keep this example simple, we will consider just these two types of fixed costs "Quality Assurance" is the only process with "Fixed Wages". Open its specifications and add the material "Fixed wages". Use the drag&drop function to get the cost type from the project explorer into the specification. By analogy to the other materials, the variable name for cost will be (A00, A01, etc.). Once the cost type is in the specification, a cost input place outside the process will automatically be created. The process specification for the "Quality Assurance" still needs to be completed. In order to calculate the "Fixed Wages", assign this material to the new cost place and switch to the "Parameter" tab and create a new parameter "FW" for the "Fixed Monthly Salary". This is used to avoid a stressed working environment. Set the value to 5,000 €. Open the "user defined functions" and add the following code line to enable the calculations. Tutorial 2b Efficiency Page 37 Umberto NXT ifu Hamburg GmbH Figure 46: Implementation of fixed wages in user defined Functions Variable Costs The next step is to define cost drivers that allow one to calculate the variable portion of the process cost. They are used to set the material flow of a process in relation to the process cost. Typical real cost drivers are working hours, machine hours, driving time, setup time, area,... Again, to prepare the calculation of the variable costs, create two variable cost types and call them "Maintenance" and "Wages" The process costs themselves must be calculated in each process specification. Thus, we have to specify how the wages are calculated in every process. Go to the process "Incoming Goods" and open the parameter tab. Add a new input "Wages". Once again, the cost place appears automatically. The calculation for the wages consists of a function that considers the "Salary per Hour" (SPH) and the "Time per Parcel" (TPP). Define these two parameters in the parameter tab of the process. The SPH is supposed to be 7.50 per unit and the TPP 2 per unit. Convert the process "Incoming Goods" to "user Defined", open the function window. And type in the function according as shown in the figure below. Figure 47: Cost functions "incoming goods" The next process to implement variable costs is the "Cutting" in the subnet for the "Production Line Biopolymer, Ink-Shape". Insert the cost type "Maintenance" and also create a new parameter "Cost for Sharpening Cutters" Page 38 Tutorial 2b Efficiency ifu Hamburg GmbH Umberto NXT (SC) and set the cost for this parameter to 80 €. Open the "Function" window and enter the following code lines. Figure 48: Cost functions "Cutting" The last process to implement the cost calculation is the "Assembly". Open the specification, add the cost type "Wages" and enter the following code into the "Function" window. Figure 49: Cost functions "Assembly" Furthermore, we have to consider the fact that some of the processes are multi-product processes. For material flows we had set allocation rules. In the same way process costs have to be allocated to the reference flows of the processes. This is done on the allocation tab in the specification window. In the figure below the allocation tab is shown with the wages that would have to be allocated. For the sake of simplicity, the cost allocations are not considered for any process in this example. Tutorial 2b Efficiency Page 39 Umberto NXT ifu Hamburg GmbH Figure 50: Allocation tab for cost allocation Calculate the total flows and the product flows and cost in order obtain the overall results. Try out the different possibilities for viewing the results aggregated, disaggregated or assigned to processes, places and so on. For instance, the different cost types for each process can be viewed by selecting the Inventory tab > Cost per product by processes. Figure 51: Costs per product by processes The figure below shows the product related costs in Sankey diagram mode. Page 40 Tutorial 2b Efficiency ifu Hamburg GmbH Umberto NXT Figure 52: Sankey for product related costs Scenario Comparison The results of the material and energy flow analysis can be stored and then used for scenario comparisons. This enables one to use the modelling tool for possible improvements in the network and also helps to detect possibilities for further improvements. The export of raw data and creation of Pivot graphs provide additional possibilities. Use 'Export Raw Data' to export all data, and create Pivot Tables and Pivot Charts in Excel. This will allow creating virtually any type of diagram for the result analysis. First store the results from the previous calculation by using the "Export Cost Raw Data". Select the file place and give the file a name like "Scenario 1 whiteboard marker". After having calculated the whiteboard marker model, click the 'Export Cost Raw Data' button in the 'Results' tab. This is independent of the current column layout. Choose a file name and select a folder to save the Excel file to. After a successful export transaction a dialog is shown asking whether the Excel file should be opened. Figure 53: Export cost raw data Tutorial 2b Efficiency Page 41 Umberto NXT ifu Hamburg GmbH The export uses a template file that has the required settings and options for Pivot Tables and Pivot Graphs. The Excel file opens with the 'Charts' tab in front and different (sample) diagrams based on the raw data exported for results. Then create a new model called "Assembly Zero Waste". Copy the current white board marker model (CTRL+A to select all, CTRL+C to copy) and paste it (CTR+V) into the new "Assembly Zero Waste" model. Insert the manual flows for the whiteboard marker again and use the same quantity values as in the previous model. Set the parameter for rejection rate 'RR' in the process "Assembly" and the parameter 'CW' in the "Cutting" process to zero (0.00). Run the calculation and store the "Cost Raw Data" into a second file. For a comparison of both models we need to join them in one file and then use this as the basis for a Pivot Graph. To this end the Excel export of raw data also contains the name of the project, the model, the net and a timestamp for the export. If the results are for two different model calculations within the same model, use the 'Timestamp' column to differentiate the two exports. Should you have different names for the system reference flow (the product), this can be used to differentiate the two exports in the column 'Product'. Combine both Excel files into one by copying and pasting one table below the other. Now click inside the data and choose the tab 'Insert' and 'PivotChart'. You are asked to choose the data while Excel will select the entire table by default. Choose the option 'New Worksheet' to copy the chart into a new sheet. Compare these results with the results that had been calculated previously in the scenario with waste rejection. What significant changes would the suggested changes produce? Model Export and Safety Copy For reports and presentations the model can be exported into a graphic file format as ‘.png’-file. Select the "File" menu and then choose "Export model." To save different states of your model, just open the file in the windows explorer where the Umberto project was stored in the beginning. Copy and paste the Umberto file and give the copy a new name. Page 42 Tutorial 2b Efficiency ifu Hamburg GmbH Umberto NXT For further information about the functions covered in this tutorial have a look at the Umberto User Manual. Thank you for completing tutorial 2b. Tutorial 2b Efficiency Page 43 Umberto NXT ifu Hamburg GmbH Notes: Page 44 Tutorial 2b Efficiency Umberto® NXT Universal (v7.1) Tutorial 4 ifu Hamburg GmbH Max-Brauer-Allee 50 22765 Hamburg / Germany www.ifu.com DocVersion: 1.5 Date: October 2014 Publisher: ifu Hamburg GmbH http://www.umberto.de ifu Hamburg GmbH Umberto NXT Universal ® Umberto is a registered trademark of ifu Hamburg GmbH Microsoft and MS are registered trademarks. Windows and Excel are trademarks of Microsoft Corp. Other brand and product names are trademarks or registered trademarks of their respective holders. While every precaution has been taken in the preparation of this tutorial, no responsibility for errors or omissions can be assumed. The information in this manual is subject to change without notice. All figures are for demonstration purposes only and contain fictitious data. Reproduction or translation of any part of this manual in any form (electronic or mechanic) without prior written permission of the copyright owner is unlawful. Requests for permission should be addressed to ifu Hamburg GmbH, Hamburg, Germany. ifu Hamburg GmbH Umberto NXT Universal Tutorial 1:Umberto NXT Simple Example Time: 1 h Pages: 20 Level: New User Requirements: none What you will learn: Umberto NXT work area and window handling Create a project, a model and a first process Specify a process Calculate a small model View the calculation results Create Sankey diagrams Use the Module Gallery Tutorial 2a: U NXT LCA/UNIV Tutorial 2b: U NXT EFF/UNIV Time: 1-2 h Pages: 40 Level: Beginner Time: 3-4 h Pages 40 Level:Beginner Requirements: Tutorial 1 or experience with Umberto 5 for Life Cycle Assessment and general knowledge about LCA What you will learn: Working with activity datasets Product life cycle phases LCA calculation and results Disposal and transport activities Function and parameters Group-By Box Material type Calculation log Requirements: Tutorial 1 or experience with Umberto 5 What you will learn: User defined process specification Create subnets Analysis of input/output inventory Function and parameters Cost accounting for MFA Allocations Generic materials Co-products Sankey diagrams Tutorial 3: U NXT LCA/UNIV Tutorial 4: U NXT UNIV Time: 1-2 h Pages: 48 Level: Advanced Time: 1-2 h Pages: 15 Level: Advanced Requirements: Tutorial 1 and 2 or experience with Umberto 5 for Life Cycle Assessment and knowledge about LCA Requirements: Tutorial 1 and 2 for LCA and Efficiency and 3 or experience with Umberto 5 for Life Cycle Assessment and knowledge about LCA What you will learn: Allocations Generic materials Set multiple virtual reference flows Co-products Working with functional units Sankey diagrams Results by products Print and export results Advanced Features Tutorial 4 What you will learn: Integrate costs LCA Material Mapping Calculate Selection Page 1 ifu Hamburg GmbH Umberto NXT Universal Introduction Umberto can be used for Material Flow Analyses (MFA) in the Efficiency context and for Life Cycle Assessments (LCA). For this fourth tutorial a model for MFA has been extended for LCA studies, thus combining both use cases. In reality these models are often created separately, as the emphasis of customer projects is either more on LCA or more on Efficiency/MFA/Cost. In this case Umberto NXT Universal is used accordingly either for building and calculating the Life Cycle Assessment model, or, for building and calculating the material and energy flow model with integrated costs. Nevetheless, a real use case might require that an efficiency model has been developed and later needs to be extended for doing and environmental assessment with a product perspective. This is the use case shown in this tutorial. The LCA study was covered in Tutorial 2a and the material and energy flow (MFA) model was featured in Tutorial 2b. This fourth tutorial merges the two, making it possible to assess the environmental impact of the products produced and the efficiency and cost of the production process. To be able to learn how to use Umberto NXT LCA, the examples used in the tutorials are designed to be independent of LCI databases that require a license. Hence, the activity data sets used in the tutorials contain fictitious values that can be used without having to access ecoinvent data. For further information about the functions covered in this tutorial please consult the Umberto NXT Universal User Manual, which can be accessed in the software via the Help menu. Page 2 Tutorial 4 ifu Hamburg GmbH Umberto NXT Universal Tutorial 4: Combination of LCA and Efficiency Models Content An existing LCA model will be supplemented with a submodel that contains detailed production data and cost. The assembly stage of the LCA model will be supplemented with a subnet. The subnet will be copied from the Module Gallery The model will be adapted by translating/mapping flows Getting Started All changes made while working on a project are written into the project database as soon as they are made. There is no need to actively save the work in progress. A dialog window will be shown asking whether to save the project file onto the hard disk. Please find an appropriate name for the Umberto project file, such as "Tutorial 4". Tutorial 4 Page 3 Umberto NXT Universal ifu Hamburg GmbH Preparation Steps The idea is to integrate an Umberto NXT Efficiency Model into an existing Umberto NXT Universal model to obtain an assessment of the environmental impact and the cost for the life cycle of a product. We will integrate the whiteboard marker production line created in the Umberto NXT Efficiency tutorial (2b) into the whiteboard marker life cycle example we have created in tutorial 2a for Umberto NXT LCA / Universal. To this end, you can either reuse models previously when working on tutorial 2a and 2b, or, use the prepared sample models provided in Umberto NXT Universal. Fig. 1: Integration of an submodel with efficiency/cost perspective into a LCA model in Umberto NXT Universal First, create a new project and a new model. You may call it "Tutorial 4 Combination LCA & Efficiency", for example. Alternatively, you can continue to use an existing project where you you have created other models before. Next, it is required to copy the latest version of the model you have created in tutorial 2a on Life Cycle Assessment. This should be a model that calculates and yields calculation results (see figure 27 on page 29 of tutorial 2a). Should you not have access to the LCA model any more you can open the sample model "whiteboard marker, LCA" linked on the start page in Umberto NXT Page 4 Tutorial 4 ifu Hamburg GmbH Umberto NXT Universal Universal and copy the last version called "Tutorial 3.4 User Defined Functions". Copy by marking all elements of the model (CTRL+A) and copying them (CTRL+C) to the clipboard. Close this project (Menu File > Close). Switch to the freshly created model and paste the content of the clipboard there. Note that copying large models with many activity datasets included via the clipboard to another model may take some seconds. You may want to give a name to the newly created model. Manual flows are not taken over when models are copied. Therefore, add the manual flow 'whiteboard marker' with a flow quantity of 20,75 g in the arrow that leaves the 'Use' process (see section 'Preparation for Calculation of the Model' on page 29 of tutorial 2a). The next step is to copy a model from tutorial 2b (on Efficiency) to the Module Gallery to be able to integrate it as a submodel for the assembly into the LCA model. This model was called "Assembly Zero Waste" should calculate and produce calculation results including costs (see page 41 of tutorial 2b). Should you not have access to this model any more, you can find the prepared the sample model "whiteboard marker production, costs" linked on the start page in Umberto NXT Universal. Copy the entire model called "Assembly Zero Waste" (CTRL+A to mark all elements, CTRL+C to copy). Open the Module Gallery and paste the model (via context menu on on folder of the module gallery, or using the button 'Paste clipboard data to Module Gallery'). Fig. 2: The whole model is copied to the Module Gallery Modules in the module gallery are stored as files on the hard disk and can be accessed from any other Umberto NXT application. The path can be seen in the properties panel under "Location". If you want, you can also give a name Tutorial 4 Page 5 Umberto NXT Universal ifu Hamburg GmbH to the stored module by overwriting the default name. E.g. name the module "Subnet Assembly Zero Waste". Copying Subnet into existing Model The next step is optional, but is helpful for later: The connection places do not have names assigned. These were previously removed or hidden in order not to overload the graphical model with labels. However, these labels would be helpful to understand, which places delivers a flow into the subnet and to assign the correct place/arrow to it. Therefore, assign names to the connection places. E.g. label the connection places based on the name flow delivered from the neighboring process (marker shell, ethanol, marker cap, electricity, biopolymer / whiteboard marker on the output side). Finally, in the copied model convert the process "T1: Assembly" into a subnet. Do this choosing the command 'Convert To' / 'Subnet' from the context menu of the process. Fig. 3: Named connection places facilitate assignments The subnet opens in a new editor tab. It only shows the connection places as port places (indicated by a dot inside the circle). Next, bring the Module Gallery to front and select the previously stored module "Assembly Zero_Waste". Insert it via drag&drop into the newly created subnet of "T1: Assembly". Typically, the places would just have to be merged, to complete the integration of this subnet model section into the model. However, since we have worked with different names for flows in tutorial 2a (focused on Life Cycle Assessment, with flow names from an external tutorial LCI database) and tutorial 2b (focused on efficiency and costs, with flow names defined by ourselves), these names somehow need to be matched. Page 6 Tutorial 4 ifu Hamburg GmbH Umberto NXT Universal To this end, the fastet solution is to create processes that translate and/or map the material names of the imported subnet model of the assembly to the naming taxonomy used in the current model. The following list shows the name mappings that need to be done: Name used in LCA model (tutorial 2a) from tutorial LCI database Name used in efficiency model (tutorial 2b) polyester-complexed starch biopolymer biopolymer (yard good, unpressed) ethanol, without water, in 95% … ethanol colour solution, colour solution, colour solution, colour solution, black blue green red marker cap marker shell marker cap marker shell electricity, medium voltage electricity waste, plastic mixture rejected ink cartridges and cuttings scrap, biopolymer Mapping Names using Translators In the subnet the copied model needs to be linked to the port places to connect the flows to the upper level. Translator processes will be used. On the input side there will be three material inputs linked to the process 'Incoiming Goods' as shown in the figure below. Fig. 4: Incoming goods mapped to flow names of the model using translator processes. Tutorial 4 Page 7 Umberto NXT Universal ifu Hamburg GmbH Biopolymer Create a process "Mapping biopolymer". Connect it to the port-place for the material "polyester-complexed starch biopolymer" and add this material with 1 kg on the input side of the process. Then, convert the input place "biopolymer"of the copied assembly subnet to a connection place (switch the type in the place properties window). Connect it to the translator process. Add the material "biopolymer (yard good, unpressed)" – which can be found in the folder "Imported Materials" with a quantity of 1 kg to the output side of this translator process. Fig. 5: Translator "Mapping biopolymer" – input side Fig. 6: Translator "Mapping biopolymer" – output side Ethanol & Colour The four colour solutions (each 0.005g) together account for total mass proportion of about 0.025% of the total whiteboard marker mass (20.075g). It is assumed, that the colour solutions do not contain toxic substances and that their production required no energy intensive processes. The cut off rule from the LCA study can therefore be applied thus excluding the colour solutions. The total amount of ethanol is augemented by 0.005g in order to have a balanced mass equation . Create a process "Mapping ethanol". Link it to the port place for the material "ethanol, without water, in 95% …" and add this material onto the input side of the translator process. Now, convert the input place "ethanol & colour" of the copied assembly subnet to a connection place and link it to the translator. Add the materials "ethanol", "colour solution, black", "colour solution, blue", "colour solution, green", "colour solution, red" (all to be found in the folder "Imported Materials") to the output side of this translator process. This is a 5:1 mapping: five streams differentiated in the assembly are all subsumed under one material flow name. Fig. 7: Translator "Mapping ethanol" – input side Page 8 Tutorial 4 ifu Hamburg GmbH Umberto NXT Universal Fig. 8: Translator "Mapping ethanol" – output side Convert the process to specification type 'User Defined Function' (use 'Convert To' / 'User Defined' from the context menu or the button 'Edit User Defined Functions' in the process specification) and insert a formula which defines the input material as sum of the five outputs. Note that the calculation direction will be limited to run from known outputs to the input when using the assignment X00 = Y00+Y01+Y02+Y03+Y04. Fig. 9: Translator "Mapping ethanol" – user defined functions Attention: Make sure to set the 'Default Allocation Method' to 'Physical'. Fig. 10: Translator "Mapping ethanol" – allocations Marker Cap & Shell Create a translator process "Mapping marker shell & cap". Link it input sided to the port places for the materials "marker shell" and "marker cap". Add these two materials onto the input side of the translator. Next, convert the input place "marker cap & shell" of the copied module to a connection place and link it to the process. Add the materials "marker cap" and "marker shell" also to the output side of this translator process. Fig. 11: Translator "Mapping marker shell & cap" – input side Tutorial 4 Page 9 Umberto NXT Universal ifu Hamburg GmbH Fig. 12: Translator "Mapping marker shell & cap" – output side Note: This is actually a dummy translator. However, since it is not possible to merge two port places in the subnet, it would require changing the arrows on the main level to only have one connection place that serves as port place. For sake of simplicity this example used two separate port places that deliver "marker shell" and "marker cap". Convert the process specification into a process of the type 'User Defined Function'. Insert the two assignments X00=Y00 and X01=Y01. Fig. 13: Translator "Mapping marker shell & cap" – user defined functions Again, check to set the allocations to the correct factors! The 'marker cap' expenses are 100% assigned to the production of 'marker cap' (marker shell factor '0', marker cap factor '1'), the 'marker shell' expenses are 100% assigned to the production of 'marker shell' (marker shell factor '1', marker cap factor '0') Fig. 14: Translator "Mapping marker shell & cap" – allocations Electricity Create a translator process "Mapping electricity" and link it to the port-place for the material "electricity, medium voltage". Add this material with 1 kWh on the input side of the process. Convert the input place "electricity" to a connection place (switch the type in the place properties window). Link it to the process. Add 1 kWh of the material "electricity" (from the material group folder "Imported Materials") to the output side of this translator. Fig. 15: Translator "Mapping electricity" – input side Page 10 Tutorial 4 ifu Hamburg GmbH Umberto NXT Universal Fig. 16: Translator "Mapping electricity" – output side This is a simple name translation, the quantitie don't change (1:1 mapping). Waste Treatment The original whiteboard marker LCA example in tutorial 2a did not consider waste in the manufacturing process. The assembly of the whiteboard marker was loss free in the Life Cycle Assessment model (see section 'Assembly Process' and figure 5 of tutorial 2a). The fact that we are no building a hybrid model with a more detailed representation of the assembly requires that we do have waste flows emerging from the assembly process. These waste flows must be considered. A waste treatment process has to be added to the production phase of the LCA study. During manufacturing two types of waste are produced: 'rejected ink cartridges' and 'cuttings' from the biopolymer. For the sake of simplicity both materials will be dealt with using the dataset predefined LCI dataset "treatment of waste plastic mix, sanitary landfill [ifu tutorial dataset]". Fig. 17: Treatment of waste plastic mix, connected to T1: Assembly subnet A process for waste treatment has to be added to account for the rejected cartridges and the biopolymer scrap. This is done on the top level of the model (Main Net). Search for the tutorial dataset activity "treatment of waste plastic mix, sanitary landfill (ifu tutorial dataset) [CH]" and add it to right of the Tutorial 4 Page 11 Umberto NXT Universal ifu Hamburg GmbH assembly subnet process in the manufacture phase. Then link it to to the process T1 'Assembly'. Switch to the subnet of the assembly again. Create a translator process "Mapping waste treatment" and link it to the new port-place which leads to waste treatment. Convert the output places "scrap" and "rejected cartridges" to a connection type and link it to the translator. On the input side add the materials "rejected cartridges" and "scrap, biopolymer". On the output side add "waste, plastic mixture". Fig. 18: Translator "Mapping waste treatment" – input side Fig. 19: Translator "Mapping waste treatment" – output side Convert the process specification into a specification of the type 'User Defined Functions". Define the output flow as the sum of the input flows. Fig. 20: Translator "Mapping waste treatment" – user defined functions Attention: Make sure to set the 'Default Allocation Method' to 'Physical'. Products In the LCA model in tutorial 2a the manufacture of an average set of whiteboard markers was considered. In this case 'average' means a mix of four colours. Therefore use a mix of the current four markers in what follows. Create a translator process "Mapping whiteboard marker" and link it to the port place that delivers the material "whiteboard marker". Fig. 21: Mapping for whiteboard marker Page 12 Tutorial 4 ifu Hamburg GmbH Umberto NXT Universal Add 1 kg of this material on the output side of the process. Next, convert the output place "products" to a connection place and link it to the translator process. Add the materials "whiteboard marker, blue", "whiteboard marker, black", "whiteboard marker, green", "whiteboard marker, red" from the folder "Imported Materials" to the input side of this translator process. Fig. 22: Translator "Mapping whiteboard marker" – input side Fig. 23: Translator "Mapping whiteboard marker" – output side Convert the process specification into a specification of the 'User Defined Functions' type. Insert a formula that describes an average production mix. A whiteboard marker on the output side corresponds to a marker on the input side for each and every colour. This is a 4:1 mapping that assigns the values to four input streams from one given output flow. Note that this process can only calculate upstream (=determine iinputs from a known output quantity). Fig. 24: Translator "Mapping whiteboard marker" – user defined functions The translations and mapping should be complete now. The subnet model should look more or less as in the figure below. You can try to see if the model calculates, if you like. Hint: If you calculate the model a warning for not connected portplaces will pop up. This warning addresses virtual places for costs and can be ignored by clicking on 'Yes'. Tutorial 4 Page 13 Umberto NXT Universal ifu Hamburg GmbH Fig. 25: Model of the assembly from tutorial 2b with translator processes to integrate it as subnet into the LCA model from tutorial 2a (Subnet T1: Assembly) Page 14 Tutorial 4 ifu Hamburg GmbH Umberto NXT Universal Calculating Costs Once you have finally integrated the assembly sub-model from tutorial 2b into the LCA model created in tutorial 2a you can calculate the environmental impacts (LCIA) and the costs of your integrated model. LCIA results will show immediately in the Results pane. The results should be slightly different to the ones calculated for the model in tutorial 2a, given that the waste treatment process was added to the LCA model. For calculating the costs it is necessary to open the subnet. Then, mark all processes in the assembly subnet except the mapping processes (all processes within the floor plan of the production, see figure below). Fig. 26: Process selection for calculating costs in the subnet model Choose "Calculate Selection" (Alt+F9) from Menu Calculation. When the calculation is finished, navigate to the results area and choose "Costs per Product" to see the calculated costs. Costs have only been specified for the materials and processes in the assembly model. Flows from the background processes do not have market prices assigned to them. Hence, calculating the costs for the whole model would not yield any cost information, since the flows in the inventory (the flows that cross the system boundary) do not have market price tags. Also, the processes along the life cycle do not have activity costs assigned to them. Tutorial 4 Page 15 Umberto NXT Universal ifu Hamburg GmbH Fig. 27: Calculated costs of the model section assembly that yields four whiteboard markers Scenario Comparison The environmental impact of two different production scenarios will now be compared. The first scenario is based on the assumption of zero waste whereas the second scenario assumes that waste will be produced in the manufacture of whiteboard marker production processes. Please prepare two copies of the model used: Name them 'Tutorial 4 Combination LCA & Eff' and 'Tutorial 4 Cobination_Zero Waste' Please adjust the parameter "Cutting Waste as % of input material" in the process "Cutting" of the subnet "Production Line Biopolyymer, ink-shape" of the subnet "Assembly" to 10% in the first model and 0% in the model 'Tutorial 4 Combination_Zero Waste'. Also adjust the parameter "Rejection Rate" in the process "Quality Assurance" of the subnet "Assembly" to 10% in the model 'Tutorial 4 Combination LCA & Eff' and to 0% in the model 'Tutorial 4 Combination_Zero Waste'. Make sure, that both models use the same manual flow. Perform the calculation and "Export LCIA Raw Data" for both models. Combine both pivot raw data table and create the following graph for:    Axis Field (Categories): Model Legends Fields (Series): LCIA Model (Climate Change); Phase (Manufacture; Raw Materials) Values: Sum of Quantity Page 16 Tutorial 4 ifu Hamburg GmbH Umberto NXT Universal 0.45 0.4 0.034445877 0.029805 0.35 0.3 0.25 0.2 0.375294819 0.351547745 0.15 0.1 0.05 0 Tutorial 4 Combination LCA & EFF Tutorial 4 Combination_Zero Waste ReCiPe Midpoint (H) w/o LT - climate change w/o LT, GWP100 w/o LT - Raw Materials ReCiPe Midpoint (H) w/o LT - climate change w/o LT, GWP100 w/o LT - Manufacture Fig. 28: Calculated costs of the integrated Efficiency model The zero waste scenario affects the raw materials and manufacturing phase only. The carbon footprint of the whiteboard maker ('Climate Change' impact category) is reduced by 1.65% through the zero waste scenario. Other parameter variations and conclusions are possible using the LCIA impact assessment factors. Tutorial 4 Page 17 Umberto NXT Universal ifu Hamburg GmbH Notes: Page 18 Tutorial 4