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

EGG 2004+ New Materials: Flame Retardants
Environmental and economic implications of a shift tohalogen-free printed wiring boards
Kerstin Lichtenvort, Technical University Berlin, Germany
Carl Gunnar Bergendahl, IVF, Sweden
Glenn Johansson, IVF, Sweden
Mats Zackrisson, Aspocomp Oy, Finland
Jonna Nyysönen, Aspocomp Oy, Finland
September 7, 2004, 12:30-13:00

www.grEEEn.it
Dipl.-Ing. K. Lichtenvort
Institute for Environmental EngineeringEGG 2004+, 6-8 September 2004 in Berlin, Germany

grEEEn consortium
Funded by the EuropeanCommission

grEEEn is partner of theCARE network

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

2 University institutes:
2 Research institutes:
4 Industrial partners:

2 Service providers:
Dipl.-Ing. K. Lichtenvort
Institute for Environmental EngineeringEGG 2004+, 6-8 September 2004 in Berlin, Germany

grEEEn cost management system
grEEEn target group
Environmental experts supporting
the product design teamgrEEEn method and tool
provideCalculation of resultsl Economic profilel Legal compliance withWEEE, RoHS, EoLVl Environmental profile
Scenario definition andrecalculation
Design recommendations
Dipl.-Ing. K. Lichtenvort
Institute for Environmental EngineeringEGG 2004+, 6-8 September 2004 in Berlin, Germany

Method: grEEEn method
Product andits Life Cycle

Economicprofile

Production

EnvironmentalprofileUse

End ofLife

Legalcompliance

Scenarios

Support for DesignDecisions
Dipl.-Ing. K. Lichtenvort
Institute for Environmental EngineeringEGG 2004+, 6-8 September 2004 in Berlin, Germany

Method: Process Model
Life cycle structure

Processes within the life cycle

Pre-production
Material production
Component production
Production
Research & development
Pre-manufacturing
ManufacturingDistribution
Use
Operation
MaintenanceEnd of life
Takeback
Sorting
Disassembly
Pre-Treatment
Recycling
Disposal

Dipl.-Ing. K. Lichtenvort
Institute for Environmental EngineeringEGG 2004+, 6-8 September 2004 in Berlin, Germany

Method: Product Model
Product Model definitionl Material definitionl Product hierarchyl Connections/ disassembly operations
Productmodel:- Components- StructureRawmaterials

Preproduction

Components
Materials- Materials

Production

newproductUseusedproductEnd of life
Waste

Process model
Dipl.-Ing. K. Lichtenvort
Institute for Environmental EngineeringEGG 2004+, 6-8 September 2004 in Berlin, Germany

Method: Economic Profile
direct costdirect costdirect cost

prepreproduction
production

production
productionuseuseindirect costindirect costindirect cost

Main costelements
materials
energypersonneltransportmachinerydirect cost

EOLEOLindirect coste.g.
revenues, end of lifevaluematerial costenergy costpersonnel costtransport costmachinery costproduction
production

disposal cost…

Supplementary
cost elements
servicetooling
storagetaxes...
Dipl.-Ing. K. Lichtenvort

Institute for Environmental EngineeringEGG 2004+, 6-8 September 2004 in Berlin, Germany

Method: Environmental Profile

Simplified Indicators
Number of materials
MassToxicity index

Inventory Indicators
Energy consumption
Total waste generated

Design for Recycling
Rate of recovery
Rate of re-use and recycling
Rate of energy recovery
Recycling efficiency rate

Impact Assessment Indic ators
Raw material consum ption
Greenhouse index
Ozone depletion index
Aggregated single score

Eco-indicator 99

Dipl.-Ing. K. Lichtenvort
Institute for Environmental EngineeringEGG 2004+, 6-8 September 2004 in Berlin, Germany

Method: Eco-indicator 99 (1/2)
lConsolidation of an LCA Inventory to a single score

lAggregation based on damage analysis for three damage
categories:− human health− ecosystem− mineral and fossil resourceslMarginal damages conceptlIntegration of cultural theory, calculation based on different
perspectives possible (egalitarian, individualist, hierarchist)l

Weighting based on results of a panel procedure among Swiss
LCA interest group

Dipl.-Ing. K. Lichtenvort
Institute for Environmental EngineeringEGG 2004+, 6-8 September 2004 in Berlin, Germany

Method: Eco-indicator 99 (2/2)
Damage tomineral andfossil resources[MJ surplus
energy]Surplus energy for future extraction

Concentration minerals

Surplus energy for future extraction

Fossil fuel availability (p. type)

Regional effect on vascular plant species

Change in habitat size

Local effect on vascular plant species

Indicator

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

Damage tohuman health[disabilityadjusted life
years (DALY)]

Normalisation
and weighting

Damageanalysis

Acidif./eutr. (occurrence target species)

Changed pH and nutrient avail.

Ecotoxicity: toxic stress (PAF)

Concentr. Urban, agri, nat. soil

Climate change (disease and displacem.)

Concentration greenh. gases

Ozone layer depl. (cancer and cataract)

Concentr. ozone depl. gases

Ioniz. Radiation (cancer cases and types)

Concentration radionuclides

Respiratory effects (cases and type)

Concentration SPM and VOC’s

Carcinogenesis (cancer cases and type)

Concentration in air water, foodExposure andEffect analysis

Extraction of minerals
and fossil fuels
Land-use:
occupation andtransformation
NOx
SOx
NH3
Pesticides
Heavy metals
CO2
HCFC
Nuclides (Bq)
SPM
VOC’s
PAH’s

Resource analysis
Land-use analysis
Fate analysisSource: The Eco-indicator 99 Methodology Report 3rd Edition, Goedkoop & Spriensma, 2001, electronic version downloaded from www.pre.nl

Dipl.-Ing. K. Lichtenvort
Institute for Environmental EngineeringEGG 2004+, 6-8 September 2004 in Berlin, Germany

Method: Legal Compliance
1000
900

1000

900

900
800
600

mass in [ppm]700

Arbitrary
backgroundlevel:
Fulfilled:

500

600
500

Not fulfilled:

400
300
200

100

100

60

100 80100
201000lead

mercury

restricted substances

cadmium hexavalentchromium

Compliance with RoHS: NoPBB

PBDE

Yes q
Dipl.-Ing. K. Lichtenvort
Institute for Environmental EngineeringEGG 2004+, 6-8 September 2004 in Berlin, Germany

Case Study: ProductProductTraditional PWBs containing a halogenatedflame retardant vs. PWBs containing a halogenfree flame retardantResearch design

Functional unit
A PWB production panel containing 54 repeated
4-layer laser drilled PWBs for mobile phones

Focus
Two life cycle phasesl The design phasel The manufacturing phase (including preproduction)
Dipl.-Ing. K. Lichtenvort
Institute for Environmental EngineeringEGG 2004+, 6-8 September 2004 in Berlin, Germany

Case Study: Modelling
Process model

Product modelDesignDesignX = 555 mm
Y = 610 mm
Z = 0,9 mm

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

Production
Photo resist
ExposeDevelop

Etching
Stripping

Depositionof bond oroxide layerPressing

Photo resist
ExposeDevelop

Cleaning
and hole
metalisation

Desmear-ing

Drilling

Copperand tin
plating

Solder
Mask

Cleaning
Oxide
protection

Machining
Electrical testing
Final inspection

Dipl.-Ing. K. Lichtenvort
Institute for Environmental EngineeringEGG 2004+, 6-8 September 2004 in Berlin, Germany

Case Study: Scenarios
Process step

Traditional
PWB

Halogen-free PWB
Worst caseBest case

DesignOriginal process

Increased design
cycle time

No increase indesign cycle time

Pressing

Original process

Increased cycle
time

Increased cycle
timeDrilling

Original process

Reduction in
number of panels
that can be drilled
at the same time

No reduction in
number of panels
that can be drilled
at the same time

Desmearing

Original process

Increased cycle
time

No increase incycle time

Solder mask

Original process

Increased cycle
time

Increased cycle
time

Dipl.-Ing. K. Lichtenvort
Institute for Environmental EngineeringEGG 2004+, 6-8 September 2004 in Berlin, Germany

Case Study: Economic Profile (1/2)
Cost increase in percentage per cost element(a)%50403020100(b) %Personnel (Design)

Materials

Aggregated
Personnel/...

Personnel (Design)

Materials

Aggregated
Personnel/...

Worst case (a)andbest case (b)

4030
20100

Dipl.-Ing. K. Lichtenvort
Institute for Environmental EngineeringEGG 2004+, 6-8 September 2004 in Berlin, Germany

Case Study: Economic Profile (2/2)
Comparison of cost effects in % between
worst case and best case%60

Worst caseBest case5040302010"Totalcost"

PressingDesmearing
So
lderm
askLa
minatePr
ep
reg
En
try
boarBadckup
boardDrillingDe
sign0

Dipl.-Ing. K. Lichtenvort
Institute for Environmental EngineeringEGG 2004+, 6-8 September 2004 in Berlin, Germany

Case Study: Environmental Profile (1/2)
Analysis of the environmental profile
Worst case (a) and best case (b)PWB
PWB production
Material production
3000

Ecoindicator 99 (mPt)

Ecoindicator 99 (mPt)

3000
2500
2000
1500
1000

2500
2000
1500
1000

500

500

00

Traditional
material

Halogen-freematerial(a)Traditional
material(b)Halogen-freematerial
Dipl.-Ing. K. Lichtenvort

Institute for Environmental EngineeringEGG 2004+, 6-8 September 2004 in Berlin, Germany

Case Study: Environmental Profile (2/2)
Increase in environmental impact.

(b)

Eco-indicator 99 (mPt)(a)

Eco-indicator 99 (mPt)

Worst case (a) and best case (b)4035302520
1510509876543210

CopperLaminate

Prepreg

Drilling

Pressing Desmearing Solder mask

CopperLaminate

Prepreg

Drilling

Pressing Desmearing Solder mask
Dipl.-Ing. K. Lichtenvort
Institute for Environmental EngineeringEGG 2004+, 6-8 September 2004 in Berlin, Germany

Conclusionsl

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

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

l

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

l

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

lWith increasing manufacturing volumes the materials cost for halogenfree laminates is expected to decrease.

l

Cost ranging between nearly zero and 10 € per panel.
Dipl.-Ing. K. Lichtenvort
Institute for Environmental Engineering