Manual for the CCaLC Optimisation Tool (Demo version)
Contents
1. Gubraphecaton Potentia ig Phop Eg u W Opona Liye Depetion Fotentis fo Pl iB fF ou Paiga Chane Deaan Polenaa eg Ethere fig a Human Toodoilhy Potentia eg CXBHEig uu Carbon Footprint ay CO2 6q Fu Figure 6b The form for defining optimisation constraint s Step 3 Optimising e The Excel status bar shows progress during optimisation Figure 7 This may take some time During the optimisation the user can terminate the procedure by pressing Esc e When the Solver finds an optimum result the message box shows Done and the button View Optimisation Report is enabled The optimisation results can then be accessed by clicking on this button examples shown in Figures 8 amp 9 e f the Solver cannot find a feasible solution the message box shows Tool did not find a result Click Back to the top level at the top of the screen to go back and review the data input or constraints Status Bar Figure 7 The view during optimisation View Carbon View Other Back to the View Details of Footprint Environmental View Operating Top Level Each Stages Graph Impacts Cost Life cycle stages CO eq kq f u Operating Costs GBP f u Stage Optimum Base Case CF Reduction Optimum Base Case COSt Reduction Case Case i 236 86 239 0 47 93 106 22 41 25 Storage 169 Use 1549 100 000 Summary Results Optimum Relative ase Base Ca2. Stages use Market entry for Paint Demo Appliance used in this SEA Eei Stage r Define alternatives for Appliance Group 1 Refrigerator category A Refrigerator category B Refrigerator category C Refrigerator category D Refrigerator category E Refrigerator category F Refrigerator category G Freezer category 4 Freezer category 4 Freezer category 4 Freezer category B Freezer category C Freezer category D 4 Refrigerator category A a Refrigerator category 4 Multiple selection allowed Update Exit Applicance Alternatives Figure 20 The Use Form 2 for defining the optional information for the use stage 8 5 Waste management The information on the waste management stage can be reviewed by clicking on the Waste Management box at the top level of the tool e Click the box Waste Management on the top level of the tool to bring up the Waste Management Form 1 Figure 21 e For each waste stream the waste management alternatives are listed in the alternative s list or shown in the Waste Management Scenario e Select the check box Define cost of alternatives and click Update details to review the cost in Waste Management Form 2 The generic Waste management scenarios used in the demo version are shown in Table 1 14 Waste i thd a 1 prn Waste tian agement Form 2 Cost of waste management paper Location PU 27 Incitver ation paper
3. e g kg f u and the quantity is a fixed number lf Composition is selected the unit of the raw materials is of product and quantity is a fixed number If Composition Range is selected the unit of the raw materials is of product and the composition is set as variable in the optimisation e g as in the optimisation study case Paint Demo J Foal D i r Nnfinn Define Define Yiu Optimisation Optimisation Optimisation oe Optimisation Ruwi x Details Objective Boundary Optimisation pp Optimisation a ae gt lt Optimisation Details Functional unit f u Paint Demo Objective Minimise Carbon Footprin Defina properties of the optimisation probbern Optimisation category Fonnat of nav mataria quantity Figure 10 The form for defining reviewing optimisation details 7 2 System boundary Clicking on the System Boundary button brings up the form to view the product life cycle stages included in the optimisation see Figure 11 The life cycle stages considered in the optimisation are shown on the right hand side of the user form In the demo version of the tool these cannot be changed In the full version the stages can be selected and de selected as desired EX Microsoft Excel E t Tow 2003 theme L x HLT ie y ma F hira an Preis bea Smee a ae ka RE h hira Data SeN ee FIR Defne Dem Deine Op misatan Optimkaton Optimisation Detar Capac Boundary i a Functional
4. Amount 5 of associated Pigment lt 30 product Cost 1 GBP kg Link with Raw material is an optional constraint in the optimisation procedure which can be defined in the production stage Energy The energy alternatives for heat and electricity are presented in Tables 4 amp 5 In the production process energy consumption is defined with a unit of kWh kg product in this study With different paint generation the energy amount is calculated by the tool In the storage and use stages the energy is defined as associated alternative which links with the input material As presented in Table 5 the alternatives for high performance and market entry are different Table 4 Energy alternatives in the production stage Energy Base Case energy AE a Optimisation Quantity kWh kg product E EU grid Electricity from heavy fuel a Table 5 Energy alternatives in the storage stage and use stage Energy Base Energy alternatives Quantity Link with Case Optimisation Case kWh kg Storage stage Electricity from heavy fuel 0 008 Electricity UK grid Oil Electricity UK grid 0 008 Market entry Electricity EU grid Heat from heavy fuel Heat from heavy fuel oil oil Heat from natural gas Electricity UK grid 0 011 High Energy Group 1 Electricity from hydro 0 014 performance Electricity EU grid 0 3 Energy Group 1 4 gt Market entry Electricity France grid 06 El
5. With a different objective function for example Maximise profit the difference between the selling price and operating costs a different optimised case can be obtained Market entry is now chosen as the best alternative because more of this type of paint is needed to cover the same area which results in the higher total profit However the carbon footprint increases significantly compared to the previous optimisation case or even with the base case as shown in Table 6 19 Table 6 Summary results objective maximise profit Optimum Base Cas Relative Case Difference comment Carbon Footprint kg f u 336 71 283 17 18 91 Operating Costs GBP f u 96 78 65 86 46 95 Profit GBP f u 141 22 85 00 66 14 The carbon footprint and the profit can be balanced by selecting Maximise profit per unit of carbon footprint reduced as objective function The results are presented in Table 7 Market entry is selected as the best paint Table 7 Summary results maximise profit per unit of carbon footprint reduced Relative Optimum Base Difference Comments Case Case Carbon Footprint kg f u Carbon Footprint kg f u 258 57 283 17 Operating Costs GBP f u 108 73 65 86 65 09 Profit GBP f u 129 27 52 08 9 1 5 Conclusions The results show that the carbon footprint of the system can be reduced by 32 compared with the base case However this reduction is at the expense of other envi
6. w energy credt Location EU 27 Paper cardboard Scenario Cost GEP unk waste Define waste Gsposaifrecyding for Waste stream i CCalC database Ecowrwernt database Ext Figure 21 Forms for waste management information Table 1 Waste Management Scenario laterals _ 1 Landfill E Incineration with E lt lt recovery Aluminum C 3460 60 65 40 40 00 61 70 38 30 0 00 Glass 30 8870 00 Source Department of Environment Food and Rural Affairs DEFRA Making the most of packaging A strategy for a low carbon economy 2009 8 6 The transport stages To review the transport steps between the life cycle stages e Click the relevant box Transport at the top level of the tool which brings up the Transport Form 1 The materials from the associated stage are shown in List Box Transport Form T e Select the target transport stage and Click Define Transport to show Transport Form 2 Transport alternatives can be viewed by selecting the item in Transport Alternatives list In the optimisation transport type and distance are set as variables e Click Exit to leave Transport Form 2 e Click Exit in Transport Form 1 which brings up the Message box If No is selected Transport Form 71 will be closed If Yes then transport steps that are being reviewed should be selected Transport Form 2 Transport Form 1 Doline transport Tr
7. Armour kg 0 17 Use Destination Packagings for Output WA of Output Outpt Packaging 1 3 974 Outpt in the optimisation case High performance Destination Amourt kg per unt acolkation Cost GBP ip Packaging for current output Output Packaging 2 Procluction Form 3 Define product from stage Cost GP kg Add constraints associated with Link with raw material composition Coenposition Details for current output High performance To Use High performance Const Pigment gt 30 Figure 15 The form for the outputs in the production stage For example in Paint Demo there are two alternative outputs Market entry Link with material pigment lt 30 of product and High performance When pigment gt 30 of product Note that the output cost is the selling price Packaging for the outputs can also be defined at this stage via the button Define the Packaging for Output Figure 16 The packaging for the output is set as an associated parameter which means it will be calculated with the associated output but not optimised Production Fom 1 Palni manulacture Input Materials Energy Output waste Rages Pairt manufacture Outpt in the Output Market entry Base Case Amak kg appkcation 0 17 Dest Packagings for Output w of Outpt Output Packaging 1 3 974 Output in the Optimisation Case Output Market ertry Amak kolAppicaton pon G Modify cur
8. the raw material quantity it is expressed as a fixed number with unit Mass unit function unit or Mass unit unit product depending on the Optimisation Category defined in Optimisation Details e f composition is defined as raw material quantity it is expressed as a fixed number of the final product Raw Maternal Form 1 Raw Material Form 2 Define Details of Raw Materials Raw Mater bots Row material for product Detals in Base Case Row material ancl aternatiwes Detak n Race Case eee Fiber 2 Compostiorc 20 To agn Part mansi active Namec Filer 2 i aS To dape Par t marsi atre ListBox1 Compostion range Keep 2 came oc Base Case ro avedable abernetives for thes esterus a Cost EP AQ t am material Choose aRernative s for Fiber 2 fg i ser Select database Sewn Assooated ri toron materials Database section Ad maera bd Oeteoaso CCa tcomwert Podagra for raw material Pier 2 lt Wood pslet 0 liaig tan materna ARornative s bt Waste from rae mater AA AA AA 2 Sh a i i i i i ie oe i i 42 2 2 2 22a RBZ AM 3333333333335 r rr AAA AAAAS _ ttt tt ttt tS saa aa aa a8 3535 4 Figure 12 The forms for raw materials information 8 2 The production stage The information on the production stage can be reviewed by clicking on the Production box at the top level Figure 13 10 e Click the box Production at the top level to go to the production stages Fig
9. e 13 8 4 WISE StaG 6 icaccadsaiaicncndeacncnaraeiel a a 13 8 5 Waste management ii ctedivavenneseutieeddesudd aa suiuw eben deete ancuamdenmienincehl Mutiunvelluesiludseonens 14 8 6 TEAMS DOME SAG 6 nir r EE 15 9 Example CASS SILIGICS sacumessumesonrerauntvoutvechusudeuupiatiy EEEE E a EREEREER RASE 16 9 1 Pant DEMO kerniinoniun i E E A A E ern ene er een 16 9 1 1 MOGUCOM aia a N ch aectaencenecch as 16 9 1 2 Goal and scope of the StUQY nescia a E A 17 9 1 3 Alternative description scsasccttesadsccscdoeasteseeevedtecdictadiadebsetessidanieteettectea ee 17 9 1 4 impact assessment cnrs rii pis EEEE ENE TE 18 9 1 5 GONGCIUSIONS sianie a a a i 20 APERO Arrea a A E reer crate erent ere 21 Apendi B asau E a a dem ated eaanpmndliaaalara deep fuaniiee 22 ADDENGIN O oiie ra nann E E EE A 22 1 System requirements The CCaLC Optimisation Tool was designed and built using the English version of Microsoft Excel 2003 and 2007 for Windows XP It may not run properly on non English operating systems as well as on older versions of Excel or Windows The tool is designed for use on PCs and is not suitable for use on Mac computers Before using the tool please ensure that Solver is loaded in Excel see Appendix C This Demo version of the Optimisation tool is independent of the CCaLC Tool and can be run without the need to download the CCaLC Tool first Please note that depending on the speed of your computer some operations may take longer to comple
10. ectricity from natural i E High Electricity from hydro performance Waste Management and Transport The transport distances and the transport types are defined as the optimisation variables for the Transport stage which can be reviewed by clicking the relative boxes in the worksheet In the Waste Management phase the optimisation variables are the alternative methods for each waste stream 9 1 4 Impact assessment With the objective of minimising carbon footprint the results of Paint Demo as optimised in the tool are shown in Figure 23 High performance one of the paint alternatives is chosen as the optimum paint The optimised carbon footprint is 192 6 kg CO eq per 1000 m of painted area Compared with the Base Case the carbon footprint is reduced by 32 However this results in 4 increase in the human toxicity potential from the Base Case as shown in Figure 24 Carbon Footprint 3 00E 02 2 50E 02 2 00E 02 1 50E 02 1 00E 02 CO2 eq fu 5 00E 01 0 00E 00 Optimisation study Life cycle stage o Base case Figure 23 Carbon footprint for the optimised case compared with the base case Human Toxicity Potential 100 00 80 00 60 00 2 i 40 00 20 00 0 00 20 08 y Q Optimisation study Life cycle stage O Base case Figure 24 Human toxicity potential for the optimised case compared with the base case
11. erripecerl Paget Pee F Tl dat bears Zot Puce Par a e fire gt Production Part marufectune Addit 1 Production Pant manuf scture Addii 2 gt Production Pant manufacture Water gt Production iPad marl schure Trarpart Type J x Packiig Gers hira Cos of beah aE u Trepi Aiens De you art bo update ang other sernative aart of the mai from khi ha i Figure 22 The form for defining transport stages 9 Example case studies To demonstrate the capability of the tool the demo version of the CCaLC Optimisation Tool has two example case studies built in addressing two types of optimisation problems i Identification of optimum product and its composition given the alternative products Paint Demo identifies the best type of paint and optimises its composition for painting a specified wall area This case study is loaded up when the Demo CCaLC optimisation tool is opened li Optimisation of a product system along the whole supply chain Bioethanol Demo case study optimises the supply chain in the Bioethanol production system The optimisation tool chooses optimum raw materials production conditions etc according to the objective function and the constraints selected This can study can be loaded from the menu CF study Load optimisation study For both case studies the system boundary and the information on the life cycle stages have already been defined and t
12. hese can be reviewed by clicking the relevant box for each life cycle stage on the top level of the tool e g Raw materials Processing etc The user can run optimisation with the default values or change some of the default settings if desired Paint Demo is detailed below as an example to illustrate the capability of the CCaLC Optimisation Tool 9 1 Paint Demo 9 1 1 Introduction This section provides a brief description of the optimisation case study Paint Demo The following sections describe the goal system boundaries and inventory data used for the case studies Two types of the paint market entry and high performance are available for painting an area of 1000 m The components of these two paints are the same but are mixed in 16 different proportions This determines their performance which is in turn determined by the objective function s and constraints For example the objective function could be to minimise the carbon footprint and or costs subject to the constraints on production Capacities and certain environmental impacts The optimisation tool then chooses the best type of paint and optimises its composition to satisfy the objective function and the constraints 9 1 2 Goal and scope of the study Goal of the study The main goal of this study is to answer the questions such as which paint should be chosen for painting what is the optimised composition for the chosen paint which alterna
13. ifies the degree of integer tolerance This argument applies only if integer constraints have been defined You can adjust the tolerance value which represents the percentage of error allowed in the optimal solution when an integer constraint is used on any element of the problem A higher degree of tolerance allowable percentage of error might speed up the solution process Convergence A number between O and 1 that specifies the degree of convergence tolerance for the nonlinear problem When the relative change in the target cell value is less than this tolerance for the last five iterations the optimisation converges to a solution 21 Appendix B Load the Solver Add in by the tool The tool automatically checks if the Solver is loaded properly when the users open it If the Solver was not added into this tool properly the tool will reload it Message as shown in Figure B 1 To confirm this reloadiing the tool will be saved and closed automatically this operation may take longer time to complete Then open the tool again i Microsoft Excel The tool has added Solver into the add in list This File will be saved and closed Please open the File again Figure B 1 Appendix C Load the Solver Add in in a new workbook e In Microsoft Office Excel 2007 8 uo et ee Open Microsoft Office Excel 2007 Click the Office Button Click Excel Options Bottom right Click Add Ins Click Go Bottom middle Check the box f
14. inimise Carbon Footprint Figure 1 Top level view of the CCaLC Optimisation tool 6 Life cycle optimisation with a demonstration case study 6 1 Starting the optimisation tool Figure 2 shows the opening screen of the optimisation tool When the tool is opened it automatically checks whether the Solver is installed or linked properly During this procedure the tool may reload the Solver see Appendix B In that case the tool will be saved and closed automatically this operation may take a short time to complete The user should then open the tool again CCaLC Optimisation Carbon Optimisation over the Life Cycle of Industrial Activities CaLC http www ccalc org uk About CCaLC CCaLC was developed by a research group at The University of Manchester led by Professor Adisa Azapagic The project was funded by Carbon Trust EPSRC and NERC grant no EP FOO3501 1 The optimisation tool was developed by Yu Rong The following researchers were also involved in the development of the CCaLC Optimisation tool Haruna Gujba a CCaLC Optimisation Anthony Morgan i fe ne By downloading the CCaLC Optimisation tool the user accepts the CCaLC Optimisation 2010 following terms and conditions To use the tool solely for their own purposes Not to use the tool for any income generating consulting services Not to copy or distribute the tool to a third party CCaLC Optimisation 2010 Figure 2 The opening screen of the CCaLC O
15. ity high voltage Electricity high voltage Electricity high voltage Electricity high voltage Electricity high voltage Multiple selection allowed Exit Ecoinvent database Search in Database Electricity From heavy Fuel Oil Electricity UK gridfLocation G Be G D E Fi Ft a Figure 18 Storage form 2 8 4 The use stage The information on the use stage can be reviewed by clicking on the Use box at the top level of the tool Use Form 1 Figure 19 pops up with the basic information for the use stage e Product Which product s from the production stage is are used in this stage e Application What is the product used for e g to eat e Quantity according to Optimisation Category as defined in Optimisation details Section 7 1 quantity could be expressed as Amount e g Bioethanol Demo or Application amount e g Paint Demo 13 The procedure for reviewing the Use stage is summarised as follow e Click on the box Use on the top level e Select the stage in the Existing stage list and click Define Use This brings up Use Form 2 Figure 20 which allows for other details to be reviewed Energy Waste and Appliances Define Use fx Product Market entry Application Amount imz ieee pdate Existing stage Use Market entry For Paint Demo Beane Use High performance for Paint Demo ilies Remove Energy Waste Appliances
16. of Mancheste calc Manual for the CCaLC Optimisation Tool Demo version October 2010 List of contents 1 SVS Ml POCUINGINCINS srske cians atthe at eau A eee 2 2 Tooldevelopment credits odanin aeee TE 2 3 PCKMOWI EGO SINGIN oian e a a endecale Mant aaa 2 4 WAINO GU CUO cieri prn E E 2 5 CCaLC tool overview CCaLC Optimisation tool D MO ccceeeeeeeeeeeeeeeeees 2 6 Life cycle optimisation with demonstration case StUCY cccsseeeseeeeseeeeeneeeenees 3 6 1 Stang Ne OpllmMiISAlON 1OOl cartes eeetes E a 3 6 2 LO AGING KAN AMaly SIS erir na canmneecetsheaaine Gel S 4 6 3 Simplified procedure to optimise the existing SYSTEM cccccccceececeeeeeeeeeeeeees 5 7 Reviewing the defined information of the life cycle optimisation cccceees 8 7 1 Optimisation detalls simis nesa e E 8 7 2 DV SUS MN OUNCE zirenaren sheath eaeatea ante antaentenaes eee aete tale ie ee eetees ee 9 8 Reviewing the defined information in each life cycle Stage ccccecseeeeeseeeeeeees 9 8 1 Raw MaLellalS Slade Airc itucindandceteerantritiatitieciamectindteeceameleeie tiniest tcc veates 10 8 2 Productions tagG eenen a cna tennceusaateanignnaventesdsatiesaucsaaseee 10 8 2 1 Production Stage Energy cccccccsseecceseeecceeeecsneecesueseeseeeeeseaeessaneeseas 11 8 2 2 Production stage OQUP acna N 11 8 3 no 6c 0 Inst Fe a gt DeRnne men Cnn Onan ete Sent Auer rie Ineo E nee enters nee tre
17. onal constraints The CCaLC Optimisation Tool works in conjunction with the CCaLC Tool The CCaLC Tool is used first to estimate a range of environmental impacts and value added along a supply chain The Optimisation tool can then be used to optimise on the carbon footprint or costs profits However for this Demo version of the tool the Optimisation Tool can be used without the CCaLC Tool 5 CCaLC Optimisation Tool Demo overview The tool has been developed in Microsoft Excel and is run by macros The worksheets are locked and are not accessible to the user Information can be entered into the tool via user forms that are activated by clicking buttons at the top of the worksheets and the relevant box for each stage The user can navigate around the tool using the links provided Figure 1 shows the top level layout of the tool This represents a map of a typical product life cycle and includes the following stages Raw materials Production Storage Use Transport and Waste The Excel menu bars and toolbars are largely disabled although the in built excel File Save functions can be used to save the tool at any point during the analysis There are several menus specific to the tool the functions of which are described later in this manual Define Detine Detine Start jE Ea Optimisation Optimisation Optimisation S Optimisation r a Details Objective Boundary H Report RUM Satori Functional unit f u Paint Demo 1000 m2 Objective M
18. onfirm the change To delete the constraint select the defined constraint in the list and click Remove Click Next to confirm the change e Constraints over life cycle Figure 6b Select the economic or environmental constraint over the life cycle and provide the maximum value Click Next to confirm the change To remove constraints de select the check box Click Next to confirm the change e Tool Options Figure 6b The user may alter the information for each edit box on this tab and click Update The description for each option is detailed in Appendix A Click Next button on the Constraints in Optimisation form which brings an overview form and click Optimise Define Define Define Start Reset Optimisation Optimisation Optimisation a E measol Details Objective Boundary plimigation Optimisation Zi a ee Constraints in Optimisation Functional unit f u Objective Minimise C Process Capacity Constraints over Life Cycle Tool Options Stages in production z Max Capacity kg ea Figure 6a The form for defining optimisation constraint s Constraints over life cycle Tool Options Constraint in Optimisation Constraints in Optimisation Process Capacity Constraints ower Life Cycle Tool Opora Fe Max Operating Costs GEPI Fu 200 Errei greeni integers Be Acidification Potential hg S02 Eg fu
19. or Solver Add In If Solver Add In is not listed use Browse to locate SOLVER xlam in the application file e g C Program Files Microsoft Office OFFICE12 Library SOLVER SOLVER xlam and Click OK If prompted that Solver is not installed click Yes to install Insert the install media if prompted e In Microsoft Office Excel 2003 FUE D O Open Microsoft Office Excel 2003 Click the Tools on the top menu Click Add Ins If Solver Add In is not listed use Browse to locate SOLVER xla in the application file e g C Program Files Microsoft Office OFFICE11 Library SOLVER SOLVER xla Check the box for Solver Add In and Click OK 22
20. ptimisation Tool 6 2 Loading an analysis There are two optimisation studies built in the demo version of the CCaLC Optimisation Tool to demonsirate how the performance of a system can be optimised On opening the tool the first case study Paint Demo is loaded up The second case study Bioethanol Demo can be loaded by clicking on the CF study menu item at the top of the screen see Figure 3 CF study Share Data Data Impor Load optimisation study Save optimisation study Start new study Delete optimisation study 3 Figure 3 CF study menu options Select Load optimisation study from the CF Study menu option A form for loading the case study pops up Figure 4 The user can then select the study from the list and click Load This loads the base case study and the related specification for optimisation as specified for the demonstration purposes To optimise the case study after loading it the user needs to click Start Optimisation at the top of the top level view This is explained in the next section Existing optimisation case study Paint Demo Bioethanol Demo Figure 4 The form for loading a demonstration case study Note e n the demonstration version of the optimisation tool the functions of the rewriting deleting case study and starting new study are disabled These are fully functional in the full version of the tool 6 3 Simplified procedure for optimising the e
21. rent output Cost GBP fg C Add new output Oon Packaging for Current Output Output Packaging Ea Packaging Production Form 4 Packaging for Output Output Packaging Amak of output 4 Cost GBP kg packaging 0 8 Figure 16 The form for output packaging 12 8 3 The storage stage The information on the storage stage can be reviewed by clicking on the Storage box at the top level Figure 17 Click Define Existing Storage which brings up the Storage Form 2 Figure 18 This shows information on Energy and Waste The steps in this form are similar to those used in the Production stage see Section 8 Storage Form 1 Define Storage Functional u Objective shasta Output material Destination Existing storage Storage Market entry Storage High performance Storage Energy Waste Stages Energy used in the Base Case Electricity UK grid Amount Heat From heavy Fuel oil Amount 10 m2 Storage Market entry 8 06 kwh i e 8 06e 03 k vh unit F u 7 kWh i e 1 05e 02 kwh unit F u a Keep the selected energy same as Base Case no available alternatives Define alternativets For Electricity UK grid CCaLC database Bio diesel From rape seed Bio ethanol from corn Diesel used in Farm machine Electricity high voltage Ar Electricity high voltage Electricity high voltage Electricity high voltage Electric
22. ronmental impacts notably human toxicity potential Optimisation on profits results in a 66 increase of profit but the carbon footprint is now 19 higher than in the base case Simultaneous optimisation on both objectives leads to an 8 7 reduction in the carbon footprint and 52 increase in profit in comparison to the base case 20 Appendix A Tool options The user can control several options used by the optimiser through the Tool Options tab on Constraints in Optimisation form Figure A 1 Tool Options Constraints in Optimisation Figure A 1 Tab for tool options Max Time The maximum amount of time in seconds will soend solving the problem The value must be a positive integer The default value in the tool 3000 is adequate for most small problems but you can enter a value as high as 3276 7 Iteration The maximum number of iterations use in solving the problem The value must be a positive integer The default value 3000 is adequate for most small problems but you can enter a value as high as 32767 Precision A number between 0 and 1 that specifies the degree of precision to be used in solving the problem The default precision is 0 000001 A smaller number of decimal places for example 0 0001 indicate a lower degree of precision In general the higher the degree of precision you specify the smaller the number the more time tool will take to reach solutions Tolerance A decimal number between O and 1 that spec
23. se pimorenee gy Comments Ope f u i e rating Costs Profit GBP f u 129 27 85 00 62 08 _ Increasing Figure 8 Example results for an optimised study summarised in tables E Microvolt Excel Opt care OT Rename PS Bio Edt yew art Format Took Qata Mindre bio adio POF imj i Global Warming Potential CO eg Hu Figure 9 Example results for an optimised study shown graphically 7 Reviewing the defined information of the life cycle optimisation 7 1 Optimisation details The Optimisation details can be reviewed by clicking on the Define Optimisation Detail button at the top of the screen at the top level of the tool The user form is then activated as shown in Figure 10 Note that in the Demo version of the tool the information in this form is locked Click Exit after reviewing The information includes 1 The details of the functional unit used in optimisation This is normally the same as the name of the functional unit in the Base Case which is being optimised 2 The units for mass energy distance and volume used in the optimisation 3 The description of the optimisation problem e Optimisation category this defines what the optimisation will be targeted at for example Product for different use or Various products for specified use e Format of the raw material quantity f Amount is selected the unit of the raw materials is mass unit functional unit
24. te Normally the hour glass will indicate that the system is busy If it appears that there is no response after clicking on an option or action button or the cursor does not turn into the hour glass please wait a few seconds as the system is busy and may take some time to complete the action 2 Tool development credits The CCaLC family of tools CCaLC and CCaLC Optimisation has been developed by a research group based at the University of Manchester and led by Professor Adisa Azapagic The CCaLC Optimisation Tool was developed by Yu Rong The following researchers were also involved in the development of the CCaLC Optimisation tool e Haruna Gujba e Harish Jeswani and e Anthony Morgan For further information contact adisa azapagic manchester ac uk 3 Acknowledgements The CCaLC project was funded by the Carbon Trust EPSRC and NERC grant No EP F003501 1 Numerous industrial partners have contributed to the development of the tool and their help is gratefully acknowledged For more information visit www ccalc org uk 4 Introduction The CCaLC Optimisation Tool has been developed to help minimise carbon footprints along supply chains In addition to carbon footprints economic costs and profits can also be optimised and the trade offs between the carbon and costs profits examined Other environmental impacts e g human toxicity acidification eutrophication etc as well as process capacity can be included in optimisation as opti
25. tives should be used to substitute those in the existing study what are the trade offs for other environmental impacts e g human toxicity acidification eutrophication etc and what is the optimised case Functional unit The functional unit of this study is defined as the amount of paint needed to paint an area of 1000 m Scope and system boundary The system boundaries are from cradle to grave The life cycle stages in this case study include Raw materials and transport to the paint production site Paint production Paint storage Use of the paint Transport between the above stages and Waste management in the life cycle 9 1 3 Description of alternatives Raw materials The alternatives defined in the raw materials compositions as the optimisation variables are presented in Table 2 Table 2 Raw materials Quantity of the product Pigment 9 94 Additive 1 ama 2 2 5D i con ee pea K E aS KO Range is selected as Format of the raw material quantity when defining the optimisation details described in Section 6 2 a default constraint is that the total raw material quantity is 100 Table 3 Descriptions of the two paints Alternative Unit quantity Costs Description of packaging Link with Raw product kg m GBP kg material Output Packaging 1 A a Amount 4 of associated Pigment gt 30 p product Cost 0 8 GBP kg Output Packaging 2 i 5 Market entry 0 17 1 4
26. unit f u Bioethandt sere ererres Objective Minimise Carbon Foo Figure 11 The optimisation boundary form 8 Reviewing the defined information in each life cycle stage The information for each life cycle stage can be reviewed by clicking on the relevant life cycle box on the top level of the tool In the demonstration version of the tool the buttons on the user forms are largely disabled In the full version of the tool they are fully flexible allowing the user to make the necessary changes 8 1 The raw materials stage The information on the raw materials stage can be reviewed by clicking on the Raw Materials box at the top level Figure 12 e Click the Raw Material box at the top level This brings up the form Raw Material Form 1 e Select the raw material in List Box 1 which lists all raw materials used in the base case The defined raw material alternatives in the optimisation are shown in Alternative s list and e Click Update Details and Raw Material Form 2 pops up In this form the details of the raw materials alternatives include the quantity cost packaging and waste Only the raw material quantity is essential The expression of the raw material quantity in the optimisation e In Optimisation Details See Section 7 1 if composition range is defined as raw material quantity the user needs to define the lower and upper range of the final product for the relevant material e f amount is defined as
27. ure 13 This activates the Production Form 1 see Figure 14 The form has the Input Materials Energy Output and Waste tabs The user can review the defined information by selecting tabs saa seme fs sans f suet e fst fp Figure 13 The layout of the production stages Stage5 8 2 1 The production stage Energy The energy options used are listed in List Box 7 Figure 14 The alternatives for the base case energy are listed in the alternative s list on the right hand side e Click on the Update Energy Alternatives button to view the alternative energy options amounts and costs Production Form 1 Production Fom 2 Crergy henares Electricity from heavy fuel Of List Box 1 Heep the selected energy same as Base Case O evadatie aernutives Define sternative s for Dectrety OJ gw CCaC Gataboce Coomwert dat adese Cay hese from ane seed eo offered i yn nira aQacgcdaadaiagai 55555555 27 SVVVEVITS SS ane eeneneaenmn Seeeeeeee 9939963966 SRR RRR Figure 14 The form for energy in the production stage 8 2 2 The production stage Output The production stage outputs are listed in List Box 7 Figure 15 In the full version of the tool these can be modified see Figure 15 in the demo version they are disabled 11 Production Form 1 Paint manufacture Input Materials Energy Output waste Paint man facture Output Market entry
28. xisting case studies To start optimisation click on Define Optimisation Objective button on the top level of the tool as shown in Figure 5 For each demonstration case study the user can carry optimisation on one of the objective functions shown in Figure 5 Further constraints can also be defined The simplified optimisation procedure is describe below Step 1 Define the objective function by clicking Define Optimisation Objective at the top of the screen at the top level of the tool Figure 5 Reon 2 Functional unit f u Paint Demo 1000 mi Objective Minimise Carbon Footprint Defra r Definer Diiira Optemesation Optimisation Optimisation Objective Boundary a a Oplimitation Objective Sekt ohjel Poe option Tibia Pan bien Catear Pootpire D Hanrapa Prot C Pinin profit added per unt of carbon footprint reduced Figure 5 The form for defining objective functions in the optimisation Step 2 Define the optimisation constraints by clicking Start Optimisation at the top of the screen to bring up the Constraints in Optimisation form Figures 6a amp 6b where the optional constraints relevant to process capacity economic and environmental impacts may be defined e Process capacity constraint Figure 6a Select the Stage in production from the dropdown list and provide the maximum capacity for the stage and click Update to add it to the list Click Next to c
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