befcd824-f151-43b2-a49a-b1940db35a4ePolyurethane flexible foam (PU) - TDI-based, with flame retardantreaction of TDI with long-chain polyether polyol and foamingproduction mix, at producerdensity 40 to 54 kg/m³ - hardness 3.5 to 5.8 kPaMaterials productionPlasticsThe main data source was a data collection from European producers of polyurethane flexible foam (PU). Primary data on gate-to-gate polyurethane flexible foam (PU) production is derived from site-specific information for processes under operational control supplied by the participating companies of this eco-profile. About 60 % of the European polyurethane flexible foam (PU) production capacity (EU-27) in 2013 is covered.
In the case of TDI-based PU flexible foam with flame retardant, five different producers with five plants in four European countries participated in the primary data collection.0Primary production data for the TDI-based PU flexible foam with flame retardant production is from five different producers with five plants in four European countries (Italy, Poland, Switzerland and The Netherlands). Fuel and energy inputs in the system reflect average European conditions and whenever applicable, site specific conditions were applied, to reflect representative situations.Foreground system:
Polyurethane is made by reacting diisocyanates and polyols. To generate PU foam, addition of water to the main reagents causes a side reaction producing carbon dioxide, which acts as a blowing agent. Depending on the application the foam will be used for, a number of additives are also being added to the formulation to control its properties, density and cell-size. Flexible slabstock polyurethane foams are produced as large blocks using a continuous process with minimal human handling. Continuous foam machines are the standard in Europe today.
While the machinery may be different from one manufacturer to the other, the general principle is always the same: the raw materials are delivered into a mixing head, which pours the foam mixture onto a pour plate, which delivers the rising foam onto a moving conveyor (usually horizontal, sometimes vertical). Both the conveyor and the mixing head are located in a ventilated tunnel fitted for exhausting vapors released during the foaming process. From an eco-profile point of view, the different machinery technologies used for continuous slabstock foam production can be considered as very similar.
Background system:
* Electricity: Electricity is modelled according to the individual country-specific situations. The country-specific modelling is achieved on multiple levels. Firstly, individual energy carrier specific power plants and plants for renewable energy sources are modelled according to the current national electricity grid mix. Modelling the electricity consumption mix includes transmission / distribution losses and the own use by energy producers (own consumption of power plants and "other" own consumption e.g. due to pumped storage hydro power etc.), as well as imported electricity. Secondly, the national emission and efficiency standards of the power plants are modelled as well as the share of electricity plants and combined heat and power plants (CHP). Thirdly, the country-specific energy carrier supply (share of imports and / or domestic supply) including the country-specific energy carrier properties (e.g. element and energy content) are accounted for. Fourthly, the exploration, mining/production, processing and transport processes of the energy carrier supply chains are modelled according to the specific situation of each electricity producing country. The different production and processing techniques (emissions and efficiencies) in the different energy producing countries are considered, e.g. different crude oil production technologies or different flaring rates at the oil platforms.
* Thermal energy, process steam: The thermal energy and process steam supply is modelled according to the individual country-specific situation with regard to emission standards and considered energy carriers. The thermal energy and process steam are produced at heat plants. Efficiencies for thermal energy production are by definition 100% in relation to the corresponding energy carrier input. For process steam the efficiency ranges from 85%, 90% to 95%. The energy carriers used for the generation of thermal energy and process steam are modelled according to the specific import situation (see electricity above).
* Transports: All relevant and known transport processes are included. Ocean-going and inland ship transport as well as rail, truck and pipeline transport of bulk commodities are considered.
* Energy carriers: The energy carriers are modelled according to the specific supply situation (see electricity above).
* Refinery products: Diesel fuel, gasoline, technical gases, fuel oils, lubricants and residues such as bitumen are modelled with a parameterised country-specific refinery model. The refinery model represents the current national standard in refining techniques (e.g. emission level, internal energy consumption, etc.) as well as the individual country-specific product output spectrum, which can be quite different from country to country. The supply of crude oil is modelled, again, according to the country-specific situation with the respective properties of the resources.Long Chain Polyether Polyols mixToluene diisocyanate (TDI)Flexible polyurethane foam is used to manufacture mattresses, upholstered furniture and car seats, but also acoustic insulation boards, carpet underlays, household sponges, clothing and sportswear, packaging and many other applications More specifically, the high density TDI-based grades are typically used in furniture and bedding, whereas the low-density TDI-based grades are preferred for insulation, packaging, building and footwear. The MDI-based foams are increasingly used for bedding applications due to their viscoelastic properties (also known as “memory” and pressure-relieving properties.plastics_tdi-based flexible polyurethane foam (pu)_europur.jpgThe calculation follows the vertical calculation methodology, i.e. that the averaging is done after modelling the specific processes. Restrictions on competition and confidentiality do not allow displaying and describing the systems and analysing details.LCI resultAttributionalNoneAllocation - market valueAllocation - net calorific valueAllocation - exergetic contentNot applicableForeground system: price allocation on marketed outputs of the flexible polyurethane foam production process.
For details please see the document "GaBi Databases Modelling Principles"All data used in the calculation of the LCI results refer to net calorific value.NoneIn the foreground processes all relevant flows were considered, without cut-off of material and energy flows.
According to the GaBi Databases 2013, used in the background processes, at least 95 % of mass and energy of the input and output flows were covered and 98 % of their environmental relevance (according to expert judgment) was considered, hence an influence of cut-offs less than 1 % on the total in expected. All transports in the pre-chain contribute maximum 0.2% to the overall environmental burden. Including production the contribution of all transports is expected to be less than 1 %, thus transports are excluded from this investigation.None60% coverage of the European industryNoneThe data set represents the specific situation in Europe, focusing on the main technologies used for producing TDI-based PU flexible foam with flame retardant in Europe. Primary production data for theTDI-based PU flexible foam with flame retardant production comes from five different suppliers in Europe.NoneGaBi Modelling PrinciplesGaBi Water Modelling PrinciplesULLMANN'S Encyclopedia of Industrial Chemistry60.0The considered participants covered 60% of all flexible polyurethane foam producers in Europe in 2013.European producers act as a main source of data for the production of flexible polyurethane foam on the basis of a direct questionnaire. Primary data on gate-to-gate flexible polyurethane foam production is derived from site specific information for processes under operational control supplied by the participating companies of this study. The data for the upstream supply chain until the precursors are taken from the database of the software system GaBi 6.2013NoneThe data set can be used for all LCA/CF studies where the product is needed. Combination with individual unit processes using this commodity enables the generation of user-specific (product) LCAs.
Flexible polyurethane foam is used to manufacture mattresses, upholstered furniture and car seats, but also acoustic insulation boards, carpet underlays, household sponges, clothing and sportswear, packaging and many other applications More specifically, the high density TDI-based grades are typically used in furniture and bedding, whereas the low-density TDI-based grades are preferred for insulation, packaging, building and footwear. The MDI-based foams are increasingly used for bedding applications due to their viscoelastic properties (also known as “memory” and pressure-relieving properties.No statementAs part of the PlasticsEurope programme management and quality assurance, DEKRA Consulting GmbH conducted an external independent critical review of this work. The outcome of the critical review is reproduced below.
The subject of this critical review is the development of the Eco-profiles for four different grades of Flexible Polyurethane (PU) Foams, i.e. a TDI-based, high density PU foam without flame retardants (FR), a TDIbased, low density PU foam without FR, a TDI-based PU foam with FR and a MDI-based PU foam without FR.
The review process included various meetings/web-conferences between the LCA practitioner and the reviewer, which encompassed a model and database review as well as spot checks of data and calculations. Furthermore, the Eco-profile report was reviewed by the reviewer as well as industry participants involved in this project. Both the results and the report were also presented and discussed in detail with representatives of EUROPUR. All questions and recommendations were taken forward to the LCA practitioner, and the report was adapted and revised accordingly.
Primary industry data were collected for the foreground processes comprising the production of the four grades of flexible PU foam and taking into account the specific production processes of the participating companies. Background data representing the main precursors, i.e. long-chain polyether polyol, TDI and MDI were taken from existing Eco-profiles [ISOPA 2012 PP; ISOPA 2012 MDI-TDI]. All other relevant material and energy inputs were taken from the GaBi database. Primary industry data for the four grades of flexible PU foam was collected from 7 producers and 9 plants, which lead to an estimated overall representativeness of 60% of the installed EU27 production capacity in 2013.
The potential environmental impacts for flexible PU foam are largely dominated by the precursors across all impact categories (except ADPe). Both salt (needed for the production of deionised water) and other additives contribute to the impact category ADPe. The use of both electrical and thermal energy do not contribute to the potential environmental impacts of flexible PU foam production in any significant manner. For further details, please refer to the main report.
Due to the fact that the choice of the allocation approach for the co-product HCl in MDI and TDI production leads to significant differences in potential environmental impact results and was discussed in great detail during the respective project (and in depending other Eco-profile projects afterwards), this also had to be considered in this project. Not least, it is given LCA practice to investigate how different methodological choices in the Eco-profile of flexible PU foam production influence the results. To be consistent with the existing Eco-profile of MDI and TDI, the mass allocation approach was chosen as a base case, and a sensitivity analysis was performed considering a price allocation between TDI/MDI and the co-product HCl. The results of the sensitivity analysis are presented in the main report exemplarily for the indicators GWP and primary energy and show the expected outcomes.
With regards to the comparison of this Eco-profile with a previous version published in 2005 (with data from 1996), the potential environmental burdens for flexible PU foam could be reduced. However, the comparison is difficult due to different methodological aspects as listed in the main report.
The LCA practitioners have demonstrated very good competence and experience, with a track record of LCA projects in the chemical and plastics industry. The critical review confirms that this Eco-profile adheres to the rules set forth in the PlasticsEurope’s Eco-profiles and Environmental Declarations – LCI Methodology and PCR for Uncompounded Polymer Resins and Reactive Polymer Precursors (PCR version 2.0, April 2011). As a result, this dataset is assessed to be a reliable and high quality representation of flexible PU foam produced in Europe.
Name and affiliation of reviewer:
Reviewer: Matthias Schulz, DEKRA Assurance Services GmbH, Stuttgart, GermanyDEKRAAll data sets in the GaBi Databases are constantly used, compared, benchmarked and reviewed by a broad GaBi user community. Calculated results are published frequently in various external, professional and third party LCA literature, papers, and other media within industry, academia and politics. The incorporation of feedback provided by the GaBi users is standard practice in the maintenance and update procedure, and leads to stable, quality-assured and constantly improved data. The internal review is done with several iterative steps involving raw data validation, raw data documentation, representativeness, completeness and consistent modelling with regard to ISO 14040 and 14044. The data set documentation is correct in respect to the appropriateness of the information available. It includes all relevant information in relation to data quality and the scope of application of the respective LCI result.Sphera Solutions GmbHGaBi conformity systemFully compliantFully compliantFully compliantFully compliantFully compliantNot definedUNEP SETAC Life Cycle InitiativeNot definedNot definedNot definedNot definedNot definedNot definedILCD Data Network - Entry-levelFully compliantFully compliantFully compliantFully compliantFully compliantNot definedEUROPURThis background LCI data set can be used for any types of LCA studies. LCA studies considering the full life cycle (»cradle-to-grave«) of an application or product allow for comparative assertions to be derived. It is essential to note that comparisons cannot be made at the level of the polymer or its precursors. In order to compare the performance of different materials, the whole life cycle and the effects of relevant life cycle parameters must be considered. It is intended to be used by member companies, to support product-orientated environmental management; by users of plastics, as a building block of life cycle assessment (LCA) studies of individual products; and by other interested parties, as a source of life cycle information.Sphera Solutions GmbH2021-02-01T00:00:00.000ILCD format 1.1Sphera Solutions GmbHNo official approval by producer or operator2021-02-01T00:00:00.00000.00.001Data set finalised; entirely publishedGaBi databasesEUROPURtrueOtherGaBi (source code, database including extension modules and single data sets, documentation) remains property of Sphera Solutions GmbH. Sphera Solutions GmbH delivers GaBi licenses comprising data storage medium and manual as ordered by the customer. The license guarantees the right of use for one installation of GaBi. Further installations using the same license are not permitted. Additional licenses are only valid if the licensee holds at least one main license. Licenses are not transferable and must only be used within the licensee's organisation. Data sets may be copied for internal use. The number of copies is restricted to the number of licenses of the software system GaBi the licensee owns. The right of use is exclusively valid for the licensee. All rights reserved.Polyurethane flexible foam (PU) - TDI-based, with flame retardantOutput1.01.00.000Mixed primary / secondaryMeasuredvaluable