Key economic and environmental advantages

High availability of more than 98%

Life-time of 20 years
High effciency of the pump strongly contributes to lower energy consumptions and emissions
Frequency inverter driver would allow fexible and energy effcient adaptation to the effective power used
Comprehensive training and professional service enable customers to operate the pump cost and energy effciently
Retroft service allows to reestablish the best effciency point in case of changed operation conditions
Simple to dismantle, best suited for recycling due to high quantity of high alloyed steels (> 95 weight %) that easily can be separated
(metal parts marked to identify composition).
Components included:
Pump including casing, baseplate, shaft, impeller, bearings
Skid including motor, valves and piping
Gearbox Motor Frequency inverter Piping system
Electricity mix considered for downstream processes: Europe (UCTE)
Environmental Product Declaration - EPD
Environmental and economic life cycle performance including climate-related data
1)
e.g. oil, varnishes, seals
Key economic and environmental indicators over life cycle of 20 years
MD 150-360 - High Pressure Stage
Casing Pump with Skid
The pump characterized in this EPD is confgurable.
Confguration and effciency depends on customer
specifcation. The data given below are illustrative and
only valid for the defned parameters (see pages 4 ff).
Main applications:
Power generation, i.e. boiler feed in industrial power
plants and combined cycle power plants.
Type:
Horizontal, radially split, centerline mounted, multistage
ring section pump. Pump confgured according to
customer requirements.
Rated power:
2 300 kW
Manufacturer:
Sulzer Pumpen (Deutschland) GmbH, Germany
CPC classication:
43220
3.0 million GJ-Eq
1 310 GJ-Eq / kW
Energy consumption
Procurement 0.02%
Manufacturing <0.01%
Usage 99.98%
CO
2
emissions
139 750 tonnes CO
2
-Eq
61 tonnes CO
2
-Eq/kW
Procurement 0.03%
Manufacturing <0.01%
Usage 99.97%
Weight & composition
13 700 kg
5.96 kg / kW
Cast iron 23%
Steel 71%
Copper,
aluminium 3%
Others
1)
3%
Costs
30.5 million
Procurement /
manufacturing 1%
Usage: electricity 98.6%
Usage: service 0.4%
Functional unit
The functional unit is 1 kW of rated hydraulic power at best effciency point.
More than 50% of the pump consists of high alloyed
steels, 40% of cast iron and other steels. The
indicated quantity of oil refers to the initial fll of the
pump, the oil is replaced every second year during
the downstream processes.
Not included parts are e.g. seals. They amount to less
than 1% of the total weight.
Composition of the product
Non-renewable resources
Procurement
2)
Manufacturing at Sulzer Usage / end of life
kg kg / kW kg kg / kW kg kg / kW
Steel (alloyed), casting
3) 3)
for pump 7 100 3.09 6 800 2.96 6 800 2.96
for spare parts 300 0.13 290 0.13 290 0.13
Oil 5 490 2.39 5 490 2.39 5 490 2.39
Lubricants 1 900 0.83 1 900 0.83 1 900 0.83
Waste production (total) n.a. n.a. 1 220 0.53 8 990 3.91
Hazardous waste n.a. n.a. 150 0.07 1 900 0.83
Municipal waste n.a. n.a. 270 0.12 n.a. n.a.
Recycling (total) n.a. n.a. 800 0.348 7 090 3.08
metals (pump) n.a. n.a. 300 0.130 6 800 2.96
metals (spare parts) n.a. n.a. 10 0.004 290 0.13
others n.a. n.a. 490 0.213 n.a. n.a.
Renewable resources kg kg / kW kg kg / kW kg kg / kW
Wood (packaging) 20 1.18 20 1.18 20 20
Water consumption
4)
n.a. n.a. 24 100 1417.6 n.a. n.a.
Material kg %
1)
kg / kW
3)
Cast iron 3'150 23% 1.37
Steel (high alloyed) 7'345 54% 3.19
Other steel 2'350 17% 1.02
Aluminium (motor) 120 1% 0.05
Copper (motor) 344 3% 0.15
Paint and impregnation resin (motor) 35 0% 0.02
Insulation material (motor) 90 1% 0.04
Oil 170 1% 0.07
Parts not included
2)
100 1% 0.04
Total 13'704 100% 5.96
Material consumption during life-cycle per pump
1)
(material balance sheet)
Procurement
2)
Manufacturing at Sulzer Usage / end of life
3)
Total
GJ-Eq GJ-Eq/kW GJ-Eq GJ-Eq/kW GJ-Eq GJ-Eq/kW GJ-Eq GJ-Eq/kW
Electricity 94.6 0.0411
6) 6)
3 009 630 1 310 3 009 720 1 309
Gases
1)
7.0 0.0030
6) 6)
0 0 7.0 0.0030
Fuel oils 32.6 0.014
6) 6)
0 0 32.6 0.014
Fuels n.a. n.a. 0 0 0 0 0.0 n.a.
District heating
8)
n.a. n.a. 0 0 0 0 0.0 n.a.
Materials 740 0.32 0 0 0 0 740 0.32
Transports 15.8 0.007 36.5 0.016 459 0.20 511 0.222
Disposal, waste water
7)
n.a. n.a. 0.4 0.000 -450 -0.195 -449 -0.195
Non-renewable
energy sources
5)
815 0.355 36.3 0.0158 2 824 850 1 230 2 825 700 1 229
Total renewable
energies
4) 5)
75 0.0324 0.5 0.0002 184 780 80 184 860 80
Total energy sources
5)
890 0.3870 36.8 0.0160 3 009 640 1 310 3 010 567 1 309
Primary energy consumption during life cycle (primarily from usage / end of life)
1)
By weight.
2)
Weight not included in assessment.
3)
Rated power.
n.a.: not available, values per kW related to 10 700 kW rated power.
1)
Material resources related to supply of energy to site are not considered.
2)
Covers all
resources procured during the life cycle by Sulzer, including the oil used to operate the pump.
3)
Machining during the manufacturing produces recyclable waste
of around 4% by mass of the metals bought in.
4)
In manufacturing: used for testing purposes.
Eq: equivalents, kW related to 10 700 kW rated power.
The pump is used in Europe, the European energy mix was applied
(UCTE mix).
1)
Natural gas, butane, propane.
2)
Including transportation to Sulzer
(< 1%).
3)
Including transportation to customer (< 1%).
4)
Hydro
power, solar power, wind power, wood.
5)
Including waste and
waste water treatment.
6)
Fully allocated to upstream processes.
Life-cycle coverage, assumptions, and exclusions
System boundary: The EPD covers all relevant environmental
aspects in relation to the below described life-cycle phases.

The construction of buildings, machines to manufacture products,
means of transport, (including roads or railways) are excluded.
Procurement comprise the extraction of raw materials and
production of semi-fnished products, consumables, and energies
by suppliers. Production data were adopted from the EcoInvent
Database based on parts lists of Sulzer.
Considered parts externally sourced have been limited to casing,
baseplate, shaft, impeller, motor, gearbox, and bearings that cover
more that 99% of the product weight.
Due to minor importance solvents, varnishes and plastics (for e.g.
seals) have not been included.
Manufacturing at Sulzer comprises all activities conducted at
the manufacturing site in relation to the product manufacturing
(engineering, welding, grinding, machining, painting, assembly).
Considered data origin from the yearly Sulzer SEED data collection
and comprise energy (e.g. electricity, natural gas, butane, propane,
fuels, fuel oils, district heating, coal coke, district heating) and water
consumptions, emissions, waste water and waste production. The
energy used includes manufacturing as well as offce activities.
The emissions from the use of varnishes and solvent are included,
related consumption of the varnishes and colors are excluded. The
environmental burden caused by waste and wastes water treatment
has been adopted from the EcoInvent Database.
The pump is assembled in Germany, the European electricity mix
has been considered.
The packaging of the pump for the transport to the customer is
included (wooden box).
Procurement Manufacturing at Sulzer Usage / end of life
1)
Total
t kg / kW t kg / kW t kg / kW t kg / kW
Greenhouse Gas Potential
(CO
2
-equivalents)
54.7 23.76 2.40 1.04 139 690 60 735 139 750 60 761
Acidifcation potential
(SOx-equivalents - AP)
2.3 0.979 0.101 0.044 2 263 984 2 265 985
Photosmog potential
(ethylene equivalents)
0.022 0.009 <0.001 <0.001 5.6 2.41 5.6 2.42
Ozone depleting potential
(CFC11-equivalents)
<0.001 <0.001 0
2)
0
2)
0.008 0.003 0.008 0.003
Biological Oxygen Demand
(O
2
-equivalents)
0.41 0.180 n.a. n.a. 53.6 23.3 54.0 23.5
Emissions during life cycle (primarily from usage / end of life)
n.a.: not available, kW related to 10 700 kW rated power.
1)
Emissions are dominated by emissions in usage from electricity consumption.
2)
Ozone depleting substances are not in use at the manufacturing site.
Usage / end of life comprise the usage and servicing of the
product. It includes the manufacturing and disposal of spare parts
and the oil.
The pump is used in Europe, the European energy mix was applied
(UCTE mix). The price for electric
The performance of the motor is 96.8% and has been adotpte from
an EPD of ABB (AC machine type AMA 450, 1600 kW power).
The yearly costs for maintenance are at 2% of the purchase price
of the pump, the assumed average increase in prices is at 2% per
year.
4% of the total weight of the pump is to be replaced during the
lifetime what includes bearings, seals, impeller, and wearing rings.
During the life-time and including the initial fll, totally 1 700 kg of oil
is used to operate the pump.
For recycling a beneft of 50% of the initial environmental burden to
produce the pump has been applied.
Costs for dismantling are not considered (minor compared to
energy costs during usage). Monetary benefts through selling the
pump as scrap have not been considered (life-time of product too
long for appropriate estimation).
Spent oil is disposed as hazardous waste and incinerated
accordingly; its environmental burden has been adopted from the
EcoInvent Database based.
Transports to Sulzer (depending on the location of the supplier
by truck, train, ship, or airplane) are included in the upstream
processes phase, transports to the customer in the manufacturing
phase (by truck), and transports for service activities in the
downstream processes (by van for service at the customer site, by
truck if pump is serviced at Sulzer). Transports of the dismantled
pump are not considered.
Allocation: In the manufacturing the yearly collected consumption
of energy and water, emissions, waste water and waste production
(SEED data collection), have been divided by the total number of
pumps produced by the site to estimate the resource consumption
per pump. For upstream processes and usage all resources,
emissions, and wastes have been fully allocated to the product.
Procurement
Manufacturing
at Sulzer
Emissions
Emissions
Wastes
Emissions
Wastes
Usage /
End of life
Transport
Transport
Phases of load level
Duration of phase Operating hours
per year
Efciency Effective Rating
years hours / year % kW
Phase 1: full load 10 8 000 81.5% 2 300
Phase 2: middle load 5 5 000 79% 2 000
Phase 3: low load 5 3 000 70% 1 620
Applied load levels of pump during life cycle
The applied load levels are summarized in the table below. The pump is operated in three sequential load level phases that differ from
duration, yearly operating hours, effciency, and power consumption.
Glossary
Life cycle assessment, LCA is a management tool for appraising
and quantifying the total environment impact of products or
activities during the entire life cycle.
Life cycle costs are based on LCAs and cover the total costs of a
product during the entire life cycle from the extraction of resources
to the disposal of the product.
A Functional Unit is a concept that is used to compare the life
cycle costs of different products on a like-for-like basis.
CPC (Central Product Classifcation) is a UNbased scheme for
statistical division of product categories and service types.
EcoInvent Database contains international industrial life cycle
inventory data.
Acidication occurs through deposition of soluble sulphur and
nitrogen compounds from agricultural and combustion processes.
Acidifcation can be harmful to sensitive ecosystems.
Eutrophication is the often anthropogenic enrichment of bodies
of water by nitrates and phosphates. This increases the growth
of aquatic plants that deoxygenate water and outcompete other
aquatic life.
Global warming potential, GWP is the potency of 1 kg of a gas
as a radiative forcing agent relative to an emission of 1 kg of carbon
dioxide over 100 years.
Ozone depletion potential, ODPs are calculated as the
change that would result from the emission of 1 kg of a
substance compared to that from the emission of 1 kg of CFC-11
(trichlorofuoromethane).
Photochemical ozone creation potential, POCP refers to the
change in of ground level ozone concentration potentially caused by
the emission of 1 kg of a gas compared to that from the emission of
1 kg of ethene.
SEED is the database that Sulzer uses to collect, validate, and
report on social, economic, and ecological data.
EPD related information
The document was prepared based on the EPD General Program
Instruction, the ISO 14025:2010 standard, and the Product
Category Rules for Submersible pumps and mixers.
The EPD has not been externally verifed. It is valid for 3 years until
November 2013.
The EPD is published by Sulzer Ltd, Corporate QESH, 8401
Winterthur, Switzerland, December 2010. For questions and
feedback please contact sustainability@sulzer.com
Sulzer Pumps
Sulzer Pumps is a world leader in reliable products and innovative
pumping solutions. The global network of modern manufacturing
and packaging facilities together with sales offces, service centers
and representatives located close to major markets provide fast
responses to customer needs.
Sulzer Pumps has a long history of providing innovative pumping
solutions to business partners in the following industries: Oil
and Gas, Hydrocarbon Processing, Pulp and Paper, Power
Generation, General Industry, Chemical Process Industry, Water
and Wastewater
All manufacturing sites dispose on managements systems certifed
against ISO 9001, ISO 14001, and OHSAS 18001.
Further information about Sulzer Pumps: can be found at www.
sulzerpumps.com.
References
The International EPD Cooperation, EPD General Instructions for
Environmental Product Declaration, EPD Version 1.0; 2008-02-29.
The Swedish Environmental Management Council;
Product Specifc Requirements for Submersible pumps and mixers;
PSR 2002:5; 2002
Swiss Center for Life Cycle Inventories, EcoInvent Database 2.2, St.
Gallen, 2009
Environmental labels and declarations Type III environmental
declarations Principles and English version EN ISO 14025:2010,
Berlin 2010
Environmental Product Declaration ABB; AC machine type AMA
450, 1600 kW power; ABB Industry Oy, Helsinki.
Further information about products of Sulzer Pumps can be found
at www.sulzerpumps.com/products
This and other EPDs are available online at:
www.sulzer.com/sustainability.
Further information about Sulzer: www.sulzer.com
Further information about the Sulzer sustainability program:
www.sulzer.com/sustainability