Life Cycle Assessment – The View of Things to Come

Many observers question marketing claims being made for green or environmentally responsible products.  The sometimes extravagant and careless way in which green products claims are made drives skepticism and begs questions concerning the actual environmental benefits to be achieved versus extra costs consumers may be asked to pay.

In our recent efforts for clients on cleaner, greener displays and solid state lighting, we have found that Life Cycle Assessment (LCA) methods for determining and making comparisons of energy consumption, carbon footprint and environmental impact are quickly becoming the norm.  We expect that LCA methods and reporting will soon be broadly appreciated by consumers and used as the basis for purchase decisions.

The summary of a recent study released by Osram (Note: PDF) comparing the environmental impact of incandescent (denoted GLS), compact fluorescent (CFL) and light emitting diode (LED) light bulbs (lamps) exemplifies this move to the LCA approach.  Osram is a manufacturer of all three bulb types and thus is in good position to perform such an analysis.

Osram Parathom A55 photo and schematic

The particular lamp models chosen for the analysis were selected to have comparable lumen output and form factor, and color rendering index > 80.  An important distinction between the lamp types was product lifetime that ranged from 1,000 hour (incandescent), 10,000 hour (CFL), to 25,000 hour (LED).  The aim of the Osram LCA was to analyze the environmental impact of an LED lamp over its entire lifetime – from raw materials, to end of life disposal – and to compare that impact to CFL and incandescent lamps.  The overall life cycle impact was analyzed as illustrated below:

Life Cycle Assessment

The LCA was divided into five stages – raw material production, manufacturing and assembly, transport, use, and end of life.  The life cycle analysis comprised not only resource consumption and primary energy input, but also six environmental impacts including acidification, eutrophication, greenhouse gas emissions, photochemical ozone creation, resource depletion, and toxicity.

Over the entire life cycle of the lamps, including manufacturing, use, and end of life, the Osram study found that for all three lamp types the use phase dominated the manufacturing phase in terms of energy consumption as shown below.

Primary Energy Demand

The other six environmental impacts followed roughly the same pattern as primary energy demand for the three lamp types.  The study concludes that less than 2% of the total energy demand is needed for production of the LED lamp, and that the other six environmental impacts for LED lamps were very similar in degree to those of CFL lamps.  Osram claims that the study “has dismissed any concern that production of LEDs particularly (sic) might be very energy intensive.”

The Osram LCA of the three lamp types points out that LED and CFL lamps are comparable today in their overall environmental impact, and that both CFLs and LEDs are superior to incandescent lamps.  Osram also makes the case that LEDs have the potential for further improvements in performance (~2x) as compared to mature incandescent and CFL lamp technologies.  Although proper recycling of lamps was discussed in the summary of the Osram LCA, the toxicity of the mercury (Hg) content of CFL lamps and of mercury releases from coal-fired electricity consumed during all lamp manufacturing and use were not explicitly mentioned in the summary of the Osram LCA.

Taking the results of the Osram LCA at face value, we conclude that efforts in various countries to ban incandescent lamps may indeed lead to significant environmental benefits.  While some lighting consumers still complain of deficiencies in CFL lamps, they clearly yield energy savings that will pay for the somewhat increased cost of CFL lamps.

What is not yet as clear are the economic benefits of LED lighting to the broad range of lighting consumers.  A check on the web reveals that the Osram Parathom 8 W lamp sells for $54.  This is a high cost for lighting consumers to pay for a lamp rated to last 2.5x as long (25,000 hours) as a comparable CFL lamp and having a comparable environmental impact.  In their LCA, Osram points out that future improvements in LED lamp luminous efficacy of perhaps 2x are to be expected.  We also hope to see price reductions that will make LED lighting still more attractive as manufacturing technology improves.

With LED lamp lifetime of 25,000 hours today and perhaps 50,000 hours or more in future, consumers may think differently when purchasing light bulbs.  If LED lamp prices stay relatively high but LED lamps offer long term energy savings that offset their cost, consumers may feel they are making an investment in their future when buying bulbs.  However with high-priced, long-lived bulbs new business models may emerge.  Consumers may wish to trade in used lamps with say 25,000 hours of life remaining.  Or hand down long lived lighting to their descendants.  Perhaps a key upside to the adoption of greener and more energy efficient solid state lighting will emerge as consumers pass down their light bulbs to successive generations that live on a cleaner, sustainable earth.

New OLED Lighting Products Reaching Market – Global Competition Looms

In 2009 Philips and now OSRAM have launched new Organic Light Emitting Diode (OLED) lighting products extending their efforts to deliver greener, energy efficient lighting.  Philips’ Lumiblade lamp and OSRAM’s new ORBEOS lighting panel are the first commercially available OLED lamp products offering lighting designers the opportunity to explore and adopt this new form of light source.  The ORBEOS OLED panel (below right) has an 80mm diameter lighting area, is 2.1 mm thick, and offers a luminous efficacy of 25 lm/W.  ORBEOS lamp

Now that we have a number of OLED lamps of various shapes and sizes, it will be interesting to see if lighting designers respond with creative yet saleable OLED lighting fixtures.

OSRAM have set out their case for OLED lighting in an interesting slide presentation (Note: PDF).  Included in their presentation are several OLED lighting fixture designs (examples below) that were entries in the 2009 PPML OLED design contest.  The PPML OLED design contest provides a useful glimpse of designers’ ideas on applying OLED lighting.  OSRAM’s presentation includes a slide describing their market development outlook for the OLED market for high end to high volume applications from 2009 through 2016 and beyond.  And this is where it gets interesting.

ORBEOS fixtures

OLED lighting research and development have been ongoing in Europe, the US, and Asia since early in the present decade.  European lighting firms Philips and OSRAM are working in government sponsored consortia with European universities and supply chain participants (BASF, Merck, Applied Materials, Novaled and others) to commercialize OLED lighting and reach mass production scale.  Corresponding efforts have been ongoing in the US under the auspices of the US Department of Energy’s Solid State Lighting Program.  Japan has a number of firms conducting OLED lighting materials and device development with companies including Lumiotec and Konica Minolta planning to begin mass production of OLED lamps in 2010 and later.  Until recently, the South Korea OLED display leaders Samsung and LG have not appeared to be addressing the OLED lighting market.

This situation is changing.  Samsung Mobile Display in 2009 has begun showing lighting prototypes as shown in the photo below (left) from the May 2009 SID conference.  Moreover, LG Chem has also begun to show OLED lighting panel prototypes (below right) and is reported to have plans to begin OLED lighting mass production in 2010 or 2011.

Samsung and LG OLED Lighting

The competitive landscape for OLED lighting is beginning to take shape.  Multiple European and Asian firms are taking a firmer position on OLED lighting mass production.  The US DOE program has identified the manufacturing issues for OLED lighting mass production in its September 2009 Solid State Lighting Manufacturing Roadmap.

Although some large US headquartered companies including Kodak and GE have substantial OLED lighting related R&D programs, only GE has stated an intention to enter OLED lighting manufacturing.  Looking forward, we see a bright future for efficient solid state lighting.  And we will be looking to the above mentioned industry leaders and their supply chain partners for further progress toward mass production of OLED lighting.