Preparatory Studies: Improvement of Energy and Environmental Performance for Water and Wastewater Pumps within Europe

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European Joint Masters Degree Program in Management and Engineering of Environment and Energy

20-22 Villa Deshayes ECOLE DES MINES DE NANTES

75014 Paris

Master Thesis Report

Preparatory Studies: Improvement of Energy and Environmental Performance for Water and Wastewater Pumps within Europe

July 2013

Company Supervisor: Benoît TINETTI University Tutor: Professor Laurence LE COQ

Submitted by: Pooi Yin CHANG

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Master Thesis Report

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Index Note

Report Title Preparatory Studies: Improvement of Energy and Environmental Performance for Water and Wastewater Pumps within Europe

Curriculum Master in Management and Engineering of Energy and Environment (ME3)

Placement title Environmental Consultant

Year 2013

Author Pooi Yin CHANG (Clarisse)

Company Bio Intelligence Service S.A.S Number of employees 60

Address 20-22 Villa Deshayes, 75014 Paris, France Company tutor Benoît Tinetti

Function/Position Project Manager

School tutor Laurence Le Coq

Keywords Ecodesign, Energy Efficiency, Life Cycle Assessment (LCA)

Summary This is a thesis report on the preparatory studies of Lot 28 and Lot 29 launched by the European Commission, DG Energy, under the Ecodesign Directive. The studies focus on the analysis of pumps improvement potential during the product design phase covering the aspects of energy and environmental performance. The objectives of the studies are to support the European Commission in developing environmental policy to regulate water and wastewater pumps in Europe.

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Acknowledgement

I would like to express my utmost gratitude to everyone that has assisted me in successfully completing the European Joint Masters in Management and Engineering of Environment and Energy Program (ME3).

Furthermore, I am grateful for the opportunity given to be an intern in Bio Intelligence Service and would like to personally thank Eric Labouze and Shailendra Mudgal for the warm welcome to the big family.

I would like to acknowledge with appreciation the crucial role of my academic tutor Professor Laurence Le Coq for the invaluable guidance during the project. My truly indebted and thankful to my company supervisor Benoît Tinetti and company mentor Sandeep Pahal for the patient guidance and advice throughout the period of internship. Without them, this work would never be possible to be completed.

A special thanks to Alvaro de Prado Trigo, Andreas Mitsios and Adrian R. Tan for being extremely helpful during the project analysis and appreciate the sharing of knowledge.

In additional, I am utterly thankful to all my colleagues and my classmate for creating a pleasant and yet memorable experience through the two years study. I also owe sincere and earnest thanks to my closest friends and family for the support and encouragement.

Finally yet importantly, my deepest appreciates also go to the European Commission (EACEA) and ME3 consortium for providing the unique opportunity to advance my knowledge through the Erasmus Mundus Master Program.

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List of Tables

Table 1: Pumps within ENER Lot 28 scope ... 19

Table 2: Pumps within ENER Lot 29 scope ...20

Table 3: Summary of market data ... 21

Table 4: Generic economy data in EU-27 (Extracted from Task 2 report)... 23

Table 5: Base-Cases selected for ENER Lot 28...26

Table 6: Base-Cases selection for ENER Lot 29 ... 27

Table 7: Life cycle cost of BC-1 to BC-7 for ENER Lot 28 ...29

Table 8: Life cycle cost of BC-1 to BC-12 for ENER Lot 29 ...29

Table 9: Annual energy consumption and emissions of EU stock of pump products ... 31

List of Figures

Figure 1: The life cycle of a product. (1) ... 11

Figure 2: Projected saving for the first 13 Ecodesign measures (2)... 13

Figure 3: Ecodesign Process from a Preparatory Study to Implementation Measures (1) ... 14

Figure 4: MEEuP Methodology (1) ... 15

Figure 5: Schedule of work ... 17

Figure 6: EU-27 Stock Distribution in 2011 (Units). ... 21

Figure 7: Technical and economical lifetime of ENER Lot 28 pumps. ...22

Figure 8: Technical and economical lifetime of ENER Lot 29 pumps. ...22

Figure 9: Consumer Expenditure for ENER Lot 28 ... 23

Figure 10: Consumer Expenditure for ENER Lot 29 ... 23

Figure 11: Distribution of the BC-1 environmental impacts by life cycle phase (extracted from Task 5) ....28

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Abstract

Facing the world challenges of energy crisis and global warming, Ecodesign Directive is one of the most effective action plan developed by the European Commission (EC) to move toward sustainability. The directive aims to establish new implementing measures and regulation for Energy-Using-Products (EuPs) and Energy-related-Products (ErPs), which targeting on product energy efficiency as well as reduce environmental impacts.

Under this Directive, preparatory studies of Lot 28 and Lot 29 are launched to focus on water and wastewater pumps that are widely used and have a great energy saving potential. Ecodesign Methodology is applied in the studies to assess the technology development together with the consideration of human, social and economic constraints.

This report provides the main pumps’ market data and summarizes the results from the life cycle assessment (LCA). The outcome of EcoReport analysis on 18 base-cases concluded that the Ecodesign implementation measures should focus on the use phase, which has the highest improvement potential. While considering the consumer adaptability, economy impact and technical feasibility, the possible policy option could be the cutoff of 10% worst pumps in Europe within 3 years. The energy saving on pump products will significantly reduce the total energy consumption in Europe and enables the achievement of the EU 2020 target.

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Chapter 1: Context of Internship

This report presents the thesis project that was conducted during the 4^th Semester of ME3 Master Program¹. The six-month internship provides a unique experience for students to apply the study into practice and gain insights in the field of their interest which mainly related to environment and energy.

The role as an intern in the Sustainable Policy Department of BIO Intelligence Service (BIOIS) provides the extensive exposure to work as a professional environmental consultant. Beside the main tasks on ENER Lot 28 and ENER Lot 29 Preparatory Studies, the participation in tendering project provides insight to other interesting project within the job scope of a consultant.

The objectives of the master thesis in BIOIS are to develop the technical, economical and analytical skills as well as personal skills while performing the preparatory studies. The real life experience working on the European project (Ecodesign Directive) as well as the collaboration with the European Commission completing the learning process with a concrete knowledge of the process of the implementation of environmental policy in EU level. The contributions toward EU energy saving will be an invaluable experience in determining the future career path on sustainability development.

The report has been carefully structured to provide a brief introduction of the necessity of Preparatory Studies and bring into context the ENER Lot 28 and ENER Lot 29 studies. Subsequently the working group and personal contributions are discussed under Chapter 3 to provide the understanding of the scope of involvement in the study and the level of collaboration with each party.

Description of Ecodesign Directive is provided as the background of the project to visualize the importance of the studies and is followed by the explanation of the MEEuP/ MEErP methodology.

Subsequently, Chapter 6 presented the results that are the main concerns in the studies and also discussed about the analysis that were conducted during the internship period. Finally, a conclusion is drawn and recommendations are provided for the next step on the studies.

The thesis report presents as precise and concise as possible the up-to-date outcome of the studies.

Nevertheless, the preparatory studies cover comprehensive information on the pumps thus it is impractical to provide an extensive explanation on all tasks in the preparatory study. Instead, the report covers the work done within the internship period. The complete report is available on the project websites².

The results (figures and tables) presented are based on the draft version and is subject to be updated with the latest feedback and comments from stakeholders.

1 European Joint Master Degree Program in Management and Engineering of Environment and Energy

2 The websites for both lots are http://lot28.ecopumps.eu/ (ENER Lot 28) and http://lot29.ecopumps.eu/ (ENER Lot 29).

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Chapter 2: Introduction to the Project

The growth of population and economy undeniably cause the energy demand surplus the supply.

The energy crisis is not a new topic today but more effective solutions are yet to be developed. As the Europe region is lacking the geographic advantage in developing the conventional fuel source, energy security and energy independence are severe issues that will affect the growth of the economy in Europe market.

The European Commission (EC) recognizes that the renewable energies are not the sole solution to resolve the energy crisis. The development of renewable technologies is promising but will be time consuming and high capital investment. In order to achieve the target of EU Energy 2020, one of the priority strategies are efficient use of energy. Ecodesign Directive is part of the EC action plan in improving the energy efficiency and environmental performance of various energy related products.

The directive establishes a framework to define the implementing measures and setting environmental requirements of the energy products.

The preparatory studies of ENER Lot 28 and ENER Lot 29 of Ecodesign Directive focus on the wastewater and water pumps are launched under Article 15 of Ecodesign Directive 2009/125/EC. The topics are:

ENER Lot 28³ - Ecodesign Preparatory Study on pumps for private and public wastae water and for fluids with high solid content

ENER Lot 29⁴ - Ecodesign Preparatory Study on pumps for private and public swimming pools, ponds, fountains and aquariums, as well as clean water pumps larger than those regulated under Lot 11

ENER Lot 28 and ENER Lot 29 studies were started since December 2011 and will consists of 8 tasks which analyze the pump product groups and addressing all relevant social, economic, and environmental aspects. It is scheduled that the studies are to be finalized in June 2014. The overview of Ecodesign Directives is presented in Chapter 4.

3 http://lot28.ecopumps.eu/

4 http://lot29.ecopumps.eu/

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Chapter 3: The working group

The Ecodesign Preparatory Studies on ENER Lot 28 and ENER Lot 29 are thorough studies of the current pumps market. The parties involved in the studies include the project teams (BIOIS and Atkins), the European Commission and the stakeholders in the EU market.

The project team has a neutral position in the working group to enable a balanced and impartial analysis. The team is entirely independent from the product and component manufacturing industry, material manufacturing associations, and other stakeholders.

BIO Intelligence Service

BIO Intelligence Service (BIOIS) is an environment and sustainable development consultancy company aiming to create a better world through protecting the environment. BIOIS addressing the global major challenges such as responsible consumption, the social and environmental responsibility of companies, energy efficiency and climate change, sustainable resource and waste management, sustainable food production and biodiversity.

Since the launch of the Ecodesign Directive in 2005, BIOIS has actively been involved in 20 preparatory studies for Energy-using products (EuP) and Energy-related products (ErP). As a leading player in the field, the company expertises in sustainable environmental and economic development encourage the continuous collaboration with the European Commission. Some of the latest preparatory studies that the company are working on include the ENER Lot 28 and ENER Lot 29 which focusing on the water and wastewater pumps.

BIOIS collaborates with Atkins and leads the project team in the ENER Lot 28 and ENER Lot 29 to analyse the environmental and energy performance of pumps mainly used in wastewater industries and water pumps that have not been covered by the earlier study on water pumps (ENER Lot 11).

The project team works with the stakeholders from the EU market and the DG ENER of European Commission on the preparatory studies. The reports will be used as the basis to establish ecodesign implements measures for the Lot 28 and Lot 29 pumps.

My four years experience in water and wastewater industries, paths a good foundation for me to follow up on the studies and actively involved in both Lot 28 and 29 studies.

DG ENER of European Commission

DG ENER⁵ is the Directorate of Energy of the European Commission which is focused EU Energy development. The Directorate sets EU energy policy aiming to improve the competitiveness of internal energy market, develop renewable energy sources, reduce energy dependence and reduce energy consumption. The Energy Roadmap 2050 was set by DG ENER with the aim to present different pathways to reach the objectives of sustainable energy systems. The Ecodesign Directive is part of the action plan towards the reduction of energy consumption.

5http://ec.europa.eu/energy/index_en.htm

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Stakeholders

The stakeholders of ENER Lot 28 and ENER Lot 29 are a group of professionals in the water and wastewater industry that had expressed their interests in supporting the studies. There are more than 80 stakeholders in each lot who represent the pump manufacturers from the water and wastewater industry, environmental NGOs, consultancy firms, international agency and pump organization. The stakeholders played an important role in reflecting the actual market situation and provided reliable technical and economical data for the studies. Europump⁶, the European Association of Pump Manufacturers, has actively contributed information, provided guidance and shared their professional knowledge to facilitate the study. Europump is a very reliable source of information as the group representing 18 National Associations in 15 EU Member states, Turkey, Russia and Switzerland, as well as 450 companies that have a collective production of €10 billion in the European Market.

Atkins

The collaboration of BIOIS with Atkins gathered professionals from both groups to provide diverse analysis on technical, social, economic and environmental aspects. As the world’s 11^th largest design firm engineering and design consulting firm, Atkins has extensive experience in the application of water and wastewater pumps. The technical analysis is mainly conducted by Atkins with the support from BIOIS.

My contributions

BIOIS encourages work exposure and provide the fair opportunity to perform the tasks as the other professional environmental consultant in the company. My contribution in ENER Lot 28 and ENER Lot 29 are mainly covering task 1 to task 5.

The job scope during the internship period includes carrying out market research, performing life cycle analysis (LCA) with the MEEuP/ MEErP methodology and prepared the report with the results from LCA analysis. My other tasks are ensuring a good communication within stakeholders by keeping stakeholder updated through publishing new documents and maintaining the communication platform of Lot 28 and Lot 29.

A constant collaboration and interaction with stakeholders is essential and is made possible by frequent teleconferences and meetings with the work partner, the stakeholder and the user (e.g.

Suez Environment). My responsibilities also include addressing stakeholder comments and compiling them for the record. During the second stage of the Preparatory Studies, some other additional involvements are preparation of material for presentation of the second stakeholder meeting and the participation in the meeting. Other involvement includes exposure to the tender preparation, resource efficiency study and survey have allowed the understanding of the task of a consultant.

6 http://www.europump.org/

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Chapter 4: Background information

Ecodesign Directive

Ecodesign Directive (2009/125/EC) is the Framework Directive that serves as a product-based policy tools which is used to set the implementation requirements for Energy-related Products (ErP). It enables the integration of environmental aspects into product design and aiming for product life cycle improvement in the environmental performance. Design phase is the main area of studies as the majority of the environmental and cost impacts are determined during this phase. Figure 1 illustrates the Ecodesign principle that focuses on the entire life cycle of the products.

Figure 1: The life cycle of a product. (1)

Ecodesign principle

For the past few years, Ecodesign has been used to provide a coherent and integrated framework to allow the setting of mandatory Ecodesign requirements for certain products. One of the examples of the implementation is the Ecodesign Regulation on the standby requirement for many of the domestic products. Products such as washing machines, TV or personal computers are regulated with the design requirement of lower than 0.5W energy consumption during off mode as of 2013. (2) The Ecodesign Directive takes into account that the establishment of new requirements must not contribute to any of the negative impacts on:

lower the functionality of the products causing safety issues

impact on its affordability impact on consumers’ health

The products covered by the Ecodesign Directive are Energy-using products (EUPs) which use, generate, transfer or measure energy. In 2009, the scope of Ecodesign Directive has broadened to include other energy related products (ERPs) that aren’t necessarily using energy but have direct or indirect impact on energy consumption and will contribute to energy saving.

During the transitional period (2005-2008) and the first working plan of Ecodesign (2009-2011) of Ecodesign Directive, the Commission had launched 18 broad indicative product groups which have 37 preparatory studies and had adopted 17 implementing measures for specific types of products.

Design phase

Raw

materials Production Transport End-of-

Use life

Design determines impacts throughout the life

cycle of a product

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The adopted implementation measures consist of 12 Ecodesign regulations and 5 energy-labelling regulations. In addition to that, 39 standardization mandates were launched from the results of the preparatory studies. For the Second Ecodesign Working Plan 2012-2014, 12 broad product groups will be considered. (3) (4)

ENER Lot 28 and ENER Lot 29 are grouped under electric motor systems which is one of the 8 broad product groups identified during the transitional period. The preparatory studies were launched during the end of 2011 and the aiming for the adoption of Ecodesign requirement in 2015.

Aim of the directive

Ecodesign Directive has been created to be the key element of community strategy on integrated product policy within the EU-27 on Energy-related products. The main objective of the Directive is to improve the energy and environmental performance of products for the entire life cycle, from cradle to grave; while taking into consideration the industry, consumer, and all other stakeholders’

concerns and effectively moving in the direction of sustainable development. The Ecodesign assessment considers the impact from every stage of the products from raw material selection to the end-of-life of the products.

The implementation of Ecodesign measure is one of the most effective ways to promote energy saving and thus enhance security of energy supply. It is also the key approach for greenhouse gas reduction and safeguarding the environment (3). The implementation of requirements such as power consumption thresholds, efficiency levels, mechanical design and material use restrictions, requirements for labelling and consumer information are some of the measures established from the Ecodesign studies. The potential of energy saving is described in the next section.

Coherently, Ecodesign requirements promote sustainable competitiveness and avoid negative impacts on administrative burden. The development of improved-performance products allows the manufacturers to be at the competitive edge in the market. The harmonization of regulation at EU level encourages the economic scale of production and provides new opportunities for the manufacturers, consumers and society.

Projected Outcome of Ecodesign Directive

Among the product groups that had been studied, the implementation of Ecodesign regulation for the first 13 measures is projected to have more than 12% annual energy saving by 2020 compared to the energy consumption of the EU in 2009 (‘business as usual’ scenario). Figure 2 presents the projected energy saving from the first 13 Ecodesign measures. The total energy saving is significant and is a favourable approach toward sustainable future.

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Figure 2: Projected saving for the first 13 Ecodesign measures (2)

Product Selection

Ecodesign Directive targets for certain product groups that fulfil the following criteria:

The group represents a significant volume of sales in the EU market and the indicative sales is more than 200,000 units per year.

There must involve a significant environmental impact The potential of improvement is significant

Under the Article 15 of the Directive, the implementing measures have to consider the whole life- cycle of the products and all significant environmental aspects. Assessment of the impacts on consumers and manufacturers is the next aspect that has to be taken into account. (3)

The adoption of a new implementation is a 6-stage process and is represented by the Figure 3. The setting of a “working plan” by the European Commission is the first step. According to the priority list, the investigation of environmental improvement potential of Energy using and related products is carried out over a period of 3 years.

The second stage is the preparatory study for the product groups where external consultancy is conducted according to Ecodesign MEEuP and MEErP Methodology (These Methodology will be further described in the Chapter 5).Preparatory study is meant to assist into the assessing of energy and environmental improvement potential, cost impacts to the industry and consumers and market data compilation. The input data from the stakeholder will greatly influence the validity of the study.

Subsequently, a draft of the EC regulation is submitted to the Consultation Forum that consists of representatives from all EU and EEA member states and around 30 stakeholders from business association, manufacturers, NGOs and other related organization. The Consultation Forum provides comment and feedback on the implementation measures. Then, the draft is submitted to the Regulatory Committee that consists of representatives from all EU members for evaluation and finalization.

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The fifth stage of the adoption is an assessment by the European Parliament for a period of 3 months. Finally the Commission Regulation gets approved and voted by the European Parliament to be an EU Regulation.

Figure 3: Ecodesign Process from a Preparatory Study to Implementation Measures (1)

European Commission

Eco-design Preparatory Study

Stakeholder Consultation

Consultation Forum Impact assessment

Regulatory Committee Working Plan

1

2

3

4

EU Parliament

5

Working Document

Draft Implementing

Measure

Adoption

Consultants

We are

here!

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Chapter 5: Methodology

Ecodesign Methodology (5)(6)

Ecodesign methodology (6) is a set of procedure and specific tools developed to enable the investigation of appropriate Ecodesign requirements for Energy-using and Energy-related products.

The methodology is required to be followed by every preparatory study performed by the external consultant during the second stage of Ecodesign Directive.

The Methodology for the Ecodesign of Energy-using Products (MEEuP) was developed since 2005 for the evaluation of energy-using products. The methodology developed during 2005 further revised to Methodology for the Ecodesign of Energy-related Products (MEErP)(5). MEErP was endorsed by the Ecodesign Consultation Forum on 20 January 2012 and covered a broaden group of products which is energy relating products.

Ecodesign Methodology evaluates the life cycle of the products, environmental aspects as well as technical and economic issues in eight tasks. The first five tasks analyze the current situation that includes the simulation of the product life cycle analysis (LCA) with Ecoreport tool. Subsequently, the next three tasks set out the product improvement potential.

The implementation of MEErP method is slightly different compared to the MEEuP method as it is improved to include a preliminary screening system that is essentially useful for pre-data collection.

The preparatory studies of ENER Lot 28 and Lot 29 mainly followed the MEEuP method but at the same time integrated with some of MEErP elements such as the screening analysis to improve the accuracy of the reported data. The eight tasks for the MEEuP methodology are as shown in Figure 4.

Figure 4: MEEuP Methodology (1)

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For each specific task defined in the MEEuP method, the scope covered is targeting on different aspects. While the methodology has defined the number of tasks, the working group decided to carry out the tasks in 3 Stages. A stakeholder meeting is held at the end of each stage to discuss the main concerns and allow concession within the stakeholder. The scope of each task is as follows:

Stage 1:

 Task 1 (Product Definition) is the main section to define the product categories and setting the system boundaries for water and wastewater pumps. This step is crucial to draw a fine line within the wide range of pumps available in the market and ensuring the scope is not overlapping of information with other Lots of Preparatory Studies. The relevant existing test standards, legislation, voluntary agreements and labelling initiatives are identified during this task.

 Task 2 (Economic and Market Analysis) compiled market and generic economic data which include the fixed cost and the operation cost which will be the part of the input for Task 5 report. At the same time, this task provides insight on the market trends.

 Task 3 (Consumer Behaviour and Local Infrastructure) is the main section that present the real-life condition of the product groups from the aspects of social, cultural and infrastructure. The frequency and characteristics of use of the product are studied and the possible barriers for the implementation of new Ecodesign measures are determined.

Stage 2:

 Task 4 (Technical Analysis) further describes the technical aspects of water and wastewater pumps in the market at product, component and system levels which includes detailed material contents and the energy efficiency of the pump. This section also provides the recommendations on mandates and serves as the background information for Task 5 base- cases grouping and environmental impact analysis.

 Task 5 (Assessment of Base-Cases) selects the base-cases and further assesses the environmental impacts and life-cycle cost (LCC) of each base-case with MEEuP/ MEErP methodology and EcoReport tool. The assessment is a sequential analysis of the entire product life cycle from production phase, distribution phase, use phase to end-of-life phase.

Stage 3:

 Task 6 (Technical Analysis BAT) entails a description and the technical analysis of Best Available Technologies (BAT) and Best Not yet Available Technologies (BNAT) for performance improvement on pump products. The introduction of BAT at product levels is expected to be shorter, within 2 to 3 years compare to BNAT which subjected to research and development. The technical assessment serves as the input data for task 7 improvement potential analysis.

 Task 7 (Potential Improvement) suggests the design improvement options, quantify the environmental impact of each base case and identify the LCC for the consumer. One or more solutions of BAT and with least life cycle cost (LLCC) needs to be identified during this task.

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 Task 8 (Scenario, Policy, Impact and Sensitivity Analysis) summarizes the outcomes from previous tasks and suggests the appropriate policy options to achieve the potential improvement. Scenarios until 2025 are developed for the policy option suggested and are compared with Business-as-Usual scenario to quantify the impact of each policy options in terms of environmental performance and cost at EU-level. Finally, a sensibility analysis is carried out to ensure the accuracy of the study.

Mission and Duties

ENER Lot 28 and ENER Lot 29 Preparatory Studies have been carried since the end of 2011 and the first draft of Task 1 to 3 reports were produced and published in the project websites since 2012.

However, these tasks still undergoing improvement to provide reliable economic and market data.

My contributions during my internship period on these tasks are related to the wastewater definition, research and refine market data and address of the stakeholder comments.

In order to ensure a good communication within stakeholder, one of the key communication tools is the project website⁷. Part of my responsibilities is to maintain the platform that is meant to update stakeholder with new published documents, allow transparent information sharing and announce the latest news on stakeholder meeting.

My involvement is mainly on the second stage of the studies that involved supporting Atkins with technical analysis and carried out impact assessment with EcoReport tool for 7 base-cases (BC) defined under ENER Lot 28 and 11 base-cases under ENER Lot 29. Life cycle assessment (LCA) for each BC is simulated with EcoReport tool to examine the contributions of environmental impacts from the BC and analyze the life cycle cost (LCC) of the product.

The involvement in Task 6 is limited as it is at the early stage of the task. Nevertheless, tasks 1 to 5 reports served as the input data to task 6, 7 and 8, thus the general concept on the remaining tasks is studied.

o: ENER Lot 28 x: ENER Lot 29 2: ENER Lot 28 and ENER Lot 29

Figure 5: Schedule of work

7 The websites for both lots are http://lot28.ecopumps.eu/ (ENER Lot 28) and http://lot29.ecopumps.eu/ (ENER Lot 29).

Week 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26

Introduction to the company, project team ² Literature and Document Review ^o ^x

Market research (Data Refine) ^o ^x

Economic Analysis (Data Refine) ^o ^x

Analyze Environmental Impact of Pumps

using MEEuP/ MEErP ^o ^o ^x ^x

Address stakeholder comments ^o ^x

Review and update of Task 1-5 report in

consistent to the new data ^o ^x

Publish of New Version of Task 1-5 online for

stakeholder comments ^o ^x

Second Stakeholder meeting (Preparation

and Organization) ^o ^x

Second Stakeholder meeting ²

Technical Scope Review and Refine ^o ^x

Clarification of Issues ^o ^x

Task 1-5 update and drafting of Task 6-8 ^o ^x

Conclusion and Presentation of Thesis ² ² ² ² ² ²

June July

Jan Feb March April May

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Chapter 6: Outcome of the Preparatory Studies

Overview (Scope of the Preparatory Studies) (7)(8)

Water and wastewater pumps have been classified into the priority product groups for the preparatory studies as pumps are energy-using products that are widely used in the market. The application of these pumps is broad as the water is an essential element for all human activities and wastewater is generated from these processes.

The preparatory studies of ENER Lot 28 and ENER Lot 29 focused on pumps that are mainly used to transfer water (Lot 29) and wastewater (Lot 28). While pumping can be defined as additional of energy to transfer the fluid to move from one point to another, it is the main energy consumption device and the improvement on the system essentially contributes to energy saving.

As the pumps products are studied in a few Lots, a clear definition of product groups covered by each Lot is essentially important. Preparatory study ENER Lot 28 cover pumps for the private and public wastewater and for fluids with high solids content. While ENER Lot 29 covers pumps for private and public swimming pools, ponds, fountains, and aquariums, as well as the clean water pumps that are larger than those regulated under TREN 11.

The scope of wastewater pumps was further refined to exclude positive displacement pumps such as Archimedean screw pump, progressive cavity pump and peristaltic pump since a separate lot will be launched for these pumps. The latest defined scope is presented in Table 1 and Table 2.

During the second stakeholder meeting, an upper capacity limit for the pump to be evaluated is set to be 160kW. The justification is that above this capacity, the pump is an engineered product and is not within the scope of study. For ENER Lot 29 pumps, the upper capacity limit is set as 1MW.

Wastewater definition is included in the report during the second revision as a scientific description of wastewater content is necessary to regulate the wastewater pumps in real life operation condition. However, a general characteristic of wastewater is yet to be determined in the TU Berlin project that is still ongoing. The preparatory study will integrates this information into the report as soon as it is available.

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Table 1: Pumps within ENER Lot 28 scope

Pump Code

Submersible pump

Radial sewage pumps 1 to 10 kW CS RSP 1 to 10

Radial sewage pumps >10 to 25 kW CS RSP 10 to 25

Radial sewage pumps >25 to 160 kW CS RSP 25 to 160

Mixed flow & axial pumps CS MFAP

Shredding, grinding pumps CS1 SG

Radial sewage pumps 1 to 10 kW CS1 RSP 1 to 10

Where volute is part of a tank CS1 V

Centrifugal submersible domestic drainage pump < 40 mm passage CSDD

Submersible dewatering pumps SDP

Centrifugal dry well pump

Radial sewage pumps 1 to 10 kW CDWP 1 to 10

Radial sewage pumps >10 to 25 kW CDWP 10 to 25

Radial sewage pumps >25 to 160 kW CDWP 25 to 160

Mixed flow & axial pumps CDWP MFAP

Slurry Pump Slurry Pumps SP

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Table 2: Pumps within ENER Lot 29 scope

^Pump ^Code

Swimming Pool pumps (integrated motor+pump)

Domestic with built in strainer up to 2.2 kW SPPS

Domestic/commercial with built in strainer over 2.2 kW SPPL

Fountain, pond, aquarium, spa and counter-current pumps

Fountain and pond pumps to 1 kW FPP

Aquarium pumps (domestic/small aquarium - non-commercial) to 120 W AP

Aquarium power head to 120W APH

Spa pumps for domestic & commercial spa’s SPA

Counter-Current Pumps CCP

End Suction water pumps (over 150kW-P2)

End Suction Close Coupled from 150 kW to 1 MW ESCC End Suction Close Coupled Inline from 150 kW to 1 MW ESCCI

End Suction Own Bearing from 150 kW to 1 MW ESOB

Submersible bore-hole pumps

8” Submersible bore-hole pumps SBHP08

Submersible bore-hole pumps larger than 12” SBHP12+

Vertical multi-stage pumps

Vertical multi-stage pump (25 to 40 bar and/or 100 to 180 m3/hr) VMSPS Vertical multi-stage pump (>40 bar and/or >180 m3/hr) VMSPL

During the scope definition, the screening analysis has also considered the annual energy consumption and potential saving of the pumps. The estimated total annual energy consumption of 2011 for ENER lot 28 pumps and ENER Lot 29 pumps are 27,637 GWh and 80,552 GWh respectively.

While the potential level of energy saving is estimated to be 2,423 GWh and 1,939 GWh. However, the improvement potential is estimated to be higher thus the potential of saving will be further reviewed and updated.

Pumps in EU Market (9)(10)

Throughout the first stage of preparatory study, the economic and market analysis for the pump sector in Europe as well as the consumer behaviour was evaluated and eventually formulating the base-case(s) in Task 5. The installed pumps in Europe region for ENER Lot 28 and ENER Lot 29 were estimated to be around 31 million units since the year 2011 and the growth rate is expected to be 2 to 3% for the next 4 years until 2015. The summary of the market data is presented in Table 3 and the distribution of the installed stock is illustrated in Figure 6.

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Table 3: Summary of market data⁸

Units ENER Lot 28 ENER Lot 29

EU installed stock in 2011 (total) Million Units 15.4 16.6

EU installed stock in 2005 (total) Million Units 13.7 14.7

EU annual sales in 2011 (total) Million Units 2.0 2.0

EU annual sales in 2005 (total) Million Units 1.5 1.5

The reported data is based on the consultation of the main market players⁹, Europump¹⁰ organization, professionals in the field and main users in the market such as Suez Environment. The official statistics based on PRODCOM was not used since the classification is not matching precisely with the group defined in task 1. However, this source of information has been referred in order to provide a broad overview for the verification of the data estimated.

Lot 28 Lot 29

Figure 6: EU-27 Stock Distribution in 2011 (Units).

Product Life Cycle is one of the indicators that reflects the sales of the product in the market.

Moreover, it is one of the key parameters in the life cycle assessment analysis to evaluate the product life cycle cost and environmental impacts. The economical life and technical life are estimated to be the same and the lifetime of each product group for both lots is presented in Figure 7 and Figure 8.

Economic life: is the duration that the product is in service

8 Data presented is the latest available data on 16 June 2013. The data might be reviewed as per discussed during the second stakeholder meeting.

9 Main market players that are involved in the data compilation, ENER Lot 28 and ENER Lots 29 studies include Sulzer, Grundfos, Flowserve, Siemens, Xylem, DAP, Wilo, BPMA, Askoll, Pentair, Fluidra, Agoria, Profluid, etc.

10 The European Association of Pump Manufacturers: http://www.europump.org/

CS RSP 1 to 10 7%

CS1 SG 2%

CS1 RSP 1 to 10 6%

CS1 V 2%

CDWP 1 to 10 1%

CSDD 78%

SDP 2%

Other 2%

SPPS 29%

AP 48%

FPP 11%

CCP 6%

APH 2%

SBHP08 1%

SPPL

1% SBHP10

1%

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Technical life: is the time to until which the pump functions sustaining minimum acceptable performance criteria

Figure 7: Technical and economical lifetime of ENER Lot 28 pumps.

Figure 8: Technical and economical lifetime of ENER Lot 29 pumps.

The economic analysis is further focused on consumer expenditure, which consists of the purchase prices, installation cost, maintenance costs and repair cost as well as the applicable rate for running costs. Other financial parameters such as taxes, the rate of interest and inflation rates are also being considered in the studies. Figure 9 and Figure 10 provide an overview of the cost contributions of each group of pump products.

10 10 15

10 7 8 10 7

10 15 15 15 20

8 0 5 10 15 20 25

Y ea r

Technical life time Average economical life time

20 20

9 5 5

20 20 20 20 20

11 11 11 11 12 12

0 5 10 15 20 25

Y e a r

Technical life Average economical life

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Figure 9: Consumer Expenditure for ENER Lot 28

Figure 10: Consumer Expenditure for ENER Lot 29

The electricity and water rate is standardized in the MEErP Methodology for all preparatory studies and is presented in Table 4. The MEErP Methodology also suggests that a default value of 4% as the EU average discount rate.

Table 4: Generic economy data in EU-27 (Extracted from Task 2 report)

Unit Domestic incl.

VAT

Long term

growth per year

Non-domestic excl.

VAT

Electricity €/kWh 0.18 5% 0.11

Water €/m³ 3.70 2.50%

Energy escalation rate % 4%

VAT % 20%

0 5000 10000 15000 20000 25000 30000 35000 40000

Cost €

Maintenance Repair Installation Purchase

0 10000 20000 30000 40000 50000

Cost €

Repair & Maintenance Installation Purchase

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Main findings

From the exhaustive market survey and analysis, some of the main findings are as below:

Europe has mature infrastructure for water and wastewater treatment system thus the demand for new installation is relatively low. 30% of the sales in EU market are for new installations and 70% are for the replacement.

The product groups that dominate the market are:

ENER Lot 28: Centrifugal submersible domestic drainage pump <

40mm passage pumps (78%)

ENER Lot 29: Aquarium pumps (domestic/ small aquarium – non- commercial) to 120W (56%)

Main design development is concerned about ENER Lot 28: impeller design.

ENER Lot 29: advancement of VSD motors and controls for regulation of the water flow.

Timeframe for redesign (Large pumps are always custom designed) ENER Lot 28: estimated to be 2 to 4 years

ENER Lot 29: estimated to be 2 to 5 years

Pumps have positive scrap value as they are mainly constructed by metal, thus it is very like that the pump will be sold as scrap at the end of life which not occurred any disposal cost.

Consumer Behaviour (11)(12)

Consumer behavior has a significant direct effect in the use phase and end-of-life phase of the products. The real life efficiency of the pump is very dependent on the appropriate applications, the frequency of use and best practice in sustainable product use.

In general, the consumer might intentionally or unintentionally disregarded certain energy saving and environmental aspects. Wastewater pump users are prompted to opt for reliable operation and accept the efficiency penalty for clogging resistant impeller.

For clean water pump application, there are great concerns on the energy saving of large clean water pumps where the variable speed drive is commonly used for better system performance.

However, the amount of efforts on performance optimization of smaller pump is limited.

From the report of SAVE study(13), the potential of energy savings associated with the appropriate pump application are identified as follows:

Proper pump sizing: 4%

Better installation/maintenance: 3%

Improvement on System Design: 10%

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Better System Control: 20%

The consumer behavior is the major consideration for the implementation of new measures and regulation. Main barriers for the implementation of Ecodesign Measures are commonly related to the investment cost and the consumers’ mindset. Most of the consumers are fear of complexity, lack of knowledge about the products or preferred stabilized technologies.

Technical Analysis (14)(15)

Technical analysis and the impact assessment are the second stage of the preparatory studies. The technical analysis covered the analysis of different pump groups’ technical characteristics which include the fluid flow and common pump technologies.

The study also took into account different life cycle stages of the pumps:

Production phase Distribution phase Use phase

End-of-life phase

Data of the material contents in pumps and the packaging is presented as Bill of Materials (BoMs) in the technical analysis report (Task 4) and will be part of the input of Task 5 analysis.

The main findings from the technical analysis of Lot 28 pumps are:

Wastewater pumps are available in a variety of sizes and configurations to suit the different pumping applications and most of them are centrifugal pumps.

There is a wide range of impellers available for pumping wastewater, these include Single vane impellers

The impellers are designed to have large free passages that allow solids to easily flow through.

Vortex impellers

The impellers are able to create a whirlpool within the pump body where the solids are able to pass through the pump without coming into contact with the impeller.

From the aspect of motor and system control, wastewater pump are:

Commonly coupled with an AC induction motor

The control is normally based on the fluid level in the wet well

Intelligent network controllers are used for managing multiple pumping stations at once or to enable steady flow control system.

While for ENER Lot 29 pumps, the main findings are:

All the pumps in the study are classified as centrifugal pumps.

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The pump impellers are designed with various dimensions and can be physically trimmed to meet the exact required duty (maximum efficiency is achieved with the full sized impeller).

The efficiency of the pumping operation relies on the appropriate combination of motors, controls and sensors with a pump.

Impact Assessment (16)(17)

The previous tasks have formed the basis for the task 5 impact assessment. Base-case (BC) was identified and was used as a “conscious abstraction of reality” to represent a range of similar products on the market. By applying MEEuP Methodology, the EcoReport tool is used to quantify:

The product life cycle contributions on the environmental impacts The product economic Life Cycle Costs (LCC)

The MEEuP methodology has outlined the selection criteria for the base-cases where the targeted product groups should meet these criteria:

Significant share of market Significant environment impact Significant potential of improvement

Seven most appropriate BCs have been selected for the preparatory study of ENER Lot 28 and eleven BCs are selected for preparatory study of ENER Lot 29. The high number of BCs is necessary to cover the broad range of pumps in both lots. Table 5 and Table 6 present the selected BCs for ENER Lot 28 and ENER Lot 29 and the related energy data that were referred for the BC selection.

Table 5: Base-Cases selected for ENER Lot 28

Pump Type

Hydraulic pmu power

Energy consumption of

stock

Share of energy consumption

kW GWh/year %

BC 1 Centrifugal submersible pump:

Radial sewage pumps 1 to 160 kW 7 15,028 56

BC2 Centrifugal submersible pump:

Mixed flow & axial pumps 50 858 3

BC3 Centrifugal submersible pump – once a day operation 2 70 0.26

BC 4 Centrifuge submersible domestic drainage pump < 40 mm

passage 0.3 88 0.33

BC5 Submersible dewatering pumps 7 2,940 11

BC6 Centrifugal dry well pump 10 3,267 12

BC 7 Slurry Pumps 75 4,450 17

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Table 6: Base-Cases selection for ENER Lot 29

Base-case Pump type (and sub-categories)

Hydraulic pump power

Energy consumption

of stock

Share of energy consumption

kW GWh/yr %

BC-1 SPPS Domestic with built in strainer up to 2.2 kW 1.4 17,870 12.4 BC-2 SPPL Domestic/commercial with built in strainer over 2.2 kW 5 3,105 2.2

BC-3 FPP Fountain and pond pumps to 1 kW 0.02 266 0.2

BC-4 & 5 AP

Aquarium pumps (domestic/small aquarium - non- commercial) to 120 W

0.005 421 0.3

Aquarium power head to 120W 0.005 18 0

BC-6 SPA Spa pumps for domestic & commercial spa’s 1.1 19 0

BC-7 CCP Counter-Current Pumps 3 72 0

BC-8 ESCC ES Close Coupled from 150 kW to 1 MW 150 1,080 0.7

BC-9 ESCCIL ES Close Coupled Inline from 150 kW to 1 MW 150 1,080 0.7

BC-10 ESOB ES Own Bearing from 150 kW to 1 MW 325 10,725 7.4

BC-11 SBHP

8” Submersible bore-hole pumps 33 27,899 19.3

Submersible bore-hole pumps larger than 12” 288 6,516 4.5

BC-12 VMSP

Vertical multi-stage pump (25 to 40 bar and/or 100 to 180 m3/hr)

68 10,649 7.4

Vertical multi-stage pump (>40 bar and/or >180 m3/hr) 125 2,480 1.7

The environmental impacts of the Base-Cases throughout all the life cycle stages are examined. The results calculated using the EcoReport tool detailed the impacts from production phase, distribution phase, use phase and end-of-life phase. Moreover, the methodology tracks 17 environmental impact categories, that are classified into three main categories:

Resources and waste

Total energy (GER - gross energy requirement) Electricity (in primary MJ)

Water (process) Water (cooling)

Waste, non hazardous/landfill Waste, hazardous/incinerated Emissions (air)

Greenhouse gases in GWP100

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Ozone depletion, emissions Acidification, emissions

Volatile organic compounds (VOC) Persistent organic pollutants (POP) Heavy metals into air

Polycyclic aromatic hydrocarbons (PAHs) Particulate matter (PM, dust)

Emissions (water)

Heavy metals into water Eutrophication

Persistent organic pollutants (POP)

The outcome of the environmental analysis for BC-1 in Lot 28 is illustrated in Figure 11. BC-1 is one of the pump groups that have biggest potential energy saving within the pumps study in Lot 28. The results showed that use phase is the predominant phase that contributes to the environmental impacts which is also the typical results from most of the pump groups that have been studied. The same analysis using the MEEuP methodology has been carried out for all the BCs that have been listed in Table 5 and Table 6. The complete reports of Task 5 as well as a sample Ecoreport are attached in the annexes.

Figure 11: Distribution of the BC-1 environmental impacts by life cycle phase (extracted from Task 5)

From the Ecoreport analysis on 18 BCs, it can be concluded that

For both ENER Lot 28and Lot 29 BCs, the use phase is the dominating phase that contributes to significant environmental impacts.

0%

10%

20%

30%

40%

50%

60%

70%

80%

90%

100%

Material Manufacturing Distribution Use End-of-life

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The second largest contribution to environmental impacts is the production phase whereby the main contribution is to non-hazardous waste generation/ landfill, Persistent Organic Pollutants (POP), Heavy Metals into air and water, PAHs and Eutrophication.

Distribution phase contributes to particulate matter, volatile organic compounds and PAHs.

End-of-life phase contributes to hazardous/incinerated waste generation, heavy metal in air and water, particulate matter and Eutrophication.

The results from the analysis will be used as a reference when analyzing the improvement potential of design options in Task 6.

Life cycle cost (LCC) is also analyzed with EcoReport tool and all the consumer expenditures throughout the life span of the product are considered which include average sales prices, the average installation costs, average repair and maintenance costs. Moreover, the operational cost such as average electricity rates, average lifetime of the Base-Case and average annual energy consumption are also incorporated into the calculation.

Table 7: Life cycle cost of BC-1 to BC-7 for ENER Lot 28

BC-1 BC-2 BC-3 BC-4 BC-5 BC-6 BC-7*

% % % % % % %

Product price 30% 20% 73% 47% 34% 20% -

Installation/ acquisition costs (if any) 5% 3% 21% 47% 2% 3% -

Electricity 63% 76% 1% 1% 63% 76% -

Repair & maintenance costs 2% 1% 4% 5% 1% 1% -

Total LCC (Euro) 11,313 50,061 2,647 639 14,768 20,196 -

*BC-7 is added into the scope after the second stakeholder meeting held recently. Data compilation is still ongoing for this BC.

Table 8: Life cycle cost of BC-1 to BC-12 for ENER Lot 29

BC-1 BC-2 BC-3 BC-4&5 BC-6 BC-7 BC-8 BC-9 BC-10 BC-11 BC-12

% % % % % % % % % % %

Product price 8 5 64 79 19 69 <1 <1 <1 2 1

Installation/

acquisition costs (if any)

4 1 0 0 32 25 <1 <1 <1 1 <1

Electricity cost 88 94 30 21 48 5 99 99 100 98 98

Repair &

maintenance costs <1 <1 5 0 1 1 <1 <1 <1 <1 1

Total LCC (Euro) 6,313 42,884 389 123 1,422 2,003 1,624,871 1,624,871 2,925,465 241,782 432,285

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In general, the energy cost during the use phase is the main contribution to the life cycle cost (LCC) for most BCs. Therefore, the gains in energy efficiency of these pumps significantly reduce the LCC.

BCs in this category are:

ENER Lot 28: BC-1, BC-2, BC-5 and BC-6 (energy cost is more than 60% of LCC).

ENER Lot 29: BC-1, BC-2, BC-8, BC-9, BC-10, BC-11 and BC-12 (energy cost is more than 85% of LCC).

For some of the other cases, product price is the major contribution of LCC cost when the pump has low operating hours. The BCs that fall under this category are:

ENER Lot 28: BC-3 and BC-4

ENER Lot 29: BC-3, BC-4&5 and BC-7

The result of the impact analysis is still at the preliminary stage and very much affected by the data from the market information and technical analysis presented in the previous section. For ENER Lot 28, the life cycle cost for BC-4 is anticipated to be at the high end thus the input data from previous task will be rectified. The main contribution to the total energy consumption cost of ENER Lot 29 is from BC-11 which has high average hydraulic power requirement. However, stakeholder doubt that the total energy consumption for ENER Lot 29 will surplus the total energy consumption of TREN Lot 11 pumps which consists of the wide group of water pumps with the capacity up to 150kW.

The highest contribution to overall environmental impacts at the EU level for both lots is identified and the outcomes are:

ENER Lot 28

BC 1 (Centrifugal submersible radial sewage pumps 1 to 160 kW) represents more than 50% of both the overall energy consumption and the overall greenhouse gas emissions of ENER Lot 28 pumps.

The high contribution of environmental impacts caused by the large number of centrifugal submersible radial sewage pumps for 1 to 160 kW installed in the EU. Moreover, the annual energy consumption of the pumps is high.

ENER Lot 29

BC-11 (submersible borehole pumps) represents more than 65% of both the overall energy consumption and the overall greenhouse gas emissions ENER Lot 29 pumps.

The high environmental impact is due to the significant number of submersible borehole pumps with the high hydraulic power requirement is installed in the EU.

Task 5 results indicate that the assessment on improvement of the energy efficiency of these pumps is essential. Annual energy consumption and emissions of EU stock of pump products are presented in the Table 9.

Environment analysis has reflected that the impacts are mainly from the use phase thus the environment impacts are contributed by the activity in related to energy consumption. Therefore,

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the result again indicated that the main focus for the implementation measures should be on energy efficiency.

Table 9: Annual energy consumption and emissions of EU stock of pump products

Geographical

scope

Primary Energy consumption

per year (PJ)

Primary Energy consumption

per year (TWh)

Emissions mtCO²eq per

year

Emissions ktSO²eq per

year

ENER Lot 11 EU-25 1,496 415.6 64 386

ENER Lot 29 EU-27 1,517 421.4 66 391

ENER Lot 28 EU-27 194 53.8 9 51

Preparatory Studies: Improvement of Energy and Environmental Performance for Water and Wastewater Pumps within Europe

European Joint Masters Degree Program in Management and Engineering of Environment and Energy

Master Thesis Report

Preparatory Studies: Improvement of Energy and Environmental Performance for Water and Wastewater Pumps within Europe

July 2013

Company Supervisor: Benoît TINETTI University Tutor: Professor Laurence LE COQ

Submitted by: Pooi Yin CHANG

Index Note

Acknowledgement

Table of Contents

Contents

List of Tables

List of Figures

Abstract

Chapter 1: Context of Internship

Chapter 2: Introduction to the Project

Chapter 3: The working group

BIO Intelligence Service

DG ENER of European Commission

Stakeholders

Atkins

My contributions

Chapter 4: Background information

Ecodesign Directive

Ecodesign principle

Design phase

Design determines impacts throughout the life

cycle of a product

Aim of the directive

Projected Outcome of Ecodesign Directive

Product Selection

European Commission

1

2

3

4

5

Consultants

Chapter 5: Methodology

Ecodesign Methodology (5)(6)

Mission and Duties

Chapter 6: Outcome of the Preparatory Studies

Overview (Scope of the Preparatory Studies) (7)(8)

Pumps in EU Market (9)(10)

10 10 15

10

7 8 10 7

10

15 15 15 20

8

0 5 10 15 20 25

Y ea r

Technical life time Average economical life time

20 20

9

5 5

20 20 20 20 20

11 11 11 11 12 12

0 5 10 15 20 25

Y e a r

Technical life Average economical life

Main findings

Consumer Behaviour (11)(12)

Technical Analysis (14)(15)

Impact Assessment (16)(17)