Life-Cycle Analysis of Polymer,

Porcelain & Glass Insulators

D. Kellett, B.Sc
K-Line Insulators Ltd.
 Life-Cycle Analysis
• Effective tool for accurate environmental cost of good or
service
• Considers impacts from each life-cycle stage
• ISO 14040 & 14044 provide guidelines and methodology
for accurate and replicable LCA [1, 2]
• Inputs (raw materials, energy, etc) and outputs
The Stages of a product’s Life-Cycle
(emissions, waste, etc) must be accurately modelled for
each life-cycle stage
Important Terms
Life Cycle Stage
The results of an LCA are expressed as: Functional Unit
System Boundary
Midpoint Impacts – Specific and measurable quantities Life Cycle Inventory (LCI)
& Life Cycle Impact Assessment (LCIA)
Endpoint Impacts – Broad and general ‘scores’

References:
[1] 14040, ISO, Switzerland, 2006.
[2] 14044, ISO, Switzerland, 2006.
 Conducting a Life-Cycle Analysis

Goal and Scope

Definition

Life-Cycle Inventory
Analysis (LCI)

Life-Cycle Impact
Assessment (LCIA)

Interpretation of
Results
 LCA: Calculation of Results
Midpoint Impacts
Climate Change
Freshwater Ecotoxicity Endpoint Impacts
Marine Ecotoxicity
Terrestrial Ecotoxicity
Damage to
Freshwater Eutrophication
Human Health
Marine Eutrophication
Terrestrial Acidification
Life Cycle Ozone Formation, Ecosystems
Inventory Results ReCiPe Ionizing Radiation Damage to
ReCiPe
(emissions from Human Toxicity, Cancer Ecosystems
model outputs) Human Toxicity, Non-Cancer
Particulate Formation
Ozone Formation, Human
Ozone Depletion Resource
Land Use Scarcity
ASSESSMENT METHOD: ReCiPe 2016 [1] Fossil Depletion
LCA DATABASE: Ecoinvent 3.9.1
Metal Depletion
Freshwater Consumption
Sources:
[1] M. A. Huijbregts et al., "ReCiPe2016: a harmonised life cycle impact assessment method at midpoint and endpoint level," The International Journal of Life Cycle Assessment, vol. 22, pp.
138-147, 2017.
 LCA: Calculation of Results
Midpoint Impacts
Climate Change
Freshwater Ecotoxicity Endpoint Impacts
Marine Ecotoxicity
Terrestrial Ecotoxicity
Damage to
Freshwater Eutrophication
Human Health
Marine Eutrophication
Terrestrial Acidification
Life Cycle Ozone Formation, Ecosystems
Inventory Results ReCiPe Ionizing Radiation Damage to
ReCiPe
(emissions from Human Toxicity, Cancer Ecosystems
model outputs) Human Toxicity, Non-Cancer
Particulate Formation
Ozone Formation, Human
Ozone Depletion Resource
Land Use Scarcity
ASSESSMENT METHOD: ReCiPe 2016 [1] Fossil Depletion
LCA DATABASE: Ecoinvent 3.9.1
Metal Depletion
Freshwater Consumption
Sources:
[1] M. A. Huijbregts et al., "ReCiPe2016: a harmonised life cycle impact assessment method at midpoint and endpoint level," The International Journal of Life Cycle Assessment, vol. 22, pp.
138-147, 2017.
 LCA: Calculation of Results
Midpoint Impacts
Climate Change
Freshwater Ecotoxicity Endpoint Impacts
Marine Ecotoxicity
Terrestrial Ecotoxicity
Damage to
Freshwater Eutrophication
Human Health
Marine Eutrophication
Terrestrial Acidification
Life Cycle Ozone Formation, Ecosystems
Inventory Results ReCiPe Ionizing Radiation Damage to
ReCiPe
(emissions from Human Toxicity, Cancer Ecosystems
model outputs) Human Toxicity, Non-Cancer
Particulate Formation
Ozone Formation, Human
Ozone Depletion Resource
Land Use Scarcity
ASSESSMENT METHOD: ReCiPe 2016 [1] Fossil Depletion
LCA DATABASE: Ecoinvent 3.9.1
Metal Depletion
Freshwater Consumption
Sources:
[1] M. A. Huijbregts et al., "ReCiPe2016: a harmonised life cycle impact assessment method at midpoint and endpoint level," The International Journal of Life Cycle Assessment, vol. 22, pp.
138-147, 2017.
 LCA: Calculation of Results
Midpoint Impacts
Climate Change
Freshwater Ecotoxicity Endpoint Impacts
Marine Ecotoxicity
Terrestrial Ecotoxicity
Freshwater Eutrophication
Damage to
Human Health
Marine Eutrophication
Terrestrial Acidification
Life Cycle Ozone Formation, Ecosystems
Inventory Results ReCiPe Ionizing Radiation Damage to
ReCiPe
(emissions from Human Toxicity, Cancer Ecosystems
model outputs) Human Toxicity, Non-Cancer
Particulate Formation
Ozone Formation, Human
Ozone Depletion Resource
Land Use Scarcity
ASSESSMENT METHOD: ReCiPe 2016 [1] Fossil Depletion
LCA DATABASE: Ecoinvent 3.9.1
Metal Depletion
Freshwater Consumption
Sources:
[1] M. A. Huijbregts et al., "ReCiPe2016: a harmonised life cycle impact assessment method at midpoint and endpoint level," The International Journal of Life Cycle Assessment, vol. 22, pp.
138-147, 2017.
 LCA: Calculation of Results
Midpoint Impacts
Climate Change
Freshwater Ecotoxicity Endpoint Impacts
Marine Ecotoxicity
Terrestrial Ecotoxicity
Freshwater Eutrophication
Damage to
Human Health
Marine Eutrophication
Terrestrial Acidification
Life Cycle Ozone Formation, Ecosystems
Inventory Results ReCiPe Ionizing Radiation Damage to
ReCiPe
(emissions from Human Toxicity, Cancer Ecosystems
model outputs) Human Toxicity, Non-Cancer
Particulate Formation
Ozone Formation, Human
Ozone Depletion Resource
Land Use Scarcity
ASSESSMENT METHOD: ReCiPe 2016 [1] Fossil Depletion
LCA DATABASE: Ecoinvent 3.9.1
Metal Depletion
Freshwater Consumption
Sources:
[1] M. A. Huijbregts et al., "ReCiPe2016: a harmonised life cycle impact assessment method at midpoint and endpoint level," The International Journal of Life Cycle Assessment, vol. 22, pp.
138-147, 2017.
 LCA: Calculation of Results
Midpoint Impacts
Climate Change
Freshwater Ecotoxicity Endpoint Impacts
Marine Ecotoxicity
Terrestrial Ecotoxicity
Damage to
Freshwater Eutrophication
Human Health
Marine Eutrophication
Terrestrial Acidification
Life Cycle Ozone Formation, Ecosystems
Inventory Results ReCiPe Ionizing Radiation Damage to
ReCiPe
(emissions from Human Toxicity, Cancer Ecosystems
model outputs) Human Toxicity, Non-Cancer
Particulate Formation
Ozone Formation, Human
Ozone Depletion Resource
Land Use Scarcity
ASSESSMENT METHOD: ReCiPe 2016 [1] Fossil Depletion
LCA DATABASE: Ecoinvent 3.9.1
Metal Depletion
Freshwater Consumption
Sources:
[1] M. A. Huijbregts et al., "ReCiPe2016: a harmonised life cycle impact assessment method at midpoint and endpoint level," The International Journal of Life Cycle Assessment, vol. 22, pp.
138-147, 2017.
 LCA: Calculation of Results
Midpoint Impacts
Climate Change
Freshwater Ecotoxicity Endpoint Impacts
Marine Ecotoxicity
Terrestrial Ecotoxicity
Damage to
Freshwater Eutrophication
Human Health
Marine Eutrophication
Terrestrial Acidification
Life Cycle Ozone Formation, Ecosystems
Inventory Results ReCiPe Ionizing Radiation Damage to
ReCiPe
(emissions from Human Toxicity, Cancer Ecosystems
model outputs) Human Toxicity, Non-Cancer
Particulate Formation
Ozone Formation, Human
Ozone Depletion Resource
Land Use Scarcity
ASSESSMENT METHOD: ReCiPe 2016 [1] Fossil Depletion
LCA DATABASE: Ecoinvent 3.9.1
Metal Depletion
Freshwater Consumption
Sources:
[1] M. A. Huijbregts et al., "ReCiPe2016: a harmonised life cycle impact assessment method at midpoint and endpoint level," The International Journal of Life Cycle Assessment, vol. 22, pp.
138-147, 2017.
 Why LCA?
GROWING DEMAND, GROWING INFRASTRUCTURE
• Global Electricity Consumption projected to increase by 70% by 2050 [1]
• US Energy Demand is projected to increase by 22% by 2050 [2, 3]
• Canada’s Energy Demand is projected to increase by 47% by 2050 [4]
• Environmental impacts embodied in construction materials are most significant contributor
• Reduction environmental impacts through appropriate material selection

LCA in T&D Industry

• Enables utilities to compare system types (over vs. underground) and compare material choices within
a given system [5-7]
• Most recent academic review identifies 16 LCA studies focusing on T&D networks [8]
• Few studies focus specifically on insulators

Sources: [5] G. Blackett, et. al, "An evaluation of […] transmission," Building and environment, vol. 43, no. 7, pp. 1326-1338, 2008.
[1] U.S. Energy Information Administration. (2021). International Energy Outlook 2021 with Projections to 2050: Narrative [7] S. Bumby, et al., "Life cycle assessment of overhead and underground[…]," Environmental science & technology, vol. 44, no. 14, pp. 5587-5593, 2010.
[2] U.S. Energy Information Administration. (2023). Annual Energy Outlook. [Online] Available: https://www.eia.gov/outlooks/aeo/ [7] C. I. Jones and M. C. McManus, "Life-cycle assessment of 11 kV electrical overhead lines and underground cables,"
[3] Energy Information Administration. (2023). U.S. energy consumption increases between 0% and 15% by 2050. [Online] Available: https://www.eia.gov/todayinenergy/detail.php?id=56040# Journal of Cleaner Production, vol. 18, no. 14, pp. 1464-1477, 2010.
[4] Canada Energy Regulator. (2021). Canada’s Energy Future 2021: Energy Supply and Demand Projections to 2040. [8] A. Gargiulo, et. al, "LCA of electricity networks: a review," The International Journal of Life Cycle Assessment, vol. 22, pp. 1502-1513, 2017.
 Polymer LCA: Goal and Scope
Goals of the Polymer Insulator LCA

 Accurately determine the environmental impacts of polymer

transmission and distribution suspension insulators

 Determine the sources of highest environmental impact: whether

material, manufacturing process, or life-cycle stage

 Evaluate the sensitivity of impacts with respect to changes end-of-life

recycling and use of recycled metallic inputs

Scope
The study will consider all life-cycle stages (ie cradle-to-grave), with the exception of electrical loses during the
usage phase.
 Polymer LCA: Functional Unit
Climate Change Potential per kg
Careful selection is important:

 Proper selection = represents actual use of product

 Determines whether results are comparable to

other studies

 Consistency with other research

OR? OR?
Polymer LCA: System Model

Simplified model of the polymer insulator’s life-cycle

Polymer LCA: System Model

Simplified model of the polymer insulator’s life-cycle

 Polymer LCA: Data Collection
At the production facility, direct measurement of inputs and outputs for each manufacturing step

Energy Raw Materials Waste

• Electricity to power machines • Aluminum • Process wastes: casting and

• Natural gas consumed in • Silicon Rubber Mix injection mold runners,
furnace • Cast Iron trimmings, etc
• Steel • Tested and reject parts
• Chemicals
Polymer LCA: Life Cycle Inventory
MASS DISTRIBUTION OF POLYMER INSULATORS
Polymer LCA: Midpoint Impacts by Material
Sensitivity Study: Metals

- Raw materials cause most impacts,

followed by manufacturing
- Consistent with other insulator LCA
studies

Midpoint Impact Sensitivity to Metallic Content for Polymer Insulators

Polymer LCA: Effect of Metals Recycling
Distribution Insulator Transmission Insulator
Midpoint Impacts: Which Life-Cycle Phase?

- Raw materials cause most impacts,

followed by manufacturing

- Consistent with other insulator LCA

studies
Percent contribution of each Life-Cycle Phase to Midpoint Impacts for Polymer Insulators
Which Insulator Type has the Lowest Life-Cycle Cost?
MASS COMPARISON
Midpoint Impact Comparison

• Construction differences between polymer,

porcelain, and glass
• Comparison between units with corresponding
mech. and elec. specifications
Which Insulator Type has the Lowest Life-Cycle Cost?
CONSTRUCTION COMPARISON

Endpoint Impact Comparison

+
…
 Leakage Current: A Constant Life-Cycle Cost
High leakage currents = increased life-cycle costs

- Polymer Insulators have low leakage currents [1]

- Polymer Insulators are inherently hydrophobic
- High leakage currents increase life-cycle impacts due to energy losses
- Not quantified in current study

Further Work:
- Robust study of leakage current for each insulator type should be incorporated into future
insulator LCA

Sources:
[1] R. Filter and D. Mintz, "CEA 265D748: The prevention of pole fires," 1997.
 Conclusions
Ranking of Life-Cycle Impacts by Insulator Type
(lowest to highest environment impact)

Polymer Glass Porcelain

Polymer Insulators have low life-cycle impacts due to:

 Less metallic content per insulator

 Lightweight construction

For all insulator types, reduction in life-cycle impacts can be most easily achieved by:

 Reducing metallic content (especially aluminum)

 Increasing end-of-life metals recycling / using recycled metals as inputs