Energy-consumption and carbon-emission analysis of vehicle and component manufacturing.

A model is presented for calculating the environmental burdens of the part manufacturing and vehicle assembly (VMA) stage of the vehicle life cycle. The approach is bottom-up, with a special focus on energy consumption and CO{sub 2} emissions. The model is applied to both conventional and advanced vehicles, the latter of which include aluminum-intensive, hybrid electric, plug-in hybrid electric and all-electric vehicles. An important component of the model, a weight-based distribution function of materials and associated transformation processes (casting, stamping, etc.), is developed from the United States Council for Automotive Research Generic Vehicle Life Cycle Inventory Study. As the approach is bottom-up, numerous transformation process data and plant operational data were extracted from the literature for use in representing the many operations included in the model. When the model was applied to conventional vehicles, reliable estimates of cumulative energy consumption (34 GJ/vehicle) and CO{sub 2} emission (2 tonnes/vehicle) were computed for the VMA life-cycle stage. The numerous data sets taken from the literature permitted the development of some statistics on model results. Because the model explicitly includes a greater coverage of relevant manufacturing processes than many earlier studies, our energy estimates are on the higher end of previously published values. Limitations of the model are also discussed. Because the material compositions of conventional vehicles within specific classes (cars, light duty trucks, etc.) are sensibly constant on a percent-by-weight basis, the model can be reduced to a simple linear form for each class dependent only on vehicle weight. For advanced vehicles, the material/transformation process distribution developed above needs to be adjusted for different materials and components. This is particularly so for aluminum-intensive and electric-drive vehicles. In fact, because of their comparatively high manufacturing energy, batteries required for an electric vehicle can significantly add to the energy burden of the VMA stage. Overall, for conventional vehicles, energy use and CO{sub 2} emissions from the VMA stage are about 4% of their total life-cycle values. They are expected to be somewhat higher for advanced vehicles