Detailed process analysis
An OSRAM Opto Semiconductors` study on the life-cycle assessment (LCA) of LED lamps shows the latest generation of lamps achieves a very high score for environmental friendliness. This study involved a close look at their entire life-cycle – how much energy and raw materials the lamp consumes in terms of production, use and disposal and the environmental impact involved in the process. The result was clear: today’s LED lamps achieve the LCA values of compact fluorescent lights and are far superior to conventional incandescent lamps.
In order to evaluate lamps and how they actually deal with energy and resources, it is not enough just to consider energy consumption while they are in use. The aim of OSRAM Opto Semiconductors’ LCA is therefore to analyse the environmental impact of an LED lamp over its entire life and to compare it with a compact fluorescent lamp and an incandescent lamp, all of them are commercially available.
The relevant material and energy supplies were determined in detail for all the LED lamp’s components and production processes. Apart from a detailed analysis of each individual production stage, for LED chips and lamp housings, for example, these also include all necessary transports such as the transport of an LED lamp from its production site in China to its place of installation in Europe.
Apart from direct input of raw materials, the energy input, materials and emissions associated with the retrieval of resources are recorded. The results allow for conclusions not only on resource consumption and primary energy input but also acidification, eutrophication, the greenhouse effect, ozone depletion and toxicity.
Comparing the primary energy demand it´s clear that the use phase in the overall life cycle is dominating and that manufacturing is negligible.
Independent experts are currently verifying the study. A summary will be available in October on this website.
Energy saving production for energy efficient products
For years OSRAM has operated certified environmental management systems and complies with the relevant standards worldwide – this applies to many areas of production, purchasing and health & safety. And this covers not only the technologies for chips and associated products but also the use of energy and resources. Highly qualified environmental coordinators and safety engineers support management and employees in all our work.
OSRAM Opto Semiconductors is the only manufacturer of opto semiconductor components in Europe. At our site in Regensburg we have the world’s most advanced optical chip fabrication plant. When we expanded our headquarters and constructed new facilities we launched an energy program based on making the best use of heat, reusing waste heat and reducing the generation of new heat to the absolute minimum. The heat generated in the fabrication process is reused (compressed air, process cooling water). It is used for example as a heat source for the demineralized water needed for production, raising it from 10°C to around 23°C.
“Free cooling” was later added to the concept. This involves using the cold outside air in the winter to reduce the energy consumption of the cooling loop. At full production capacity from 2011 onward the energy-saving concept will be fully exploited, saving a total of around 20 GWh in electricity and gas. In 2004, this concept gained us the Energy Award from the Bavarian Ministry of Economic Affairs.
Despite further expansion of capacity, water consumption has been maintained at the same level.
The reasons for this are as follows:
- Savings through reuse, for example purification of exhaust air in scrubbers
- Expansion of production, e.g. greater utilization with more wafers for the same water consumption
- Introduction of laser separation instead of conventional sawing and therefore a reduction in water consumption in this part of the production process to zero
The use of solvents has also been reduced. Organic agents such as acetone need large quantities of energy for their production and disposal. By making changes to the process flow, the mode of use and by finding replacements for the solvents we have succeeded in making savings of more than 50% within two years.
