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Process Data set: Polymer Hybrid Aluminum Electrolytic Capacitor (PHAEC) Production ; Polymer Hybrid Aluminum Electrolytic Capacitor (PHAEC) >2cm ; ; Primary Aluminum Ingot (en) en zh

Key Data Set Information
Location CN
Reference year 2022
Name
Polymer Hybrid Aluminum Electrolytic Capacitor (PHAEC) Production ; Polymer Hybrid Aluminum Electrolytic Capacitor (PHAEC) >2cm ; ; Primary Aluminum Ingot
Use advice for data set When using the LCA data for PHAEC production, consider the dataset's reference year (2016) and source (Gabi database version 10.6.1.35) to ensure accuracy of the environmental impact assessments. Integrate the detailed Life Cycle Inventory (LCI) data only for applicable PHAEC manufacturing and take into account the additional forming solution used in the manufacturing process compared to LAECs. Pay special attention to the introduction of conductive polymers (PEDOT, PEDOT:PSS) and adjust the manufacturing LCI where cathode foil LCI data for PHAECs is unavailable, using similar processes from PAECs. For end-of-life considerations, use the analysis and calculations provided to evaluate environmental impact comprehensively.
Technical purpose of product or process Polymer Hybrid Aluminum Electrolytic Capacitors (PHAECs) are designed for high-performance electronic applications, where a combination of solid polymer and liquid electrolyte offers improved lifespan and stability for capacitive components. They are typically used in power supply circuits, energy storage systems, and electronic devices that require reliable and long-lasting capacitors larger than 2cm.
Classification
Class name : Hierarchy level
  • ILCD: Materials production / Metals and semimetals
General comment on data set 聚合物杂化铝电解质电容器 (PHAEC) 生产阶段 ; 25V 150uf
Copyright No
Owner of data set
Quantitative reference
Reference flow(s)
Time representativeness
Time representativeness description Literature published on 2022-11-15 in the literature The reference year of the elementary data (alumminum ingots, separator paper, tansport, electricity, and water) is around 2016 and qcruired from the Gabi database (Version: 10.6.1.35)
Technological representativeness
Technology description including background system The manufacturing stage of the AECs is divided into several sub-stages in this study based on the actual fabrication segmentation in the AEC industry. First, the high-purity aluminum ingots will be smelt, cast, rolled, and annealed into the aluminum foil with a thickness of about 10–100 μm. Then, anode foil and cathode foil for the AECs will be fabricated, respectively. The same manufacturing processes are applied toward anode foil in three types of AECs. The aluminum blank foil will be etched by the weak acids to increase the superficial area of the foil, and the electrochemical reaction can further form the dielectric (Al2O3). But cathode foil of three types of AECs varies in structure and manufacturing processes due to the differences in electrolytes. The cathode foil of LAECs is made by the etched process, while the cathode foil of PAEC is made by the carbon coating process after the etched process. In PHAECs, when liquid-state electrolyte and solid-state polymer are used simultaneously, the carbon-coated cathode aluminum foil of the PAECs is also replaced by the aluminum foil with TiO2 film to overcome the potential problems on capacitor cycling life. After obtaining the anode and cathode foil, the AECs can be manufactured, assembled, and packed. Besides, there are some differences in the AEC fabrication sub-stage. The specific processes of the three types of AECs are shown in Fig. 2. In detail, the differences in manufacturing processes among the three types of AECs are mainly due to the change of repair conditions of the capacitor dielectric (Al2O3 film) and the introduction of conductive polymer. On the one hand, PAECs and PHAECs cannot use the electrolyte to repair the dielectric layer in the aging process like LAECs, so an additional forming solution is required to perform forming process, which adds extra manufacturing steps. On the other hand, the conductive polymer needs to be effectively introduced into the middle of anode and cathode foils. The conductive polymer (PEDOT) in PAECs is formed by the polymerization reaction of EDOT and oxidizing agents in the capacitor manufacturing process, while the conductive polymer (PEDOT:PSS) in PHAEC is introduced into the capacitors by the dispersive solution. The collected inventory data of LAECs, PAECs, and PHAECs by the FU are summarized in Table 2. The details of the inventory data are available in Sheets 5–7 of Supporting Info B.
Flow diagram(s) or picture(s)
  • QL21bJIXBohvCAxPv8tcCZndn9b.png Image
LCI method and allocation
Type of data set Unit process, single operation
Deviation from LCI method principle / explanations None
Deviation from modelling constants / explanations None
Data sources, treatment and representativeness
Deviation from data cut-off and completeness principles / explanations None
Data selection and combination principles The material information and performance parameters of the three types of AECs are from the investigated manufacturer. Moreover, through the field research of several factories in the AEC industry, the original data on aluminum blank foil fabrication (made from aluminum ingots), anode/cathode foil fabrication (made from aluminum blank foil), and capacitor fabrication were obtained. Due to technical confidentiality, the LCI data of the fabrication of the cathode foil for PHAECs cannot be obtained directly from the supplier. Therefore, the manufacturing LCI of aluminum cathode foil in PHAECs is adjusted according to the coating process data of cathode foil of PAECs, considering their similarity. In the transportation stage, the data of the main raw materials from the material origin to the capacitor manufacturer and the data of the manufactured capacitor products from the manufacturer to the customers are from the supply chain system of the manufacturer. The energy consumption in the use stage is calculated based on the physical equations and the electrical parameters of the AECs. To ensure the completeness of the analysis, the data of the end-of-life stage is obtained based on the analysis and calculation.The reference year of the elementary data is around 2016. The elementary data (i.e., aluminum ingots, separator paper, transport, electricity, and water) are acquired from the Gabi database (Version: 10.6.1.35). In addition, some background data, including 3, 4-ethylene dioxythiophene (EDOT), ammonium adipate, ammonium citrate, etc., are not available in the Gabi database. They are estimated based on the chemical reactions with the material preparation process from the existing raw materials in the Gabi database. The data on the preparation process of the dispersive solution (PEDOT:PSS, 1%wt) for PHAECs' fabrication are scaled from the lab data. The detailed LCI data of the three types of AEC and unit impact of the substance flow is provided in Sheets 5–7 and Sheet 2 of Supporting Info B.
Deviation from data selection and combination principles / explanations None
Deviation from data treatment and extrapolations principles / explanations None
Data source(s) used for this data set
Completeness
Completeness of product model No statement
Validation
Type of review
Dependent internal review
Reviewer name and institution
Data generator
Data set generator / modeller
Data entry by
Time stamp (last saved) 2024-04-30T20:23:58+08:00
Publication and ownership
UUID 50ea3706-fd23-4aa8-813f-af4c2bf0cf28
Date of last revision 2024-05-13T14:41:10.965354+08:00
Data set version 01.00.005
Permanent data set URI https://lcadata.tiangong.world/showProcess.xhtml?uuid=50ea3706-fd23-4aa8-813f-af4c2bf0cf28&version=01.00.000&stock=TianGong
Owner of data set
Copyright No
License type Free of charge for all users and uses

Inputs

Type of flow Classification Flow Location Mean amount Resulting amount Minimum amount Maximum amount
Product flow
Energy carriers and technologies / Electricity 23893.56 MJ23893.56 MJ
General comment Electricity grid mix (China)
Product flow
Materials production / Metals and semimetals 292.7 kg292.7 kg
General comment 292.7=219.8(99.99% Al ingots)+72.9(99.9% Al ingots)
Product flow Materials production / Water 70856.9 kg70856.9 kg
Product flow Materials production / Other mineralic materials 31347.7 kg31347.7 kg
Product flow
Materials production / Metals and semimetals 486.8 m3486.8 m3
General comment Aluminum profile (China)
Product flow Materials production / Paper and cardboards 82.4 kg82.4 kg
Product flow
Materials production / Other materials 131.8 kg131.8 kg
General comment Rubber from Gabi database ({401c53f8-0ace-410b-9cc7-9a586f8ac2e6})
Product flow
Materials production / Metals and semimetals 2.12 kg2.12 kg
General comment substance flow is leads (Fe) but database from Gabi database is steel wire ({d3e4d4d7-66ee-4bea-b6eb-9704682a0b8a})
Product flow
Materials production / Metals and semimetals 15.94 m315.94 m3
General comment Tab (alluminium profile (China) )
Product flow
Materials production / Plastics 4.2517 kg4.2517 kg
General comment Tape(PP film ,from Gabi {7d6d2565-aeb4-4f36-a049-f715a80fe954})
Product flow
Materials production / Inorganic chemicals 60.6473 m360.6473 m3
General comment H3PO4
Product flow
Materials production / Inorganic chemicals 10.7606 kg10.7606 kg
General comment HBO3
Product flow
Materials production / Inorganic chemicals 38.6649 kg38.6649 kg
General comment HCl (31%)
Product flow
Materials production / Inorganic chemicals 47.5771 kg47.5771 kg
General comment NaOH (30%)
Product flow
Materials production / Inorganic chemicals 230.4429 kg230.4429 kg
General comment H2SO4 (98%)
Product flow
Materials production / Inorganic chemicals 11.5995 kg11.5995 kg
General comment HNO3 (98%)
Product flow
Materials production / Organic chemicals 7.5919 kg7.5919 kg
General comment Rolling oil
Product flow
Materials production / Inorganic chemicals 20.7249 m320.7249 m3
General comment Ammonium citrate
Product flow
Emissions / Inorganic covalent compounds 5.6844 kg5.6844 kg
General comment Ammonium pentaborate
Product flow
Materials production / Inorganic chemicals 28.8565 m328.8565 m3
General comment Ammonium adipate
Product flow
Materials production / Organic chemicals 148.5926 kg148.5926 kg
General comment Electrolyte (liquid) 2
Product flow
Materials production / Inorganic chemicals 0.9473 m30.9473 m3
General comment NH4H2PO4
Product flow
Materials production / Metals and semimetals 30.901 kg30.901 kg
General comment Titanium coating paste
Product flow
Materials production / Organic chemicals 642.8571 kg642.8571 kg
General comment PEDOT:PPS solution (1%wt)

Outputs

Type of flow Classification Flow Location Mean amount Resulting amount Minimum amount Maximum amount
Product flow
Emissions / Inorganic covalent compounds 7.6267 kg7.6267 kg
General comment AlPO4 (by-product)4
Waste flow
Wastes / Production residues 62925.1701 Item(s)62925.1701 Item(s)
General comment Capacitors (waste)
Waste flow
Wastes / Waste water 60169.2396 m360169.2396 m3
General comment Waste water
Product flow
Energy carriers and technologies / Crude oil based fuels 7.1776 kg7.1776 kg
General comment Sludge
Product flow
Materials production / Metals and semimetals 20.1195 m320.1195 m3
General comment Al scraps
Elementary flow
Emissions / Emissions to water / Emissions to water, unspecified 2.3634 kg2.3634 kg
General comment COD
Product flow
Systems / Electrics and electronics 1000000.0 Item(s)1000000.0 Item(s)
General comment capacitors (product)