This thesis work, developed in collaboration with Baker Hughes, aims to assess the environmental performance of a critical component of steam turbines: the axial exhaust casing. Through the application of the Life Cycle Assessment methodology, standardized by ISO 14040 and ISO 14044, the study analyzes three different sizes of axial exhaust casing in order to quantify their environmental impacts, identify the main hotspots, and support Eco-design strategies. The analysis was conducted using a cradle-to-gate approach, including raw material extraction, pre-production, transportation to the production site, and manufacturing stages, comprising machining, welding, and painting. The modeling was carried out using SimaPro software, the EcoInvent v3.10 database, and the Environmental Footprint assessment method. A distinctive element of the study is the development of a customized parametric approach capable of correlating environmental impacts with the main design and production variables, such as final mass, amount of filler material, and painted surface areas, thereby overcoming some of the limitations associated with the use of generic datasets. The results show that the raw material, consisting of S275 J2 steel, is the phase that contributes most significantly to environmental impacts, particularly in the Climate Change category. Among the different components of the casing, the Lower Half is the most impactful. Furthermore, the geographical location of production processes and the electricity mix used significantly influence environmental performance: production in areas characterized by more emission-intensive energy mixes generates higher impacts. Logistics, on the other hand, generally has a limited contribution when based on land or sea transport, while it can become highly relevant in the case of air transport. In conclusion, the study confirms the strategic role of the LCA methodology as a tool to support design and industrial decision-making. In particular, the results obtained highlight the importance of directing improvement strategies toward reducing component mass, optimizing production processes, and managing the supply chain more sustainably, thereby contributing to the development of energy solutions with lower environmental impact.
Il presente lavoro di tesi, sviluppato in collaborazione con Baker Hughes, ha l’obiettivo di valutare le prestazioni ambientali di un componente critico delle turbine a vapore: la cassa di scarico assiale. Attraverso l’applicazione della metodologia Life Cycle Assessment, standardizzata dalle norme ISO 14040 e ISO 14044, lo studio analizza tre differenti taglie di cassa scarico assiale, al fine di quantificarne gli impatti ambientali, identificare i principali hotspot e supportare strategie di Eco-design. L’analisi è stata condotta secondo un approccio cradle-to-gate, includendo l’estrazione delle materie prime, la pre-produzione, i trasporti verso il sito produttivo e le fasi di fabbricazione, comprendenti lavorazioni meccaniche, saldatura e verniciatura. La modellazione è stata realizzata mediante il software SimaPro, utilizzando il database EcoInvent v3.10 e il metodo di valutazione Environmental Footprint. Un elemento distintivo dello studio è rappresentato dallo sviluppo di un approccio parametrico customizzato, in grado di correlare gli impatti ambientali alle principali variabili progettuali e produttive, quali massa finale, quantità di materiale d’apporto e superfici di verniciatura, superando alcune limitazioni associate all’impiego di dataset generici. I risultati mostrano che la materia prima, costituita da acciaio S275 J2, è la fase che incide maggiormente sugli impatti ambientali, in particolare sulla categoria Climate Change. Tra i diversi componenti della cassa, il Lower Half risulta quello più impattante. Inoltre, la localizzazione geografica dei processi produttivi e il mix elettrico utilizzato influenzano in modo significativo le prestazioni ambientali: le produzioni in aree caratterizzate da mix energetici più emissivi generano impatti superiori. La logistica presenta invece un’incidenza generalmente limitata quando basata su trasporti terrestri o marittimi, mentre può diventare molto rilevante nel caso di trasporto aereo. In conclusione, lo studio conferma il ruolo strategico della metodologia LCA come strumento di supporto alle decisioni progettuali e industriali. In particolare, i risultati ottenuti evidenziano l’importanza di orientare le strategie di miglioramento verso la riduzione della massa dei componenti, l’ottimizzazione dei processi produttivi e una gestione più sostenibile della catena di fornitura, contribuendo allo sviluppo di soluzioni energetiche a minore impatto ambientale.
Valutazione dell’impatto ambientale di una componente di turbina a vapore mediante Life Cycle Assessment
D'ISIDORO, SIMONE
2025/2026
Abstract
This thesis work, developed in collaboration with Baker Hughes, aims to assess the environmental performance of a critical component of steam turbines: the axial exhaust casing. Through the application of the Life Cycle Assessment methodology, standardized by ISO 14040 and ISO 14044, the study analyzes three different sizes of axial exhaust casing in order to quantify their environmental impacts, identify the main hotspots, and support Eco-design strategies. The analysis was conducted using a cradle-to-gate approach, including raw material extraction, pre-production, transportation to the production site, and manufacturing stages, comprising machining, welding, and painting. The modeling was carried out using SimaPro software, the EcoInvent v3.10 database, and the Environmental Footprint assessment method. A distinctive element of the study is the development of a customized parametric approach capable of correlating environmental impacts with the main design and production variables, such as final mass, amount of filler material, and painted surface areas, thereby overcoming some of the limitations associated with the use of generic datasets. The results show that the raw material, consisting of S275 J2 steel, is the phase that contributes most significantly to environmental impacts, particularly in the Climate Change category. Among the different components of the casing, the Lower Half is the most impactful. Furthermore, the geographical location of production processes and the electricity mix used significantly influence environmental performance: production in areas characterized by more emission-intensive energy mixes generates higher impacts. Logistics, on the other hand, generally has a limited contribution when based on land or sea transport, while it can become highly relevant in the case of air transport. In conclusion, the study confirms the strategic role of the LCA methodology as a tool to support design and industrial decision-making. In particular, the results obtained highlight the importance of directing improvement strategies toward reducing component mass, optimizing production processes, and managing the supply chain more sustainably, thereby contributing to the development of energy solutions with lower environmental impact.| File | Dimensione | Formato | |
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Tesi Simone D'Isidoro.pdf
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https://hdl.handle.net/20.500.12075/28073