I want to write a booklet on efficient lighting (and to bash CFLs somewhat), i want some reliable quotable data like :

How much energy in J takes to make an incandescent ? a CFL ?

How much energy in J takes to transport it ovrseas (for 1 piece) ?

How much mercyry or CO2 is emitted from the power plant ? from the lamp manufacturing plant ?



Also something that confuses me a bit :

In 40W T12 switch start fixture, 40W is lamp only or lamp + ballast ? How much W lamp + how much W ballast ?

How does this change when the lamp is replaced with 36W T8 ?

Is the 430mA rating of the ballast for 40W only and actual current is lower for 36W ? (what confuses me here is that the newer ballasts dropped the 40W rating and left with the 36W only (though they can run 40W) and the current rating is still 430mA unchanged)

How much mercyry or CO2 is emitted from the power plant ?

Assume the powerplant is burning clean carbon, what release about 30MJ of heat per burned kg.
The typical plant efficiency is about 50%, what mean output of 15MJ per kg of burned carbon.
The mass of the carbon atom is 12, of the oxygen atom is 16, so the burning 1kg of carbon release 3.7kg of CO2.
So we have about 4MJ of electricity per kg of CO2 emission.
But all that numbers are quite optimistic, as other components of coal reduce the heat output per kg of contained carbon...

With 100W incandescent lamp burned for 6000hours it mean about 540kg of CO2, so about 150kg of burned carbon.
For the mercury release it depend, how much is the mercury content in the coal...

In 40W T12 switch start fixture, 40W is lamp only or lamp + ballast ? How much W lamp + how much W ballast ?

The 40W is power input of the tube only (assume unity BF), ballast losses are in the 10..20W range, so 50..60W total.
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How does this change when the lamp is replaced with 36W T8 ?

The power delivered to the tube is 36W, ballast losses about the same, so overall power input is 46..56W

Is the 430mA rating of the ballast for 40W only and actual current is lower for 36W ? (what confuses me here is that the newer ballasts dropped the 40W rating and left with the 36W only (though they can run 40W) and the current rating is still 430mA unchanged)

The current is the same for both lamps (to be more exact, the 36W would run on slightly higher current then the 40W with exactly the same ballast, it's temperature and mains voltage, but the difference is less then a percent, so way below other tolerances of the system parameters)

How about manufacturing resources / pollution for the lamps ?

Are the phosphors (triphosphor) an ecological hazard or issue (besides being rare and extincting) ?

How much phosphor / mercury is getting into the lamps vs getting spilled at the factory (normal figures for Chinese factory with Chinese working conditions) ?

I don't know about F40T12, but for many other types of lamp maximum allowed power input to the system (so including ballast loss) for all Energy Efficiency Index classes except the since a long time ago banned (in EU) D, can be found in this PDF (starts at page 15). In the EU, maximum allowed loss for magnetic ballasts is currently EEI class B2. For example this is 43 W for F36T8. I am not sure if contemporary "EU-compatible" ballast really give the lamp true full power, because I might have read somewhere that the ballasts now have a BF of 0.95, but I don't have any reliable source for this claim.

About mercury getting spilled, I have read somewhere (again, don't have the source and I don't remember if I would today consider it reliable) a figure of the average releases (mg of mercury released in the environment for each mg sold) during mercury production (globally IIRC). I don't remember the exact figure, but it was a significant fraction of the mercury that ended up at the customer. And, I don't think Chinese mines would be below average in releases..