ENVIRONMENTAL PRODUCT DECLARATION as per ISO 14025

Transcription

1 ENVIRONMENTAL PRODUCT DECLARATION as per ISO Owner of the Declaration Publisher Programme operator Declaration number Issue date Valid to Çimsa Çimento San. ve Tic. A.Ş. Institut Bauen und Umwelt (IBU) Institut Bauen und Umwelt (IBU) EPD-CIM E CEM IV / B(P)32,5R Çimsa Çimento San. Ve Tic. A.Ş.

2 1 Summary Çimsa Çimento San. Ve Tic. A.Ş. Programme holder IBU - Institut Bauen und Umwelt e.v. Rheinufer 108 D Königswinter Declaration number EDP-CIM E This Declaration is based on the Product Category Rules: Requirements on the EPD for Cement, ] (PCR tested and approved by the independent expert committee (SVA)) Issue date Valid to CEM IV / B(P)32,5R Owner of the Declaration Çimsa Çimento San. Ve Tic. A.Ş. Malatya Karayolu 35. km Bünyan,Kayseri Turkey Declared product / Declared unit CEM IV / B(P)32,5R / 1 t Scope: Within this study a life cycle analysis according to ISO 14040/44 is performed for CEM IV / B(P)32,5R pozzolanic cement produced by Çimsa Çimento San. ve Tic. A.Ş. at the production plant located in Kayseri. This analysis relies on transparent, plausible and documented basis data. All the model assumptions, which influence the results, are declared. The life cycle assessment is representative for the products introduced in the declaration for the given system boundaries. The life cycle assessment covers the manufacturing of the products from cradle to gate. The declaration holder is liable for underlying data and supporting documents. Verification The CEN standard EN serves as the core PCR. Verification of the EPD by an independent third party as per ISO Prof. Dr.-Ing. Horst J. Bossenmayer (President of the Institut Bauen und Umwelt e.v.) internally x externally Prof. Dr.-Ing. Hans-Wolf Reinhardt (Chairman of the SVA) 2 Product 2.1 Product description The product considered is pozzolanic cement. This product is produced by grinding clinker, gypsum, and pozzolanic materials (mineral additives). The composition of this product is in accordance with the TS EN 197-1:2002 for CEM IV/B (P) 32,5 R cement. CEM IV/B (P) 32,5R cement is produced by grinding of the mixture composed from mineral additives (pozzolanic materials), portland cement clinker, and gypsum. 2.2 Application CEM IV/B (P) 32,5R pozzolanic cement is used for creation of concrete types which do not require high strength and in manufacturing of briquette. It is also used in reinforced concrete structures and lean concrete structures. Another field of application is preparation of plaster mesh, masonry mortar, and surface / ground concrete. This type of cement is used in construction of sidewalks, parks, gardens, and architectural buildings. 2.3 Technical Data Appearance and smell: Gray powder and scentless Solubility in Water: Negligible (0.1-1 M-%) ph in water : Specific gravity: 2,82 g/cm 3 Initial setting time : 180 min Dr. Eva Schmincke (Verifier appointed by the SVA) Early strength: 17Mpa Nt/mm2 Standard strength: 37 Mpa Nt/mm2 2.4 Placing on the market / Application rules Cement- Part 1: Compositions and conformity criteria for common cements TS EN Delivery status Specific gravity : 2,82 g/cm 3 Blaine fineness : 4710 cm 2 /g Color: Light green Quantity: 50 kg/package, t in case of bulk deliveries 2.6 Base materials / Ancillary materials Clinker: (M-%) Natural Puzzolan: (M-%) Minor Additional component: 0-5 (M-%) Gyspum: (2-2,5 M-%) Grinding aid and strength enhancing chemicals are used as additional auxilary materials. 2.7 Manufacture During the manufacturing process it is aimed to produce the most suitable product (cement- CEM/IV B (P) 32,5R) in terms of quality requirements and cus- 2 Environmental Product Declaration Çimsa Çimento San. ve Tic. A.Ş. CEM IV / B(P)32,5R

3 tomer needs. Therefore, the production process is optimized in which natural trass is used maximally and the GHG emissions are minimized. Raw materials are gathered after required tests are performed in the raw material quarries. The raw materials which provide the required quality are carried with trucks to the production plant. After arrival of the raw materials at the production plant, they are crushed by the crusher. After crushing, the raw materials are stored in the storage area. Before use of raw materials, a second set of tests are performed to examine, if they comply with the relevant standards. The raw material mixture, which consists of limestone and clay, is fed to the raw mill for grinding. Raw meal is transfered to the raw meal silo. Then, the raw meal is fed to the kiln system. In the rotating kiln the clinker production takes place and the clinker is transferred to the clinker cooler. After the cooling process the clinker is transferred to the clinker storage. Next step, the clinker is fed to the roller press for the realization of the comminution process. After comminution is completed crumbled clinker is transferred to the cement mills. Grinding aids are used in cement mills to ease the grinding of the clinker. Different cement types are produced at the production plant other than CEM IV/B (P) 32,5R. According to the type of cement additives are added to the crumbled clinker. There are three different additives used in the production process. These are limestone, gypsum, and trass. The amount and type of the additive differs according to the cement type. The amounts of compounds/materials are adjusted according to the quality control analysis done by the operators. Samples are taken according to the periods which are predefined in the quality plan. Cement which is produced in the cement mills according to the standards are transferred to the ultimate cement silos. Daily samples are taken from the product and controlled according to the standards. According to the preferences of clients the product is sold as packaged cement or as bulk cement. Samples are taken from the products before they are sent to clients and quality control of the product is performed. The quality control is included in every step of the whole production process. The process flow is demonstrated in Figure 1. Figure 1 Process flow diagramm 2.8 Environment and health during manufacturing Environmental friendly technologies are applied at the production plant. All raw materials and products are stored in closed storages.bag filters are used to prevent dust emissions during transportation of the materials. Additionally, natural pozzolan is dried through the waste gas derived from the rotary kiln. Fossil fuels are not used for drying process of natural pozzolan. Natural pozzolan is used to reduce CO 2 emissions during production. The plant owns Environmental Management System Certificate TS EN ISO The Plant has TS EN Energy Management System which is used to decrease specific energy consumption and emissions. GHG emissions are reduced as a result of the systematic management of energy. In order to be able to minimize and avoid risks during manufacturing various preventions are taken at the production facility. Additionally, personal protective equipments such as safety shoes, helmets, glasses, gloves, dust masks, ear protection and visors are used in case of dust, noise, heat, welding glows etc. Work permission procedures such as energy cutting procedure, permission for working at heights and hot zones, permission for entering closed containers are implemented at the plant. All these measures and preventions are applied in accordance with the effective Turkish legislation on health and safety. The plant owns Occupational Health and Safety Management System Certificate TSE ISG OHSAS TS 18001: Product processing / Installation The raw materials are stored in closed storages. In addition, the 5 stage pre calcination unit generates low NO X emissions. In order to reduce the dust generated during the production process and to comply with the Turkish regulations on incineration of waste and control of air pollution caused by industries, all stacks are equipped with electrostatic and bag filters. The wastewater generated in the plant is collected via a sewerage system and is treated in the biological wastewater treatment plant, before it is discharged. The discharged wastewater complies with the requirements of the Turkish regulation on the control of wastewater treatment. In order to reduce noise level during production process steps, sources of noise and workers ambients are enclosed. In addition, noise level of the equipments is measured and evaluated with respect to Turkish regulations as well as sign boards, which are placed to warn the employees to take the necessary precautions. NO X, SO 2, TOC, HCl, HF and heavy metals emission measurements are performed according to the requirements of the Turkish regulation on control of air pollution caused by industries. The measurement results are below the limit value set by the regulation Packaging Paper bags are used for packaging. Packaging materials are collected separately and sent to licensed companies for recovery. In 2010, 37% of packaging waste is sent to recovery. The End-of-life stage of packaging materials is not part of this study. 3 Environmental Product Declaration Çimsa Çimento ve San. ve Tic. A.Ş. CEM IV / B(P)32,5R

4 2.11 Condition of use In case of exposure to dust it can cuase irritation of upper respiratory tract, cough, dyspnea and wheezing. According to the material safety data sheet of cement, pozzolanic cement may contain crystal silica, which may generate risk of cancer. In order to keep the dust level under the required level set by OSHA, MSHA and ACGIH, filtration systems (general and local) have to be used. If it is not possible to decrease the dust level under the limit value by the use of general and local filtration systems, dust masks must be used Environment and health during use According to the material safety data sheet of cement, the presence of Cr+6 may cause drying, chaps, and irritation on skin in case of exposure to dry cement. Direct contact of wet cement with the skin may cause burning of the skin and some other skin diseases. In order to prevent direct contact of cement with the skin, gloves (impermeable and resistant to alkali ph), boots, long sleeved shirts, long trousers should be used Reference service life In the scope of this study only the production stage information module (from A1 to A3) is declared. As stated in FprEN the reference service life has to be declared only in EDPs which cover the use stage. As the EPDs prepared for CEM IV/B (P) 32,5R do not cover the use stage, the reference service life of these product groups is not declared Extraordinary effects Fire The mentioned product CEM IV/B (P) 32,5R belongs to the A1 non flammable category according to DIN 4102, TS EN (Construction products Fire Classification), and Communication on Building Material Response Classes of Fire, Fire Resistance of Building Elements and Fire Performance of Roofs and Roof Coatings in the scope of the Construction Product Directive (89/106/EEC). Water After cement has been processed and turned into concrete-plaster, it undergoes a very weak alkaline reaction with water. Attention should be paid to contact with water used during fire extinguishing. Leaking of cement, should be avoided into drains, since cement builds up a mixture with water and solidifies within between 1 and 6 hours. Solidified cement can clog the water and sewage channels. Mechanical destruction Mechanical destruction of the product does not cause any hazards Re-use phase There are no applications about the re use of the mentioned product Disposal The disposal activities of the product are realized according to the 27th Clause of the Regulation on Control of Excavation Soil and Construction Waste (date of issue: , Turkish Official Journal Number: (Reg ). As cement is used for production of concrete and bricks as raw material, the corresponding waste code according to the European Waste Catalogue can be defined as or Further information No further information is given about the product. 3 LCA: Calculation rules 3.1 Declared unit The declared unit is 1 t of CEM IV/B (P)32,5R. 3.2 System boundary Type of EPD: cradle to gate The system boundary includes the production of CEM IV/B (P) 32,5R pozzolanic cement from extraction of raw material to the production of finished packaged product at the factory gate (cradle to gate). In this study, the product stage information modules A1, A2, and A3 are considered. These modules include production of raw material extraction and processing (A1), processing of secondary material input (A1), transport of the raw materials to the manufacturer (A2), manufacturing of the product (A3) and the packaging materials (A3). 3.3 Estimates and assumptions All estimations and assumptions regarding the cut off criteria and the allocation are declared within the related parts of this section 3 LCA: Calculation rules. There are no other additional estimations and/or assumptions in the scope of this study. 3.4 Cut-off criteria Criteria for the exclusion of inputs and outputs (cutoff rules) in the LCA and information modules and any additional information are intended to support an efficient calculation procedure. All inputs and outputs to a (unit) process are included in the calculation, for which data were available. The applied cut off criteria is 1 % of renewable and non-renewable primary energy usage and 1 % of the total mass input of that unit process in case of insufficient input data or data gaps for a unit process. The total of neglected input flows per module, e.g. per module A, B, C or D is a maximum of 5 % of energy usage and mass. 3.5 Background data Background processes are taken from the publicly available professional GaBi 4.4 databases as far as available (GaBi DOC 2010). Country and region specific data on energy sources including electricity and region specific data on raw materials such as limestone and clay and gypsum were taken from GaBi databases. 3.6 Data quality The process data and the used background data (GaBi DOC 2010) are consistent. In addition, the origin of the data is documented. Additional information is gathered regarding the age of the data. The input and output data of the whole process plant was strongly emphasized. The supplied data 4 Environmental Product Declaration Çimsa Çimento San. ve Tic. A.Ş. CEM IV / B(P)32,5R

5 (processes) were provided by Çimsa Çimento San. ve Tic. A.Ş and checked for plausibility. Therefore, the data quality can be described as good. All data applied in this study are not older than 5 years. 3.7 Period under review The period under review is defined as one year. The monthly data is collected by the producer and is averaged to obtain the yearly data. As explained here, the average data for the year 2010 is utilized within this study. 3.8 Allocation There are four co-products in the manufacturing of CEM IV/B (P) 32,5R which can be listed as: CEM I 42,5 R, CEM II A/M (P-L) 42,5R, CEM IV/B(P) 32,5R. In this case an allocation per mass is applied for these products, since the production of all the products shows the same manufacturing procedure, but only the amount of raw materials and the sort of the auxiliary materials differs from each other. Therefore, the data related these materials (the amount of raw materials and the auxiliary materials consumed during production of CEM IV/B (P) 32,5R) are collected separately. The data for CEM IV/B (P) 32,5R except for the data related to the raw materials and the auxiliary materials is calculated by multiplying the yearly total production values with the percentage (considering the yearly mass of all the different products) of CEM IV/B (P) 32,5R out of the total production. In addition to this co product allocation, the secondary and primary fuels and direct emissions were allocated by the content of the clinker. This allocation was performed in which the product output was fixed to 1 t and the corresponding clinker amount for 1 t of product was calculated. In the next stage the allocation of primary and secondary fuels and direct emissions was realized accordingly. On the other hand, the allocation of waste, cardboard effort, and power was performed according to the product outcome which is fixed to 1 t in the model. 3.9 Comparability 4 LCA: Scenarios and additional technical information The modules A4, A5, B1, B2, B3, B4, B5, reference service life, B6, B7 and C1 C4 are not considered and declared in this study. Basically, a comparison or an evaluation of EPD data is only possible if all the data sets to be compared were created according to EN and the building context, respectively the product-specific characteristics of performance, are taken into account. 5 Environmental Product Declaration Çimsa Çimento ve San. ve Tic. A.Ş. CEM IV / B(P)32,5R

6 5 LCA: Results DESCRIPTION OF THE SYSTEM BOUNDARY (X = INCLUDED IN LCA; MND = MODULE NOT DECLARED) PRODUCT STAGE CONSTRUCTION PROCESS STAGE USE STAGE END OF LIFE STAGE BENEFITS AND LOADS BEYOND THE SYSTEM BOUNDARYS Raw material supply Transport Manufacturing Transport Construction-installation process Use Maintenance Repair Replacement Refurbishment Operational energy use Operational water use De-construction demolition Transport Waste processing Disposal Reuse- Recovery- Recyclingpotential A1 A2 A3 A4 A5 B1 B2 B3 B4 B5 B6 B7 C1 C2 C3 C4 D X X X RESULTS OF THE LCA - ENVIRONMENTAL IMPACT: 1 t CEM IV/B (P) 32,5R Manufacturing Parameter Unit A1- A3 GWP [kg CO 2-Äq.] ODP [kg CFC11-Äq.] 1.15E-06 AP [kg SO 2-Äq.] 2.16 EP [kg PO Äq.] 0.07 POCP [kg Ethen Äq.] 0.11 ADPE [kg Sb Äq.] 8.98E-04 ADPF [MJ] 2865 GWP = Global warming potential; ODP = Depletion potential of the stratospheric ozone layer; AP = Acidification potential of land and water; EP Caption = Eutrophication potential; POCP = Formation potential of tropospheric ozone photochemical oxidants; ADPE = Abiotic depletion potential for non fossil resources; ADPF = Abiotic depletion potential for fossil resources RESULTS OF THE LCA - RESOURCE USE: 1 t CEM IV/B (P) 32,5R Manufacturing Parameter Unit A1 - A3 PERE [MJ] PERM [MJ] 0 PERT [MJ] PENRE [MJ] 3029 PENRM [MJ] 0 PENRT [MJ] 3029 SM [kg] 0 RSF [MJ] 0 NRSF [MJ] 0.13 FW [m³] 0.15 Caption PERE = Use of renewable primary energy excluding renewable primary energy resources used as raw materials; PERM = Use of renewable primary energy resources used as raw materials; PERT = Total use of renewable primary energy resources; PENRE = Use of non renewable primary energy excluding non renewable primary energy resources used as raw materials; PENRM = Use of non renewable primary energy resources used as raw materials; PENRT = Total use of non renewable primary energy resources; SM = Use of secondary material; RSF = Use of renewable secondary fuels; NRSF = Use of non renewable secondary fuels; FW = Use of net fresh water RESULTS OF THE LCA OUTPUT FLOWS AND WASTE CATEGORIES: 1 t CEM IV/B (P) 32,5R Manufacturing Parameter Unit A1 - A3 HWD [kg] 9.81E-03 NHWD [kg] 581 RWD [kg] 1.45E-02 CRU [kg] MFR [kg] MER [kg] EE [MJ] EE [MJ] Caption HWD = Hazardous waste disposed; NHWD = Non hazardous waste disposed; RWD = Radioactive waste disposed; CRU = Components for re-use; MFR = Materials for recycling; MER = Materials for energy recovery; EE = Exported energy per energy carrier 6 Environmental Product Declaration Çimsa Çimento ve San. ve Tic. A.Ş. CEM IV / B(P)32,5R

7 6 LCA: Interpretation The use of non - renewable sources is very high compared to the use of renewable sources. The reason for this is the distribution of the energy sources in the power grid mix and the type of fuels (petrol coke, lignite, fuel oil) used during production. In addition, the primary energy input regarding the resources (renewable and non renewable) used as raw materials is zero, since the raw materials used in cement production are inorganic materials and do not have a calorific value. The net fresh water utilization is quite low 0.15 m 3, since the cement manufacturing process requires only small amount of water. A significant amount of water usage is due to the pre-processes of the raw materials used in the production process and the power grid mix. Similar to the case of water utilization, some fractions of the waste is generated due to the pre 7 Requisite evidence 7.1 Radioactivity Measurement of the nuclide-content in Bq/kg for Ra- 226, Th-232, K-40 is performed on the sample of the product CEM IV/B (P) 32,5R by the application of Gamaspectrometric Method ASTM E 181: The analysis was performed by Turkish Atomic Energy Authority Sarayköy Nuclear Reasearch and Training Center on 29 December The statment about the evaluation of the results is made according to the limit values stated in the Document of the European Comission Radiation Protection 112. The measurement results are below the defined limit values, therefore the use of the product as building material do not cause any radiological harm. The report regarding the test results is 8 References Institut Bauen und Umwelt 2011 Institut Bauen und Umwelt e.v., Königswinter (pub.): Generation of Environmental Product Declarations (EPDs); General principles for the EPD range of Institut Bauen und Umwelt e.v. (IBU), PCR 2011, Part A Institut Bauen und Umwelt e.v., Königswinter (pub.): Product Category Rules for Construction Products from the range of Environmental Product Declarations of Institut Bauen und Umwelt (IBU), Part A: Calculation Rules for the Life Cycle Assessment and Requirements on the Background Report. July processes of raw materials and the power grid mix. Although radioactive compounds are not used in the manufacturing process itself, a small amount of radioactive waste appears on the results. This small amount arises due to the power grid mix and pre processes of petrol coke. All impact categories, with the exception of Abiotic Depletion Potential Elements (ADPE), are dominated by the influence of the clinker production process and the power grid mix. The primary energy sources utilized by clinker production process such as petrol coke, fuel oil, and lignite constitute a significant amount of environmental burdens along with the power grid mix. The use of gypsum as a raw material for the declared product CEM IV/B (P) 32,5R also contributes to the environmental impacts. The impact of gypsum can be observed through its contribution to ADPE. presented as an evidence in form of a seperate document to this EPD. 7.2 Chromate Measurement of Cr (VI) is performed on the sample of the product CEM IV/B (P) 32,5R by the application of the experimental standard TS EN (DS 1020). The analysis was performed by the Turkish Cement Producers Association on 14 December The report indicates that the sample of the Cr (VI) content of the product is 0.8 ppm, which is below the limit value (2 ppm) set within the scope of the the European Regulation (EC) 1907/2006 "REACH Regulation" and the Prohibition of Chemicals Ordinance. The report regarding the test results is presented as an evidence in form of a seperate document to this EPD. PCR 2011, Part B Institut Bauen und Umwelt e.v., Königswinter (pub.): Product Category Rules for Construction Products from the range of Environmental Product Declarations of Institut Bauen und Umwelt (IBU), Part B: Requirements on the EPD for Cement ISO DIN EN ISO 14025: : Environmental labels and declarations Type III environmental declarations Principles and procedures FprEN FprEN 15804: : Sustainability of construction works Environmental Product Declarations Core rules for the product category of construction products 7 Environmental Product Declaration Çimsa Çimento ve San. ve Tic. A.Ş. CEM IV / B(P)32,5R

8 Publisher Institut Bauen und Umwelt e.v. Tel. +49 (0) Rheinufer 108 Fax +49 (0) Königswinter Germany Web Programme holder Institut Bauen und Umwelt e.v. Tel. +49 (0) Rheinufer 108 Fax +49 (0) Königswinter Germany Web Owner of the Declaration Çimsa Çimento ve San. ve Tic. A.Ş. Tel Malatya Karayolu 35. km Fax: Bünyan,Kayseri Tukey Web Author of the Life Cycle Assessment PE INTERNATIONAL AG Tel Gümüşsuyu Mah. İsmet İnönü Cad. Fax: Park Palas 23/7 Beyoğlu İstanbul Turkey Web