Work Book Extracts. Life Cycle Inventory. 13mm Standard Plasterboard. Unit Operations

Transcription

1 Work Book Extracts Life Cycle Inventory 13mm Standard Plasterboard Unit Operations to 1998 Boral and Pioneer Operations delivering to NSW Only Working draft extracts only released for review and not for citation as completed work product

2 TABLE OF CONTENTS 1 INTRODUCTION concept of life cycle assessment goal of the life cycle inventory intended Use of the LIFE CYCLE INVENTORY 2 2 LCA METHODOLOGY Normative References Scope and System Boundary Functional Unit lci model setup Data Quality Analysis critical review 3 3 RESULTS and DISCUSSION General raw materials energy Emissions to Air Emissions To Water Solid Wastes 7 4 Conclusions General process technology overall 8 5 Recommendations use of this lci Refining this lci expanded lci life cycle assessment (LCA) 9 6References and Bibliography 9 7GLOSSARY OF TERMS 10 APPENDIX a 13 ASSUMPTIONS and data quality statements on the unit operations 13 general transport operations gypsum mining lake macdonell, sa rail delivery gypsum to thevenard wharf sea delivery of gypsum to pyrmont, sydney Road delivery of gypsum to plasterboard plant calcination of calcium sulphate to stucco machine glazed kraft paper re plasterboard 10mm 14 Definitions of Data Quality Descriptors Error! Bookmark not defined. Appendix B Recipes updated to

3 1 INTRODUCTION 1. 1 CONCEPT OF LIFE CYCLE ASSESSMENT The provision of goods and services to society is linked with effects on the environment. Society is increasingly interested in understanding these effects and where possible, reducing them. Methods are available to determine, understand and reduce the environmental impact of human activity. Issues such as resource depletion and waste management can be measured and their significance evaluated. For these reasons a system of environmental accounting called life cycle analysis (LCA) has been developed. Figure 1 shows a schematic of a typical industrial system and the scope of LCA. Figure 1 Scope of LCA in a typical industrial process The scope of any LCA work is defined within a system boundary. The boundary selected is based on the needs and objectives of the analysis. The analysis may be limited to a product manufacture boundary known as from cradle to gate or a fuller analysis from cradle to grave. A cradle to grave analysis assesses the environmental impacts associated with a product from raw material acquisition to use and final disposal. The LCA process accounts for the environmental impacts associated with raw materials acquisition; energy use; manufacture, use of the product or service, maintenance, reuse and recycling. At the first stage, LCA attempts to quantify the following through a life cycle inventory (LCI) raw materials and energy use, emissions to air and water and solid wastes. As shown in Figure 2, these quantities are counted in the life cycle inventory when they pass through the system boundary. Figure 2 Schematic of the LCA process and system boundary Impacts of the product or service on the environment are later assessed in an impact assessment report. A life cycle improvement assessment is then conducted to investigate options for improving the environmental performance of a product or service, usually through the reduction of environmental burdens. This report presents a life cycle inventory.

4 1. 2 GOAL OF THE LIFE CYCLE INVENTORY To conduct a LCI to quantify the raw materials, energy use and waste emissions associated with producing 10 mm recessed edge plasterboard. Detailed discussion on the environmental impacts of these quantities is not the goal of this LCI. However, the information contained in the LCI is required to make informed impact and improvement assessments. Some comment may be made on possible environmental impacts and areas for improvement, where applicable INTENDED USE OF THE LIFE CYCLE INVENTORY This LCI document is for research purposes only. This LCI is an outdated part of a database on building materials for the construction industry. The database is a tool to recommend environmentally appropriate products and technologies to be used in projects owned or managed by various agencies. 2 LCA METHODOLOGY 2. 1 NORMATIVE REFERENCES The references consulted to conduct this LCI included Standards Australia ISO 14040Life Cycle Assessment - General Principles and Practices and ISO Life Cycle Assessment - Inventory Analysis. The methodology outlined in the standards is adopted unless redefined in the text of this report. Definitions of terms used in this report are listed in the Glossary SCOPE AND SYSTEM BOUNDARY This LCI is concerned with the manufacture of 10 mm recessed edge plasterboard. Figure 3 is a simplification of the processes incorporated in the LCI, which (for all building materials) include extraction of raw materials; manufacture of the plasterboard and all transport steps up to the manufacturing process. The supply, installation, use, maintenance and final disposal of the plasterboard is not included. Figure 3 Processes occurring within the LCI system boundary This LCI presents the cumulative results and assumptions for the final step of Figure 3. That is, the results are the total of all the raw materials, energy use and waste emissions for all processes leading up to the production of the plasterboard. Geographic system boundary The scope of this study is the manufacture of the plasterboard in NSW. However, raw materials and intermediate products may be sourced from interstate. For example the gypsum for the plasterboard is mined in South Australia (Appendix A). Data for this LCI is taken from various international and Australian site specific and generic sources and applied to NSW. Overall, the study is best described as having a geographic boundary related to NSW, Australia. Temporal system boundary The temporal system boundary of a LCI is made up of the time period when the data was collected and the life cycle of the system being studied. This study was conducted in 1996/1997 and information sources were reviewed in this period. However, the data sets have been collected at different times. See Appendix A for discussion on the source and quality of the information. The material manufacturing operations utilise technology as discussed in Appendix A. This technology also forms part of the system boundary, as different technologies and manufacturing methods will produce different environmental considerations.

5 2. 3 FUNCTIONAL UNIT The overall system functional unit is one square metre of 10 mm thick recessed edge plasterboard LCI MODEL SETUP Input operations were allotted reference numbers and were entered into the Boustead Model 3 database (Boustead 1997). This database includes details on generic operations such as fuel and energy production and use, as well as specific material production operations. The operations are based on an international database. Where specific Australian site data is known the model reflects this data. In other cases, the database values are used. The actual model input values used are presented in Appendix B DATA QUALITY ANALYSIS This LCI has been subject to a data quality assessment on the source, specificity, age, collection period and peer review as shown in Table 2. Table 1 Data quality indicators based on quality descriptors Source Specificity Age years) Data collection Period Peer Review Primary Site Process Current Annual Expert Secondary Site Plant >5 Quarterly Industry Local Industry Region >10 Monthly External Regional Industry Industry >20 Nominal Source Public Statistics Generic Not known Generic Internal 2. 6 CRITICAL REVIEW This LCI has been reviewed for scientific and technical validity of the methods used; appropriateness and reasonableness of the data used and validity of the conclusions based on the goal of the study. A critical internal review was carried out by the modeller of the LCI and another team member. 3 RESULTS AND DISCUSSION 3. 1 GENERAL Detailed results from the LCI model are given in Appendix C. The results are summarised and discussed in the following sections on raw materials, energy, emissions to air and water and solid wastes. The values given are the cumulative totals of all the operations leading to the manufacture of the plasterboard. The results have been compared to LCA results supplied by Boral Plasterboard and in the Environmental Resource Guide 1996 Material Report on Gypsum Board Systems. While results of this LCA agree to within 15% of references found, a complete statistical comparative study has not been undertaken. Significance of results This LCI is conducted on a mass basis, as discussed in Section 2. When discussing the results, comments are made on their significance. This term is used in this section comparatively, based on mass. For example, carbon dioxide is described as the most significant air emission as it has the highest mass. This LCI does not attempt to perform an impact assessment, therefore use of the term most significant does not necessarily imply most environmentally significant. Some emissions are more environmentally significant because of toxicity, ozone depleting potential or greenhouse warming potential even at low mass. Definition of phase types See the Glossary for definitions of the phase types. Note that there is a difference between the phases for energy use and emissions (including air, water and solid waste). The emissions data has an extra phase called process. In the energy and waste emissions section, the fuel use (process) phase refers to the fuel energy used during the process operations and the emissions attributed to the direct use of this fuel. An example is the carbon dioxide emitted when burning gas for heat. The emissions from the process phase are those attributed directly to the process, for example the dust from gypsum quarrying. These are emissions not attributable to fuel use during the process.

6 3. 2 RAW MATERIALS Table 3 shows the quantities of significant raw materials > kg. Note that this table shows all raw materials, including fuels and feedstocks. Fuels such as coal and gas are used to provide energy, for example coal is burned to produce electricity. They are included as raw materials as they are required in the production process. Fuels and feedstocks are discussed in more detail in Section Table 2 Significant raw materials including fuels Raw Material kg Raw Material kg Raw Material kg Calcium sulphate Lignite Clay Wood (50% water) Crude oil Potassium chloride Gas Limestone Sodium chloride Coal Biomass A figure 4 illustrates the total raw materials graphically. Water is the major raw material at 85% by mass. Water is used extensively in raw materials acquisition and material manufacture. Note that only water from the public supply is included in the LCI. Water involved in wood growing is assumed to be rainwater and is not included. Figure 5 illustrates the raw materials excluding water. Gypsum or Calcium Sulphate and wood are the only other significant raw materials. Figure 4 Major raw materials (mass %) Figure 5 Major raw materials except water (tonnes) 3. 3 ENERGY This section is concerned with the type and quantity of energy used in producing and delivering building materials to Northern NSW. Table 4 shows the source of the total energy used, listed by fuel type. The sources of energy may be used directly, for example the burning of wood waste for heat in the timber drying process, or indirectly in the burning of coal to produce electricity. Table 3 Primary energy source and use (MJ) Energy Source Fuel Production Fuel Use (Process) Transport Fuels Feedstock Total Total Excl Feedstock Gas Wood Coal Oil Lignite Biomass Hydro Total Feedstock energy and energy used as fuel In this report, energy usage is broken into two broad groups. Feedstock energy is the energy representation of a raw material making up a product, which remains locked up in the product until decomposition or incineration. The second type of energy is that used (termed expended ) as a fuel. It is used irreversibly in fuel production, transport and any other process. Feedstock energy is energy which is locked up in the product, and represents the mass of the product in energy terms. For example, plastic is a crude oil

7 derivative. The energy required to make a mass of plastic would include a feedstock energy value for oil, which instead of being burnt for energy, is used as a raw material. Therefore feedstock energy is used to make a product, but not used irreversibly as a fuel. If the mass of plastic is later burnt as a fuel, this feedstock energy of oil would then be irreversibly used. The high feedstock value of wood (see Table 3 and Figures 7 and 8) comes from the Kraft paper backing on the plasterboard. This represents the energy provided by the sun when the tree is growing. It remains locked in the paper, and will only be released on final disposal through incineration or decomposition. The total energy is the sum of the feedstock energy and energy expended as a fuel. Total energy Figures 6 to 9 illustrate the total energy (feedstock plus energy expended as a fuel) involved in providing the major building materials. The total energy is about 66 MegaJoules (MJ). Gas, wood and coal, and are the major suppliers of this energy. Gas is used as a fuel during the plasterboard manufacturing process, including calcination and drying of the plaster. Wood is important because of the high feedstock value, but it is not used as a fuel. Coal is used in electricity generation. Figure 6 Primary energy source (MJ) (incl feedstock)figure 7 Energy source (% incl feedstock) Significant phases and components for total energy The most significant phase for total energy use is fuel use (process), which include raw materials extraction and product manufacture and accounts for 43% of the total energy. Fuel production accounts for 20% of the total energy as shown in Figures 8 and 9. Of the total energy from all sources, 33% is feedstock energy (see Figure 10). All of the feedstock energy is attributed to the paper backing, due to wood use. Transport operations account for 4% of the total energy. Figure 8 Energy by phase (MJ) (incl. feedstock) Figure 9 Energy by phase (% incl. feedstock) The most significant component for the total energy use is the Kraft paper backing. It alone accounts for 50% of the total energy used. The processing of the gypsum and preparation of the finished plasterboard accounts for the remaining 50% (see Appendix D). Energy expended as a fuel Sixty seven percent (67%) of the total energy attributed to the plasterboard is expended as a fuel during fuel production, transport or process operations. As Figures 10 and 11 show, most of this energy comes from gas and coal use. The coal is used mainly as a fuel in electricity production. Gas is used primarily in process operations for heat, for example for calcining the gypsum and drying the plasterboard. Oil is used in fuel production (petrol and diesel are derived from oil), transport and process operations.

8 Figure 10 Fuel use (MJ) (not feedstock) Figure 11 Fuel use (%) (not feedstock) Significant phases and components for energy expended as a fuel As for total energy, the fuel use (process) is the most significant phase. Fuel used for fuel production is also significant. An example of this use is the burning of coal to produce electricity. See Figures 12 and 13. Figure 12 Fuel use by phase (not feedstock Figure 13 Fuel use by phase (not feedstock) The processing of gypsum and the final preparation of the plasterboard is accountable for 78% of the energy used as a fuel. The Kraft paper production is accountable for the remaining 22% (see Appendix D) EMISSIONS TO AIR The emissions to air associated with the manufacture of the plasterboard are shown in Table 4. See Section 3. 1 and the Glossary for definitions of the phase types. Table 4 Emissions to air (kg) Emission Type Fuel Production Fuel Use (Process) Transport Process Biomass Total (kg) Carbon dioxide Methane Nitro- oxides Sulfur oxides Dust Carbon monoxide Hydrocarbons Total As Table 7 and Figure 14 indicate, the most significant air emission is carbon dioxide, which accounts for 97% of the air emissions by mass. Overallm1. 2 kg of carbon dioxide is released to the atmosphere. Significant phases and components for carbon dioxide emissions The most significant phases for carbon dioxide emissions are the fuel use (process) and fuel production phases as in Figure 15. The biomass operations (which include growing and decomposition of plant matter) were significant due to the negative carbon dioxide emission. This is due to carbon dioxide uptake during

9 tree growing for paper production. Therefore the paper is significant in carbon dioxide emissions. Note that the scope of the LCI is to the manufacture of the plasterboard only. If the scope is widened so that final disposal is considered, it is expected that the carbon dioxide will be released due to decomposition or incineration of the paper backing. Figure 14 Emissions to air (mass %) Figure 15 Carbon dioxide emissions by phase Air emissions other than carbon dioxide Methane, oxides of sulphur and nitrogen and dust are the most significant air emissions excluding carbon dioxide. Figure 16 illustrates these emissions. Methane is produced in during the decomposition of plant matter during wood growing and harvesting. Figure 16 Air emissions not carbon dioxide (kg) 3. 5 EMISSIONS TO WATER Overall, the mass of emissions to water is quite low for the plasterboard. The only significant emission is suspended solids, which account for 99% of all water emissions as in Table 5 and Figure 17. Table 5Emissions to water Figure 17Emissions to water (mass %) Water Emission kg Suspended solids Chemical Oxygen Demand Biochemical Oxygen Demand Significant materials for water emissions All suspended solids and other water emissions came from process operations. There were negligible amounts produced during fuel production, transport or fuel use. The only significant operation for the suspended solids emissions is the gypsum mining operation. However, this operation is based on European data, and may not accurately reflect the situation in Ceduna, South Australia. The mining of gypsum requires further investigation in this respect SOLID WASTES

10 Solid wastes generated are shown in Table 6. A total of 2. 2 kg of solid waste is produced. Ninety four percent (94%) of the solid waste is generated in process operations. Most of the waste (70%) is mineral waste and 28% is paper waste from the paper and plasterboard manufacture operations. Note that a major assumption in this LCI is that the waste plant matter (for example leaves, bark and branch off-cuts) from the wood growing operation and the saw mill is assumed to decompose to carbon dioxide and methane (Hall and Janssen 1996). If it is assumed that this plant matter does not decompose, then it should be treated as solid putrescible waste, and total solid wastes would increased significantly. Table 6 Solid wastes generated (kg) Figure 18 Solid wastes generated (mass %) Waste Type Fuel Production Process Total Mineral Paper and board Slags/ash Mixed industrial Total The gypsum mining operation is responsible for all of the process mineral waste. It is assumed in that kg of waste is produced per 1 kg of gypsum mined (see Appendix B). As discussed in Section 3. 5, this operation requires further investigation. 4 CONCLUSIONS 4. 1 GENERAL As discussed in Sections 1 and 2, the purpose of this LCI is to quantify the raw materials and energy use and the air, water and solid waste emissions due to the manufacture of plasterboard. Generally, it is only useful to compare the LCI results for materials which are made for a common purpose. For example, it is not useful to compare structural steel with plasterboard, although it may be useful to compare structural timber with structural steel PROCESS TECHNOLOGY The technology used to produce the material has an important effect on the results. Environmental benefits can be made if technologies which use less energy and raw materials and emit less waste to air, water and land are utilised. Therefore a comparison of technologies to produce the same building material is just as useful as a comparison of different building products OVERALL The environmental attributes of the technology used to make and transport the building material, along with the mass of the material determine the overall results of the LCI. Generally technologies and materials are preferred which require less raw materials; use less energy; create less air and water emissions create less solid waste and or are able to be reused and recycled. Decisions should be made in design which optimise the above attributes, while at the same time minimise the amount of building materials (in volume and mass) used to serve the required purpose. 5 RECOMMENDATIONS 5. 1 USE OF THIS LCI This LCI will provide a useful tool for comparing the environmental burdens between building products on a manufacture only basis. Any comparison with other LCI s should be done on the basis of the same scope, use and design life REFINING THIS LCI Further information on the following is required to refine this LCI

11 refined information on raw materials extraction operations in Australia, for example gypsum mining refined information on the processing of gypsum, paper and adhesive for plasterboard production refined sea and road transport operations which more accurately reflect the Australian situation 5. 3 EXPANDED LCI The following should be considered to expand the scope of this LCI the resource requirements and waste emissions associated with supply, construction, maintenance and final disposal of the plasterboard in buildings 5. 4 LIFE CYCLE ASSESSMENT (LCA) This LCI has quantified the following for the manufacture of plasterboard raw materials and energy use air and water emissions solid wastes A full LCA would assess the environmental impacts of the results found in this LCI. This LCA will be the subject of further reports, when the LCI model has been further refined. 6 REFERENCES AND BIBLIOGRAPHY Boustead, I (1997) Conversion Factors, The Boustead Model for life-cycle inventory calculations Boustead, I (1997) Core Operations, The Boustead Model for life-cycle inventory calculations Boustead, I (1997) Operating Manual Version 3, The Boustead Model for life-cycle inventory calculations International Standards Organisation ISO 14041, Life Cycle Assessment - Inventory Analysis Standards Australia/ New Zealand, Life Cycle Assessment - General Principles and Practices, DR94442, Dec 1994 Environmental Resource Guide 1996 Material Report Gypsum Board Systems. Report number MAT 09250

12 7 GLOSSARY OF TERMS Biomass (actual) Weight of living material, usually expressed per unit area or volume. Biomass (as in the Results and Discussion section) Air emissions attributed to making or use of biomass. Burden The quantitative value assigned to any input or output for a given industrial system. By-product A useful product that is not the primary product of a process or system. In LCA, by-products are treated as co-products. Co-product A marketable by-product from a process or system. This includes materials that traditionally may be defined as wastes, such as industrial scrap, but that are subsequently used as raw materials in a different manufacturing process. Product and co-product share the environmental burdens of the system or subsystem from which they derive. Cradle to gate analysis of the impact of a product from the acquisition of its raw materials to the moment when it leaves the factory gate. Cradle to grave analysis of the impact of a product through the following stages component extraction; manufacture; product installation; product use and product removal to either recycle or waste. Environmental burden The total releases of pollutants of different classes to the environment. Environmental profile: A list of environmental effects associated with life-cycle of a product. Feedstock value (energy of material resource) Fuel value of a raw material used to make a product. Fuel production (as in the Results and Discussion section) : values listed in the report under this heading reflect energy use and emissions produced while actually producing fuel used in other operations. Fuel use (Process) (as in the Results and Discussion section): Values listed in the report under this heading reflect energy use and emissions while actually using energy in production. An example is burning natural gas to provide heat to fire clay. The energy consumed and waste emissions are attributed to the process as fuel use. Functional unit The specific function identified as a unit of comparison, e g paint for 1 square metre of wall over a period of 10 years. Gross air emissions: Quantities and types of air emissions during the defined life cycle of a product. Gross energy requirements: A description of how energy is utilised during the defined life cycle of a product, whether as a fuel, or as electricity, or in some other usage (e g as a feedstock). Gross fuel & feedstock requirements A tabulation of gross fuel and feedstock requirements for each operation. The tables enumerate the sources and energy utilised during the defined life cycle of the products. Gross raw materials requirements A tabulation of the total quantity of raw materials associated with each operation during the defined life cycle of the product. Gross solid wastes A description of the quantities and types of solid wastes produced during the defined life cycle of the product. Gross water emissions A description of the quantities and types of water emissions during the defined life cycle of a product. Impact analysis The analysis of the environmental impacts associated with a system, function, product or service and usually identified with the life-cycle inventory (LCI) stage.

13 Industrial system Group of operations that makes a product and co-products, together with all associated product packaging. It includes those operations associated with each defined life cycle stage of the product and co-products, from the extraction of raw materials through final use and disposal. Inputs to unit operations A cumulative tabulation of the results of calculations performed for each of the operations associated with the LCI study. The Boustead model begins with the last operation in the system and calls data from each upstream operation. Each of those operations calls on others which may call on others, and so on, until all outputs for all operations have been calculated and added to the final operation. Inputs: Specific environmental burdens including resources and energy and pollution. Intermediate materials Material made from raw materials which go to make final products. Life cycle analysis (LCA) A concept and a method to evaluate the environmental effects of a product or activity holistically, by analysing its entire life cycle. This includes identifying and quantifying energy and materials used and wastes released to the environment, assessing their environmental impact, and evaluating opportunities for improvement. The life cycle analysis consists of four complimentary components - initiation, inventory, impact and improvement. Life cycle inventory (LCI) The identification and quantification of energy, resource usage and environmental emissions for a particular product, service or activity over a stated life cycle. Life cycle stages: Sequential stages that a product or service passes through over the course of its existence from cradle to grave. For all products, four generic stages apply raw materials and energy acquisition, manufacturing (including materials manufacture, product fabrication, and filling/packaging/ distribution steps), use/reuse/maintenance and recycle waste management. Operation A defined step, or steps, within an industrial process which may appear on a schematic diagram or flow chart; a discrete set of data identified with a code number used in computer calculations. Outputs: Specific environmental burdens which cross from the system to the environment. These outputs include environmental releases - emissions into air, emissions into water, and solid wastes - as well as products and co-products. Process An operation performed on one or more raw materials or intermediates leading towards the production of a product. Process (as in the Results and Discussion section) Emissions and waste produced in the handling and conversion of raw materials into a product, other than those produced by using fuel. An example is the dust emitted when rock is crushed in a mining operation. Product Something produced that has an existing value or potential use. Raw material A primary or secondary (e g recovered and/or recycled) feedstock used in a subsequent manufacturing process. Recycling Set of processes for reclaiming material as input to new system, otherwise disposed of. Renewable resource Natural resource that is capable of regeneration. Solid waste Material generated by an industrial production system which is not released into the air or water. Subsystem A group of operations which, when acting together, perform a defined function, and which constitute a working or useful subset of a defined system. System A group of operations which, when acting together, perform a defined function. In a life cycle inventory, the scope of the system is defined by the boundary conditions. Transport Fuels (as in the Results and Discussion section): Fuel used during all the transport operations in the LCI, for example diesel used by trucks for transport. Useful life :The period of time from when a product arrives at end user to the point when it is discarded.

14 Waste An output with no marketable value that is disposed of to the environment. Any material with no beneficial use released to the environment through air, water, and land and crosses the system boundary into the environment.

15 APPENDIX A ASSUMPTIONS AND DATA QUALITY STATEMENTS ON THE UNIT OPERATIONS This LCI is a model for the manufacture of 10mm recessed edge plasterboard. Unit operations are linked to form the overall production process as shown in Figure 3. In developing the LCI, assumptions are made concerning the inputs and outputs of each operation. These assumptions involve considering the available data and deciding the appropriate values to use in the unit operations. Values to be considered include the energy and raw material use and waste emissions associated with each operation. Where available, process or site specific data has been used. In other cases, data has been extracted from reference material. Boral Plasterboard supplied relevant information for the LCA model (see Appendix E). If no other relevant data is available, then the operations have been based on those in the Boustead Model for lifecycle inventory calculations version 3 (Boustead 1997). The source of the data is noted in these assumptions and in the statement of data quality. Definitions of Data Quality Descriptors are given at the end of the assumptions. Detailed math working are not provided GENERAL TRANSPORT OPERATIONS As shown in the input tables in Appendix B, general transport operations were used for the LCI model. These operations were based on the Boustead database. For example, for transport by a tonne truck, the Boustead operation 3542 was used. However the operation was slightly modified to reflect use of Australian fuel. Generally the input for the transport operations (in vehicle-km) was calculated using the following formula Kilometres travelled/ 1000 x vehicle tonnage. The result is multiplied by 1. 7 if the return trip is empty. GYPSUM MINING LAKE MACDONELL, SA Data quality statement Source Specificity Age (years) Data collection period Peer Review Primary Site Process Current Annual Expert Secondary Site Plant >5 Quarterly Industry Local Industry Region >10 Monthly External Regional Industry Industry >20 Nominal Source Public Statistics Generic Not known Generic Internal Assumptions Gypsum is calcium sulphate in its hydrated form (CaSO 4. 2H 2 O). The gypsum is mined in Lake MacDonnell, Ceduna, South Australia. The operation is based on the Boustead Model operation 9526 Gypsum Mining. The major changes were changing the fuel use fields to Australian use and decreasing the solid mineral waste amount from 1 kg to kg per kg of mined gypsum. This assumes that the stripped overburden is used later for quarry rehabilitation and not actually wasted. The original Boustead operation classes any soil which is moved as waste, however this over emphasises the waste. The water usage was also decreased from 1 to 0. 5 litre per kg of mined gypsum. RAIL DELIVERY GYPSUM TO THEVENARD WHARF Assumptions The distance travelled from Ceduna to the wharf is 65 km. The operation used for rail freight is a direct copy of the Boustead operation, with the country field changed to Australia SEA DELIVERY OF GYPSUM TO PYRMONT, SYDNEY Assumptions The distance travelled from the wharf to Sydney is 2400 km on a tonne vessel. The operation used

16 for sea freight is a direct copy of the Boustead operation, with the country field changed to Australia. ROAD DELIVERY OF GYPSUM TO PLASTERBOARD PLANT Assumptions The distance travelled from Pyrmont to the plant at Camellia is 15 km on a 25 tonne truck. The operation used for road freight is a direct copy of the Boustead operation, with the country field changed to Australia. CALCINATION OF CALCIUM SULPHATE TO STUCCO Data quality statement Source Specificity Age (years) Data collection period Peer Review Primary Site Process Current Annual Expert Secondary Site Plant >5 Quarterly Industry Local Industry Region >10 Monthly External Regional Industry Industry >20 Nominal Source Public Statistics Generic Not known Generic Internal Assumptions The gypsum undergoes a two stage process when incorporated into plasterboard. In the first stage, it is ground finely in a pan mill and then calcined from the hydrated form (CaSO 4. 2H 2 O) to produce stucco (CaSO 4. 1/2H 2 O). This process involves using natural gas as a fuel in a fluid bed kettle calciner. The values used in this operation are based both on the Boustead database, and information supplied by Boral Plasterboard. A small amount of waste and air emissions are included in the operation. MACHINE GLAZED KRAFT PAPER Assumptions The plasterboard is assumed to be lined with paper similar to machine glazed Kraft paper. The operation for the production of machine glazed Kraft paper is based on the Boustead operation 4360 Machine glazed Kraft paper. The major change is that the wood for the paper production is taken from the Wood growing, harvesting and debarking (Hall and Janssen (1997) DPW&S). The energy use is also based on the Boustead version of energy use in Australia. RE PLASTERBOARD 10MM Assumptions The plasterboard is assumed to be lined with paper similar to machine glazed Kraft paper. The operation for the production of machine glazed Kraft paper is based on the Boustead operation 4360 Machine glazed Kraft paper. he energy use is also based on the Boustead version of energy use in Australia.

17 APPENDIX B RECIPES UPDATED TO Mine Air Dry & Export AU Gypsum CaSO4@CNV /kg 216 Water emission - susp solid mg 405 Raw material - calcium sulphate (CaSO4) kg 6044 Use Other Oil Fuels in Australia 4V MJ 6060 Use Electricity in Australia Average V MJ Sea Transport Bulk Material Carrier 5V tonne-km 6523 Rail Transport of AU General Freight 5V tonne-km 6552 Road Transport Rigid 21 tonne Tipper4V vehicle-km 6637 Mine Air Dry & Rail SA Gypsum 400k to Port V /kg 216 Water emission - susp solid mg 6628 Mine Air Dry & Export AU Gypsum CaSO4@CNV kg 3542 Road transport - articulated tonne vehicle-km 3544 Rail transport - general freight tonne-km 6293 Use Other Oil Fuels in South Australia 5V MJ 6305 Use Electricity in SouthAustralia5V MJ 7620 Machine Glaze Kraft Paper 20%recycled /kg 1 Air emission - dust (process) mg 2 Air emission - CO (process) mg 4 Air emission - SOX (process) mg 5 Air emission - H2S (process) mg 6 Air emission - Mercaptans (process) mg 201 Water emission - COD mg 202 Water emission - BOD mg 207 Water emission - NO mg 209 Water emission - metals mg 214 Water emission - S mg 216 Water emission - susp solid mg 223 Water emission - phosphate as P2O mg 224 Water emission - other N mg 628 Solid waste - to recycling kg 6008 Deliver Town Water (process) Australia Average V litre 6044 Use Other Oil Fuels in Australia 4V MJ 6049 Use Other Fuel in Australia 4+ V MJ 6060 Use Electricity in Australia Average V MJ 6613 Collect & Deliver Used Papers 25k 100% recycle kg 6629 Quarry Ship Calcine &Truck Local Clay100kV kg 6646 Produce & Rail AU Calcium Oxide 1750 kv kg 6669 Burn Sulphur for Sulphuric Acid V kg 6717 Make & Deliver Sodium Hydroxide Pellets500kV kg 6730 Synthesise & Truck Sodium Sulphate 500kV kg 7599 Ship & Truck Cut Raw Lumber 500k To Kraft Mill V kg 7640 Calcine Gypsum to CaSO4 in Mill V Data per kg 1 Air emission - dust (process) mg 6036 Use Gas Oil in Australia 5V MJ 6048 Use Natural Gas in Australia 5 V MJ 6060 Use Electricity in Australia Average V MJ 6637 Mine Air Dry & Rail SA Gypsum 400ktoPortV kg

18 7590 Grow Harvest Import Truck USA Wheat & Corn V Data per kg 1 Air emission - dust (process) mg 7 Air emission - NOX (process) mg 8 Air emission - NH3 (process) mg 15 Air emission - organics (process) mg 27 Air emission - dust (transport) mg 65 Air emission - CO2 (biomass) mg 201 Water emission - COD mg 202 Water emission - BOD mg 207 Water emission - NO mg 210 Water emission - NH mg 215 Water emission - diss org mg 216 Water emission - susp solid mg 222 Water emission - diss solid mg 223 Water emission - phosphate as P2O mg 224 Water emission - other N mg 261 Water emission - Pesticides mg 610 Solid waste - putrescibles kg 3151 Gas oil use - US MJ 3153 Diesel use - US MJ 3175 Electricity use - US MJ 3181 Biomass feedstock - US MJ 3535 Road transport - rigid tonne vehicle-km 3544 Rail transport - general freight tonne-km 3547 Sea transport - average tonne-km 3607 Water production litre 3652 Potassium sulphate production kg 6724 Ammonium nitrate production kg 6773 Phosphoric acid production kg 6522 Road Transport Articulated 25+tonne4V vehicle-km 6525 River Transport Ship 4V tonne-km 7591 Make Unmodified Starch Ex Imported US Corn V /kg 1 Air emission - dust (process) mg 202 Water emission - BOD mg 216 Water emission - susp solid mg 217 Water emission - deterg/oil mg 226 Water emission - SO mg 457 Raw material - biomass (including water) kg 610 Solid waste - putrescibles kg 6004 Deliver Town Water(process)In Victoria V litre 6177 Use Natural Gas in Victoria 5V MJ 6187 Use Electricity in Victoria 5V MJ 6717 Make&DeliverSodiumHydroxidePellets500kV kg 6747 Make Truck West Hydrochloric acid 100k V kg 6755 Make&TruckHydrogenPeroxide500kV kg 7590 Import Ship Deliver US Maize To Starch Mill V kg

19 7593 Make Unmodified Starch Imported US Corn V /kg 1 Air emission - dust (process) mg 202 Water emission - BOD mg 216 Water emission - susp solid mg 217 Water emission - deterg/oil mg 226 Water emission - SO mg 458 Raw material - water(public supply-cool) kg 610 Solid waste - putrescibles kg 3662 Sodium hydroxide by brine electrolysis kg 3694 Hydrochloric acid production kg 6117 Use Natural Gas InNewSouthWales5V MJ 6187 Use Electricity in Victoria 5V MJ 7590 Import Ship Deliver US Maize To Starch Mill V kg 7594 Bag Pallet Unmodified Starch Ex Corn USA V /kg 7592 Deliver Re-useable (x10)timberpallet50kv kg 7593 Make Unmodified Starch ex Imported US Corn V kg 7596 TruckPaperSackForStarch50k20%recycled kg 7595 MakePaperSackForStarchProduct20%recycled /kg 607 Solid waste - paper kg 6044 Use Other Oil Fuels in Australia 4V MJ 6060 Electricity use - AU MJ 7157 Ship&TruckKraftSackPaper400k20%recycled kg 7596 TruckPaperSackForStarch50k20%recycled /kg 6521 Road Transport Articulated 18-25tonne4V vehicle-km 7595 MakePaperSackForStarchProduct20%recycled kg 7597 Import ex USA Truck Packed Starch 100k to Mill/ kg 7591 Make Unmodified Starch Ex Import US Corn V kg 7592 Deliver Re-useable (x10)timberpallet50kv kg 7596 TruckPaperSackForStarch50k20%recycled kg 7643 Make Deliver 13mm Plasterboard 1%recycled /kg 1 Air emission - dust (process) mg 30 Air emission - CH4 (process) mg 6001 Deliver Town Water(process)inAustralia5V litre 6036 Use Gas Oil in Australia 5V MJ 6048 Use Natural Gas in Australia 5 V MJ 6060 Use Electricity in Australia Average V MJ 6522 Road Transport Articulated 25+tonne4V vehicle-km 7597 Import exusatruckpackedstarch100ktomillv kg 7620 Machine Glaze Kraft Paper 20%recycled kg 7640 Calcine Gypsum to CaSO4 in Mill V kg 7643 MakeDeliver13mmPlasterboard1%recycled kg