ENVIRONMENTAL PRODUCT DECLARATION as per ISO and EN 15804

Transcription

1 ENVIRONMENTAL PRODUCT DECLARATION as per ISO and EN Owner of the Declaration Alfa Acciai Program operator Publisher Declaration number Registration number Issue date The International EPD System Institut Bauen und Umwelt e.v. (IBU) S-P MR-ENV-EPD-ALF EN (Revision) Valid to Hot-rolled reinforcing steel for concrete in bars and coils Alfa Acciai Registered under the scope of mutual recognition between Institut Bauen und Umwelt e.v. (IBU) and The International EPD System Umwelt Produktdeklaration Name des Herstellers Name des Produkts

2 1. alfa acciai group Alfa Acciai Group comprises several well-established companies specialized in various areas in the production of steels for reinforced concrete, a guarantee of products and services qualifying the Brescia-based group as an excellent business partner in a wide range of sectors, first and foremost in building construction. Being involved in the entire steel production chain, with an integrated system upstream and downstream of the parent company, the Alfa Acciai Group is able to meet its customers operating requirements and to guarantee a superior standard of quality at all stages of the production process. ALFA ACCIAI, the Brescia-based parent company, is one of the largest EAF steel mills in Italy. There is a steel shop department with 2 EAF (electric arc furnaces), 2 LF (ladle furnaces) and 2 continuous casting machines (10 lines). The hot rolling department is equipped with 3 rolling mills for rebars, coils and wired rod; the cold rolling department has 12 cold rolling mills and 5 welded mesh machines. This EPD is specifically about steel bars and coils for concrete produced in Brescia parent plant. ACCIAIERIA DI SICILIA is the only steel mill operating in Sicily. High production capacity, state-of-the-art technology and a wide range of products have earned the company a good position in the European steel making industry and help it make good use of its strategic location for serving south Mediterranean markets. Thyssen Sonnenberg Recycling, in Bottrop, Germany, is run as a joint venture and has become one of world s leading companies producing and selling ferrous and non-ferrous scrap ( FERROBERICA is the largest company in Italy involved in the pre-shaping and laying of reinforcing steel for all kinds of structural work, for roads, railway, and maritime infrastructures, as well as public, industrial and civil buildings. The company handles the final stage of the group s production chain and guarantees a high standard of quality for the end users, i.e. leading building contractors. 2

3 2. the product Hot-rolled reinforcing steel for concrete in bars and COILS This EPD refers to construction products, hot rolled structural steel bars and coils, produced at Alfa Acciai plant placed in Brescia (Italy), with electric arc furnace route, starting from post and pre consumer steel scraps. The homogeneous and repeatable mechanical features of steel guarantee excellent performance in any type of construction and geographical area, since they have high ductility. EPD reference products have a chemical composition in compliance with national regulation of destination countries where they are sent. In general, the main materials of the final product are: iron > 96%; alloy elements (e.g. manganese, silicon, carbon) 2% c.a.; other elements (e.g.. copper, nickel, chromium), complementary to 100%. information Product identification Product features Product properties (under EN10080:2005) Plant features Description Hot-rolled reinforcing steel for concrete in bars and coils Bars: Diameters from 6 mm to 32 mm Length up to 18 m Weight: 2,300 kg Coils: Diameters from 6 to 16 mm Weight from 1,450 to 3,000 kg Steel coming from post and pre consumer steel scraps produced in electric arc furnace route (EAF) and further hot rolling process. Adherence and surface geometry f R or f P : - for 5 Ø 6 mm f R or f P 0.035; - for 6 < Ø 12 mm f R or f P 0.040; - for Ø >12 mm f R or f P Weldability: C eq < 0.52 Typical yield stress: 400 MPa Cv 600 MPa Elongation: Agt > 5% Successful in bend and rebend test Content of recycled materials 97% (Certificate IGQ n. C057 following ISO 14021) Successful in strength test and oligocyclic strength test Total production of EPD covered products, year 2013: 804,932 t Total production, for selling purpose, year 2013: 1,006,672 t/anno On-site air emission control system On-site waste water control system On-site system to recycle water used in process In/out materials/products and melting process monitored to prevent nuclear radiation Plant air emissions accounted under ETS (Emission Trading System) 3

4 3. METHODOLOGY The environmental burden of the product has been calculated according to EN 15804: and PCR 2012:01 Construction products and Construction services. This declaration is a cradle to gate with options EPD type, developed within the International EPD System and based on the application of Life Cycle Assessment (LCA) methodology 2 to the whole life-cycle system. In the whole LCA model, infrastructures and production equipments are not taken into account. Hot rolling steel bars at plant level, were described by using specific data from manufacturing facility (Brescia, Italy) for year Customized LCA questionnaires were used to gather in-depth information about all aspects of the production system (for example, raw materials contents and specifications, pre treatments, process efficiencies, air and water emissions, waste management), in order to provide a complete picture of the environmental burden of the system from raw materials supply (A1) to Transport (A2) and Manufacturing (A3). The use phase and end of life were not considered according to EN:15804 and PCR 2012:01, while transport to final destination was considered (A4). 1 EN (2012) Sustainability of construction works Environmental product declarations Core rules for the product category of construction products. 2 The LCA methodology is standardized at international level by ISO and ISO Declared Unit According to EN:15804, the declared unit is 1 ton of bars. 4

5 4. system boundaries UPSTREAM PROCESS CORE MODULE DOWNSTREAM PROCESS Scrap pretreatment Supplying transport Billets production Shearing Hot rolling process A1 Shredding Sorting A2+A3 Packaging Internal handling A4 Market transport Ancillary materials and activities Raw material and Energy production Air emission Water emission Waste management Broad scheme of hot-rolled reinforcing steel for concrete production, in which the main activities included in the system boundaries, are listed and divided in the three subsystems: UPSTREAM Process, CORE Module and DOWNSTREAM Process. 5

6 5. Upstream process Steel scrap collection (shredded both in external and internal plants) and other raw materials production. Production of alloy elements. Scheme of the considered system boundaries (Upstream processes) Specific secondary materials pre-treatments, where appropriate. A1 - Raw Materials Supply Generation of electricity and other fuels from primary and from secondary energy resources (excluding waste treatments). 6

7 6. core process Raw materials transportation from production or collection facilities to the production plant and internal transportation. A2 - Transportation Rolling mill, production, including utilities. Scheme of the considered system boundaries (core processes). Packaging materials. Steel mill production, including utilities. A3 - Manufacturing Treatment of waste generated from the manufacturing processes. 7

8 7. downstream process Transport to the customers (general market average). Distances estimated considering the transported quantities and the distances from Brescia's plant to the client. From Brescia (in the North of italy) final products are delivered to many national (59% of the total sold product) and international areas such as Algeria (around 30%), France, Switzerland and Germany, mentioning the main countries. The means of transport used to deliver steel bars and coils are truck and freight ship. On average, finished product is transported for 317 km by road and 301 km by ship. A4 - Distribution 8

9 8. environmental performance The detailed environmental performance (in terms of use of resources, pollutant emissions and waste generation) is presented for the three phases, Upstream, Core and Downstream and related sub-phases (A1-A2-A3-A4). The numbers reported in the following tables are the outcome of rounding. For this reason total results could slightly differ from the sum of contributions of the different phases. TOTAL RENEWABLE Resources A1 Raw materials supply A2 Transportation A3 Manufacturing A4 Distribution Use of RENEWABLE primary energy excluding renewable primary energy resources used as raw materials [MJ, net calorific value] ,005 Use of RENEWABLE primary energy resources used as raw materials [MJ, net calorific value] Total use of RENEWABLE primary energy resources (primary energy and primary energy resources used as raw materials) [MJ, net calorific value] ,005 9

10 TOTAL non RENEWABLE Resources A1 Raw materials supply A2 Transportation A3 Manufacturing A4 Distribution Use of NON RENEWABLE primary energy excluding non renewable primary energy resources used as raw materials [MJ, net calorific value] 10, ,067 Use of NON RENEWABLE primary energy resources used as raw materials [MJ, net calorific value] Total use of NON RENEWABLE primary energy resources (primary energy and primary energy resources used as raw materials) [MJ, net calorific value] 10, ,253 10

11 Use of secondary resource A1 Raw materials supply A2 Transportation A3 Manufacturing A4 Distribution TOTAL Use of secondary material [kg] 1, ,218 Use of renewable secondary fuels [MJ] Use of non renewable secondary fuels [MJ] TOTAL net use of fresh water A1 Raw materials supply A2 Transportation A3 Manufacturing A4 Distribution Net use of fresh water [m 3 ] 3 < <

12 waste production and treatment A1 Raw materials supply A2 Transportation A3 Manufacturing A4 Distribution TOTAL Hazardous waste disposed [kg] < Non hazardous waste disposed [kg] Radioactive waste disposed [kg] environmental impact parameters A1 Raw materials supply A2 Transportation A3 Manufacturing A4 Distribution TOTAL Global Warming Potential, GWP [ kg CO 2 eq ] Ozone Depletion Potential, ODP [ kg CFC-11 eq ] Photochemical Ozone Creation, POCP [ kg C 2 H 4 eq] Acidification Potential, AP [ kg SO 2 eq ] Eutrophication Potential, EP [ kg PO 4 3- eq ] Depletion of abiotic resourceselements, ADP-elements [ kg Sb eq ] Depletion of abiotic resources-fossil, ADP-fossil fuels [ MJ ] < 0.1 < 0.1 < 0.1 < 0.1 < < < < 0.1 < < 0.1 < 0.1 < 0.1 < 0.1 < 0.1 9, ,197 12

13 9. additional information Other environmental characteristics of Brescia plant are: 1. Alfa Acciai in Brescia is equipped with a scrap park (in which the steel scrap is sorted for the following crushing phase) and a section where steel scrap is prepared; there are also two casting lines, provided with air and water emissions treatment systems. The plant has also a production line dedicated to long products. 2. Alfa Acciai has committed to improve the environmental performance of its production process with different measures: - environmental mitigation measures under the ALFA 2000 project, supervised by the Brescia Town Council, that has led in ten years to the creation of the Tornquist soundproofing barrier; - installation of a new more powerful off-gas filtering system for furnace 1 and redesigning of the off-gas suction hood for furnace 2 in order to increase the volume; - installation of active carbons filters along the suction lines of both furnaces allowing to further reduce the organic micro pollutants in air emissions; - installation of a modern continuous sampling system for micro pollutants on the stacks of both furnaces for a constant emissions monitoring. 3. Alfa Acciai plant in Brescia is equipped with prevention and reduction systems for (PCDD /F) and (PCB ) emissions, a recirculating loop cooling to minimize water consumption and a waste management plan to prevent and reduce waste generation. In accordance with general EPD requirements the LCA study used specific, generic and other generic data. This last data are contributing to the environmental indicators less than 10%. 13

14 10. reference This declaration has been developed referring to the International EPD System, following the General Program Instruction and Supporting Annexes (ver /09/18); further information and the document itself are available at: Software: SimaPro ver ( Main database: Ecoinvent 2.2 Report LCA: Life Cycle Assessment (LCA) for hot-rolled reinforcing steel for concrete in bars and coils produced by Alfa Acciai for EPD purpose - 11/03/2015 FINAL report Geographical scope of the EPD: Italy and other countries according to sales market conditions (North Africa and Europe) Environmental declarations published within the same product category, though originating from different programs, may not be comparable. In particular EPDs of construction products may not be comparable if they do not comply with EN Contacts In order to get more information about this environmental declaration or about Alfa Acciai activities, please contact: Alessandro Giovannelli (a.giovannelli@alfaacciai.it) Phone: (+39) Technical support to Alfa Acciai was provided by Life Cycle Engineering, Italy. (info@studiolce.it, LIFE CYCLE ENGINEERING we support your sustainable business 14

15 Independent verification CEN standard EN served as the core PCR (PCR 2012:01 Construction products and Construction services, Version 2.0, ) PCR review was conducted by: The Technical Committee of the International EPD System. Chair: Massimo Marino. Contact via Independent verification of the declaration and data, according to EN ISO : 2010 EPD process certification (Internal) EPD verification (External) Third party verifier: ICMQ SpA, via De Castillia, Milano ( Accredited by: Accredia 15