NOVOGRES S.A. Environmental Product Declaration. Glazed Stoneware tiles. Registration Code: GlobalEPD rev.01 NOVOGRES S.A.

Transcription

1 Environmental Product Declaration Glazed Stoneware tiles Registration Code: GlobalEPD rev.01

2 TABLE OF CONTENTS 1 General information 2 Product 3 Life cycle assessment 4 Verification 2

3 1 General information 1.1. Identification and description of the organisation making the declaration This sectorial Environmental Product Declaration (EPD) has been prepared by the Instituto de Tecnología Cerámica (ITC-AICE). Cyclus Vitae Solutions S.L UNESCO Chair in Life Cycle and Climate Change for, among others, the following organization: NOVOGRES S.A Vila-real, Castellón (España) 1.2. Identification of product This environmental product declaration complies with standards ISO and ISO and provides environmental information on the life cycle of Ceramic tiles belonging to water absorption group BIb (Glazed Stoneware), a classification based on standard UNE-EN 14411: 2012 (equivalent to standard ISO 13006:1998), the tiles being manufactured by 1.3. Functional or declared unit The Functional Unit is 1 m2 covering of a surface with ceramic tiles of BIb group (Glazed Stoneware) Name of the programme AENOR GlobalEPD programme Génova, Madrid - Phone: aenordap@aenor.es Identification of the Product Category Rules (PCR) Descriptive title of the PCR Panel that approved this PCR PCR registration date and code PCR version number 001 Public consultation period for the PCR Approval date of the PCR Ceramic coverings CERAMIC COVERINGS RCP-002-AENOR GlobalEPD to PCR valid until Programme administrator Asociación Española de Normalización y Certificación C/ Génova, Madrid 1.6. Date of issue of the declaration and period of validity This EPD with the registration code GlobalEPD rev.1 has been issued on the date and is valid for 5 years Information modules This environmental product declaration refers to the environmental performance of the Glazed Stoneware product manufactured by, taking into account its entire life cycle, and it includes the following stages: 3

4 Product stages (modules A1, A2 and A3) Raw materials and transport (A1 and A2) The Glazed Stoneware product essentially consists of clay, sand, feldspar, recycled ceramic material, and glaze.. The raw materials used are of different origin, according to their nature and properties. The raw materials that come from abroad are transported by freighter to the port of Castellón, and they are then trucked to the plants. For sea transport, a type of transoceanic freighter was chosen that travels a different distance in each case, depending on the origin. All raw materials are transported in bulk, i.e. they require no packaging. The most common glaze raw materials are quartz, kaolin, alkaline feldspars, calcium carbonate, borates, zircon, clay, calcined alumina, ceramic frits, pigments, and additives such as suspending agents, deflocculants, or binders. As with the body raw materials, these materials have different origins and are transported in bulk by transoceanic freighter. Manufacturing (A3) The raw materials are prepared at a specialised company, located in L Alcora. Once the different raw materials have been received at this facility, they are stored for subsequent mixing. After mixing, the raw materials are subjected to a wet milling process, followed by drying to obtain the spray-dried granules. The spray-dried powder supplier has a heat and electric energy cogeneration system installed at the spray dryer. The cogeneration produces electricity using the waste heat from combustion, through a system of steam turbines and alternators. All the hot gases are used in the spray dryer. A part of the generated electric energy is used in the production process, thus reducing the electricity demand from the grid, while the rest is sold to the grid. Once the spray-dried granules have been manufactured, they are transported in bulk in a 27 t dump truck from the spray-dried powder producer to the NOVOGRES factory. At the factory, the spray-dried powder is unloaded into storage hoppers. A feed system of conveyor belts with weight control then conveys the granules to the forming stage. The tiles are formed by dry uniaxial pressing and fed into a continuous dryer to reduce tile moisture content, thus doubling or tripling tile mechanical strength for subsequent processing. The tiles exiting the dryer are coated with one or more layers of engobe and glaze. The decoration materials are manufactured at specialised companies, where part of the raw materials is subjected to a fritting process (raw materials fusion and quenching) to obtain insoluble glasses. The frits and other raw materials are mixed and usually wet milled. They are then applied on the body using different techniques, such as bell glazing and discing. Firing is the most important stage in the ceramic tile production process because this is when the properties of the formed tiles are fundamentally changed, yielding a hard material that is resistant to water and chemicals. The products are fired in single-deck roller kilns. Once the tiles have been fired, additional mechanical treatments are applied, as required, to given tiles to provide them with specific characteristics. The most common treatments are polishing (enhancing tile surface gloss by an abrasion process) and rectification (edge-grinding, so that there are no noticeable joints between the tiles once they are installed). After the tiles have passed the relevant quality control processes, also known as sorting, they are packaged using cardboard, pallets, and polyethylene. The prepared pallet is then stored in the logistics area of the plant. In order to reduce air emissions from the different sources, so-called fabric filter baghouses and filters are used: the former consist of a textile membrane that is permeable to gases but retains dust, while the latter consists of a curtain or shower of recycled water that carries away the dust particles. 4

5 Benefits and loads beyond the system boundary from reuse, recovery, and/or recycling potentials (module D) It is assumed that loads are avoided in manufacturing (such as cardboard, film, and wood waste), in product installation (such as cardboard, plastics, and wood packaging waste), and in product end-of-life. Construction products should only be compared when they perform the same function, applying the same functional unit and level of building (either an architectural or engineering construction). That is, the comparison shall include product performance throughout its entire life cycle, as well as the specifications of section in standard UNE-EN ISO The EPDs of different Type III ecolabelling systems are not directly comparable because the assumptions, scope, and calculation rules may differ Representativeness of the EPD This Environmental Product Declaration contains environmental information on a group of products made by a single manufacturer, The results presented set out the average environmental performance, weighted by the production. The Annex to this document presents the environmental data on the tiles that exhibit a minimum and a maximum impact, thus delimiting the results obtained in the LCA Where can further information on this EPD be obtained? Further information can be found in the LCA report of the life cycle assessment study conducted on the Porcelain Stoneware product of the company To access the report, please contact the producer at. 5

6 2 Product 2.1. Description of the product This EPD refers to the product ceramic tiles belonging to water absorption group BIb (Glazed Stoneware), a classification based on standard UNE-EN 14411: 2012 (equivalent to standard ISO 13006:1998), manufactured by Different dimensions of Glazed Stoneware included in this EPD 50x50 60x60 25x60 32x59 33,3x60 14,8x70 20x70 35x70 The results of the sizes included within the scope of this EPD which exhibit the maximum and minimum values of the declared impacts are set out in the Annexes Application of the product The product is intended for use as surface covering. The main recommended use of this product is as floor covering, nevertheless, it can also be used for wall cladding. Besides, the versatility of the ceramic also allows this type of tile to be used for other purposes, e.g. at home, in offices, shops, and hospitals, etc. Please request the manufacturer s technical data sheet, according to the model. The life cycle assessment (LCA) on which this declaration is based was performed according to standards ISO and ISO and the PCR document on ceramic coverings V.001, PCR nº 2 of AENOR GlobalEPD. The Functional Unit is 1 m 2 covering of a surface with ceramic tiles of BIb group (Glazed Stoneware). This LCA is of the cradle-to-gate type; that is, it includes the product manufacturing stages. Figure 1. Product covered by this EPD The results represented correspond to various series. The results expressed in this EPD refer to an average ceramic tile product classified as BIb (Glazed Stoneware) manufactured by NOVOGRES, SA Components of the product None of the end-product components are included in the Candidate List of substances of very high concern for authorisation. Body raw materials (95%): clay, sand, feldspars and recycled unfired ceramic material. Glaze raw materials (5%): feldspars, carbonates, quartz, borates, silicates, kaolins, zirconium oxides, clays, alumina, zinc oxide 6

7 3 Results of the life cycle assessment (LCA) 3.1. System boundaries. Information modules This EPD covers the following stages and information modules within the life cycle. MANUFACTURING supply A2. Raw materials transport Clay, feldspars, kaolins, etc Declaration of environmental parameters derived from the LCAV The environmental parameters derived from the LCA for this product category are set out below. Raw materials preparation Milling Spray drying Forming Water Impact indicators The following table sets out the averaged data of the assessed impact indicators. The minimum and maximum values of the tiles included in this Environmental Product Declaration are detailed in the Annex I and II. The LCA was performed with the support of the GABI 4.4 (PE International) software for Life Cycle Assessment. The characterisation factors used are those included in method CML-2001, after the November 2009 revision. The life cycle modules not shown in the table are irrelevant from an environmental point of view according to ceramic coverings PCR v.001, PCR nº 2 of AENOR GlobalEPD. Drying Glazing and decoration Firing Sorting Packing and packaging Glazes, engobes, inks Cardboard, plastics, wood Figure2. Life cycle stages for the building assessment Information modules included in this EPD D. Benefits and loads beyond the system boundary 7

8 IMPACT CATEGORY PARAMETER UNIT BENEFITS AND LOADS BEYOND THE SYSTEM Global Warming Global Warming Potential kg CO 2 eq. 2,2 4,8E-01 7,4-1,3E-02 Ozone Layer Depletion Ozone Layer Depletion Potential kg CFC 11 eq. 2,8E-07 9,5E-10 3,7E-07-8,0E-10 Acidification Acidification Potential kg SO 2 eq. 1,3E-02 5,3E-03 1,6E-02-2,5E-05 Eutrophication Eutrophication Potential kg (PO 4 ) 3- eq. 8,2E-04 8,7E-04 2,5E-03-3,2E-06 Photochemical Ozone Creation Photochemical Ozone Creation Potential kg Ethane eq. 9,5E-04 4,1E-04 1,2E-03-1,1E-05 Abiotic Depletion (ADP-elements) Abiotic Depletion Potential for non-fossil resources kg Sb eq. 1,5E-04 1,0E-08 6,3E-07-2,1E-09 Abiotic Depletion (ADP-fossil fuels) Abiotic Depletion Potential for fossil resources MJ (net calorific value) 29,0 6,6 92,4-3,6E-01 Table 1. Parameters describing environmental impacts 8

9 Resource use The following table sets out the averaged data of the parameters describing resource use. The minimum and maximum values of the tiles included in this Environmental Product Declaration are detailed in the Annex. The modules not shown in the table are irrelevant from an environmental point of view according to ceramic coverings PCR v.001, PCR nº 2 of AENOR GlobalEPD. BENEFITS AND LOADS BEYOND THE SYSTEM PARAMETER UNIT Use of renewable primary energy excluding renewable primary energy resources used as raw material Use of renewable primary energy resources used as raw material Total use of renewable primary energy resources Use of non-renewable primary energy excluding non-renewable primary energy resources used as raw material Use of non-renewable primary energy resources used as raw materials Total use of non-renewable primary energy resources MJ, net calorific value 5,6 8,9E-03 13,2-1.5E-01 MJ, net calorific value MJ, net calorific value 5,6 8,9E-03 13,2-1.5E-01 MJ, net calorific value 39,9 6,7 142,0-4,0E-01 MJ, net calorific value MJ, net calorific value 39,9 6,7 142,0-4,0E-01 Use of secondary material kg Use of renewable secondary fuels MJ, net calorific value Use of non-renewable secondary fuels MJ, net calorific value Net use of fresh water m 3 4,9E-02 1,3E-04 2,0E-02-4,3E-05 Table 2. Parameters describing resource use 9

10 Waste categories and output flows The following table sets out the averaged data of the parameters describing waste production and output flows. The minimum and maximum values of the tiles included in this Environmental Product Declaration are detailed in the Annex. The modules not shown in the table are irrelevant from an environmental point of view according to ceramic coverings PCR v.001, PCR nº 2 of AENOR GlobalEPD. BENEFITS AND LOADS BEYOND THE SYSTEM PARAMETER UNIT Hazardous waste kg 2,4E ,6E-03 5,6E-05 Non-hazardous waste kg 6,4 1,7E-2 13,5 2,9E-2 Radioactive waste kg 2,6E-03 1,2E-05 4,7E-3 9,5E-06 Table 3. Parameters describing waste categories PARAMETER UNIT BENEFITS AND LOADS BEYOND THE SYSTEM Components for reuse kg Materials for recycling kg ,0E-03 Materials for energy valorisation (energy recovery) kg Export energy MJ per energy carrier A3.Producción D. Potencial de reutilización, recuperación y reciclado Table 4. Parameters describing other output flows 10

11 3.3. Additional environmental information One of the key objectives of our organization is to control and to minimize our environmental impact, in order to achieve products more sustainable. Thus, minimizes the use of raw materials, controlling, at all times, the consumption of these substances throughout its manufacturing process and therefore, decreasing the waste generation, emissions to the air, water discharges and noise. One of our strategic lines is to improve, day by day, to become a sustainable business with our environmental and socioeconomic environment Additional information on release of dangerous substances to air, soil, and water during the use stage compound in the compositions decomposes, yielding an inert end-product free of any volatile organic compounds that might be released in the use stage Release to soil and water Ceramic tiles release no compounds into the soil or water during their use stage because a completely inert product is involved that undergoes no physical, chemical, or biological transformations, is neither soluble nor combustible, and does not react physically or chemically or in any other way, is not biodegradable, and does not adversely affect other materials with which it enters into contact such that it might produce environmental pollution or harm human health. It is a non-leaching product, so that it does not endanger the quality of surface water or groundwater Indoor air emissions In the ceramic tile manufacturing process, tiles are subjected to a thermal process above 1000 ºC. At these temperatures, any organic 11

12 4 Verification Standard UNE-EN serves as the basis for the Product Category Rules (PCR) Ceramic coverings Independent verification of the declaration and the data, in accordance with Standard UNE-EN ISO 14025:2010 internal external Programme administrator and Third-party verifier: Programme: AENOR is founding member of ECO Platform Note 1: This EPD may not be comparable with other EPDs developed in other programmes. Note 2: Construction Product EPDs may not be comparable to others if they do not comply with the European Standard EN

13 ANNEX I Results of the LCA for the size with MAXIMUM ENVIRONMENTAL IMPACT 1. Impact indicators The data are set out in the following table: IMPACT CATEGORY PARAMETER UNIT BENEFITS AND LOADS BEYOND THE SYSTEM Global Warming Global Warming Potential kg CO 2 eq. 2,4 5,3E-01 8,4-1,3E-02 Ozone Layer Depletion Ozone Layer Depletion Potential kg CFC 11 eq. 3,1E-07 1,0E-09 4,7E-07-8,0E-10 Acidification Acidification Potential kg SO 2 eq. 1,4E-02 5,8E-03 1,8E-02-2,5E-05 Eutrophication Eutrophication Potential kg (PO 4 ) 3- eq. 8,8E-04 9,6E-04 2,7E-03-3,2E-06 Photochemical Ozone Creation Photochemical Ozone Creation Potential kg Ethane eq. 1,0E-03 4,5E-04 1,4E-03-1,1E-05 Abiotic Depletion (ADP-elements) Abiotic Depletion Potential for non-fossil resources kg Sb eq. 1,5E-04 1,1E-08 7,3E-07-2,1E-09 Abiotic Depletion (ADP-fossil fuels) Abiotic Depletion Potential for fossil resources MJ (net calorific value) 30 7, ,6E-01 Table 1. Parameters describing environmental impacts 13

14 2. Resource use The data are set out in the following table: PARAMETER UNIT BENEFITS AND LOADS BEYOND THE SYSTEM Use of renewable primary energy excluding renewable primary energy resources used as raw material Use of renewable primary energy resources used as raw material MJ, net calorific value 5,8 9,8E-03 15,5-1,5E-01 MJ, net calorific value Total use of renewable primary energy resources MJ, net calorific value 5,8 9,8E-03 15,5-1,5E-01 Use of non-renewable primary energy excluding non-renewable primary energy resources used as raw material MJ, net calorific value 42,8 7,3 162,0-4,1E-01 Use of non-renewable primary energy resources used as raw materials MJ, net calorific value Total use of non-renewable primary energy resources MJ, net calorific value 42,8 7,3 162,0-4,1E-01 Use of secondary material kg Use of renewable secondary fuels MJ, net calorific value Use of non-renewable secondary fuels MJ, net calorific value Net use of fresh water m 3 5,1E-02 1,4E-04 2,5E-02-4,3E-05 Table 2. Parameters describing resource use 14

15 3. Waste categories and output flows The data are set out in the following table: BENEFITS AND LOADS BEYOND THE SYSTEM PARAMETER UNIT Hazardous waste kg 2,4E ,6E-03 5,6E-05 Non-hazardous waste kg 7,0 1,8E-02 12,4 2,9E-02 Radioactive waste kg 2,8E-03 1,3E-05 5,8E-03 9,5E-06 Table 3. Parameters describing waste categories 4. Other output flows The data are set out in the following table: PARAMETER UNIT BENEFITS AND LOADS BEYOND THE SYSTEM Components for reuse kg Materials for recycling kg ,0E-03 Materials for energy valorisation (energy recovery) kg Export energy MJ per energy carrier Table 4. Parameters describing other output flows 15

16 ANNEX II Results of the LCA for the size with MINIMUM ENVIRONMENTAL IMPACT 1. Impact indicators The data are set out in the following table: IMPACT CATEGORY PARAMETER UNIT BENEFITS AND LOADS BEYOND THE SYSTEM Global Warming Global Warming Potential kg CO 2 eq. 2,1 4,5E-01 6,9-1,3E-02 Ozone Layer Depletion Ozone Layer Depletion Potential kg CFC 11 eq. 2,6E-07 8,8E-10 3,6E-07-8,0E-10 Acidification Acidification Potential kg SO 2 eq. 1,2E-02 4,9E-03 1,5E-02-2,5E-05 Eutrophication Eutrophication Potential kg (PO 4 ) 3- eq. 7,8E-04 8,1E-04 2,4E-03-3,2E-06 Photochemical Ozone Creation Abiotic Depletion (ADP-elements) Photochemical Ozone Creation Potential Abiotic Depletion Potential for non-fossil resources kg Ethane eq. 9,0E-04 3,8E-04 1,2E-03-1,1E-05 kg Sb eq. 1,5E-04 9,4E-09 5,9E-07-2,1E-09 Abiotic Depletion (ADP-fossil fuels) Abiotic Depletion Potential for fossil resources MJ (net calorific value) 27,0 6,1 87-3,6E-01 Table 1. Parameters describing environmental impacts 16

17 2. Resource use The data are set out in the following table: BENEFITS AND LOADS BEYOND THE SYSTEM PARAMETER UNIT Use of renewable primary energy excluding renewable primary energy resources used as raw material Use of renewable primary energy resources used as raw material MJ, net calorific value 5,4 8,3E-03 12,9-1,5E-01 MJ, net calorific value Total use of renewable primary energy resources MJ, net calorific value 5,4 8,3E-03 12,9-1,5E-01 Use of non-renewable primary energy excluding non-renewable primary energy resources used as raw material Use of non-renewable primary energy resources used as raw materials MJ, net calorific value 37,8 6,2 133,0-4,1E-01 MJ, net calorific value Total use of non-renewable primary energy resources MJ, net calorific value 37,8 6,2 133,0-4,1E-01 Use of secondary material kg Use of renewable secondary fuels MJ, net calorific value Use of non-renewable secondary fuels MJ, net calorific value Net use of fresh water m 3 4,7E-02 1,2E-04 1,8E-02-4,3E-05 Table 2. Parameters describing resource use 17

18 3. Waste categories and output flows The data are set out in the following table: PARAMETER UNIT BENEFITS AND LOADS BEYOND THE SYSTEM Hazardous waste kg 2,4E ,6E-03 5,6E-05 Non-hazardous waste kg 5,9 1,6E-02 11,9 2,9E-02 Radioactive waste kg 2,4E-03 1,1E-05 4,5E-03 9,5E-06 Table 3. Parameters describing waste categories 4. Other output flows The data are set out in the following table: BENEFITS AND LOADS BEYOND THE SYSTEM PARAMETER UNIT Components for reuse kg Materials for recycling kg ,0E-3 Materials for energy valorisation (energy recovery) kg Export energy MJ per energy carrier Table 4. Parameters describing other output flows 18

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