ENVIRONMENTAL PRODUCT DECLARATION

Transcription

1 ENVIRONMENTAL PRODUCT DECLARATION HOT-DRAWN REINFORCING STEEL FOR CONCRETE IN BARS AND COILS Based on: PCR 2012:01 Construction products and Construction services, Version 2.1, and EN:15804:2014 Revision 2 of 2017/05/05 Certification N : S-P Valid until: 2020, May 05

2 COMPANY PROFILE The Feralpi Group is one of Europe s leading manufacturers of steels for use in building construction. The parent company Feralpi Siderurgica, which was set up in 1968 in Lonato del Garda, near Brescia, has developed steadily over the years to form a group of industries that currently more than two million tonnes of steel and rolled products a year, and has a workforce of 1400 permanent employees in Italy and Europe. In over forty years of business, the company has branched out to foreign markets and have been able to face the challenge of an increasingly globalized steel industry. Starting from its lengthy tradition in steel manufacturing, the Group has developed according to a strategy of diversification into new products and markets, which has involved not only the internal organisation but also external transactions thanks to the acquisition of numerous enterprises operating in this industry. The Feralpi Group also operates in the field of special steels, cold working, structural steelwork, the environment and fish farming, not to mention financial activities and investments. Since its very origins, Feralpi has focused not only on producing the best steel grades for building construction but also on doing it in the most sustainable possible way, which has involved reducing energy consumption and emissions by using the latest technology available or developing in-house new solutions covered by patents as a result of intensive innovation and research. Feralpi, an international diversified group (2015) million tons million tons 787,526 tons million euros 68% 1, million euros Steel production Hot rolled production Cold rolled productis and derivatives Turnover Turnover abroad Employees (2016) Technical investments 2

3 THE PRODUCT Rebar is the core of reinforced steel structures. Ribs provide improved adherence to the concrete. Special chemical analysis and a monitored production process give the rebar excellent mechanical properties for use in severe or harsh applications, requiring a high standard of safety for private and industrial buildings and large motorway, railway and airport infrastructures. Thanks to its ductility properties, Feralpi reinforcing steel in bar complies fully with anti-seismic requirements. INFORMATION PRODUCT IDENTIFICATION PRODUCT FEATURES PRODUCT PROPERTIES (UNDER EN10080:2005) DESCRIPTION Hot-drawn reinforcing steel for concrete in bars and coils Bars: Diameters from 6 mm to 50 Length from 5 to 24 m Weight up to kg per bundle Coils: Diameters from 6 to 16 mm Weight from to 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 for 6 < Ø 12 mm f R or f P for Ø >12 mm f R or f P Weldability: C eq < 0.52 Typical yield stress: Re > 400 MPa and/or Rp 0.2 < 600 MPa Elongation: Agt > 5% Successful in bend and rebend test Content of recycled materials 97% Successful in strength test and oligocyclic strength test Total amount of products covered by this EPD, year 2015: t Total production, for selling purpose, year 2015: t On-site air emission control system PLANT FEATURES On-site system to recycle process water On-site system to recycle water used in process In/out materials/products and melting process monitored to prevent nuclear radiation In house photovoltaic plant of 625 kw peak capacity operating since

4 METHODOLOGY The environmental burden of the product has been calculated according to EN 15804:2014 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 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 (Lonato del Garda, BS, 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). Declared Unit According to EN:15804, the declared unit is 1 ton of hot rolled bars and coils, delivered to the final customers. 4

5 SYSTEM BOUNDARIES Scrap pretreatment Shearing Supplying transport Billets production Hot rolling process Shredding Packaging A1 A2+A3 A4 Internal handling Sorting Ancillary materials and activities Market transport 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 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 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 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 Lonato (northern Italy) final products are delivered to many national (41% of the total sold product) and international areas such as Algeria (around 23%), France, Germany and Switzerland, mentioning the main countries. The means of transport used to deliver steel bars and coils are truck and freight ship. On average, hot rolled products are transported for 271 km by road and 1,386 km by ship. A4 - Distribution 8

9 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. RENEWABLE RESOURCES A1 Raw materials supply A2 Transportation A3 Manufacturing A4 Distribution TOTAL Use of RENEWABLE primary energy excluding renewable primary energy resources used as raw materials [MJ, net calorific value] 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]

10 NON RENEWABLE RESOURCES A1 Raw materials supply A2 Transportation A3 Manufacturing A4 Distribution TOTAL Use of NON RENEWABLE primary energy excluding non renewable primary energy resources used as raw materials [MJ, net calorific value] 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]

11 USE OF SECONDARY RESOURCE A1 Raw materials supply A2 Transportation A3 Manufacturing A4 Distribution TOTAL Use of secondary material [kg] Use of renewable secondary fuels [MJ] Use of non renewable secondary fuels [MJ] NET USE OF FRESH WATER A1 Raw materials supply A2 Transportation A3 Manufacturing A4 Distribution TOTAL Net use of fresh water [m 3 ] 2 < <

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 CO2 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 <

13 ADDITIONAL INFORMATION Feralpi plant in Lonato del Garda (BS) is equipped with prevention and reduction systems for air 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%. OTHER ENVIRONMENTAL INDICATORS AIR EMISSIONS Dust from electric-arc furnace CO 2 from electric-arc furnace NOx from hot rolling process SOx from hot rolling process UNIT UP CORE DOWN TOTAL [g] [kg] [g] [g] Other environmental indicators per 1 t of hot-rolled reinforcing steel for concrete WATER EMISSIONS Total Suspended Solids [g] Other environmental indicators per 1 t of hot-rolled reinforcing steel 13

14 REFERENCE This declaration has been developed referring to the International EPD System, following the General Program Instruction and Supporting Annexes (ver /05/11); further information and the document itself are available at: Software: SimaPro ver ( Main database: Ecoinvent 2.2 Report LCA: Life Cycle Assessment (LCA) applied to hot and cold rolled reinforcing steel for concrete produced via Electric Arc Furnace for EPD purposes - 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 Feralpi activities, please contact: Italo Piras - Eric Filippini direzione@feralpi.it Phone: (+39) Technical support to Feralpi Siderurgica Spa 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 2.01, ) PCR review was conducted by: The Technical Committee of the International EPD System. Chair: Filippo Sessa. 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