Developing an EPD tool for aluminium building products: the experience of the European aluminium industry

Transcription

1 Developing an EPD tool for aluminium building products: the experience of the European aluminium industry Christian Leroy, Bernard Gilmont European Aluminium Association, Brussels, Belgium 13th LCA Case Study Symposium SETAC EUROPE 7-8 Dec 06, Stuttgart

2 Presentation overview 1. What is the European Aluminium Association? 2. Some figures about the Al industry in Europe 3. EPD project a) Introduction b) PCR document c) LCI data collection d) Process and life-cycle stages modelling e) EPD tool and results 4. Conclusions

3 What is the European Al Association? Founded in 1981, the EAA represents the aluminium industry in Europe EAA Members: European primary aluminium producers National associations representing rollers and extruders Organisation of European Aluminium Refiners and Remelters (recycling division - OEA) European association of aluminium foil producers (EAFA) EAA Objectives: Offer support to our members (e.g. statistics, lobbying, communication, etc.) Secure sustainable growth of aluminium in its markets; Maintain and improve the image of the aluminium industry towards target audiences; Promote aluminium knowledge, research & education.

4 Executive Committee General Assembly 2006 Market group Packaging Building Automotive Mass transport Service Providers - Communication - Education & Technology -EHS - Public Affairs - Education Standards & Technology - Statistics National Associations Divisions - Primary - Rollers - Extruders - OEA (Recycling) - EAFA (Foil)

5 Europe = big importer of raw material TOTAL = PRODUCTION + IMPORTS MINING 19.8 mio tonnes ±4.6 mio tonnes BAUXITE 6 plants 15.2 mio tonnes Bauxite Net import ALUMINA 11.3 mio tonnes ±8.3 mio tonnes ALUMINA 12 plants 3.0 mio tonnes Alumina import METAL 12.8 mio tonnes ±5.3 mio tonnes PRIMARY Metal Production 38 plants ±4.8 mio tonnes RECYCLED Metal plants 2.8 mio tonnes Net import SEMI S * West and Central Europe (Former CIS excluded, except Baltic states) 1 Based on statistics (includes recycling from tolled and purchased scrap) ±4.6 mio tonnes ROLLED 57 plants Foil (22%) ±3.1 mio tonnes EXTRUDED +300 plants ±3.1 mio tonnes CASTINGS plants ±1.0 mio tonnes Wire, powder, slugs... Figures of 2005

6 European Aluminium Industry Employment Figures Metal Supply (Alumina, Primary & Recycling) Casting Extrusion Rolling Lacquers Foil Anodizers Applications : aeronautics, automotive, transport, building, engineering, packaging, etc. Total (excl. applications sectors) : people Source: EAA Study on the Economic Importance of the European Aluminium Industry Coverage: EU 25, EFTA countries & Turkey Reference year 2003

7 European semi-production processes Rolling Production: 27% of world rolling capacity, 4,6 millions tonnes/year, about 60 plants (excluding foil mills) Technologically and environmentally at the top Demand: 4 million tonnes, 2.5% yearly growth/last 10 years Main markets: packaging & transport Extrusion Production: 24% of world extrusion production, 3 millions tonnes, 300 plants High productivity compared to other regions Demand: 2.8 million tonnes, 2.5% yearly growth on last 10 years Main market: Building

8 Rolled products: about 15% is used for building applications End-use markets for rolled products in Europe (2004) 15% 4% 22% Foilstock 11% Stockists Packaging (rigid) Building Engineering 16% Transport 13% 19% Consumer durables

9 Extruded products: about 50% is used in building applications End-use markets for extruded products in Europe (2004) 5% 3% 17% 41% Building Transport Engineering others stockists 15% consumer durables 19%

10 The EPD project Coordinated by the EAA Building group Objectives: Development of a web-based software tool for generating EPD s based on a PCR primarily developed Focus: products for building applications where aluminium contributes significantly to the product s performance First product chosen: aluminium windows Initiated end of 2004 Partners : PE-Europe, Five winds, FAECF (Federation of European window & curtain walling).

11 Why a web-based EPD software tool? Alu Windows Specifications encoding Building project EPD EPD for specific/customised aluminium windows EPD Building product 2 EPD Building product 3 raw material land CO 2 raw material land CO 2 energy water energy waste water waste EPD tool Processing & calculation EPD for building

12 Main project parts PROGRAM PROGRAM OPERATOR: EAA Software s back-end PCR EPD tool System bound. Allocation princ. Calculation rules Indicators... Alu environmental data, documentation modules & processes Non-alu environmental data, docum. modules & processes Product selection & technical spec. input Calculations based on: PCR Environmental data Processes involved in product selected EXTERNAL INTERESTED PARTIES EXTERNAL VERIFIERS Software s front-end EPD

13 PCR document Settle rules and foundations of the EPD tool according to ISO and ISO standards Externally reviewed / stakeholder consultation organised in Sept 2005 Define content of short EPD version and long EPD version (available on request) Define content of verifier report Define the LCI/ technical data and the environmental indicators listed in the EPD Examples : Primary energy, non-renewable [MJ], Water consumption [kg], Depletion of Abiotic Resources (ADP) [kg Sb eqv.], Global Warming Potential (GWP) [kg CO2 eqv.], etc. Describe and specify the life-cycle stages covered in the EPD and their modelling

14 Aluminium life-cycle: from cradle to cradle

15 Processes and life cycle stages of the EPD Extrusion Cooperation for data collection Thermal break Anodising process Compleme ntary products EAA LCI data available Rolling Composite production PE / Glue Surface treatment Coating process Manufacturing of product / Assemblage Erection EPD Social Environment Recycling Maintenan ce/ Repair Demolition Opera tion Economic EPD Environmental Product Declaration Building Performance Declaration

16 LCI data collection: aluminium main processes Industry segment Reference & year Area covered Industry coverage Bauxite mining IAI report 2003, year Worldwide Estimation survey: 2000 Alumina production EAA survey 2002 European 100 % Economic Area (EEA) Electrolysis EAA survey 2002 EEA 91 % Cast house EAA survey 2002 EEA 90 % Rolling (Sheet) EAA survey 2002 EEA 88 % Extrusion EAA survey 2002 EEA 33 % Remelting Aluminium EAA survey 2002 EEA 40 % scrap (process scrap) Aluminium recycling including dross & skimings recycling EAA/OEA survey 1998 EEA 53 %

17 LCI data collection: other processes Use of the LCI data from the GaBi database Aluminium downstream processes: coating, anodising, manufacturing, etc. Ancillary processes and materials: electricity, fuels production, caustic soda production, coke production, etc. Other product materials like glass, gaskets, thermal breaks, etc. Actions initiated to collect updated LCI datasets for Aluminium downstream processes: anodising and powder coating Glass Thermal breaks

18 Production processes modelling Use of the GaBi software

19 Recycling of end-of life aluminium building products: an efficient business Very high collection rates Highlighted by a TUDelft study 9 demolition sites analysed in 6 European countries Average collection rate reaches 96% of total aluminium inventory Large parts, such as windows, corrugated roof plates, curtain walls and exterior cladding plates collected and dismantled separately for direct remelting ESSUM model used for calculating metal yield during remelting: 98% A recycling rate of 94% is used for the aluminium window

20 Crediting Al recycling in LCA Substitution methodology: Recycled Al substitutes primary Al Only Al losses balanced by primary production Fully in agreement with ISO allocation procedures Recycling Bauxite Mining Replacement of lost aluminium in each life cycle stage Primary production Alumina Product. Electrolysis Use Manufacturing Casting Extrusion

21 The EPD web-tool for aluminium windows

22 EPD results

23 Conclusions & future EPD project Pioneering exercise in the EPD field Web-tool prototype ready soon Possible extension to other Al building products under discussion Final aim: integration within a full EPD for the building project Not designed for comparison purposes Market acceptance Need for harmonised EPD at European level Need for compatibility with CEN/TC 350 standards development

24 Thank you for your attention