TECNARGILLA. Rimini, 26 Settembre 2018 L INDUSTRIA CERAMICA VERSO UN MODELLO DI ECONOMIA CIRCOLARE. Andrea Morfino

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1 TECNARGILLA Rimini, 26 Settembre 2018 L INDUSTRIA CERAMICA VERSO UN MODELLO DI ECONOMIA CIRCOLARE Andrea Morfino

2 LCA & MCI indicators in ceramics: the WINCER project case Mirca Di Domenico Andrea Morfino

3 European Action Plan for Circular Economy «Closing the loop an EU Action Plan for the Circular Economy» December, 2015

4 WINCER project: Waste sinergy in the production of INnovative CERamic tiles The project aims to develop innovative ceramic tiles containing over 80 wt% of recycled materials from urban and industrial wastes. Project Website:

5 WINCER project: Waste sinergy in the production of INnovative CERamic tiles Specific objectives: sustainable waste management by recovery of the amount of soda lime glass cullet (about 30% of the total glass waste) The circularity contribution of WINCER is particularly significant through the use of scrap packaging glass from urban glass collection (post-consumer waste) (Rambaldi et al., 2016). reduction of the use of natural resources thanks to: the use of soda lime glass, coming from urban collection and the reuse of green scrap tiles, generated during the industrial process improvement of the environmental performances of the ceramic tiles sector by reducing CO 2 emissions, energy consumption and methane use

6 WINCER project: UNI Certificate & LCA study A complete characterization of these highly-recycled porcelain tiles was carried out in terms of their compliance with EN (EN ISO 14411:2016, Ceramic tiles - Definition, classification, characteristics, assessment and verification of constancy of performance and marking. ) In addition an assessment of the environmental impact, so a Life Cycle Assessment study of this tile is requested, according to: ISO (EN ISO 14040: Environmental management - Life cycle assessment - Principles and framework) ISO (EN ISO 14044: Environmental management - Life cycle assessment - Requirements and guidelines

7 WINCER project: LCA Goal & Scope Declared Unit: 1 kg of ceramic tile (results declared also for 1m 2 ) plus packaging Production sites: Marazzi Group s plants located in Sassuolo and Fiorano (Modena) Data collection: year 2016 in Sassuolo and Fiorano (Modena) plants. All secondary data come from the GaBi 2017 LCI databases and are representative of the years Cut off: polyelectrolytes for water treatment, < 0,001% of the mass input to the unit process. Methodology: CML methodology (CML 2001 April 2013) Software: GaBi 8 Software system for life cycle engineering (thinkstep AG). GaBi 2017 LCI database provides the life cycle inventory data for several of the raw and process materials obtained from the background system.

8 WINCER project: LCA System Boundaries Production Installation Use stage End-of-Life Next product system Raw material supply (extraction, processing, recycled material) Transport to manufacturer Manufacturing Transport to building site Installation into building Use / application Maintenance Repair Replacement Refurbishment Operational energy use Operational water use Deconstruction / demolition Transport to EoL Waste processing for reuse, recovery or recycling Disposal Reuse, recovery or recycling potential A1 A2 A3 A4 A5 B1 B2 B3 B4 B5 B6 B7 C1 C2 C3 C4 D X X X MND MND MND MND MND MND MND MND MND MND MND MND MND MND EN (DIN EN 15804: Sustainability of construction works - Environmental Product Declarations - Core rules for the product category of construction products) for EPD.

9 WINCER project: LCA Product System Secondary materials Raw materials Clay Secondary materials Glass wastes (SM) Sassuolo Plant Raw ceramic scraps Transport Transport Fiorano Plant Internal recovery Milling Atomization Pressing & Drying Glaze production Water treatment Glazing Water completely recovered MFR: Other production lines, Washing lines Firing Cutting & Packaging

10 WINCER project: Milling & Spray Drying Material for recycling Water to water treatment Sassuolo Plant Clay Melting Material Production scraps Ceramic mixture Milling Spray drying Clay Traditional ceramic tile average composition Others Melting material Clay WINCER tile composition Others Raw Production Scraps Raw production scraps are usually used in traditional ceramic production. Raw production scraps Silica Sand Raw production scraps Glass scraps In WINCER mixture composition it s almost completely made of secondary material Figure 1 Figure 2

11 WINCER project: Glazing, firing, cutting. Pressing & Drying Glaze production Fiorano Plant Spray dried powder Glazing Sintering Cutting & Packaging Storage

12 WINCER: Results Caption: GWP = Global warming potential; ODP = Depletion potential of the stratospheric ozone layer; AP = Acidification potential of land and water; EP = Eutrophication potential; POCP = Formation potential of tropospheric ozone photochemical oxidants; ADPE = Abiotic depletion potential for non-fossil resources; ADPF = Abiotic depletion potential for fossil resources

13 WINCER: LCA Results

14 WINCER: EN Impact Category Caption: PERE= Use of renewable primary energy excluding renewable primary energy resources used as raw materials; PERM= Use of renewable primary energy resources used as raw materials; PERT=Total use of renewable primary energy resources; PENRE= Use of non-renewable primary energy excluding non-renewable primary energy resources used as raw materials; PENRM= Use of non-renewable primary energy resources used as raw materials; PENRT=Total use of non-renewable primary energy resources; SM= Use of secondary material; RSF=Use of renewable secondary fuel; RNSF=Use of non-renewable secondary fuel s; FW= Use of net fresh water

15 WINCER: EN Impact Category Caption: HWD = Hazardous waste disposed; NHWD = Non-hazardous waste disposed; RWD = Radioactive waste disposed; CRU = Components for re-use; MFR = Materials for recycling; MER = Materials for energy recovery; EEE = Exported electrical energy; EET = Exported thermal energy

16 WINCER: Sensitivity check on raw materials Ceramic tiles - Unglazed porcelain tiles (Casiglie s Plant) MrazziGroup Srl (EPD-MAR IBC2-EN Ceramic tiles - Glazed porcelain tiles (Casiglie s Plant) MrazziGroup Srl (EPD- MAR IBC2-EN Published from Insitut Bauen und Umwelt e.v. (IBU)

17 Circular Economy: indicators project Material Circularity Indicator «The Material Circularity Indicator (MCI) for a product measures the extent to which linear flow has been minimised and restorative flow maximised for its component materials, and how long and intensively it is used compared to a similar industry-average product.» (Ellen MacArthur Foundation and GRANTA design 2015b Circularity indicators Methodology, An approach to measuring Circularity. Project Overview) In addition to the LCA study, the LCA model was used to calculate the Material Circularity Indicator of WINCER

18 Circular Economy: Material Circularity Indicator The MCI is constructed from a combination of three characteristics: V = mass of virgin raw material used in manufacture W = mass of not recoverable waste X = utility factor (length and intensity of the product s use) The range values is 0 to 1, in which zero represents a total linear product (made of virgin material and end up to landfill) and 1 a total circular product (made completely of secondary materials and completely recovered at the end of life). MCI does not consider what kind of materials are or does not provide information on other impacts of the product, but it is possible using an approach that use MCI in combination to complementary indicators, risk indicators and impact indicators types.

19 MCI: GaBi Circularity tool A tool for GaBi to calculate MCI, P. Shonfield (thinkstep UK) What you need to know: Amount of recycled/reused feedstock in a product Amount of product recyclable or reusable Recycling processes efficiency The length and the intensity product use

20 MCI: Results Metric Unit Scenario 1 Scenario X Linear Flow Index Linear Flow Index, LFI' = (V'+W')/(2M+(WF-WC)/2+(W'F-W'C)/2) - 0,16 - Material Circularity Indicator Metric Unit Scenario 1 Scenario X Material Circularity Indicator, MCI'P = max(0,1-lfi'*f(x)) - 0,86 -

21 Interpretation & Conclusion Energy consumption is the main driver for most impact categories. Glazes and inks used in this production contain several metal oxides and the production of some of them (as cobalt or antimony) have a high impact related to AP and ADPe indicators. The use of two performance assessment methodologies (LCA and MCI) could be used together to optimize the overall environmental and circularity performance of a product. These methodologies/tools could permit to save a significant amount of development time and cost

22 Thanks for your attention! Question? Nature s rules: Nature runs on sunlight. Nature uses only the energy it needs. Nature fits form to function. Nature recycles everything. Nature rewards cooperation. Nature banks on diversity. Nature demands local expertise. Nature curbs excesses from within. Nature taps the power of limits. («Biomimicry: Innovation Inspired by Nature», Janine M. Benyus)