ceramics ecoinvent

Swiss Centre for Life Cycle Inventories

A joint initiative of the ETH domain and Swiss Federal Offices

Life Cycle Inventories of Building Products Data v2.0 (2007)

Daniel Kellenberger, Hans-Jörg Althaus, Tina Künniger, Martin Lehmann EMPA, Dübendorf

Niels Jungbluth ESU-services, Uster

Philipp Thalmann Bau- und Umweltchemie, Zürich

ecoinvent report No. 7

Dübendorf, Dezember 2007

Project "ecoinvent data v2.0" Commissioners: Swiss Centre for Life Cycle Inventories, Dübendorf Swiss Federal Office for the Environment (BAFU -

FOEN), Bern Swiss Federal Office for Energy (BFE), Bern Swiss Federal Office for Agriculture (BLW), Bern ecoinvent Board: Alexander Wokaun (Chair) PSI, Villigen Gérard Gaillard, Agroscope Reckenholz-Tänikon

Research Station, ART, Zürich Lorenz Hilty, Empa, St. Gallen Konrad Hungerbühler, ETHZ, Zürich François Maréchal, EPFL, Lausanne ecoinvent Advisory Council: Norbert Egli, BAFU, Bern Mark Goedkoop, PRé Consultants B.V. Patrick Hofstetter, WWF, Zürich Roland Högger, öbu / Geberit AG, Rapperswil Christoph Rentsch, BAFU (until January 2006) Mark Zimmermann, BFE (until July 2007) Institutes of the ecoinvent Centre: Swiss Federal Institute of Technology Zürich

(ETHZ) Swiss Federal Institute of Technology Lausanne

(EPFL) Paul Scherrer Institute (PSI) Swiss Federal Laboratories for Materials Testing

and Research (Empa) Agroscope Reckenholz-Tänikon Research Station

(ART) Participating consultants: Basler & Hofmann, Zürich Bau- und Umweltchemie, Zürich Carbotech AG, Basel Chudacoff Oekoscience, Zürich Doka Life Cycle Assessments, Zürich Dr. Werner Environment & Development, Zürich Ecointesys - Life Cycle Systems Sarl. ENERS Energy Concept, Lausanne ESU-services Ltd., Uster Infras AG, Bern Software Support: ifu Hamburg GmbH Project leader: Rolf Frischknecht, ecoinvent Centre, Empa,

Dübendorf Marketing and Sales: Annette Köhler, ecoinvent Centre, Empa,

Dübendorf

Citation: Kellenberger D., Althaus H.-J., Jungbluth N., Künniger T., Lehmann M. and Thalmann P. (2007) Life Cycle Inventories of Building Products. Final report ecoinvent Data v2.0 No. 7. EMPA Dübendorf, Swiss Centre for Life Cycle Inventories, Dübendorf, CH, Online-Version under: www.ecoinvent.org. © Swiss Centre for Life Cycle Inventories / 2007

Life Cycle Inventories of Building Products

Project leader: Hans-Jörg Althaus, Empa Authors: Daniel Kellenberger, Empa Hans-Jörg Althaus, Empa Tina Künniger, Empa Niels Jungbluth, ESU-services Martin Lehmann, Empa Philipp Thalmann, Bau- und Umweltchemie Review: Roberto Dones, PSI Rolf Frischknecht, ESU-services Roland Hischier, Empa Contact address: EMPA P.O. Box CH-8600 Dübendorf www.ecoinvent.org [email protected] Responsibility: This report has been prepared on behalf of one or

several Federal Offices listed on the opposite pa-ge (see commissioners). The final responsibility for contents and conclusions remains with the au-thors of this report.

Terms of Use: Data published in this report are subject to the

ecoinvent terms of use, in particular paragraphs 4 and 8. The ecoinvent terms of use (Version 2.0) can be downloaded via the Internet (www.ecoinvent.org).

Liability: Information contained herein have been compiled

or arrived from sources believed to be reliable. Nevertheless, the authors or their organizations do not accept liability for any loss or damage arising from the use thereof. Using the given information is strictly your own responsibility.

http://www.ecoinvent.org/

http://www.ecoinvent.org/

Comments on this version 2.0 This part corresponds to the original report (Werner et al. 2003) that has been updated with the changes reported in (Frischknecht et al. 2006) and augmented with various building products and components such as window frames, doors, claddings. The report consists of the following parts:

Part I Gravel and Sand Products and Processes

Part II Cement Products and Processes

Part III Concrete Products and Processes

Part IV Clay Products and Processes

Part V Refractory Bricks

Part VI Ceramics

Part VII Lime Products and Processes

Part VIII Gypsum Products and Processes

Part IX Fibre Cement Products and Processes

Part X Sand-Lime Brick

Part XI Flat Glass Products and Processes

Part XII Glass Products and Processing for Solar Collectors

Part XIII Glass Fibre Reinforced Plastic Products

Part XIV Insulation Products and Processes

Part XV Elastomere Tube Insulation

Part XVI Cork

Part XVII Mortar and Plaster Products and Processes

Part XVIII Additional Products and Processes

Part XIX Bentonite Products and Processes

Part XX Synthetic rubber (EPDM)

Part XXI Lightweight Products and its Preliminary Products and Processes

Part XXII Natural Stone Plate

Part XXIII Bituminous Products and Processes

Part XXIV Titanium Zinc Plate

Part XXV Tin plating

Part XXVI Glazing, Window frames, Claddings and Doors

Kellenberger D., Althaus H.-J., Jungbluth N. and Künniger T. (2007) Life Cycle Inven-tories of Building Products. Final report ecoinvent Data v2.0 No. 7. EMPA Dübendorf, Swiss Centre for Life Cycle Inventories, Dübendorf, CH, Online-Version under: www.ecoinvent.org.

Final report of the project of a National Life Cycle Inventory Database "Ecoinvent 2000" commis-sioned by BUWAL/BFE/ASTRA/BLW

Part VI

Ceramics Data v2.0 (2007) Author: Hans-Jörg Althaus, EMPA, Dübendorf Review Roberto Dones, PSI

Part VI: Ceramics

Summary This part deals with the production of ceramic tiles and sanitary ceramic products. Data are taken from a LCA study of tile production in Italy and from a environmental report of one producer in Germany.

Data are not representative for engineering ceramics and they are not meant to be used for direct comparison of ceramics to other materials.

ecoinvent report No. 7 - i -

Part VI: Ceramics

Table of Contents

SUMMARY ......................................................................................................................I

TABLE OF CONTENTS .................................................................................................... 1

1 INTRODUCTION ....................................................................................................... 1

2 RESERVES AND RESOURCES OF MATERIALS............................................................. 1

3 CHARACTERISATION AND USE OF THE MATERIALS ..................................................... 1

4 SYSTEM CHARACTERISATION .................................................................................. 2 4.1 Process description ................................................................................................................ 2

4.1.1 Mixing................................................................................................................................... 2 4.1.2 Forming................................................................................................................................. 2 4.1.3 Green Machining................................................................................................................... 3 4.1.4 Drying ................................................................................................................................... 3 4.1.5 Presinter Thermal Processing................................................................................................ 3 4.1.6 Glazing .................................................................................................................................. 3 4.1.7 Firing..................................................................................................................................... 3 4.1.8 Final Processing .................................................................................................................... 4

4.2 Infrastructure ......................................................................................................................... 4 4.3 Emissions .............................................................................................................................. 4

4.3.1 Air ......................................................................................................................................... 4 4.4 Waste..................................................................................................................................... 4

4.4.1 Solid waste ............................................................................................................................ 4 4.4.2 Waste water........................................................................................................................... 4 4.4.3 Ceramics production in ecoinvent......................................................................................... 5 4.4.4 Data quality ........................................................................................................................... 6

5 CUMULATIVE RESULTS AND INTERPRETATION......................................................... 15

6 REFERENCES ....................................................................................................... 15

ecoinvent report No. 7 - 1 -

Part VI: Ceramics

1 Introduction This part deals with the production of ceramic tiles and sanitary ceramic products.

The materials and technologies used for producing technical ceramics can be quite different. If one of the inventories is used as a proxy for sanitary ceramics care has to be taken with the interpretation of the results.

2 Reserves and Resources of Materials For information about reserves and resources of ceramics see the information on the raw materials (mainly clay, feldspars and sand).

3 Characterisation and use of the materials This information is based on EPA (1998).

Ceramics are defined as a class of inorganic, non-metallic solids that are subjected to high temperature in manufacture and/or use. The most common ceramics are composed of oxides, carbides, and nitrides. Silicides, borides, phosphides, tellurides, and selenides also are used to produce ceramics.

Ceramic processing generally involves high temperatures, and the resulting materials are heat resistant or refractory.

Traditional ceramics refers to ceramic products that are produced from unrefined clay and combina-tions of refined clay and powdered or granulated non-plastic minerals. Often, traditional ceramics is used to refer to ceramics in which the clay content exceeds 20 percent. The general classification of traditional ceramics is:

- Pottery is sometimes used as a generic term for ceramics that contain clay and are not used for structural, technical, or refractory purposes.

- Whiteware refers to ceramic ware that is white, ivory, or light gray in color after firing. Whiteware is further classified as earthenware, stoneware, chinaware, porcelain, and technical ceramics.

- Earthenware is defined as glazed or unglazed non-vitreous (porous) clay-based ceramic ware. Applications for earthenware include artware, kitchenware, ovenware, tableware, and tile.

- Stoneware is vitreous or semi-vitreous ceramic ware of fine texture, made primarily from non-refractory fire clay or some combination of clays, fluxes, and silica that, when fired, has prop-erties similar to stoneware made from fire clay. Applications for stoneware include artware, chemicalware, cookware, drainpipe, kitchenware, tableware, and tile.

- Chinaware is vitreous ceramic ware of zero or low absorption after firing that are used for non-technical applications. Applications for chinaware include artware, ovenware, sanitary-ware, and tableware.

- Porcelain is defined as glazed or unglazed vitreous ceramic ware used primarily for technical purposes. Applications for porcelain include artware, ball mill balls, ball mill liners, chemi-calware, insulators, and tableware.

- Technical ceramics include vitreous ceramic whiteware used for such products as electrical in-sulation, or for chemical, mechanical, structural, or thermal applications.


Part VI: Ceramics

Ceramic products that are made of highly refined natural or synthetic compounds and designed to have special properties are referred to as advanced or technical ceramics. Advanced ceramics can be classi-fied according to application as electrical, magnetic, optical, chemical, thermal, mechanical, biologi-cal, and nuclear.

Most ceramic products (including sanitary ceramics and ceramic tiles) are clay-based and are made from a single clay or one or more clays mixed with mineral modifiers such as quartz and feldspar. The types of commercial clays used for ceramics are primarily kaolin and ball clay.

4 System Characterisation 4.1 Process description This chapter is mainly based on EPA (1998).

The basic steps of ceramic production include raw material procurement, possibly beneficiation, mix-ing, forming, green machining, drying, presinter thermal processing, glazing, firing, final processing, and packaging. Procurement and (if necessary) beneficiation of raw material are dealt with in the re-spective reports. The following paragraphs describe the remaining operations in detail.

Sanitary ceramic and ceramic tiles are produced by slurry processing. No powder processing is inven-toried in ecoinvent. The information is given for comprehensibility reasons only.

4.1.1 Mixing The purpose of mixing or blunging is to combine the constituents of a ceramic powder or slurry to produce a more chemically and physically homogenous material for forming. Pug mills often are used for mixing ceramic materials. Several processing aids may be added to the ceramic mix during the mixing stage. Binders and plasticizers are used in dry powder and plastic forming. In slurry process-ing, deflocculants, surfactants, and antifoaming agents are added to improve processing. Liquids also are added in plastic and slurry processing. Binders are polymers or colloids that are used to impart strength to green or unfired ceramic bodies. Water is the most commonly used liquid in plastic and slurry processing. Organic liquids such as alcohols may also be used in some cases. Deflocculants also are used in slurry processing to improve dispersion and dispersion stability. Surfactants are used in slurry processing to aid dispersion, and antifoams are used to remove trapped gas bubbles from the slurry.

4.1.2 Forming In the forming step, dry powders, plastic bodies, pastes, or slurries are consolidated and moulded to produce a cohesive body of the desired shape and size. Dry forming consists of the simultaneous com-pacting and shaping of dry ceramic powders in a rigid die or flexible mold. Jiggering is widely used in the manufacture of small, simple, axially symmetrical whiteware ceramic such as cookware, fine china, and electrical porcelain. Slurry forming of ceramics generally is accomplished using slip cast-ing, gelcasting, or tape casting. In slip casting, a ceramic slurry, which has a moisture content of 20 to 35 percent, is poured into a porous mould, often made of gypsum. Capillary suction of the mould draws the liquid from the mould, thereby consolidating the cast ceramic material. After a fixed time the excess slurry is drained, and the cast is dried. Slip casting is widely used in the manufacture of sinks and other sanitaryware, figurines, porous thermal insulation, fine china, and structural ceramics with complex shapes.


Part VI: Ceramics

4.1.3 Green Machining After forming, the ceramic shape often is machined to eliminate rough surfaces and seams or to mod-ify the shape. The methods used to machine green ceramics include surface grinding to smooth sur-faces, blanking and punching to cut the shape and create holes or cavities, and laminating for multi-layer ceramics.

4.1.4 Drying After forming, ceramics must be dried. Drying must be carefully controlled to strike a balance between minimising drying time and avoiding differential shrinkage, warping, and distortion. The most com-monly used method of drying ceramics is by convection, in which heated air is circulated around the ceramics. Air drying often is performed in tunnel kilns, which typically use heat recovered from the cooling zone of the kiln. Periodic kilns or dryers operating in batch mode are also used. Convection drying is carried out in divided tunnel dryers, which include separate sections with independent tem-perature and humidity controls. An alternative to air drying is radiation drying in which microwave or infrared radiation is used to enhance drying.

4.1.5 Presinter Thermal Processing Prior to firing, ceramics often are heat-treated at temperatures well below firing temperatures. The purpose of this thermal processing is to provide additional drying, to vaporize or decompose organic additives and other impurities, and to remove residual, crystalline, and chemically bound water. Pre-sinter thermal processing can be applied as a separate step, which is referred to as bisque firing, or by gradually raising and holding the temperature in several stages.

This process step is not commonly done for sanitary ceramics or ceramic tiles.

4.1.6 Glazing For traditional ceramics, glaze coatings are often applied to dried or bisque-fired ceramic ware prior to sintering. Glazes consist primarily of oxides and can be classified as raw glazes or frit glazes. In raw glazes, the oxides are in the form of minerals or compounds that melt readily and act as solvents for the other ingredients. Some of the more commonly used raw materials for glazes are quartz, feldspars, carbonates, borates, and zircon. A frit is a prereacted glass. To prepare glazes, the raw materials are ground in a ball mill or attrition mill. Glazes generally are applied by spraying or dipping. Depending on their constituents, glazes mature at temperatures of 600 ° to 1500 °C.

4.1.7 Firing Firing is the process by which ceramics are thermally consolidated into a dense, cohesive body com-prised of fine, uniform grains. This process is also referred to as sintering or densification. Firing re-sults are depending on material properties and on properties of the green ceramics as well as on firing parameters.

Material properties that affect firing include particle size (powder), material surface energy, diffusion coefficients, fluid viscosity, and bond strength.

Properties of the green ceramics affecting firing are the density and the shape.

Parameters that affect firing include firing temperature, time, pressure, and atmosphere. A short firing time results in a product that is porous and has a low density; a short to intermediate firing time results in fine-grained, high-strength products; and long firing times result in a coarse-grained products that are more creep resistant.


Part VI: Ceramics

Applying pressure decreases firing time and makes it possible to fire materials that are difficult to fire using conventional methods. Oxidizing or inert atmospheres are used to fire oxide ceramics to avoid reducing transition metals and degrading the finish of the product.

Conventional firing is accomplished by heating the green ceramic to approximately two-thirds of the melting point of the material at ambient pressure and holding it for a specified time in a periodic or tunnel kiln. Periodic kilns are heated and cooled according to prescribed schedules. The heat for peri-odic kilns generally is provided by electrical element or by firing with gas or oil.

4.1.8 Final Processing After firing, some ceramic products are processed further to enhance their characteristics or to meet dimensional tolerances. Ceramics can be machined by abrasive grinding, chemical polishing, electrical discharge machining, or laser machining. Annealing at high temperature, followed by gradual cooling can relieve internal stresses within the ceramic and surface stresses due to machining. In addition, sur-face coatings are applied to many fired ceramics. Surface coatings are applied to traditional clay ce-ramics to create a stronger, impermeable surface and for decoration. Coatings also may be applied to improve strength, and resistance to abrasion and corrosion. Coatings can be applied dry, as slurries, by spraying, or by vapour deposition.

4.2 Infrastructure The infrastructure needed for ceramic production consists basically of a building, storage for raw ma-terials, mills, mixers and kilns.

4.3 Emissions 4.3.1 Air Besides the emissions from heat generation, only dust emissions from the handling of the raw materi-als are of relevance. Nicoletti et al. (2002) mention a relevant dust emission from grinding of the raw materials for tiles but they don't give any quantitative information. Thus the total of the values given in EPA (1998) for "comminution" and "ceramic glass spray booth" (controlled) is inventoried (8.71E-03 kg/kg). Since the ceramic powder has a grain size around 1 μm and fabric filters or wet scrubbers are utilised to abate dust emissions, the particles are inventoried as PM 2.5.

If organic plasticizers are used (which usually is not the case for sanitary ceramics and ceramic tiles), emissions from burning them are relevant too.

4.4 Waste 4.4.1 Solid waste Wastes to disposal are often oil-contaminated. A major part of the non contaminated production waste can be recycled in the process.

4.4.2 Waste water If ceramics are produced in slurry processing emissions of the raw materials to water occur. This water is usually pre-treated in house and disposed to a municipal wastewater treatment plant. For one plant in Austria measurements of the wastewater composition (after internal pre-treatment) are available. They are presented in Tab. 4.1.


Part VI: Ceramics

Tab. 4.1 Waste water composition (after internal treatment) of sanitary ceramic production in Gmunden (ÖSPAG (2002))

element measured value value used in this study unit Zn 0.012 1.200E-02 g/m3

Ni < 0.05 2.500E-02 g/m3

Pb < 0.05 2.500E-02 g/m3

Cu < 0.01 5.000E-03 g/m3

Cr < 0.05 2.500E-02 g/m3

Co < 0.05 2.500E-02 g/m3

Cd < 0.016 8.000E-03 g/m3

Ba 0.48 4.800E-01 g/m3

4.4.3 Ceramics production in ecoinvent Sanitary ceramic and ceramic tiles are produced by slurry processing.

The modules "sanitary ceramics, at regional storage" and "ceramic tiles, at regional storage " are based on information from a major producer of sanitary ceramics in Europe (ÖSPAG (2002)) and on a LCA case study with inventory data for one producer in Italy (Nicoletti et al. (2002)) respectively. Because the data are meant to represent consumption in Switzerland, the electricity and other products con-sumed are not inventoried with the specific modules for the country where the data come from but with European average modules since the production for Swiss consumption is not limited to one country.

The input and output data for the sanitary ceramics production stem from the environmental report of a company (ÖSPAG (2002)). They refer to the years 2000 and 2001 and to two factories. A weighted mean value of the flows from the different years and factories is calculated. Detailed information on production waste is reported. This degree of detail is not available for input material. Thus some waste fractions without corresponding input are inventoried.

The standard distances from to Frischknecht et al. (2007)) for the transportation of the metal inputs are used. The transport of the product to the consumption in Switzerland is inventoried with 600 km rail freight.

The infrastructure is calculated and estimated based on information from ÖSPAG (2002) (see Tab. 4.2).


Part VI: Ceramics

Tab. 4.2 Estimation on infrastructure

Factory Wilhelmsburg Gmuden Unit Category Remarks Year 2000 2001 2000 2001 total area 88'673 88'673 48'200 48'200 m2 ÖSPAG (2002) sealed area 55'635 55'635 19'200 19'200 m2 ÖSPAG (2002) vegetation area 33'038 33'038 29'000 29'000 m2 ÖSPAG (2002) built up area 44'508 44'508 15'360 15'360 m2 paved parking lot 11'127 11'127 3'840 3'840 m2

land use

estimation based on photography: 80% of sealed area is built up

building hall 40'057 40'057 13'824 13'824 m2 estimation based on photography: 90% built up area

building multy-storey

35'606 35'606 12'288 12'288 m3

buildings

estimation based on photography: 10% built up area, 3 storeys

machines 100'000 100'000 50'000 50'000 kg machines rough estimation Product output 4'597'000 5'231'000 3'159'000 4'798'000 kg

The lifetime of the buildings is assumed 50 years, that of the machines 25 years. Thus the machines are inventoried twice for the total operation time of the plant.

The ecoinvent meta-information for the ceramic production is given in Tab. 4.3 and the input and out-put flows for "sanitary ceramics, at regional storage", "ceramic tiles, at regional storage" and "ceramic plant" are given in Fig. 4.1, Fig. 4.2 and Fig. 4.3, respectively.

4.4.4 Data quality Data uncertainty is derived using the Pedigree matrix as described in (Frischknecht et al. (2007)).

All data are from sources of unknown representativeness. Both inventories are based on information from one single company (except particle emissions). On the other hand, the sources used are fairly detailed and comprehensible. Thus the overall quality must be described as mediocre.


Part VI: Ceramics


Tab. 4.3 ecoinvent meta information for the ceramic production processes

Name sanitary ceramics, at regional storage

ceramic tiles, at regio-nal storage ceramic plant

Location CH CH CH Infrastructure Process 0 0 1 Unit kg kg unit DataSet Version 2.0 2.0 2.0

Included Processes

Gate to gate production of sanitary ceramics, includ-ing transports of raw mate-rials to factory and of prod-uct to Switzerland

Gate to gate production of ceramic tiles, including transports of raw materials to factory and of product to Switzerland

Includes land use and ma-terials used in buildings and machinery as well as their disposal

Amount 1 1 1

Local Name Sanitärkeramik, ab Re-gionallager

Keramikplatten, ab Re-gionallager Keramikwerk

Synonyms China //Chinaware//Porzellan Steinzeug//stoneware

General Comment to ref-erence function

Data from one producer only. Composition of ce-ramic might differ from case to case. This dataset refers to oxidic ceramics.

Data from one producer only. Composition of ce-ramic might differ from case to case. This dataset refers to oxidic ceramics.

Life time of 50 years for buildings and of 25 years for machines is assumed. Dataset refers to a factory with yearly output of 5'000 t of ceramic products.

StartDate 1998 1998 2001 EndDate 2002 2002 2002 Data Valid For Entire Pe-riod 1 1 1

Other Period Text

Geography text Data from two factories of one producer in Austria Data from Italy Data from two factories of

one producer in Austria

Technology text Large scale production in Europe. Gas fired kiln

Large scale, single fired production in Europe. Gas fired kiln

Large scale production plant in Europe.

Representativeness [%] Production Volume Unknown Unknown Unknown Sampling Procedure Environmental report Publication Environmental report Extrapolations See Geography See Geography See Geography Uncertainty Adjustments None None None

Part VI: Ceramics

InputProcess Name

Output Remarks Cate gory Sub categoryInfra struc ture

Loca tion

Modul name in ecoinvent Mean value UnitSource mean

valueType

StDv 95%

General Comment

feldspar for ceramic massconstruction materials

others No RER feldspar, at plant 3.79E-01 kg ÖSPAG (2002) 1 1.13 (1,3,1,3,1,4,3)

recycled production waste

for ceramic mass (from in-house production)

8.97E-02 kg ÖSPAG (2002) 1 1.13 (1,3,1,3,1,4,3)

kaolin for ceramic mass chemicals inorganics No RER kaolin, at plant 4.08E-01 kg ÖSPAG (2002) 1 1.13 (1,3,1,3,1,4,3)

clay for ceramic massconstruction materials

additives No CH clay, at mine 4.25E-01 kg ÖSPAG (2002) 1 1.13 (1,3,1,3,1,4,3)

silica meal, porcelain meal, refractories

for ceramic massconstruction materials

additives No DE silica sand, at plant 2.20E-01 kg ÖSPAG (2002) 1 1.13 (1,3,1,3,1,4,3)

ancillary materials

for ceramic mass chemicals inorganics No GLOchemicals inorganic, at plant

2.75E-03 kg ÖSPAG (2002) 1 1.13 (1,3,1,3,1,4,3)

oxydic minerals for glazingconstruction materials

additives No DE silica sand, at plant 3.17E-02 kg ÖSPAG (2002) 1 1.13 (1,3,1,3,1,4,3)

pigments for glazing chemicals inorganics No GLOchemicals inorganic, at plant

2.87E-04 kg ÖSPAG (2002) 1 1.13 (1,3,1,3,1,4,3)

kaolin refractories, silica meal

for glazing chemicals inorganics No RER kaolin, at plant 3.63E-02 kg ÖSPAG (2002) 1 1.13 (1,3,1,3,1,4,3)

gypsum for mouldconstruction materials

binder No CH stucco, at plant 1.25E-01 kg ÖSPAG (2002) 1 1.13 (1,3,1,3,1,4,4)

plastic forms for mould plastics polymers No RERpolyethylene, HDPE, granulate, at plant

1.51E-03 kg ÖSPAG (2002) 1 1.13 (1,3,1,3,1,4,4)

natural gas for heating natural gas heating systems No RERnatural gas, burned in industrial furnace >100kW

2.41E+01 MJ ÖSPAG (2002) 1 1.13 (1,3,1,3,1,4,1)

electricity total consumption electricity production mix No UCTEelectricity, medium voltage, production UCTE, at grid

8.78E-01 kWh ÖSPAG (2002) 1 1.13 (1,3,1,3,1,4,2)

well water total consumption resource in water Water, well, in ground 1.06E-02 m3 ÖSPAG (2002) 1 1.13 (1,3,1,3,1,4,4)

tap water total consumption water supply production No RER tap water, at user 5.41E-01 kg ÖSPAG (2002) 1 1.13 (1,3,1,3,1,4,4)

transportof final product to Switzerland: 600 km assumed

transport systems

train No CH transport, freight, rail 6.00E-01 tkm estimated 1 2.09(4,5,n.A.,n.A.,n.A.,n.A.,5)

transportof raw materials to fabrication: 50 km assumed

transport systems

road No RERtransport, lorry >16t, fleet average

8.14E-02 tkm estimated 1 2.09(4,5,n.A.,n.A.,n.A.,n.A.,5)

infrastructureLife time: 50 a; production volume: 5000000 kg/a

construction materials

others Yes CH ceramic plant 4.00E-09 unit ÖSPAG (2002) 1 3.02 (1,3,1,3,1,4,9)

Uncertainty informationGeneral Flow information Representation in ecoinvent

sani

tary

cer

amic

s, a

t re

gion

al s

tora

ge;

inpu

ts

Fig. 4.1 Flows for "sanitary ceramics, at regional storage" and its representation in the ecoinvent database


Part VI: Ceramics

InputProcess Name


Loca tion


valueType

StDv 95%

General Comment

waste ceramic (not sanded)

internally recycled (substitutes feldspar)

8.97E-02 kg ÖSPAG (2002) 1 1.13 (1,3,1,3,1,4,6)

paper recycled 7.59E-03 kg ÖSPAG (2002) 1 1.13 (1,3,1,3,1,4,6)

waste ceramic (sanded)

contamination from sanding. Cannot be recycled

waste management

sanitary landfill No CHdisposal, inert material, 0% water, to sanitary landfill

9.40E-02 kg ÖSPAG (2002) 1 1.13 (1,3,1,3,1,4,6)

rumblewaste management

sanitary landfill No CHdisposal, inert material, 0% water, to sanitary landfill

3.19E-02 kg ÖSPAG (2002) 1 1.13 (1,3,1,3,1,4,6)

filter material (inert)

waste management

inert material landfill

No CHdisposal, inert waste, 5% water, to inert material landfill

1.64E-03 kg ÖSPAG (2002) 1 1.13 (1,3,1,3,1,4,6)

gypsum recycled in cement plants 1.33E-01 kg ÖSPAG (2002) 1 1.13 (1,3,1,3,1,4,6)

clay suspension recycled in brick fabrication 1.85E-01 kg ÖSPAG (2002) 1 1.13 (1,3,1,3,1,4,6)

municipal wastewaste management

municipal incineration

No CHdisposal, municipal solid waste, 22.9% water, to municipal incineration

3.86E-02 kg ÖSPAG (2002) 1 1.13 (1,3,1,3,1,4,6)

metal containers (soiled)

waste management

underground deposit

No DEdisposal, hazardous waste, 0% water, to underground deposit

6.85E-05 kg ÖSPAG (2002) 1 1.13 (1,3,1,3,1,4,6)

refrigerators neglected (for consistency 5.49E-05 kg ÖSPAG (2002) 1 1.13 (1,3,1,3,1,4,6)lead batteries neglected (for consistency 2.97E-04 kg ÖSPAG (2002) 1 1.13 (1,3,1,3,1,4,6)fluorescent lamps

neglected (for consistency 2.06E-05 kg ÖSPAG (2002) 1 1.13 (1,3,1,3,1,4,6)

developing agent

waste management

hazardous waste incineration

No CHdisposal, solvents mixture, 16.5% water, to hazardous waste incineration

2.39E-06 kg ÖSPAG (2002) 1 1.13 (1,3,1,3,1,4,6)

used oilwaste management


No CHdisposal, used mineral oil, 10% water, to hazardous waste incineration

1.88E-04 kg ÖSPAG (2002) 1 1.13 (1,3,1,3,1,4,6)

fatwaste management



1.58E-06 kg ÖSPAG (2002) 1 1.13 (1,3,1,3,1,4,6)

oil-water mixtures

waste management


No CHdisposal, bilge oil, 90% water, to hazardous waste incineration

6.61E-05 kg ÖSPAG (2002) 1 1.13 (1,3,1,3,1,4,6)


sani

tary

cer

amic

s, a

t re

gion

al s

tora

ge;

outp

uts,

par

t 1

Fig. 4.1 Flows for "sanitary ceramics, at regional storage" and its representation in the ecoinvent database (cont.)


Part VI: Ceramics

InputProcess Name


Loca tion


valueType

StDv 95%

General Comment

waste from oil interceptor

waste management


No CHdisposal, bilge oil, 90% water, to hazardous waste incineration

1.11E-04 kg ÖSPAG (2002) 1 1.13 (1,3,1,3,1,4,6)

used oil binding agents

waste management



6.33E-06 kg ÖSPAG (2002) 1 1.13 (1,3,1,3,1,4,6)

oil contaminated ancillary materials

waste management



8.71E-05 kg ÖSPAG (2002) 1 1.13 (1,3,1,3,1,4,6)

used paintswaste management


No CH

disposal, emulsion paint remains, 0% water, to hazardous waste incineration

1.58E-07 kg ÖSPAG (2002) 1 1.13 (1,3,1,3,1,4,6)

uncured resinswaste management


No CHdisposal, plastics, mixture, 15.3% water, to municipal incineration

2.01E-05 kg ÖSPAG (2002) 1 1.13 (1,3,1,3,1,4,6)

plastic containers with rest content

waste management


No CHdisposal, plastics, mixture, 15.3% water, to municipal incineration

2.32E-05 kg ÖSPAG (2002) 1 1.13 (1,3,1,3,1,4,6)

chemical wasteswaste management


No CHdisposal, solvents mixture, 16.5% water, to hazardous waste incineration

6.69E-05 kg ÖSPAG (2002) 1 1.13 (1,3,1,3,1,4,6)

other hazardous wastes

waste management

underground deposit


3.30E-05 kg ÖSPAG (2002) 1 1.13 (1,3,1,3,1,4,6)

waste waterwaste management

wastewater treatment

No CH

treatment, ceramic production effluent, to wastewater treatment, class 3

9.83E-04 m3 ÖSPAG (2002) 1 1.13 (1,3,1,3,1,4,6)

dust emissions from grinding

no information in ÖSPAG (2002) air unspecified Particulates, < 2.5 um 8.71E-03 kg EPA (1998) 1 2.06(1,3,1,5,1,5,26)

waste heat air unspecified Heat, waste 3.16E+00 MJ calculated 1 1.13(1,3,1,3,1,4,13)

Sanitary ceramics


others No CHsanitary ceramics, at regional storage

1.00E+00 kg ÖSPAG (2002)


sani

tary

cer

amic

s, a

t re

gion

al s

tora

ge;

outp

uts,

par

t 2

Fig. 4.1 Flows for "sanitary ceramics, at regional storage" and its representation in the ecoinvent database (cont.)


Part VI: Ceramics

InputProcess Name


Loca tion


valueType

StDv 95%

General Comment

clay for ceramic bodyconstruction materials

additives No CH clay, at mine 4.89E-01 kgNicoletti et al. (2002)

1 1.13 (1,3,1,3,1,4,3)

feldspars for ceramic bodyconstruction materials

others No RER feldspar, at plant 2.72E-01 kgNicoletti et al. (2002)

1 1.13 (1,3,1,3,1,4,3)

soldering materials (feldspars)

for ceramic body; 62.5% of total soldering materials



1 1.13 (1,3,1,3,1,4,3)

soldering materials (limestone)

for ceramic body; 37.5% of total soldering materials


others No CHlimestone, milled, packed, at plant

6.10E-02 kgNicoletti et al. (2002)

1 1.13 (1,3,1,3,1,4,3)

silicious and feldspar sands

for ceramic bodyconstruction materials

additives No DE silica sand, at plant 1.56E-01 kgNicoletti et al. (2002)

1 1.13 (1,3,1,3,1,4,3)

ground fired waste

for ceramic body; reused process waste


1 1.13 (1,3,1,3,1,4,3)

ground raw waste

for ceramic body; reused process waste


1 1.13 (1,3,1,3,1,4,3)

exhausted limefor ceramic body; reused process waste


1 1.13 (1,3,1,3,1,4,3)

boron concentrate

for ceramic body; reused from water treatment


1 1.13 (1,3,1,3,1,4,3)

zinc oxidefor frit; only metal content of oxide is inventoried as metal

metals extraction No RERzinc, primary, at regional storage


1 1.13 (1,3,1,3,1,4,3)

zirconium powders

for frit; only metal content of oxide is inventoried as metal

chemicals inorganics No RERtitanium dioxide, production mix, at plant


1 1.13 (1,3,1,3,1,4,3)

colemanite for fritconstruction materials



1 1.13 (1,3,1,3,1,4,3)

dolomite for fritconstruction materials



1 1.13 (1,3,1,3,1,4,3)

penta-hydrate borax

for fritwashing agents

bleaches No RERsodium perborate, tetrahydrate, powder, at plant


1 1.13 (1,3,1,3,1,4,3)

quarz and feldspar sands

for fritconstruction materials

additives No DE silica sand, at plant 1.39E-02 kgNicoletti et al. (2002)

1 1.13 (1,3,1,3,1,4,3)

feldspars for fritconstruction materials


1 1.13 (1,3,1,3,1,4,3)cera

mic

tile

s, a

t re

gion

al s

tora

ge;

inpu

ts,

part

1


Fig. 4.2 Flows for "ceramic tiles, at regional storage" and its representation in the ecoinvent database


Part VI: Ceramics

InputProcess Name


Loca tion


valueType

StDv 95%

General Comment

aluminium oxidefor frit; only metal content of oxide is inventoried as metal

chemicals inorganics No RER aluminium oxide, at plant 3.89E-04 kgNicoletti et al. (2002)

1 1.13 (1,3,1,3,1,4,3)

lead oxidefor frit; only metal content of oxide is inventoried as metal

metals extraction No RER lead, at regional storage 6.65E-03 kgNicoletti et al. (2002)

1 1.13 (1,3,1,3,1,4,3)

barium oxide for frit chemicals inorganics No RER barite, at plant 5.56E-04 kgNicoletti et al. (2002)

1 1.13 (1,3,1,3,1,4,3)

tin oxidefor frit; only metal content of oxide is inventoried as metal

metals extraction No RER tin, at regional storage 4.90E-05 kgNicoletti et al. (2002)

1 1.13 (1,3,1,3,1,4,3)

titanium oxide for frit chemicals inorganics No RERtitanium dioxide, production mix, at plant


1 1.13 (1,3,1,3,1,4,3)

electricity general consumption electricity production mix No UCTEelectricity, medium voltage, production UCTE, at grid

3.13E-01 kWhNicoletti et al. (2002)

1 1.13 (1,3,1,3,1,4,2)

heatgiven as primary energy; natural gas assumed

natural gas heating systems No RERnatural gas, burned in industrial furnace >100kW

5.83E+00 MJNicoletti et al. (2002)

1 1.13 (1,3,1,3,1,4,1)

gypsum

no information about material for moulds in Nicoletti et al. (2002) --> half the amount of sanitary ceramic production assumed


binder No CH stucco, at plant 6.23E-02 kgassumption, based on ÖSPAG (2002)

1 1.24 (1,3,1,3,3,4,4)

water general consumption water supply production No RER tap water, at user 6.67E-01 kgNicoletti et al. (2002)

1 1.13 (1,3,1,3,1,4,4)

recycled water internal recycling 6.67E-04 m3Nicoletti et al. (2002)

1 1.13 (1,3,1,3,1,4,4)

transportof final product to Switzerland: 600 km assumed

transport systems

train No CH transport, freight, rail 6.00E-01 tkm estimated 1 2.09(4,5,n.A.,n.A.,n.A.,n.A.,5)

transportof raw materials to fabrication: 50 km assumed

transport systems

road No RERtransport, lorry >16t, fleet average

6.10E-02 tkm estimated 1 2.09(4,5,n.A.,n.A.,n.A.,n.A.,5)

infrastructureLife time: 50 a; production volume: 5000000 kg/a


others Yes CH ceramic plant 4.00E-09 unit ÖSPAG (2002) 1 3.02 (1,3,1,3,1,4,9)

cera

mic

tile

s, a

t re

gion

al s

tora

ge;

inpu

ts,

part

2


Fig. 4.2 Flows for "ceramic tiles, at regional storage" and its representation in the ecoinvent database (cont.)


Part VI: Ceramics

InputProcess Name


Loca tion


valueType

StDv 95%

General Comment

waste water to internal recyclilng

recycled to wet grinding 6.67E-04 m3Nicoletti et al. (2002)

1 1.13 (1,3,1,3,1,4,6)

waste water after internal pre-treatment

to external treatmentwaste management

wastewater treatment

No CH

treatment, ceramic production effluent, to wastewater treatment, class 3

2.00E-05 m3Nicoletti et al. (2002)

1 1.13 (1,3,1,3,1,4,6)

sludge from waste water treatment to external recycling

not inventoried 2.22E-03 kgNicoletti et al. (2002)

1 1.13 (1,3,1,3,1,4,6)

sludge from waste water treatment to landfill

assumed to be hazardous waste because it can not be recycled

waste management

underground deposit



1 1.13 (1,3,1,3,1,4,6)

wastes to internal recycling


1 1.13 (1,3,1,3,1,4,6)

wastes to external recycling


1 1.13 (1,3,1,3,1,4,6)

wastes to disposal

assumed to be hazardous wastes because they can not be recycled

waste management

underground deposit



1 1.13 (1,3,1,3,1,4,6)

dust emissions to air

Value for comminution and glace spray booth (controlled)

air unspecified Particulates, < 2.5 um 8.71E-03 kgEPA (1998), size assumed

1 1.32(1,3,1,5,1,5,28)

waste heat air unspecified Heat, waste 1.13E+00 MJ calculated 1 1.13(1,3,1,3,1,4,13)

tiles (product)construction materials

coverings No CHceramic tiles, at regional storage

1.00E+00 kg

cera

mic

tile

s, a

t re

gion

al s

tora

ge;

outp

uts


Fig. 4.2 Flows for "ceramic tiles, at regional storage" and its representation in the ecoinvent database (cont.)


InputProcess Name


Loca tion


valueType

StDv 95%

General Comment

total area transformed

resource landTransformation, from unknown

7.69E+04 m2 ÖSPAG (2002) 1 2.02 (1,3,1,3,1,4,8)

transformed to vegetation area

resource landTransformation, to industrial area, vegetation

3.59E+04 m2 ÖSPAG (2002) 1 2.02 (1,3,1,3,1,4,8)

transformed to built up area

resource landTransformation, to industrial area, built up

3.28E+04 m2 ÖSPAG (2002) 1 2.03 (3,3,1,3,1,4,8)

transformed to paved parking lot

resource landTransformation, to traffic area, road network

8.20E+03 m2 ÖSPAG (2002) 1 2.03 (3,3,1,3,1,4,8)

occupation as vegetation area

resource landOccupation, industrial area, vegetation

1.80E+06 m2a ÖSPAG (2002) 1 1.54 (3,3,1,3,1,4,7)

occupation as built up area

resource landOccupation, industrial area, built up

1.64E+06 m2a ÖSPAG (2002) 1 1.54 (3,3,1,3,1,4,7)

occupation as paved parking lot

resource landOccupation, traffic area, road network

4.10E+05 m2a ÖSPAG (2002) 1 1.54 (3,3,1,3,1,4,7)

building hallconstruction processes

buildings Yes CH building, hall 2.95E+04 m2assumption, based on ÖSPAG (2002)

1 3.03 (3,3,1,3,1,4,9)

building multy-storey

construction processes

buildings Yes RER building, multi-storey 2.63E+04 m3assumption, based on ÖSPAG (2002)

1 3.03 (3,3,1,3,1,4,9)

machinesconstruction processes

machinery Yes RERindustrial machine, heavy, unspecified, at plant

1.68E+05 kg assumption 1 3.23(5,n.A.,n.A.,n.A.,n.A.,n.A.,9)

machines to recycling

1.68E+05 kg assumption 1 3.23(5,n.A.,n.A.,n.A.,n.A.,n.A.,9)

ceramic plantLife time: 50 a; production volume: 5000000 kg/a


others Yes CH ceramic plant 1.00E+00 unit


cera

mic

pla

nt

Part VI: Ceramics


Fig. 4.3 Flows for "ceramic plant" and its representation in the ecoinvent database

Part VI: Ceramics

5 Cumulative Results and Interpretation The cumulative results can be downloaded from the ecoinvent Database (www.ecoinvent.org).

6 References EPA (1998) EPA (1998) Ceramic Products Manufacturing, Emissions Factor Documentation

for AP-42, Final Report, Section 11.7. U.S. Environmental Protection Agency (EPA), Office of Air Quality Planning and Standards, Research Triangle Park/NC, Online-Version under: http://www.epa.gov/ttn/chief/ap42/.

Frischknecht et al. (2007) Frischknecht R., Jungbluth N., Althaus H.-J., Doka G., Dones R., Hellweg S., Hischier R., Nemecek T., Rebitzer G. and Spielmann M. (2007) Overview and Methodology. Final report ecoinvent Data v2.0 No. 1. Swiss Centre for Life Cy-cle Inventories, Dübendorf, CH, Online-Version under: www.ecoinvent.ch.

Nicoletti et al. (2002) Nicoletti G. M., Notarnicola B. and Tassielli G. (2002) Comparative Life Cycle Assessment of flooring materials: ceramic versus marble tiles. In: Journal of Cleaner Production.

ÖSPAG (2002) ÖSPAG (2002) ÖSPAG Umwelterklärungen 2002 für die Standorte Gmunden und Wilhelmsburg (vereinfachte Version). ÖSPAG-Laufen, Gmunden.


http://www.epa.gov/ttn/chief/ap42/

http://www.ecoinvent.ch/

ceramics ecoinvent

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