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TECNARGILLA
Rimini, 26 Settembre 2018
Andrea Morfino
L’INDUSTRIA CERAMICAVERSO UN MODELLO DIECONOMIA CIRCOLARE
LCA & MCI indicatorsin ceramics:
the WINCER project case
Mirca Di DomenicoAndrea Morfino
«Closing the loop – an EU Action Plan for the CircularEconomy» December, 2015
European Action Plan for Circular Economy
WINCER project: Waste sinergy in the production of INnovative CERamic tiles
Project Website: www.wincer-project.eu
The project aims to develop innovative ceramic tiles containing over 80 wt% of recycled materials from
urban and industrial wastes.
WINCER project: Waste sinergy in the production of INnovative CERamic tiles
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).
Specific objectives:
– sustainable waste management byrecovery of the amount of soda lime glasscullet (about 30% of the total glass waste)
– reduction of the use of natural resourcesthanks to: the use of soda lime glass, comingfrom urban collection and the reuse of greenscrap tiles, generated during the industrialprocess
– improvement of the environmentalperformances of the ceramic tiles sector byreducing CO2 emissions, energy consumptionand methane use
WINCER project: UNI Certificate & LCA study
A complete characterization of these highly-recycled porcelain tiles wascarried out in terms of their compliance with EN 14411(EN ISO 14411:2016, Ceramic tiles - Definition, classification,characteristics, assessment and verification of constancy of performanceand marking. )
In addition an assessment of the environmental impact, so a Life CycleAssessment study of this tile is requested, according to:
• ISO 14040 (EN ISO 14040:2009-11 Environmental management - Lifecycle assessment - Principles and framework)
• ISO 14044 (EN ISO 14044:2006-10 Environmental management - Lifecycle assessment - Requirements and guidelines
• Declared Unit: 1 kg of ceramic tile (results declared also for 1m2) 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 fromthe GaBi 2017 LCI databases and are representative of the years 2011-2016.
• 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 databaseprovides the life cycle inventory data for several of the raw and process materials obtained from thebackground system.
WINCER project: LCA Goal & Scope
Production Installation Use stage End-of-LifeNext
product system
Raw
mat
eria
l sup
ply
(ext
ract
ion,
pr
oces
sing,
recy
cled
mat
eria
l)
Tran
spor
t to
man
ufac
ture
r
Man
ufac
turin
g
Tran
spor
t to
build
ing
site
Inst
alla
tion
into
bui
ldin
g
Use
/ ap
plic
atio
n
Mai
nten
ance
Repa
ir
Repl
acem
ent
Refu
rbish
men
t
Ope
ratio
nal e
nerg
y us
e
Ope
ratio
nal w
ater
use
Deco
nstr
uctio
n / d
emol
ition
Tran
spor
t to
EoL
Was
te p
roce
ssin
g fo
r reu
se,
reco
very
or r
ecyc
ling
Disp
osal
Reus
e, re
cove
ry o
r rec
yclin
g po
tent
ial
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
WINCER project: LCA System Boundaries
• EN 15804 (DIN EN 15804: Sustainability of construction works - Environmental Product Declarations - Core rulesfor the product category of construction products) for EPD.
Pressing & Drying
Glazing
Firing Cutting & Packaging
Glazeproduction
Raw ceramicscraps
Clay Glass wastes(SM)
Milling
Atomization
Transport Transport
Secondary materials
Internal recovery
Raw materials
Water treatment
MFR:Other production lines,
Washing linesWater completelyrecovered
Secondary materials
Sassuolo Plant
Fiorano Plant
WINCER project: LCA Product System
ClayMelting Material
Production scraps
Ceramicmixture Milling Spray
drying
Melting material
Silica Sand
Raw production
scraps
Clay
Others
Traditional ceramic tile average composition
Glass scraps
Raw production
scraps
Clay
Others
WINCER tile composition
Figure 1 Figure 2
Raw production scraps are usually used in traditionalceramic production.
In WINCER mixture composition it’s almost completelymade of secondary material
RawProduction
Scraps
Water to water
treatment
Material for recycling
Sassuolo Plant
WINCER project: Milling & Spray Drying
Pressing & Drying
Glazing
Sintering Cutting & Packaging
WINCER project: Glazing, firing, cutting….
Glaze production
Storage
Spray driedpowder
Fiorano Plant
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
WINCER: Results
WINCER: LCA Results
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
WINCER: EN 15804 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
WINCER: EN 15804 Impact Category
WINCER: Sensitivity check on raw materials
• Ceramic tiles - Unglazed porcelain tiles (Casiglie’s Plant) MrazziGroup Srl(EPD-MAR-20160003-IBC2-EN
• Ceramic tiles - Glazed porcelain tiles (Casiglie’s Plant) MrazziGroup Srl (EPD-MAR-20160004-IBC2-EN
Published from Insitut Bauen und Umwelt e.V. (IBU)
Circular Economy: indicators project
Material Circularity Indicator
«The Material Circularity Indicator (MCI) for a productmeasures the extent to which linear flow has beenminimised and restorative flow maximised for itscomponent materials, and how long and intensively it isused compared to a similar industry-average product.»
(Ellen MacArthur Foundation and GRANTA design 2015b “Circularityindicators – Methodology, An approach to measuring Circularity. ProjectOverview)
In addition to the LCA study, the LCA model was used tocalculate the Material Circularity Indicator of WINCER
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 endup to landfill) and 1 a total circular product (made completely of secondary materials and completelyrecovered at the end of life).
MCI does not consider what kind of materials are or does not provide information on other impacts ofthe product, but it is possible using an approach that use MCI in combination to complementaryindicators, risk indicators and impact indicators types.
MCI: GaBi Circularity tool
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
A tool for GaBi to calculate MCI,
P. Shonfield (thinkstep UK)
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 -
Metric Unit Scenario 1 Scenario X
Material Circularity Indicator
Material Circularity Indicator, MCI'P = max(0,1-LFI'*F(X)) - 0,86 -
MCI: Results
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
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 Inspiredby Nature», Janine M. Benyus)
Thanks for yourattention!
Question?