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?