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-Jrg Althaus, Tina Knniger, Martin Lehmann EMPA, Dbendorf Niels Jungbluth ESU-services, Uster Philipp Thalmann Bau- und Umweltchemie, Zrich

ecoinvent report No. 7

Dbendorf, Dezember 2007

Project "ecoinvent data v2.0"

Commissioners: Swiss Centre for Life Cycle Inventories, Dbendorf Swiss Federal Office for the Environment (BAFU FOEN), Bern Swiss Federal Office for Energy (BFE), Bern Swiss Federal Office for Agriculture (BLW), Bern Alexander Wokaun (Chair) PSI, Villigen Grard Gaillard, Agroscope Reckenholz-Tnikon Research Station, ART, Zrich Lorenz Hilty, Empa, St. Gallen Konrad Hungerbhler, ETHZ, Zrich Franois Marchal, EPFL, Lausanne Norbert Egli, BAFU, Bern Mark Goedkoop, PR Consultants B.V. Patrick Hofstetter, WWF, Zrich Roland Hgger, bu / Geberit AG, Rapperswil Christoph Rentsch, BAFU (until January 2006) Mark Zimmermann, BFE (until July 2007)

ecoinvent Board:

ecoinvent Advisory Council:

Institutes of the ecoinvent Centre: Swiss Federal Institute of Technology Zrich (ETHZ) Swiss Federal Institute of Technology Lausanne (EPFL) Paul Scherrer Institute (PSI) Swiss Federal Laboratories for Materials Testing and Research (Empa) Agroscope Reckenholz-Tnikon Research Station (ART) Participating consultants: Basler & Hofmann, Zrich Bau- und Umweltchemie, Zrich Carbotech AG, Basel Chudacoff Oekoscience, Zrich Doka Life Cycle Assessments, Zrich Dr. Werner Environment & Development, Zrich Ecointesys - Life Cycle Systems Sarl. ENERS Energy Concept, Lausanne ESU-services Ltd., Uster Infras AG, Bern ifu Hamburg GmbH Rolf Frischknecht, ecoinvent Centre, Empa, Dbendorf Annette Khler, ecoinvent Centre, Empa, Dbendorf

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Life Cycle Inventories of Building Products

Project leader: Authors: Hans-Jrg Althaus, Empa Daniel Kellenberger, Empa Hans-Jrg Althaus, Empa Tina Knniger, Empa Niels Jungbluth, ESU-services Martin Lehmann, Empa Philipp Thalmann, Bau- und Umweltchemie Roberto Dones, PSI Rolf Frischknecht, ESU-services Roland Hischier, Empa EMPA P.O. Box CH-8600 Dbendorf www.ecoinvent.org empa@ecoinvent.org This report has been prepared on behalf of one or several Federal Offices listed on the opposite page (see commissioners). The final responsibility for contents and conclusions remains with the authors of this report. 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). 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.

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

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 Part II Part III Part IV Part V Part VI Part VII Part VIII Part IX Part X Part XI Part XII Part XIII Part XIV Part XV Part XVI Part XVII Part XVIII Part XIX Part XX Part XXI Part XXII Part XXIII Part XXIV Part XXV Part XXVI Gravel and Sand Products and Processes Cement Products and Processes Concrete Products and Processes Clay Products and Processes Refractory Bricks Ceramics Lime Products and Processes Gypsum Products and Processes Fibre Cement Products and Processes Sand-Lime Brick Flat Glass Products and Processes Glass Products and Processing for Solar Collectors Glass Fibre Reinforced Plastic Products Insulation Products and Processes Elastomere Tube Insulation Cork Mortar and Plaster Products and Processes Additional Products and Processes Bentonite Products and Processes Synthetic rubber (EPDM) Lightweight Products and its Preliminary Products and Processes Natural Stone Plate Bituminous Products and Processes Titanium Zinc Plate Tin plating Glazing, Window frames, Claddings and Doors

Part VI

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

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

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

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.

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Table of Contents
SUMMARY ......................................................................................................................I TABLE OF CONTENTS .................................................................................................... 1 1 2 3 4 INTRODUCTION ....................................................................................................... 1 RESERVES AND RESOURCES OF MATERIALS............................................................. 1 CHARACTERISATION AND USE OF THE MATERIALS ..................................................... 1 SYSTEM CHARACTERISATION .................................................................................. 2
4.1 Process description ................................................................................................................ 2
4.1.1 4.1.2 4.1.3 4.1.4 4.1.5 4.1.6 4.1.7 4.1.8 Mixing................................................................................................................................... 2 Forming ................................................................................................................................. 2 Green Machining................................................................................................................... 3 Drying ................................................................................................................................... 3 Presinter Thermal Processing................................................................................................ 3 Glazing .................................................................................................................................. 3 Firing..................................................................................................................................... 3 Final Processing .................................................................................................................... 4

4.2 4.3 4.4

Infrastructure ......................................................................................................................... 4 Emissions .............................................................................................................................. 4

4.3.1 4.4.1 4.4.2 4.4.3 4.4.4 Air ......................................................................................................................................... 4 Solid waste ............................................................................................................................ 4 Waste water........................................................................................................................... 4 Ceramics production in ecoinvent......................................................................................... 5 Data quality ........................................................................................................................... 6

Waste..................................................................................................................................... 4

5 6

CUMULATIVE RESULTS AND INTERPRETATION ......................................................... 15 REFERENCES ....................................................................................................... 15

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Part VI: Ceramics

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.

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).

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 combinations 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 nonrefractory fire clay or some combination of clays, fluxes, and silica that, when fired, has properties 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, sanitaryware, 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, chemicalware, insulators, and tableware. Technical ceramics include vitreous ceramic whiteware used for such products as electrical insulation, or for chemical, mechanical, structural, or thermal applications.
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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 classified according to application as electrical, magnetic, optical, chemical, thermal, mechanical, biological, 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
4.1

System Characterisation
Process description

This chapter is mainly based on EPA (1998). The basic steps of ceramic production include raw material procurement, possibly beneficiation, mixing, 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 respective reports. The following paragraphs describe the remaining operations in detail. Sanitary ceramic and ceramic tiles are produced by slurry processing. No powder processing is inventoried 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 processing, 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 compacting 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 casting, 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.

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4.1.3

Green Machining

After forming, the ceramic shape often is machined to eliminate rough surfaces and seams or to modify the shape. The methods used to machine green ceramics include surface grinding to smooth surfaces, blanking and punching to cut the shape and create holes or cavities, and laminating for multilayer 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 commonly 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 temperature 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. Presinter 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 comprised of fine, uniform grains. This process is also referred to as sintering or densification. Firing results 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.
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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 periodic 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, surface coatings are applied to many fired ceramics. Surface coatings are applied to traditional clay ceramics 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 materials, mills, mixers and kilns.

4.3
4.3.1

Emissions
Air

Besides the emissions from heat generation, only dust emissions from the handling of the raw materials 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 m 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
4.4.1

Waste
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.

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Tab. 4.1

Waste water composition (after internal treatment) of sanitary ceramic production in Gmunden (SPAG (2002))

element
Zn Ni Pb Cu Cr Co Cd Ba

measured value
0.012 < 0.05 < 0.05 < 0.01 < 0.05 < 0.05 < 0.016 0.48

value used in this study

1.200E-02 2.500E-02 2.500E-02 5.000E-03 2.500E-02 2.500E-02 8.000E-03 4.800E-01

unit
g/m3 g/m3 g/m3 g/m3 g/m3 g/m3 g/m3 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 (SPAG (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 consumed 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 (SPAG (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 SPAG (2002) (see Tab. 4.2).

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Part VI: Ceramics

Tab. 4.2

Estimation on infrastructure

Factory Year total area sealed area vegetation area built up area paved parking lot building hall building multystorey machines Product output

Wilhelmsburg 2000 2001 88'673 88'673 55'635 55'635 33'038 33'038 44'508 44'508 11'127 11'127 40'057 40'057 35'606 35'606

Gmuden 2000 48'200 19'200 29'000 15'360 3'840 13'824 12'288

Unit Category Remarks 2001 48'200 19'200 29'000 15'360 3'840 13'824 12'288 m2 land use m2 m2 m2 m2 m2 buildings m3 SPAG (2002) SPAG (2002) SPAG (2002) estimation based on photography: 80% of sealed area is built up estimation based on photography: 90% built up area estimation based on photography: 10% built up area, 3 storeys

100'000 100'000 50'000 50'000 kg 4'597'000 5'231'000 3'159'000 4'798'000 kg

machines rough estimation

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 output 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.

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Tab. 4.3

ecoinvent meta information for the ceramic production processes

Name
Location Infrastructure Process Unit DataSet Version

sanitary ceramics, at regional storage

CH 0 kg 2.0 Gate to gate production of sanitary ceramics, including transports of raw materials to factory and of product to Switzerland 1 Sanitrkeramik, ab Regionallager China //Chinaware//Porzellan Data from one producer only. Composition of ceramic might differ from case to case. This dataset refers to oxidic ceramics. 1998 2002 1

ceramic tiles, at regional storage

CH 0 kg 2.0 Gate to gate production of ceramic tiles, including transports of raw materials to factory and of product to Switzerland 1 Keramikplatten, ab Regionallager Steinzeug//stoneware Data from one producer only. Composition of ceramic might differ from case to case. This dataset refers to oxidic ceramics. 1998 2002 1

ceramic plant
CH 1 unit 2.0 Includes land use and materials used in buildings and machinery as well as their disposal 1 Keramikwerk

Included Processes

Amount Local Name Synonyms

General Comment to reference function

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. 2001 2002 1

StartDate EndDate Data Valid For Entire Period Other Period Text Geography text Technology text Representativeness [%] Production Volume Sampling Procedure Extrapolations Uncertainty Adjustments

Data from two factories of one producer in Austria Large scale production in Europe. Gas fired kiln

Data from Italy Large scale, single fired production in Europe. Gas fired kiln Unknown Publication See Geography None

Data from two factories of one producer in Austria Large scale production plant in Europe.

Unknown Environmental report See Geography None

Unknown Environmental report See Geography None

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Part VI: Ceramics

General Flow information Input Process Name Output Remarks Cate gory Sub category Infra struc ture No

Representation in ecoinvent Loca tion Modul name in ecoinvent Mean value Unit Source mean value

Uncertainty information Type StDv 95% General Comment

feldspar recycled production waste kaolin clay silica meal, porcelain meal, refractories ancillary materials oxydic minerals pigments kaolin refractories, silica meal gypsum plastic forms natural gas electricity well water tap water transport transport infrastructure

for ceramic mass for ceramic mass (from in-house production) for ceramic mass for ceramic mass for ceramic mass for ceramic mass for glazing for glazing for glazing for mould for mould for heating total consumption total consumption total consumption

construction materials

others

RER

feldspar, at plant

3.79E-01 8.97E-02

kg kg kg kg kg kg kg kg kg kg kg MJ kWh m3 kg tkm tkm unit

SPAG (2002) SPAG (2002) SPAG (2002) SPAG (2002) SPAG (2002) SPAG (2002) SPAG (2002) SPAG (2002) SPAG (2002) SPAG (2002) SPAG (2002) SPAG (2002) SPAG (2002) SPAG (2002) SPAG (2002) estimated estimated SPAG (2002)

1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1

1.13 1.13 1.13 1.13 1.13 1.13 1.13 1.13 1.13 1.13 1.13 1.13 1.13 1.13 1.13 2.09 2.09 3.02

(1,3,1,3,1,4,3) (1,3,1,3,1,4,3) (1,3,1,3,1,4,3) (1,3,1,3,1,4,3) (1,3,1,3,1,4,3) (1,3,1,3,1,4,3) (1,3,1,3,1,4,3) (1,3,1,3,1,4,3) (1,3,1,3,1,4,3) (1,3,1,3,1,4,4) (1,3,1,3,1,4,4) (1,3,1,3,1,4,1) (1,3,1,3,1,4,2) (1,3,1,3,1,4,4) (1,3,1,3,1,4,4) (4,5,n.A.,n.A., n.A.,n.A.,5) (4,5,n.A.,n.A., n.A.,n.A.,5) (1,3,1,3,1,4,9)

sanitary ceramics, at regional storage; inputs

chemicals construction materials construction materials chemicals construction materials chemicals chemicals construction materials plastics natural gas electricity resource

inorganics additives additives inorganics additives inorganics inorganics binder polymers heating systems production mix in water

No No No No No No No No No No No

RER CH DE GLO DE GLO RER CH RER RER UCTE

kaolin, at plant clay, at mine silica sand, at plant chemicals inorganic, at plant silica sand, at plant chemicals inorganic, at plant kaolin, at plant stucco, at plant polyethylene, HDPE, granulate, at plant natural gas, burned in industrial furnace >100kW electricity, medium voltage, production UCTE, at grid Water, well, in ground

4.08E-01 4.25E-01 2.20E-01 2.75E-03 3.17E-02 2.87E-04 3.63E-02 1.25E-01 1.51E-03 2.41E+01 8.78E-01 1.06E-02 5.41E-01 6.00E-01 8.14E-02 4.00E-09

water supply production train road others

No No No Yes

RER CH RER CH

tap water, at user transport, freight, rail transport, lorry >16t, fleet average ceramic plant

of final product to Switzerland: transport 600 km assumed systems of raw materials to fabrication: 50 km assumed Life time: 50 a; production volume: 5000000 kg/a transport systems construction materials

Fig. 4.1

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

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General Flow information Input Process Name Output Remarks Cate gory Sub category Infra struc ture

Representation in ecoinvent Loca tion Modul name in ecoinvent Mean value Unit Source mean value

Uncertainty information Type StDv 95% General Comment

sanitary ceramics, at regional storage; outputs, part 1

waste ceramic (not sanded) paper waste ceramic (sanded)

internally recycled (substitutes feldspar) recycled contamination from sanding. Cannot be recycled waste sanitary landfill management waste sanitary landfill management waste inert material management landfill recycled in cement plants recycled in brick fabrication waste municipal management incineration waste underground management deposit neglected (for consistency neglected (for consistency neglected (for consistency waste hazardous waste management incineration waste hazardous waste management incineration waste hazardous waste management incineration waste hazardous waste management incineration disposal, solvents mixture, 16.5% water, to hazardous waste incineration disposal, used mineral oil, 10% water, to hazardous waste incineration disposal, used mineral oil, 10% water, to hazardous waste incineration disposal, bilge oil, 90% water, to hazardous waste incineration No CH disposal, municipal solid waste, 22.9% water, to municipal incineration disposal, hazardous waste, 0% water, to underground deposit No CH disposal, inert material, 0% water, to sanitary landfill disposal, inert material, 0% water, to sanitary landfill disposal, inert waste, 5% water, to inert material landfill

8.97E-02 7.59E-03 9.40E-02

kg kg kg

SPAG (2002) SPAG (2002) SPAG (2002)

1 1 1

1.13 1.13 1.13

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

rumble filter material (inert)

No

CH

3.19E-02

kg

SPAG (2002)

1.13

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

No

CH

1.64E-03 1.33E-01 1.85E-01 3.86E-02

kg kg kg kg

SPAG (2002) SPAG (2002) SPAG (2002) SPAG (2002)

1 1 1 1

1.13 1.13 1.13 1.13

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

gypsum clay suspension municipal waste metal containers (soiled)

No

DE

6.85E-05 5.49E-05 2.97E-04 2.06E-05

kg kg kg kg

SPAG (2002) SPAG (2002) SPAG (2002) SPAG (2002)

1 1 1 1

1.13 1.13 1.13 1.13

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

refrigerators lead batteries fluorescent lamps developing agent

No

CH

2.39E-06

kg

SPAG (2002)

1.13

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

used oil

No

CH

1.88E-04

kg

SPAG (2002)

1.13

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

fat oil-water mixtures

No

CH

1.58E-06

kg

SPAG (2002)

1.13

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

No

CH

6.61E-05

kg

SPAG (2002)

1.13

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

Fig. 4.1

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

ecoinvent report No. 7

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Part VI: Ceramics

General Flow information Input Process Name Output Remarks Cate gory Sub category Infra struc ture

Representation in ecoinvent Loca tion Modul name in ecoinvent Mean value Unit Source mean value

Uncertainty information Type StDv 95% General Comment

sanitary ceramics, at regional storage; outputs, part 2

waste from oil interceptor used oil binding agents oil contaminated ancillary materials

waste hazardous waste management incineration waste hazardous waste management incineration waste hazardous waste management incineration

No

CH

No

CH

disposal, bilge oil, 90% water, to hazardous waste incineration disposal, used mineral oil, 10% water, to hazardous waste incineration disposal, used mineral oil, 10% water, to hazardous waste incineration disposal, emulsion paint remains, 0% water, to hazardous waste incineration disposal, plastics, mixture, 15.3% water, to municipal incineration disposal, plastics, mixture, 15.3% water, to municipal incineration disposal, solvents mixture, 16.5% water, to hazardous waste incineration disposal, hazardous waste, 0% water, to underground deposit treatment, ceramic production effluent, to wastewater treatment, class 3 Particulates, < 2.5 um Heat, waste

1.11E-04

kg

SPAG (2002)

1.13

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

6.33E-06

kg

SPAG (2002)

1.13

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

No

CH

8.71E-05

kg

SPAG (2002)

1.13

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

used paints

waste hazardous waste management incineration waste municipal management incineration waste municipal management incineration

No

CH

1.58E-07

kg

SPAG (2002)

1.13

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

uncured resins plastic containers with rest content

No

CH

2.01E-05

kg

SPAG (2002)

1.13

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

No

CH

2.32E-05

kg

SPAG (2002)

1.13

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

chemical wastes

waste hazardous waste management incineration waste underground management deposit waste wastewater management treatment no information in SPAG (2002) air air construction materials unspecified unspecified others

No

CH

6.69E-05

kg

SPAG (2002)

1.13

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

other hazardous wastes

No

DE

3.30E-05

kg

SPAG (2002)

1.13

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

waste water dust emissions from grinding

No

CH

9.83E-04

m3

SPAG (2002)

1.13

(1,3,1,3,1,4,6) (1,3,1,5,1,5,26 ) (1,3,1,3,1,4,13 )

8.71E-03 3.16E+00 1.00E+00

kg MJ kg

EPA (1998) calculated SPAG (2002)

1 1

2.06 1.13

waste heat Sanitary ceramics

No

CH

sanitary ceramics, at regional storage

Fig. 4.1

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

ecoinvent report No. 7

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Part VI: Ceramics

General Flow information Input Process Name Output Remarks Cate gory Sub category Infra struc ture No No No

Representation in ecoinvent Loca tion Modul name in ecoinvent Mean value Unit Source mean value Nicoletti et al. (2002) Nicoletti et al. (2002) Nicoletti et al. (2002) Nicoletti et al. (2002) Nicoletti et (2002) Nicoletti et (2002) Nicoletti et (2002) Nicoletti et (2002) Nicoletti et (2002) Nicoletti et (2002) Nicoletti et (2002) Nicoletti et (2002) Nicoletti et (2002) al. al. al. al. al. al. al. al. al.

Uncertainty information Type StDv 95% General Comment

ceramic tiles, at regional storage; inputs, part 1

clay feldspars soldering materials (feldspars) soldering materials (limestone) silicious and feldspar sands ground fired waste ground raw waste exhausted lime boron concentrate zinc oxide zirconium powders colemanite dolomite penta-hydrate borax quarz and feldspar sands feldspars

for ceramic body for ceramic body for ceramic body; 62.5% of total soldering materials for ceramic body; 37.5% of total soldering materials for ceramic body for ceramic body; reused process waste for ceramic body; reused process waste for ceramic body; reused process waste for ceramic body; reused from water treatment for frit; only metal content of oxide is inventoried as metal for frit; only metal content of oxide is inventoried as metal for frit for frit for frit for frit for frit

construction materials construction materials construction materials construction materials construction materials

additives others others

CH RER RER

clay, at mine feldspar, at plant feldspar, at plant limestone, milled, packed, at plant silica sand, at plant

4.89E-01 2.72E-01 1.02E-01

kg kg kg

1 1 1

1.13 1.13 1.13

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

others additives

No No

CH DE

6.10E-02 1.56E-01 6.67E-03 2.78E-02 2.22E-04 6.67E-03

kg kg kg kg kg kg kg kg kg kg kg kg kg

1 1 1 1 1 1 1 1 1 1 1 1 1

1.13 1.13 1.13 1.13 1.13 1.13 1.13 1.13 1.13 1.13 1.13 1.13 1.13

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

metals chemicals construction materials construction materials washing agents construction materials construction materials

extraction inorganics others others bleaches additives others

No No No No No No No

RER RER CH CH RER DE RER

zinc, primary, at regional storage titanium dioxide, production mix, at plant limestone, milled, packed, at plant limestone, milled, packed, at plant sodium perborate, tetrahydrate, powder, at plant silica sand, at plant feldspar, at plant

3.39E-03 1.83E-02 7.22E-03 9.06E-03 6.11E-03 1.39E-02 1.23E-02

Nicoletti et al. (2002) Nicoletti et al. (2002) Nicoletti et al. (2002)

Fig. 4.2

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

ecoinvent report No. 7

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Part VI: Ceramics

General Flow information Input Process Name Output Remarks Cate gory Sub category Infra struc ture No No No No No No No

Representation in ecoinvent Loca tion Modul name in ecoinvent Mean value Unit Source mean value Nicoletti et (2002) Nicoletti et (2002) Nicoletti et (2002) Nicoletti et (2002) Nicoletti et (2002) al. al. al. al. al.

Uncertainty information Type StDv 95% General Comment

ceramic tiles, at regional storage; inputs, part 2

aluminium oxide lead oxide barium oxide tin oxide titanium oxide electricity heat

for frit; only metal content of oxide is inventoried as metal for frit; only metal content of oxide is inventoried as metal for frit for frit; only metal content of oxide is inventoried as metal for frit general consumption given as primary energy; natural gas assumed no information about material for moulds in Nicoletti et al. (2002) --> half the amount of sanitary ceramic production assumed general consumption internal recycling

chemicals metals chemicals metals chemicals electricity natural gas

inorganics extraction inorganics extraction inorganics production mix heating systems

RER RER RER RER RER UCTE RER

aluminium oxide, at plant lead, at regional storage barite, at plant tin, at regional storage titanium dioxide, production mix, at plant electricity, medium voltage, production UCTE, at grid natural gas, burned in industrial furnace >100kW

3.89E-04 6.65E-03 5.56E-04 4.90E-05 1.11E-04 3.13E-01 5.83E+00

kg kg kg kg kg kWh MJ

1 1 1 1 1 1 1

1.13 1.13 1.13 1.13 1.13 1.13 1.13

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

Nicoletti et al. (2002) Nicoletti et al. (2002) assumption, based on SPAG (2002) Nicoletti et al. (2002) Nicoletti et al. (2002) estimated estimated SPAG (2002)

gypsum

construction materials

binder

No

CH

stucco, at plant

6.23E-02

kg

1.24

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

water recycled water transport transport infrastructure

water supply production

No

RER

tap water, at user

6.67E-01 6.67E-04

kg m3 tkm tkm unit

1 1 1 1 1

1.13 1.13 2.09 2.09 3.02

(1,3,1,3,1,4,4) (1,3,1,3,1,4,4) (4,5,n.A.,n.A., n.A.,n.A.,5) (4,5,n.A.,n.A., n.A.,n.A.,5) (1,3,1,3,1,4,9)

of final product to Switzerland: transport 600 km assumed systems of raw materials to fabrication: 50 km assumed Life time: 50 a; production volume: 5000000 kg/a transport systems construction materials

train road others

No No Yes

CH RER CH

transport, freight, rail transport, lorry >16t, fleet average ceramic plant

6.00E-01 6.10E-02 4.00E-09

Fig. 4.2

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

ecoinvent report No. 7

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Part VI: Ceramics

General Flow information Input Process Name Output Remarks Cate gory Sub category Infra struc ture

Representation in ecoinvent Loca tion Modul name in ecoinvent Mean value Unit Source mean value

Uncertainty information Type StDv 95% General Comment

ceramic tiles, at regional storage; outputs

waste water to internal recyclilng waste water after internal pre-treatment sludge from waste water treatment to external recycling sludge from waste water treatment to landfill wastes to internal recycling wastes to external recycling wastes to disposal dust emissions to air

recycled to wet grinding treatment, ceramic production effluent, to wastewater treatment, class 3

6.67E-04

m3

Nicoletti et al. (2002) Nicoletti et al. (2002)

1.13

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

to external treatment

waste wastewater management treatment

No

CH

2.00E-05

m3

1.13

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

not inventoried

2.22E-03

kg

Nicoletti et al. (2002)

1.13

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

assumed to be hazardous waste waste underground because it can not be recycled management deposit

No

DE

disposal, hazardous waste, 0% water, to underground deposit

1.11E-03

kg

Nicoletti et al. (2002) Nicoletti et al. (2002) Nicoletti et al. (2002) Nicoletti et al. (2002) EPA (1998), size assumed calculated

1.13

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

not inventoried

3.47E-02

kg

1.13

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

not inventoried assumed to be hazardous waste underground wastes because they can not be management deposit recycled Value for comminution and glace spray booth (controlled) air air construction materials unspecified unspecified coverings No CH disposal, hazardous waste, 0% water, to underground deposit Particulates, < 2.5 um Heat, waste ceramic tiles, at regional storage

3.29E-02

kg

1.13

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

No

DE

8.50E-03

kg

1.13

(1,3,1,3,1,4,6) (1,3,1,5,1,5,28 ) (1,3,1,3,1,4,13 )

8.71E-03 1.13E+00 1.00E+00

kg MJ kg

1 1

1.32 1.13

waste heat tiles (product)

Fig. 4.2

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

ecoinvent report No. 7

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Part VI: Ceramics

General Flow information Input Process Name Output Remarks Cate gory Sub category Infra struc ture

Representation in ecoinvent Loca tion Modul name in ecoinvent Mean value Unit Source mean value

Uncertainty information Type StDv 95% General Comment

total area transformed transformed to vegetation area transformed to built up area transformed to paved parking lot occupation as vegetation area occupation as built up area occupation as paved parking lot building hall building multystorey machines

resource resource

land land

Transformation, from unknown Transformation, to industrial area, vegetation Transformation, to industrial area, built up Transformation, to traffic area, road network Occupation, industrial area, vegetation Occupation, industrial area, built up Occupation, traffic area, road network Yes CH building, hall

7.69E+04 3.59E+04

m2 m2

SPAG (2002) SPAG (2002)

1 1

2.02 2.02

(1,3,1,3,1,4,8) (1,3,1,3,1,4,8)

resource

land

3.28E+04

m2

SPAG (2002)

2.03

(3,3,1,3,1,4,8)

resource

land

8.20E+03

m2

SPAG (2002)

2.03

(3,3,1,3,1,4,8)

ceramic plant

resource resource resource construction processes construction processes construction processes machines to recycling Life time: 50 a; production volume: 5000000 kg/a construction materials

land land land

1.80E+06 1.64E+06 4.10E+05

m2a m2a m2a

SPAG (2002) SPAG (2002) SPAG (2002) assumption, based on SPAG (2002) assumption, based on SPAG (2002) assumption

1 1 1

1.54 1.54 1.54

(3,3,1,3,1,4,7) (3,3,1,3,1,4,7) (3,3,1,3,1,4,7)

buildings

2.95E+04

m2

3.03

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

buildings

Yes

RER

building, multi-storey industrial machine, heavy, unspecified, at plant

2.63E+04

m3

3.03

(3,3,1,3,1,4,9) (5,n.A.,n.A.,n. A.,n.A.,n.A.,9) (5,n.A.,n.A.,n. A.,n.A.,n.A.,9)

machinery

Yes

RER

1.68E+05

kg

3.23

1.68E+05 others Yes CH ceramic plant 1.00E+00

kg unit

assumption

3.23

ceramic plant

Fig. 4.3

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

ecoinvent report No. 7

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Part VI: Ceramics

Cumulative Results and Interpretation

The cumulative results can be downloaded from the ecoinvent Database (www.ecoinvent.org).

References
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 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 Cycle Inventories, Dbendorf, CH, Online-Version under: www.ecoinvent.ch. 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. SPAG (2002) SPAG Umwelterklrungen 2002 fr die Standorte Gmunden und Wilhelmsburg (vereinfachte Version). SPAG-Laufen, Gmunden.

EPA (1998)

Frischknecht et al. (2007)

Nicoletti et al. (2002)

SPAG (2002)

ecoinvent report No. 7

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