ENVIRONMENTAL PRODUCT DECLARATION
as per ISO 14025
Owner of the Declaration
Publisher
Programme operator
Declaration number
Issue date
Valid to
Çimsa Çimento San. ve Tic. A.Ş.
Institut Bauen und Umwelt (IBU)
Institut Bauen und Umwelt (IBU)
EPD-CIM-2012111-E
21.03.2012
20.03.2017
CEM IV / B(P)32,5R
Çimsa Çimento San. Ve Tic. A.Ş.
2 Environmental Product Declaration Çimsa Çimento San. ve Tic. A.Ş. – CEM IV / B(P)32,5R
1
Summary
Çimsa Çimento San. Ve Tic. A.Ş.
CEM IV / B(P)32,5R
Programme holder
IBU - Institut Bauen und Umwelt e.V. Rheinufer 108
D-53639 Königswinter
Owner of the Declaration
Çimsa Çimento San. Ve Tic. A.Ş.
Malatya Karayolu 35. km Bünyan,Kayseri – Turkey
Declaration number
EDP-CIM-2012111-E
Declared product / Declared unit
CEM IV / B(P)32,5R / 1 t
This Declaration is based on the Product Category Rules:
Requirements on the EPD for Cement, 11-2011]
(PCR tested and approved by the independent expert committee (SVA))
Scope:
Within this study a life cycle analysis according to ISO 14040/44 is performed for CEM IV / B(P)32,5R pozzolanic cement produced by Çimsa Çimento San. ve Tic. A.Ş. at the production plant located in Kayseri. This analysis relies on transparent, plausible and documented basis data. All the model assumptions, which influence the results, are de-clared. The life cycle assessment is representative for the products introduced in the declaration for the given system boundaries. The life cycle assessment covers the manufac-turing of the products from cradle to gate. The declaration holder is liable for underlying data and supporting docu-ments.
Verification
The CEN standard EN 15804 serves as the core PCR. Verification of the EPD by an independent third party as per
ISO 14025
Prof. Dr.-Ing. Horst J. Bossenmayer
(President of the Institut Bauen und Umwelt e.V.) internally x externally
Prof. Dr.-Ing. Hans-Wolf Reinhardt (Chairman of the SVA)
Dr. Eva Schmincke (Verifier appointed by the SVA)
2
Product
2.1 Product description
The product considered is pozzolanic cement. This product is produced by grinding clinker, gypsum, and pozzolanic materials (mineral additives). The composi-tion of this product is in accordance with the TS EN 197-1:2002 for CEM IV/B (P) 32,5 R cement. CEM IV/B (P) 32,5R cement is produced by grinding of the mixture composed from mineral additives (pozzolanic materials), portland cement clinker, and gypsum.
2.2 Application
CEM IV/B (P) 32,5R pozzolanic cement is used for creation of concrete types which do not require high strength and in manufacturing of briquette. It is also used in reinforced concrete structures and lean concrete structures. Another field of application is preparation of plaster mesh, masonry mortar, and surface / ground concrete. This type of cement is used in construction of sidewalks, parks, gardens, and architectural buildings.
2.3 Technical Data
Appearance and smell: Gray powder and scentless Solubility in Water: Negligible (0.1-1 M-%) pH in water : 12-13
Specific gravity: 2,82 g/cm3 Initial setting time : 180 min
Early strength: 17Mpa Nt/mm2 Standard strength: 37 Mpa Nt/mm2
2.4 Placing on the market / Application rules
Cement- Part 1: Compositions and conformity crite-ria for common cements TS EN 197-1.
2.5 Delivery status
Specific gravity : 2,82 g/cm3 Blaine fineness : 4710 cm2/g Color: Light green
Quantity: 50 kg/package, 25 - 30 t in case of bulk deliveries
2.6 Base materials / Ancillary materials
Clinker: 45- 64 (M-%)
Natural Puzzolan: 36-55 (M-%) Minor Additional component: 0-5 (M-%) Gyspum: (2-2,5 M-%)
Grinding aid and strength enhancing chemicals are used as additional auxilary materials.
2.7 Manufacture
During the manufacturing process it is aimed to pro-duce the most suitable product (cement- CEM/IV B (P) 32,5R) in terms of quality requirements and
cus-Issue date
10.03.2012
Valid to
tomer needs. Therefore, the production process is optimized in which natural trass is used maximally and the GHG emissions are minimized.
Raw materials are gathered after required tests are performed in the raw material quarries. The raw ma-terials which provide the required quality are carried with trucks to the production plant. After arrival of the raw materials at the production plant, they are crushed by the crusher. After crushing, the raw ma-terials are stored in the storage area. Before use of raw materials, a second set of tests are performed to examine, if they comply with the relevant stan-dards. The raw material mixture, which consists of limestone and clay, is fed to the raw mill for grinding. Raw meal is transfered to the raw meal silo. Then, the raw meal is fed to thekiln system. In the rotating kiln the clinker production takes place and the clink-er is transfclink-erred to the clinkclink-er coolclink-er. Aftclink-er the cooling process the clinker is transferred to the clinker storage. Next step, the clinker is fed to the roller press for the realization of the comminution process. After comminution is completed crumbled clinker is transferred to the cement mills. Grinding aids are used in cement mills to ease the grinding of the clinker. Different cement types are produced at the production plant other than CEM IV/B (P) 32,5R. According to the type of cement additives are added to the crumbled clinker. There are three different additives used in the production process. These are limestone, gypsum, and trass. The amount and type of the additive differs according to the cement type. The amounts of compounds/materials are adjusted according to the quality control analysis done by the operators. Samples are taken according to the pe-riods which are predefined in the quality plan. Cement which is produced in the cement mills ac-cording to the standards are transferred to the ultimate cement silos. Daily samples are taken from the product and controlled according to the stan-dards.
According to the preferences of clients the product is sold as packaged cement or as bulk cement. Samples are taken from the products before they are sent to clients and quality control of the product is performed. The quality control is included in every step of the whole production process. The process flow is demonstrated in Figure 1.
Figure 1 – Process flow diagramm
2.8 Environment and health during manufac-turing
Environmental friendly technologies are applied at the production plant. All raw materials and products are stored in closed storages .Bag filters are used to prevent dust emissions during transportation of the materials. Additionally, natural pozzolan is dried through the waste gas derived from the rotary kiln. Fossil fuels are not used for drying process of natu-ral pozzolan. Natunatu-ral pozzolan is used to reduce CO2 emissions during production. The plant owns
Environmental Management System Certificate TS EN ISO 14001.
The Plant has TS EN 16001 Energy Management System which is used to decrease specific energy consumption and emissions. GHG emissions are reduced as a result of the systematic management of energy.
In order to be able to minimize and avoid risks dur-ing manufacturdur-ing various preventions are taken at the production facility. Additionally, personal protec-tive equipments such as safety shoes, helmets, glasses, gloves, dust masks, ear protection and vi-sors are used in case of dust, noise, heat, welding glows etc.
Work permission procedures such as energy cutting procedure, permission for working at heights and hot zones, permission for entering closed containers are implemented at the plant. All these measures and preventions are applied in accordance with the effective Turkish legislation on health and safety. The plant owns Occupational Health and Safety Management System Certificate TSE ISG OHSAS TS 18001:2008.
2.9 Product processing / Installation
The raw materials are stored in closed storages. In addition, the 5 stage pre – calcination unit generates low NOX emissions. In order to reduce the dust
generated during the production process and to comply with the Turkish regulations on incineration of waste and control of air pollution caused by in-dustries, all stacks are equipped with electrostatic and bag filters. The wastewater generated in the plant is collected via a sewerage system and is treated in the biological wastewater treatment plant, before it is discharged. The discharged wastewater complies with the requirements of the Turkish regu-lation on the control of wastewater treatment. In order to reduce noise level during production process steps, sources of noise and workers’ am-bients are enclosed. In addition, noise level of the equipments is measured and evaluated with respect to Turkish regulations as well as sign boards, which are placed to warn the employees to take the ne-cessary precautions. NOX, SO2, TOC, HCl, HF and
heavy metals emission measurements are per-formed according to the requirements of the Turkish regulation on control of air pollution caused by in-dustries. The measurement results are below the limit value set by the regulation.
2.10 Packaging
Paper bags are used for packaging. Packaging ma-terials are collected separately and sent to licensed companies for recovery. In 2010, 37% of packaging waste is sent to recovery. The End-of-life stage of packaging materials is not part of this study.
4 Environmental Product Declaration Çimsa Çimento San. ve Tic. A.Ş. – CEM IV / B(P)32,5R
2.11 Condition of use
In case of exposure to dust it can cuase irritation of upper respiratory tract, cough, dyspnea and wheez-ing. According to the material safety data sheet of cement, pozzolanic cement may contain crystal sili-ca, which may generate risk of cancer. In order to keep the dust level under the required level set by OSHA, MSHA and ACGIH, filtration systems (gen-eral and local) have to be used. If it is not possible to decrease the dust level under the limit value by the use of general and local filtration systems, dust masks must be used.
2.12 Environment and health during use
According to the material safety data sheet of ce-ment, the presence of Cr+6 may cause drying, chaps, and irritation on skin in case of exposure to dry cement. Direct contact of wet cement with the skin may cause burning of the skin and some other skin diseases. In order to prevent direct contact of cement with the skin, gloves (impermeable and re-sistant to alkali pH), boots, long – sleeved shirts, long trousers should be used.
2.13 Reference service life
In the scope of this study only the production stage information module (from A1 to A3) is declared. As stated in FprEN 15804 the reference service life has to be declared only in EDPs which cover the use stage. As the EPDs prepared for CEM IV/B (P) 32,5R do not cover the use stage, the reference service life of these product groups is not declared.
2.14 Extraordinary effects Fire
The mentioned product CEM IV/B (P) 32,5R be-longs to the A1 non flammable category according
to DIN 4102, TS EN 13501 (Construction products Fire Classification), and Communication on Building Material Response Classes of Fire, Fire Resistance of Building Elements and Fire Performance of Roofs and Roof Coatings in the scope of the Construction Product Directive (89/106/EEC).
Water
After cement has been processed and turned into concrete-plaster, it undergoes a very weak alkaline reaction with water. Attention should be paid to con-tact with water used during fire extinguishing. Leaking of cement, should be avoided into drains, since cement builds up a mixture with water and solidifies within between 1 and 6 hours. Solidified cement can clog the water and sewage channels.
Mechanical destruction
Mechanical destruction of the product does not cause any hazards.
2.15 Re-use phase
There are no applications about the re – use of the mentioned product.
2.16 Disposal
The disposal activities of the product are realized according to the 27th Clause of the Regulation on Control of Excavation Soil and Construction Waste (date of issue: 18.03.2004, Turkish Official Journal Number: 25406 (Reg. 25406). As cement is used for production of concrete and bricks as raw material, the corresponding waste code according to the Eu-ropean Waste Catalogue can be defined as 17 01 01 or 17 01 02.
2.17 Further information
No further information is given about the product.
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LCA: Calculation rules
3.1 Declared unit
The declared unit is 1 t of CEM IV/B (P)32,5R.
3.2 System boundary
Type of EPD: cradle to gate
The system boundary includes the production of CEM IV/B (P) 32,5R pozzolanic cement from extrac-tion of raw material to the producextrac-tion of finished packaged product at the factory gate (cradle to gate).
In this study, the product stage information modules A1, A2, and A3 are considered. These modules in-clude production of raw material extraction and processing (A1), processing of secondary material input (A1), transport of the raw materials to the manufacturer (A2), manufacturing of the product (A3) and the packaging materials (A3).
3.3 Estimates and assumptions
All estimations and assumptions regarding the cut off criteria and the allocation are declared within the related parts of this section 3 “LCA: Calculation rules”. There are no other additional estimations and/or assumptions in the scope of this study.
3.4 Cut-off criteria
Criteria for the exclusion of inputs and outputs (cut-off rules) in the LCA and information modules and
any additional information are intended to support an efficient calculation procedure.
All inputs and outputs to a (unit) process are in-cluded in the calculation, for which data were available. The applied cut – off criteria is 1 % of re-newable and non-rere-newable primary energy usage and 1 % of the total mass input of that unit process in case of insufficient input data or data gaps for a unit process.
The total of neglected input flows per module, e.g. per module A, B, C or D is a maximum of 5 % of energy usage and mass.
3.5 Background data
Background processes are taken from the publicly available professional GaBi 4.4 databases as far as available (GaBi DOC 2010). Country and region specific data on energy sources including electricity and region specific data on raw materials such as limestone and clay and gypsum were taken from GaBi databases.
3.6 Data quality
The process data and the used background data (GaBi DOC 2010) are consistent. In addition, the origin of the data is documented. Additional informa-tion is gathered regarding the age of the data. The input and output data of the whole process plant was strongly emphasized. The supplied data
(processes) were provided by Çimsa Çimento San. ve Tic. A.Ş and checked for plausibility. Therefore, the data quality can be described as good.
All data applied in this study are not older than 5 years.
3.7 Period under review
The period under review is defined as one year. The monthly data is collected by the producer and is av-eraged to obtain the yearly data. As explained here, the average data for the year 2010 is utilized within this study.
3.8 Allocation
There are four co-products in the manufacturing of CEM IV/B (P) 32,5R which can be listed as: CEM I 42,5 R, CEM II A/M (P-L) 42,5R, CEM IV/B(P) 32,5R. In this case an allocation per mass is applied for these products, since the production of all the products shows the same manufacturing procedure, but only the amount of raw materials and the sort of the auxiliary materials differs from each other. Therefore, the data related these materials (the amount of raw materials and the auxiliary materials consumed during production of CEM IV/B (P) 32,5R) are collected separately. The data for CEM
IV/B (P) 32,5R except for the data related to the raw materials and the auxiliary materials is calculated by multiplying the yearly total production values with the percentage (considering the yearly mass of all the different products) of CEM IV/B (P) 32,5R out of the total production.
In addition to this co – product allocation, the sec-ondary and primary fuels and direct emissions were allocated by the content of the clinker. This alloca-tion was performed in which the product output was fixed to 1 t and the corresponding clinker amount for 1 t of product was calculated. In the next stage the allocation of primary and secondary fuels and direct emissions was realized accordingly. On the other hand, the allocation of waste, cardboard effort, and power was performed according to the product out-come which is fixed to 1 t in the model.
3.9 Comparability
Basically, a comparison or an evaluation of EPD da-ta is only possible if all the dada-ta sets to be compared were created according to EN 15804 and the build-ing context, respectively the product-specific characteristics of performance, are taken into ac-count.
4
LCA: Scenarios and additional technical information
The modules A4, A5, B1, B2, B3, B4, B5, referenceservice life, B6, B7 and C1 – C4 are not considered and declared in this study.
6 Environmental Product Declaration Çimsa Çimento ve San. ve Tic. A.Ş. – CEM IV / B(P)32,5R
5
LCA: Results
DESCRIPTION OF THE SYSTEM BOUNDARY (X = INCLUDED IN LCA; MND = MODULE NOT DECLARED)
PRODUCT STAGE
CONSTRUCTION PROCESS
STAGE
USE STAGE END OF LIFE STAGE
BENEFITS AND LOADS BEYOND THE SYSTEM BOUNDARYS R a w m a te ri a l s u p p ly T ra n s p o rt M a n u fa c tu ri n g T ra n s p o rt C o n s tr u c ti o n -i n s ta lla ti o n p ro c e s s U s e M a in te n a n c e R e p a ir R e p la c e m e n t R e fu rb is h m e n t O p e ra ti o n a l e n e rg y u s e O p e ra ti o n a l w a te r u s e D e -c o n s tr u c ti o n d e m o lit io n T ra n s p o rt W a s te p ro c e s s in g D is p o s a l R e u s e - R e c o v e ry - R e c y c lin g - p o te n ti a l A1 A2 A3 A4 A5 B1 B2 B3 B4 B5 B6 B7 C1 C2 C3 C4 D X X X
RESULTS OF THE LCA - ENVIRONMENTAL IMPACT: 1 t CEM IV/B (P) 32,5R Manufacturing
Parameter Unit A1- A3
GWP [kg CO2-Äq.] 581.7 ODP [kg CFC11-Äq.] 1.15E-06 AP [kg SO2-Äq.] 2.16 EP [kg PO4 3-- Äq.] 0.07 POCP [kg Ethen Äq.] 0.11 ADPE [kg Sb Äq.] 8.98E-04 ADPF [MJ] 2865 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 RESULTS OF THE LCA - RESOURCE USE: 1 t CEM IV/B (P) 32,5R
Manufacturing Parameter Unit A1 - A3 PERE [MJ] 152.7 PERM [MJ] 0 PERT [MJ] 152.7 PENRE [MJ] 3029 PENRM [MJ] 0 PENRT [MJ] 3029 SM [kg] 0 RSF [MJ] 0 NRSF [MJ] 0.13 FW [m³] 0.15 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 re-sources; SM = Use of secondary material; RSF = Use of renewable secondary fuels; NRSF = Use of non renewable secondary
fuels; FW = Use of net fresh water RESULTS OF THE LCA – OUTPUT FLOWS AND WASTE CATEGORIES: 1 t CEM IV/B (P) 32,5R Manufacturing Parameter Unit A1 - A3 HWD [kg] 9.81E-03 NHWD [kg] 581 RWD [kg] 1.45E-02 CRU [kg] MFR [kg] MER [kg] EE [MJ] EE [MJ]
Caption HWD = Hazardous waste disposed; NHWD = Non hazardous waste disposed; RWD = Radioactive waste disposed; CRU = Com-ponents for re-use; MFR = Materials for recycling; MER = Materials for energy recovery; EE = Exported energy per energy carrier
6
LCA: Interpretation
The use of non - renewable sources is very high compared to the use of renewable sources. The reason for this is the distribution of the energy sources in the power grid mix and the type of fuels (petrol coke, lignite, fuel oil) used during production. In addition, the primary energy input regarding the resources (renewable and non renewable) used as raw materials is zero, since the raw materials used in cement production are inorganic materials and do not have a calorific value.
The net fresh water utilization is quite low 0.15 m3, since the cement manufacturing process requires only small amount of water. A significant amount of water usage is due to the pre-processes of the raw materials used in the production process and the power grid mix.
Similar to the case of water utilization, some frac-tions of the waste is generated due to the pre –
processes of raw materials and the power grid mix. Although radioactive compounds are not used in the manufacturing process itself, a small amount of ra-dioactive waste appears on the results. This small amount arises due to the power grid mix and pre – processes of petrol coke.
All impact categories, with the exception of Abiotic Depletion Potential Elements (ADPE), are domi-nated by the influence of the clinker production process and the power grid mix. The primary energy sources utilized by clinker production process such as petrol coke, fuel oil, and lignite constitute a sig-nificant amount of environmental burdens along with the power grid mix.
The use of gypsum as a raw material for the de-clared product CEM IV/B (P) 32,5R also contributes to the environmental impacts. The impact of gypsum can be observed through its contribution to ADPE.
7
Requisite evidence
7.1 Radioactivity
Measurement of the nuclide-content in Bq/kg for Ra-226, Th-232, K-40 is performed on the sample of the product CEM IV/B (P) 32,5R by the application of Gamaspectrometric Method ASTM E 181: 2003. The analysis was performed by Turkish Atomic Energy Authority Sarayköy Nuclear Reasearch and Training Center on 29 December 2011. The stat-ment about the evaluation of the results is made according to the limit values stated in the Document of the European Comission „Radiation Protection 112“. The measurement results are below the defined limit values, therefore the use of the product as building material do not cause any radiological harm. The report regarding the test results is
presented as an evidence in form of a seperate document to this EPD.
7.2 Chromate
Measurement of Cr (VI) is performed on the sample of the product CEM IV/B (P) 32,5R by the applica-tion of the experimental standard TS EN 196 – 10 (DS 1020). The analysis was performed by the Tur-kish Cement Producers’ Association on 14 December 2011. The report indicates that the sam-ple of the Cr (VI) content of the product is 0.8 ppm, which is below the limit value (2 ppm) set within the scope of the the European Regulation (EC) 1907/2006 "REACH Regulation" and the Prohibition of Chemicals Ordinance. The report regarding the test results is presented as an evidence in form of a seperate document to this EPD.
8
References
Institut Bauen und Umwelt 2011
Institut Bauen und Umwelt e.V., Königswinter (pub.): Generation of Environmental Product Declarations (EPDs); General principles for the EPD range of In-stitut Bauen und Umwelt e.V. (IBU), 2011-06 www.bau-umwelt.de
PCR 2011, Part A
Institut Bauen und Umwelt e.V., Königswinter (pub.): Product Category Rules for Construction Products from the range of Environmental Product Declara-tions of Institut Bauen und Umwelt (IBU), Part A: Calculation Rules for the Life Cycle Assessment and Requirements on the Background Report. July 2011
www.bau-umwelt.de
PCR 2011, Part B
Institut Bauen und Umwelt e.V., Königswinter (pub.): Product Category Rules for Construction Products from the range of Environmental Product Declara-tions of Institut Bauen und Umwelt (IBU), Part B: Requirements on the EPD for Cement
www.bau-umwelt.de
ISO 14025
DIN EN ISO 14025:2009-11: Environmental labels and declarations — Type III environmental declara-tions — Principles and procedures
FprEN 15804
FprEN 15804:2011-04: Sustainability of construction works — Environmental Product Declarations — Core rules for the product category of construction products
Publisher
Institut Bauen und Umwelt e.V. Tel. +49 (0)2223 2966 79- 0
Rheinufer 108 Fax +49 (0)2223 2966 79- 0
53639 Königswinter E-mail [email protected]
Germany Web www.bau-umwelt.com
Programme holder
Institut Bauen und Umwelt e.V. Tel. +49 (0)2223 2966 79- 0
Rheinufer 108 Fax +49 (0)2223 2966 79- 0
53639 Königswinter E-mail [email protected]
Germany Web www.bau-umwelt.com
Owner of the Declaration
Çimsa Çimento ve San. ve Tic. A.Ş. Tel. +90 352 712 1607
Malatya Karayolu 35. km Fax: +90 352 712 2259
Bünyan,Kayseri E-mail: [email protected]
Tukey Web www.cimsa.com.tr
Author of the Life Cycle Assessment
PE INTERNATIONAL AG Tel. +90 212 244 6780
Gümüşsuyu Mah. İsmet İnönü Cad. Fax: +90 212 244 6782
Park Palas 23/7 Beyoğlu İstanbul E-mail: [email protected]
