life cycle analysis of dimensional stones production · 9the environmental impact of ceramic tiles...

NATIONAL TECHNICAL UNIVERSITY OF ATHENSNATIONAL TECHNICAL UNIVERSITY OF ATHENSDEPARTMENT OF MINING AND METALLURGICAL ENGINEERINGDEPARTMENT OF MINING AND METALLURGICAL ENGINEERINGLABORATORY OF METALLURGYLABORATORY OF METALLURGYGRGR--157 80 ZOGRAFOS, ATHENS157 80 ZOGRAFOS, ATHENSGREECEGREECE

Life Cycle Analysis of dimensional stones Life Cycle Analysis of dimensional stones productionproduction

M. M. TaxiarchouTaxiarchou, I. , I. KostopoulouKostopoulou

SDIMI SDIMI 20072007JuneJune 20072007, , MilosMilos, Greece, Greece

Dimensional StonesDimensional Stones

Natural stonesNatural stones been extracted been extracted from the earth in an orderly from the earth in an orderly manner, further worked by manner, further worked by cutting and processing and cutting and processing and then used in various building then used in various building activities either structurally or activities either structurally or for decorative purposesfor decorative purposes

Dimensional Stones (marble, granite, Dimensional Stones (marble, granite, limestone, etc.), due to their limestone, etc.), due to their unique unique

aesthetical and technical aesthetical and technical characteristicscharacteristics, have been , have been

extensively used for construction extensively used for construction purposes and are still preferred by purposes and are still preferred by

architects, engineers and consumers architects, engineers and consumers as as a first choice materiala first choice material in in

construction applicationsconstruction applications for for facades, floors, stairs, monuments, facades, floors, stairs, monuments,

open spaces, pavementsopen spaces, pavements, etc., etc.No other material has managed to No other material has managed to

attain the importance of marble and attain the importance of marble and granite in these applications.granite in these applications.

Dimensional Stones in constructionDimensional Stones in construction

Global Stone ProductionGlobal Stone Production

050

100150200250300350

1995 2005 2015 2025year

raw

mat

eria

l(M

t)

Trend of stone production

Expected annual

increase: 7,7%

Raw materialRaw materialGrowth rate:Growth rate: 260% (1986260% (1986--2003)2003)Value:Value: 20 billion 20 billion €€ for 2003for 2003

Finished productsFinished productsGrowth rate:Growth rate: 61% (199661% (1996--2003) 2003) Value:Value: 35 billion 35 billion €€ for 2003for 2003

The world stone production The world stone production and the volume of the global and the volume of the global

stone market will experience a stone market will experience a five time increasefive time increase until 2025until 2025

0

10

20

30

40

50

60

70

1926 1946 1966 1986year

raw

mat

eria

ls(M

t)

1986-2000average annualincrease: 7%

1926-1986average annualincrease: 1,6%

World stone production

Characteristics of the Stone IndustryCharacteristics of the Stone Industry

Although stones are inert materials, their Although stones are inert materials, their production has considerable environmental production has considerable environmental impacts:impacts:

Very low efficiencyVery low efficiency (in quarrying only 20(in quarrying only 20--25% of the original deposit is turned into 25% of the original deposit is turned into marketable product)marketable product)Huge amounts of wastesHuge amounts of wastes produced and produced and disposed in the environmentdisposed in the environmentExtended land useExtended land use for waste disposalfor waste disposalQuarries have significantQuarries have significant visual impactvisual impactIncreased dust productionIncreased dust production in quarrying in quarrying operationsoperationsHigh water consumptionHigh water consumption

These problems can be addressed by intelligent design These problems can be addressed by intelligent design of the production chainof the production chain

LCA (LCA (Life Cycle Analysis)Life Cycle Analysis)is a promising tool for this purpose as it is a promising tool for this purpose as it

provides the possibility to perform environmental provides the possibility to perform environmental improvements in combination with the rational use of improvements in combination with the rational use of

raw materials and energyraw materials and energy

What is LCA?What is LCA?

An objective methodology to measure and evaluate An objective methodology to measure and evaluate the environmental burdens associated with a product the environmental burdens associated with a product system or service by describing and assessing energy system or service by describing and assessing energy

and materials used and emissions released to the and materials used and emissions released to the environment over the life cycle.* environment over the life cycle.*

* B S / I S O 1 5 6 8 6 : S e r v i c e L i f e P l a n n i n g* B S / I S O 1 5 6 8 6 : S e r v i c e L i f e P l a n n i n g

Purpose of this studyPurpose of this study

TheThe LCALCA ofof marble and granite production cyclemarble and granite production cycle

aiming to evaluate their potential effects to the aiming to evaluate their potential effects to the

environment and to human healthenvironment and to human health

Goal and Scope Definition:Goal and Scope Definition: define the define the system to be studied, its boundaries system to be studied, its boundaries and the environmental effects to be and the environmental effects to be reviewed for the assessmentreviewed for the assessment

Inventory Analysis:Inventory Analysis: identify and identify and quantify energy and material inputs quantify energy and material inputs and environmental releasesand environmental releases

Impact Assessment:Impact Assessment: assess the human assess the human and ecological effects of the Inventory and ecological effects of the Inventory Analysis inputs and releasesAnalysis inputs and releases

Interpretation:Interpretation: evaluate the results of evaluate the results of the Inventory Analysis and the the Inventory Analysis and the Impact Assessment to take the proper Impact Assessment to take the proper decisions for reducing the decisions for reducing the environmental effects of the systemenvironmental effects of the system

Stages of LCA methodologyStages of LCA methodologySC

OPI

NG

SCO

PIN

G

IMPR

OV

EM

EN

TIM

PRO

VE

ME

NT

GoalGoaldefinitiondefinition

InventoryInventoryanalysisanalysis

ImpactImpactassessmentassessment

Studied materialsStudied materials

The two most commercial The two most commercial ornamental stones in the ornamental stones in the European market have been European market have been selected:selected:

Marble:Marble: indicative example indicative example of calcareous (soft) stonesof calcareous (soft) stones

Granite:Granite: indicative example indicative example of siliceous (hard) stonesof siliceous (hard) stones

Goal and Scope DefinitionGoal and Scope Definition

Goal of the LCA studyGoal of the LCA study:: determine the environmental load determine the environmental load associated with the production processes of marble and granite, associated with the production processes of marble and granite, to to compare their environmental profiles and identify the weak compare their environmental profiles and identify the weak points of each system.points of each system.

SystemSystem:: the set of processes that constitute the the set of processes that constitute the extractionextraction and and processingprocessing of marble and granite blocks, and the of marble and granite blocks, and the transportationtransportationbetween the quarry and the processing plant.between the quarry and the processing plant.

Calculation unitCalculation unit:: quarrying: quarrying: 1 ton1 ton ofof marble or granite marble or granite blockblock

processing: processing: 1 ton of final product1 ton of final product (slab, tile) (slab, tile)

SOLID WASTES, SOLID WASTES, GAS EMISSIONS,GAS EMISSIONS,SLURRIES, DUSTSLURRIES, DUST

NOISENOISE

PRODUCTSPRODUCTS

BANK SPLITTING TO BANK SPLITTING TO COMMERCIAL SIZE BLOCKSCOMMERCIAL SIZE BLOCKS

RAW MATERIALSRAW MATERIALS

ENERGYENERGY

MATERIAL MATERIAL CONSUMPTIONCONSUMPTION

MARBLE AND GRANITE MARBLE AND GRANITE EXTRACTIONEXTRACTION

IINNPPUUTTSS

OOUUTTPPUUTTSS

BANK BANK EXTRACTION EXTRACTION

FROM DEPOSITFROM DEPOSIT

BANK BANK OVERTURNINGOVERTURNING

BANK SPLITTING BANK SPLITTING TO COMMERCIAL TO COMMERCIAL

SIZE BLOCKSSIZE BLOCKS

TRANSPORTATIONTRANSPORTATION

System boundariesSystem boundaries

SOLID WASTES, SOLID WASTES, GAS EMISSIONS,GAS EMISSIONS,SLUDGES, DUSTSLUDGES, DUST

NOISENOISE

PRODUCTSPRODUCTSIINNPPUUTTSS

RAW RAW MATERIALSMATERIALS

ENERGYENERGY

MATERIAL MATERIAL CONSUMPTIONCONSUMPTION

OOUUTTPPUUTTSS

MARBLE AND MARBLE AND GRANITE PROCESSINGGRANITE PROCESSING

STRIP STRIP CALIBRATION AND CALIBRATION AND

POLISHINGPOLISHING

SLAB CUTTING SLAB CUTTING INTO STRIPSINTO STRIPS

BLOCK BLOCK CUTTING INTO CUTTING INTO

SLABSSLABS

STRIP CROSS STRIP CROSS CUTTING INTO CUTTING INTO

TILESTILES

System boundariesSystem boundaries

Inventory analysisInventory analysis

development of the alternative marble and granite development of the alternative marble and granite quarrying and processing scenariosquarrying and processing scenariosmapping of mapping of thethe inputs and outputsinputs and outputs in each scenario as a in each scenario as a whole and in each processwhole and in each processcollection of the datacollection of the data required for the calculation of the required for the calculation of the inventory data;inventory data;development ofdevelopment of appropriate appropriate calculation modelscalculation models based on the based on the assumptions made and the collected dataassumptions made and the collected datacalculation of inputcalculation of input (energy, raw materials, water, (energy, raw materials, water, chemicals, tools, etc.) chemicals, tools, etc.) and outputand output (products, air emissions, (products, air emissions, liquid and solid wastes) liquid and solid wastes) datadata

Quarrying scenariosQuarrying scenarios

Surface extraction of marble or granite:Surface extraction of marble or granite:a) a) direct production of commercial blocksdirect production of commercial blocksb) b) bank blocks production and cutting into commercial bank blocks production and cutting into commercial

dimensionsdimensions

Different techniques are defined by the use of different cuttingDifferent techniques are defined by the use of different cuttingmachines (Chain cutters, Diamond wire and Drilling machine). machines (Chain cutters, Diamond wire and Drilling machine). The various scenarios are created through different combinationsThe various scenarios are created through different combinationsof these techniques.of these techniques.

SCENARIO 2SCENARIO 2Drilling + Chain cutter + Diamond wireDrilling + Chain cutter + Diamond wire

SCENARIO 4SCENARIO 4Drilling + ExplosivesDrilling + Explosives

SCENARIO 3SCENARIO 3Drilling + Diamond wireDrilling + Diamond wire

SCENARIO 1SCENARIO 1Chain cutter + Diamond wireChain cutter + Diamond wire Marble




SCENARIO 1SCENARIO 1Chain cutter + Diamond wireChain cutter + Diamond wire




SCENARIO 1SCENARIO 1Chain cutter + Diamond wireChain cutter + Diamond wire Marble




SCENARIO 1SCENARIO 1Chain cutter + Diamond wireChain cutter + Diamond wire

Block processing scenarios are designed by Block processing scenarios are designed by combining various techniques, according to combining various techniques, according to the specifications of the final products, the the specifications of the final products, the characteristic properties and the restrictions characteristic properties and the restrictions set by the block. set by the block.

Scenario 1 (P1):Scenario 1 (P1): production of production of slabs (flooring and cladding slabs (flooring and cladding applications)applications)Scenario 2 (P2):Scenario 2 (P2): production of production of tiles from slabs (not suitable for tiles from slabs (not suitable for mass production).mass production).Scenario 3 (P3):Scenario 3 (P3): mass production mass production of tiles of standardised size.of tiles of standardised size.

Processing scenariosProcessing scenarios

RESIN STRENGTHENING

■ Resin application machine

BLOCK SQUARING

■ Single blade diamond frame

BLOCK CUT TO SLABS

■ Multi blade cutting frame ■ Giant disc saw

SLAB POLISHING

■ Polishing machine

HANDLING

Final productSlabs

■Slab loaders and unloaders

SCENARIO 1

Block

Air emissions: CO: 15.5, H/C:1.3, NOx:4

Diesel consumption (l/hp/h): 0.15

Number of diamonds/wire meter: 31

Cut thickness (m): 0.011

Water consumption (l/min): 15 to 50

Wire consumption (m2/m): 30 to 80

Cutting surface (m2): 3,75

18 to 56 90 (Diesel)Power engine (kW):

Type wastes: Solid, Pulp

Solid wastes weigth (kg/tn): 7.33

Ware quantity (m3/tn): 0.01587- 0.123

Air emissions (gr/hp/h):CO:1869.3,

H/C:156.78, Nox: 482.4, CO2: 47685.24

Nose (dB):70

Electric energy (kWh/tn): 0.32 to 2.30

Lubricant consumption (kg/tn): 0..057

Wire consumption (m/tn) : 0.031 – 0.0082

Diamonds consumption (no/tn): 0.1 to 0.26

Water consumption (l/tn): 15.87 to 123..46

Diesel consumption (l/h): 18.09

Productivity (m2/h): 6 to 14

Diamonds consumption(m2/7 diamonds):2000

Chain consumption (m2/m):15 - 40

Lubricant consumption (kg/h): 1.3

Cut thickness (m): 0,04

Surface Α: 3.75,Surface Β: 2.25Total surface: 6

Cutting surface (m2)

Power engine (kW): 48

Type wastes: Solid

Solid wastes weigth (kg/tn): 42.66

Electric energy (kWh/tn): 2.11

Lubricant consumption (kg/tn): 0..057

Chain consumption (m/tn) : 0.026 – 0.098

Diamonds consumption (no/tn): 0.0014

Productivity (m2/h): 9

Extraction ofExtraction ofcommercial commercial

dimensions Blocksdimensions Blocks

OutputsOutputsInputsInputsAssumptions and technical Assumptions and technical characteristicscharacteristicsMachine TypeMachine TypeProcessProcess

2,5 m

1,5

m

1.5 m

Surface C

2,5 m

1,5

m

1,5 m

Surface A

Surface B

Data collection Data collection -- calculation modelscalculation models

Energy consumptionEnergy consumption

Lower energy consumption in quarrying: combined Lower energy consumption in quarrying: combined use of drilling and explosives (many disadvantages)use of drilling and explosives (many disadvantages)

0

10

20

30

40

50

60

70

QM1 QM2 QM3 QM4 QG5 QG6 QM7 QM8 QM9 QG10 QG11

Combined with diesel equip.

Electrical equip. only

Ene

rgy

cons

umpt

ion

(KW

h/t t

ile)

0

10

20

30

40

50

60

70




Ene

rgy

cons

umpt

ion

(KW

h/t t

ile)

Energy consumption during granite extraction is 2Energy consumption during granite extraction is 2--2.5 times higher compared to marble extraction2.5 times higher compared to marble extraction

Energy consumptionEnergy consumption

Energy consumption during granite processing is 2.5 – 3 times higher compared to marble processing

0

10

20

30

40

50

60

70




Ene

rgy

cons

umpt

ion

(KW

h/t t

ile)

0

10

20

30

40

50

60

70




Ene

rgy

cons

umpt

ion

(KW

h/t t

ile)

0

100

200

300

400

500

600

700

mul

tibla

decu

tter

gian

tdis

kcu

tter

mul

tiwire

cutte

r

gian

tdis

kcu

tter

gang

saw

mul

tibla

decu

tter

gian

tdis

kcu

tter

mul

tiwire

cutte

r

gian

tdis

kcu

tter

gang

saw

disk

bloc

kcu

tter

disk

bloc

kcu

tter

PM1 PG1 PM2 PG2 PM3 PG3

Ele

ctri

cE

nerg

yco

nsum

ptio

n(k

Wh/

t)

0

100

200

300

400

500

600

700

mul

tibla

decu

tter

gian

tdis

kcu

tter

mul

tiwire

cutte

r

gian

tdis

kcu

tter

gang

saw

mul

tibla

decu

tter

gian

tdis

kcu

tter

mul

tiwire

cutte

r

gian

tdis

kcu

tter

gang

saw

disk

bloc

kcu

tter

disk

bloc

kcu

tter


Ele

ctri

cE

nerg

yco

nsum

ptio

n(k

Wh/

t)

Energy consumption during processing is about 10 times higher compared to quarrying

Water consumptionWater consumption

water recycle ratio:water recycle ratio:•• 0.5 in quarrying0.5 in quarrying•• 0.8 in processing0.8 in processing

0,0

0,1

0,2

0,3

0,4

0,5

0,6

0,7

0,8

Wat

erco

nsum

ptio

n(m

3 /t ti

le)

QM1 QM2 QM3 QM4 QG5 QG6 QM7 QM8 QM9 QG10 QG110,0

0,1

0,2

0,3

0,4

0,5

0,6

0,7

0,8

Wat

erco

nsum

ptio

n(m

3 /t ti

le)


0

10

20

30

40

50

60

70

Wat

erco

nsum

ptio

n(m

3 /t ti

le)

mul

tibla

decu

tter

gian

tdis

kcu

tter

mul

tiwire

cutte

r

gian

tdis

kcu

tter

gang

saw

mul

tibla

decu

tter

gian

tdis

kcu

tter

mul

tiwire

cutte

r

gian

tdis

kcu

tter

gang

saw

disk

bloc

kcu

tter

disk

bloc

kcu

tter


0

10

20

30

40

50

60

70

Wat

erco

nsum

ptio

n(m

3 /t ti

le)

mul

tibla

decu

tter

gian

tdis

kcu

tter

mul

tiwire

cutte

r

gian

tdis

kcu

tter

gang

saw

mul

tibla

decu

tter

gian

tdis

kcu

tter

mul

tiwire

cutte

r

gian

tdis

kcu

tter

gang

saw

disk

bloc

kcu

tter

disk

bloc

kcu

tter


Water consumption is Water consumption is about about 30 to 35 times 30 to 35 times higher in the processinghigher in the processingphasephase

Impact assessmentImpact assessment

Impact Assessment methodology used in this LCA Impact Assessment methodology used in this LCA study: study: EcoEco--Indicator 99Indicator 99

-- Electric energy from CoalElectric energy from Coal-- Embodied energy from dieselEmbodied energy from dieselFossil fuels Fossil fuels Resources Resources

DepletionDepletion

Total surface occupied by the Total surface occupied by the quarry/processing plant quarry/processing plant Land use Land use

NOxNOx, SO, SO22AcidificationAcidificationEcosystem Ecosystem

COCO22Climate changeClimate change

Dust (PM10), Dust (PM10), NONOxx, , CxHyCxHy, SO, SO22Respiratory Respiratory effects effects Human Health Human Health

Inputs/OutputsInputs/OutputsAssociated Associated Impact category Impact category

DamageDamageCategoryCategory

AcidificationAcidification

0

200

400

600

800

1000

1200

1400

QM1 QM2 QM3 QM4 QM7 QM8 QM9

Electrical equip. onlyCompined with diesel equipm.

0

200

400

600

800

1000

1200

1400



0

200

400

600

800

1000

1200

1400

QG5 QG6 Q10 QG11


0

200

400

600

800

1000

1200

1400

QG5 QG6 Q10 QG11


0

1000

2000

3000

4000

5000

6000

7000

MBC GDC MBC GDC MWC GDC GS MWC GDC GS

PM1 PM2 PM3 PG1 PG2 PG3

0

1000

2000

3000

4000

5000

6000

7000



Acidification refers to the Acidification refers to the decrease in the nature decrease in the nature resistance to acidifying resistance to acidifying depositionsdepositions

Fossil fuelsFossil fuels

0

200

400

600

800

1.000

1.200

1.400

1.600

1.800

QG5 QG6 Q10 QG11


x103

0

200

400

600

800

1.000

1.200

1.400

1.600

1.800

QG5 QG6 Q10 QG11

Electrical equip. onlyCompined with diesel equipm.Electrical equip. onlyCompined with diesel equipm.

x103

0

100

200

300

400

500

600



Compined with diesel equipm.

0

100

200

300

400

500

600




0

2

4

6

8

10

12

14

16

18

20



x106

0

2

4

6

8

10

12

14

16

18

20



x106

x 10x 1033

Environmental profileEnvironmental profile

0,1

10

1000

1x106

10x106

Resp. effect Acidification Clim. Change Fossil Fuels



0,1

10

1000

1x106

10x106



Compined with diesel equipm. QG5QG5

0,1

1

10

100

1000

10000

100000

1000000




0,1

1

10

100

1000

10000

100000

1000000



Compined with diesel equipm. QM1QM1

Most important Impact Most important Impact categories for quarrying:categories for quarrying:

Fossil fuels and AcidificationFossil fuels and Acidification

Environmental profileEnvironmental profile

0,01

1

100

10000

1x106

100x106


MWC GDC GS PG1PG1

0,01

1

100

10000

1x106

100x106


MWC GDC GS PG1PG1

Most important Impact categories for processing:Most important Impact categories for processing:Fossil fuels and AcidificationFossil fuels and Acidification

ConclusionsConclusions

Impact of quarrying and processing phases:Impact of quarrying and processing phases:

443322

11

Respiratory effectsRespiratory effectsClimate changeClimate changeClimate changeClimate changeRespiratory effectsRespiratory effectsAcidificationAcidificationAcidificationAcidification

Fossil fuelsFossil fuelsFossil fuelsFossil fuels

ProcessingProcessingQuarryingQuarrying

ConclusionsConclusions

Energy and water consumption is much higher in the Energy and water consumption is much higher in the processing phaseprocessing phase

Granite production is more energy intensive compared to Granite production is more energy intensive compared to marble productionmarble production

The environmental impact of ceramic tiles (an alternative The environmental impact of ceramic tiles (an alternative construction product) production is significantly higher construction product) production is significantly higher compared to stone production (e.g. embodied energy for compared to stone production (e.g. embodied energy for ceramic tiles is 36 kWh/m2 tile, while for stones is 13 ceramic tiles is 36 kWh/m2 tile, while for stones is 13 kWh/m2 tile)*kWh/m2 tile)*

** G.M. G.M. NicolettiNicoletti et al. Comparative Life Cycle Assessment of flooring et al. Comparative Life Cycle Assessment of flooring materials: ceramic versus marble tiles. materials: ceramic versus marble tiles. Journal of Cleaner ProductionJournal of Cleaner Production, 10 , 10 (2002), pp. 283(2002), pp. 283--296296

life cycle analysis of dimensional stones production · 9the environmental impact of ceramic tiles...

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