The LCA of a crystal production: methodological aspects R. Ridolfi, B. Rugani, S. Bastianoni Department of Chemical and Biosystems Sciences, University of Siena.

PROJECT: CIVIC (italian acronymus) The life cycle assessment of crystal production FUNDERS & PARTNERS Consorzio del Cristallo di Colle Valle d’Elsa Province of Siena Monte dei Paschi Foundation University of Siena

METHODOLOGY ISO 14040: 1997 ISO 14041: 1999 ISO 14042: 2000 ISO 14043: 2000 CIVIC project

ISO 14040: 1997 Life cycle assessment: principles and framework In this rule the main aspects of ISO series and the phases of an LCA are reported. CIVIC project

Goal of the study From ISO 14040: “The goal of an LCA study shall unambiguously state the intended application, the reasons for carrying out the study and the intended audience, i.e. to whom the results of the study are intended to be communicated ” The goal of our project is: to quantify the energetic and environmental impact of the crystal production and to develop the LCA application in our research group. CIVIC project

Function and functional unit From ISO 14040: “The functional unit is a measure of the performance of the functional outputs of the product system” The functional unit is: The kg of crystal object produced CIVIC project

System boundaries From ISO 14040: “The system boundaries determine which unit processes shall be included within LCA” System boundaries: The crystal production has been studied from the “cradle to the grave”. The LCA includes the end-life of the crystal object. CIVIC project

Data In this analysis we used three types of data: 1.Direct measurements from companies 2.Data from a database 3.Data from literature The data (1) are mainly material and resource consumptions for the crystal manufacture. Data (2) and (3) are relative to the process of preparation of raw materials or resources and in general to each process that can not be analyzed directly. CIVIC project

Phases of LCA CIVIC project Goal and scope definition Inventory analysis Impact assessment Interpretation Direct applications: - Product development And Improvement -Strategic plannig - Public policy making -Marketing -Other Inventory analysis involves data collection and calculation procedures to quantify relevant inputs and outputs of a product system The impact assessment phase of LCA is aimed at evaluating the significance of potential environmental impacts using the results of the life cycle inventory analysis Interpretation is the phase of LCA in which the findings from the inventory analysis and the impact assessment are combined together.

The model of the LCA CIVIC project The crystal production process has been divided in four main phases according to what is suggested by LCA rules: 1.Acquisition of materials 2.Production phase 3.Use phase 4.End life phase

The model of the LCA CIVIC project Manufacturing process Materials acquisitions USE phase END phase mixing melting moulding Tempering polishing cutting packaging

Analyses of the unit processes of manufacturing (1) CIVIC project MIXING Lead oxide Carbonates Sand Other chemicals INPUT electricity OUTPUT FUSION Direct emissions (dust) Mixed materials Indirect emissions (e.g. from electricity) Waste (packaging materials)

Analyses of the unit processes of manufacturing (2) CIVIC project MELTING Mixed materials Methane Refractory materials INPUT electricity OUTPUT MOULDING Direct emissions (e.g. nitrous oxide, dust) Melted material Indirect emissions (e.g. methane extraction) Waste (refractory materials)

The LCA inventory (1): CIVIC project In order to account for direct and indirect emissions (to the emissions due to the production process of raw materials) we have to use a Database and a software. The former permits to close the LCA, the latter permits to combine the various flows entering in the single unit process. In this analysis we have used the database EDIP and the software GABI4. However for processes not present in the database we had to calculate it from literature

The LCA inventory (2):

The LCA inventory (3):

The GABI4: CIVIC project

CIVIC PROJECT GaBi4 software …general plan Plan Nesting Manifacturing MIXING Lead polishing (sub-plan) Flows H 2 SO 4 process Sand

The GABI4: CIVIC project

Each time that neither EDIP nor Company is written, the process of production has been estimated according to literature (e.g. HF). European Commission, Integrated Pollution Prevention and Control (IPPC), Directorate- General JRG Joint Research Centre, Institute for Prospective Technological Studies. Reference Document on Best Available Techniques for the Manufacture of Large Volume Inorganic Chemicals - Solids and Others Industry. Dated October 2006.

1)Estimation of HF production process: 2) Inclusion of the process in the GABI4

The impact assessment: CIVIC project Global warming Acidification potential Stratospheric ozone depletion Heavy metals

First results The impact assessment (acidification potential, Kg SO 2 eq.): CIVIC project

First results The impact assessment (greenhouse gas emissions, kg CO 2 eq.):

First results The impact assessment (stratospheric ozone depletion potential, kg R11 eq.): CIVIC project

First results The impact assessment (heavy metals, kg-Pb eq): CIVIC project

Final remarks: CIVIC project LCA can be a valid method to identify the critical aspects from an energetic and environmental point of view. Moreover LCA is able to correlate a critical aspect to a unit process. LCA is a complex assessment tool and then requires much time for data searching and processing. Results from an LCA should validate in order to see if some assumptions or estimation could bring error or bias in the final results.

Final remarks (work in progress): CIVIC project We have to estimate the type of Data used (% from literature, % as direct measurements, % from database). We have to apply a sensitivity analysis (identification of critical parameters). We have to refine data (optimization of processes that are much more affected by bias). We have to evaluate possible improvements or development of the production. We have to evaluate the opportunity of beginning an environmental certification (like EPD).

Future references: CIVIC project Prof. Simone Bastianoni – University of Siena, Phd student, Benedetto Rugani – University of Siena

Thanks for the attention CIVIC project