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ENVIRONMENTAL PRODUCT DECLARATION for Portland

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ENVIRONMENTAL PRODUCT DECLARATION for Portland ENVIRONMENTAL PRODUCT DECLARATION for Portland Cement Clinker in accordance with ISO14025 and EN15804:2012+A2:2019 Programme : The International EPD® System www.environdec.com Programme Operator : EPD International AB Stockholm, Sweden EPD Registration Number: S-P-02229 Publication Date: 23.02.2021 Validity Date: 22.02.2026 Geographical Scope: Turkey PROGRAMME INFORMATION EPD Turkey, a fully aligned The International EPD® System regional programme EPD International AB SÜRATAM – Turkish Centre for Sustainable Box 210 60 Production Research & Design SE-100 31 Programme Nef 09 B Blok No:7/15 Stockholm/SWEDEN 34415 Kağıthane-Istanbul/TURKEY www.epdturkey.org www.environdec.com [email protected] [email protected] Product Category Rules (PCR): 2019:14 Version 1.1. 2020-09-14 Construction Products EN 15804:2012 + A2:2019 Sustainability of Construction Works Independent third-party verification of the declaration and data, according to ISO 14025:2006 EPD process certification X EPD verification Third party verifier: Vladimír Kočí, PhD Approved by: The International EPD® System Procedure for follow-up of data during EPD validity involves third party verifier: Yes No The EPD owner has the sole ownership, liability, and responsibility for the EPD. EPDs within the same product category but from different programmes may not be comparable. EPDs of construction products may not be comparable if they do not comply with EN 15804. For further information about comparability, see EN 15804 and ISO 14025. 2 ABOUT THE COMPANY Medcem Cement Factory, a subsidiary of Eren Holding, started production in July 2015 in Akdere/Silifke district of Mersin province. With a daily production capacity of 11,500 tons of clinker, Medcem Çimento is the biggest cement factory of Turkey and Europe with the highest production volume on a single line. The stability of the raw material quarries of Medcem and their closeness to the factory are the biggest guarantee of continuous and high quality production. With the philosophy of “quality products can be produced using high quality raw material”, the quality of raw materials in Medcem is ensured with the online analyzer. Medcem Cement Factory built using the high technology systems In order to control the environmental impact of its operation, it monitors every stage of production with computer controlled continuous emission measurement systems. With its high capacity rotary kiln and high quality clinker production, Medcem is one of the biggest supplier brands in the global market. The samples taken from each stage of the process in Medcem are analyzed in the Quality Assurance Laboratory using the most sensitive measurement methodologies. Medcem Quality Assurance Laboratory provides sustainable and high quality products to its customers by giving the accurate and fast directions to production with the high technology automation system. 3 ABOUT THE COMPANY Medcem has a 10 MW (Megawatt) power generation plant to reduce the effects of climate change and to recycle Process Waste heat as electrical energy. Fully Automatic packaging and loading systems aim to keep the health and safety of employees at the highest level. In addition to producing different types of cements in compliance with national and international norms such as TSE, EN, ASTM, Medcem offers alternative packaging options according to the demands and needs of its customers. kraft and PP bag, slingbag, stretchhood, bigbag, and bulk. Always keeping the customer satisfaction at the forefront, Medcem performs uninterrupted and fast loading even under the most demanding climate and working conditions: > Automatic loading platforms with a capacity of 12.000 tons per day > Cement silos with a capacity of 60.000 tons > Daily bulk cement loading capacity of 20.000 tons > Daily clinker loading capacity of 24.000 tons Medcem knows that it carries out all its activities for human beings and provides its employees with a safe, modern, comfortable and healthy working environment within the principle of equality. Supporting continuous development of employees With its social facilities that keep the cleanliness and hygiene at the forefront With uninterrupted health services It keeps employees’ satisfaction at the highest level. Cement and clinker export leader in Turkey. The clinker and cement produced in Medcem Cement plant are exported to different countries from the Medcem Port in nearby location which belongs to Eren Holding. It can serve 3 different ships at the same time: > 1 bulk cement silo with a capacity of 30.000 tons > 1 clinker silo with a capacity of 5.000 tons > 1 bagged cement indoor storage area with a capacity of 25.000 tons > 2 pieces of 1400 ton/hour cement/clinker loading capacity With the increasing brand value every day, Medcem is taking firm steps towards becoming the star of global cement market. 4 PRODUCT INFORMATION Cement clinker (UN CPC Code: 37430) is a solid material produced in the manufacture of portland cement as an intermediary product. Clinker occurs as lumps or nodules, usually 3 millimetres to 25 millimetres in diameter. Portland cement clinker is ground to a fine powder and used as the binder in many cement products. A little gypsum is sometimes added. Clinker, if stored in dry conditions, can be kept for several months without appreciable loss of quality. Composition and Technical Specification of Portland Cement Clinker Chemical Requirements Units of Standard Limits Typical Minimum Maximum Rapid Method, X-Ray Measurement EN 196-2, EN 196-10, EN 196-4 SiO2 % 20.65 19.50 22.0 Al2O3 % 5.30 4.10 6.30 Fe2O3 % 4.00 3.00 5.30 CaO % 66.60 62.30 67.80 MgO % Max 5.0 1.65 1.00 3.90 SO3 % 0.70 0.45 1.70 Cl ppm 100 20 600 Loss of Ignition (LOI) % 0.25 0.01 0.70 Insoluble Residue % 0.25 0.10 0.75 Free CaO % 1.45 0.40 2.50 Cr (IV) ppm 9 3 50 Na2O % 0.09 0.02 0.45 K2O % 0.55 0.30 1.20 Na2OEq (Na2O + 0.658*K2O) % 0.45 0.30 1.20 5 PRODUCT INFORMATION Composition and Technical Specification of Portland Cement Clinker Adjusted Potential Phase Units of Standard Limits Typical Minimum Maximum Composition Method, Bogue Measurement Formula Lime Saturation Factor (LSF) - 99.85 95.00 104.0 Silica Modulus (SM) - 2.20 1.90 2.60 Alumina Modulus (AM) - 1.35 0.80 1.80 Tricalcium Silicate (C3S) % 66.75 55.00 76.00 Dicalcium Silicate (C2S) % 8.85 0.20 25.0 Tricalcium Aluminate (C3A) % 7.35 2.00 11.0 Tetracalcium Aluminoferrite (C4AF) % 12.10 10.50 16.0 C3S + C2S % Min. 66.7 75.60 71.80 78.70 CaO/SiO2 - Min. 2.0 3.23 2.95 3.50 Physical and Mechanical Units of Standard Limits Typical Minimum Maximum Requirements Measurement Specific Gravity (ISO 17892-3) gr/cm3 3.15 3.10 3.24 Specific Surface (EN 196-6) cm2/g 3400 3300 3500 Residue on 0.045 nm (EN 196-6) % 16.5 11.0 24.5 Soundness (EN 196-3) mm 1.5 0.00 5.0 Normal Consistency (EN 196-3) % 23.5 22.0 25.0 Initial Setting Time (EN 196-3) minutes 115 70 210 Sieve Analysis Residue on 40 mm % 1.5 0.0 27.0 Sieve Analysis Residue on 25 mm % 18 0.0 56.0 Sieve Analysis Residue on 10 mm % 43.0 10.0 91.0 Compressive Strength Method, EN Units of Standard Limits Typical Minimum Maximum 196-1 Measurement 2 days MPa 28.0 23.0 34.0 7 days MPa 41.5 34.0 48.5 28 days MPa 51.5 46.0 59.0 6 PRODUCT INFORMATION LCA INFORMATION Functional Unit/Declared Unit The declared unit is 1 tonne of portland cement clinker. 2019 Time Representativeness Database(s) and TLCID vers. 1.0 (Turkish Lifecycle Inventory Database), EcoInvent 3.5 LCA Software Used SimaPro 9.0 System Boundary Raw Materials Transport Manufacturing Installation Transport to Site Demolition Waste Process and Disposal Benefits and Loads System Boundary 7 DEFINITION OF THE SYSTEM BOUNDARY Core Upstream Information Downstream Other Environmental Other Environmental Use Repair Disposal Replacement Maintenance Raw Material Raw Manufacturing Refurbishment Waste Processing Waste Transport to Plant to Transport Operational Water Use Water Operational Raw Material Transport Material Raw Operational Energy Use Energy Operational Future reuse, recycling or recycling reuse, Future Transport to Disposal Site to Transport energy recovery potential recovery energy Construction / Installation Construction Deconstruction / Demolition Deconstruction A1 A2 A3 A4 A5 B1 B2 B3 B4 B5 B6 B7 C1 C2 C3 C4 D X X X X ND ND ND ND ND ND ND ND ND ND ND ND ND Description of the system boundary (X = Included in LCA, ND = Not Declared) A1 : Raw Material A3 : Manufacturing This stage includes raw material extraction and pre- Manufacturing prosses comprises of heating a treatment processes before production. homogeneous mixture of raw materials in a rotary kiln at high temperature. The products of the chemical A2 : Raw Material Supply reaction aggregate together at their sintering This stage is relevant for delivery of raw materials temperature, about 1,450 °C. and intermediary products to factory gate. Transport direct from producer or producer to warehouses/ A4 : Transport to Site intermediaries then to the factory were taken into This stage involves transportation of portland cement account. Forklift usage within the factory is also clinker to the construction sites. The average distance included. was calculated as 5500 km. 8 DEFINITION OF THE SYSTEM BOUNDARY MORE INFORMATION This study is conducted according to the guidelines of ISO 14040/44 and the requirements given in the Product Category Rules (PCR) document for Construction Products with reference to EN 15804 and the general program guidelines by The International EPD System. The inventory for the LCA study is based on the 2019 production figures for portland cement clinker manufactured by Medcem in their production plants located in Mersin, Turkey.
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