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Life Cycle Analysis of Gypsum Board and Associated Finishing Products

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Life Cycle Analysis of Gypsum Board and Associated Finishing Products LIFE CYCLE ANALYSIS OF GYPSUM BOARD AND ASSOCIATED FINISHING PRODUCTS Prepared by: George J. Venta, P. Eng. VENTA, GLASER & ASSOCIATES Ottawa, Canada March 1997 DISCLAIMER Although the ATHENATM Sustainable Materials Institute has done its best to ensure accurate and reliable information in this report, the Institute does not warrant the accuracy thereof. If notified of any errors or omissions, the Institute will take reasonable steps to correct such errors or omissions. COPYRIGHT No part of this report may be reproduced in any form or by any means, electronic or mechanical, including photocopying, without written permission of ATHENATM Sustainable Materials Institute. Text 1997 ATHENATM Sustainable Materials Institute ATHENATM Sustainable Materials Institute 112 Brock St. East, P.O. Box 189 Merrickville, Ontario, Canada K0G 1N0 Tel: 613-269-3795 Fax: 613-269-3796 E-mail: [email protected] The AthenaTM Project: Gypsum Board and Associated Finishing Products CONTENTS PREFACE ACKNOWLEDGMENTS 1.0 INTRODUCTION............................................................................................................. 1-1 1.1 Research Guidelines ................................................................................................... 1-1 1.2 Study Structure........................................................................................................... 1-2 1.3 Report Structure.......................................................................................................... 1-3 2.0 GYPSUM INDUSTRY - AN OVERVIEW..................................................................... 2-1 2.1 Industry Structure....................................................................................................... 2-1 2.1.1 Gypsum and Gypsum Board...................................................................................... 2-1 2.1.2 Gypsum Fiberboard.................................................................................................... 2-4 2.1.3 Gypsum Building Plasters.......................................................................................... 2-4 2.1.4 Joint Finishing Products............................................................................................. 2-5 2.2 Gypsum Board Manufacturing................................................................................... 2-6 2.2.1 Extraction 2-6 2.2.2 Calcination Plant......................................................................................................... 2-8 2.2.3 Gypsum Board Plant ................................................................................................ 2-11 2.2.4 Types of Gypsum Board Produced .......................................................................... 2-13 2.3 Gypsum Fiberboard.................................................................................................. 2-15 2.3.1 Gypsum Fiberboard Manufacturing ......................................................................... 2-15 2.3.2 Types of Gypsum Fiberboard Produced................................................................... 2-17 2.4 Gypsum Building Plasters........................................................................................ 2-17 2.4.1 Gypsum Building Plasters Manufacturing................................................................ 2-17 2.4.2 Types of Plasters Produced ...................................................................................... 2-19 2.5 Joint Finishing Products Manufacturing................................................................... 2-20 2.5.1 Ready Mix Joint Compound..................................................................................... 2-20 2.5.2 Dry (Setting) Joint Compound ................................................................................. 2-22 2.5.3 Products Statistics..................................................................................................... 2-23 2.5.4 Joint Paper Tape ....................................................................................................... 2-23 2.6 Gypsum Industry, Energy and Environment............................................................. 2-23 2.6.1 Energy Use and Efficiency ....................................................................................... 2-24 2.6.2 Atmospheric Emissions ............................................................................................ 2-25 2.6.3 Liquid Effluent.......................................................................................................... 2-26 2.6.4 Solid Waste .............................................................................................................. 2-26 2.6.5 Recycling 2-27 References 2-28 The AthenaTM Project: Gypsum Board and Associated Finishing Products 3.0 Raw Material Requirements and Transportation........................................................ 3-1 3.1 Raw Material Requirements - Gypsum Board ........................................................... 3-1 3.2 Raw Materials Transportation - Gypsum Board ......................................................... 3-3 3.3 Raw Material Requirements - Finishing Products...................................................... 3-6 3.4 Raw Materials Transportation - Joint Finishing Products........................................... 3-7 4.0 Energy Use - Gypsum Board ........................................................................................... 4-1 4.1 Raw Material Extraction and Transportation............................................................... 4-1 4.2 Gypsum Board Manufacturing................................................................................... 4-4 4.3 Finished Gypsum Board Transportation..................................................................... 4-7 4.4 Gypsum Board - Energy Summary ............................................................................ 4-9 4.5 Energy Use in Gypsum Fiberboard (GFB) Production............................................ 4-12 References 4-14 5.0 Energy Use - Finishing Products .................................................................................... 5-1 5.1 Joint Finishing Products Raw Material Extraction and Transportation ....................... 5-1 5.2 Joint Finishing Products Manufacturing..................................................................... 5-5 5.3 Joint Finishing Products Transportation..................................................................... 5-9 5.4 Joint Finishing Products - Energy Summary............................................................ 5-11 References 5-19 6.0 Atmospheric Emissions - Gypsum Board...................................................................... 6-1 6.1 Approach .................................................................................................................. 6-1 6.2 Atmospheric Emission Estimates................................................................................ 6-2 6.2.1 Raw Materials Extraction............................................................................................ 6-2 6.2.2 Raw Materials Transportation..................................................................................... 6-4 6.2.3 Gypsum Board Manufacturing................................................................................... 6-4 6.2.4 Finished Gypsum Board Transportation..................................................................... 6-7 6.3 Atmospheric Emissions Summary.............................................................................. 6-9 References 6-20 7.0 Atmospheric Emissions - Joint Finishing Products..................................................... 7-1 7.1 Atmospheric Emission Estimates................................................................................ 7-1 7.1.1 Raw Materials Extraction............................................................................................ 7-1 7.1.2 Raw Materials Transportation..................................................................................... 7-2 7.1.3 Joint Finishing Products Manufacturing..................................................................... 7-5 7.1.4 Finished Associated Products Transportation............................................................. 7-7 7.2 Joint Finishing Products Atmospheric Emissions - Summary.................................... 7-9 References 7-19 The AthenaTM Project: Gypsum Board and Associated Finishing Products 8.0 Liquid Effluents ............................................................................................................... 8-1 8.1 Liquid Effluent Estimates - Gypsum Board................................................................ 8-1 8.1.1 Raw Materials Extraction............................................................................................ 8-1 8.1.2 Gypsum Board Manufacturing................................................................................... 8-3 8.2 Liquid Effluent - Gypsum Board Summary................................................................ 8-6 8.3 Liquid Effluent Estimates - Finishing Products .......................................................... 8-6 8.3.1 Joint Compounds........................................................................................................ 8-6 8.3.2 Joint Paper Tape ......................................................................................................... 8-6 References 8-13 9.0 Solid Wastes .................................................................................................................
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