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 ...... 9-1 9.1 Solid Wastes Estimates - Gypsum Board...... 9-1 9.1.2 Raw Materials Extraction...... 9-1 9.1.2 Gypsum Board Manufacturing...... 9-2 9.1.3 Total Solid Waste Due to Gypsum Board Production...... 9-2 9.2 The Use of Wastes in Gypsum Board Processing...... 9-3 9.3 Solid Wastes Estimates - Finishing Products ...... 9-5 References 9-5 Preface
This report was commissioned as part of the continuing program to expand the knowledge base of the ATHENA project. The project was initiated in 1990 by Forintek Canada Corp., with the support of Natural Resources Canada, under the name Building Materials in the Context of Sustainable Development. Work on the ATHENATM project is now being carried forward by the ATHENATM Sustainable Materials Institute, a not-for-profit organization dedicated to helping the building community meet the environmental challenges of the future. The ultimate goal is to foster sustainable development by encouraging selection of the material mix that will minimize a building’s life cycle environmental impact. To achieve that goal the Institute is developing ATHENA, a systems model for assessing the relative life cycle environmental implications of alternative building or assembly designs. Intended for use by building designers, researchers and policy analysts, ATHENA is a decision support tool which complements and augments other decision support tools like costing models. It provides a wealth of information to help users understand the environmental implications of different material mixes or other design changes in all or part of a building.
The ATHENATM Institute is continuing the practice of publishing all individual research reports and major progress reports to make the process as transparent as possible and to ensure the research and results are fully accessible. To ensure continuity, previously published reports are being reissued as part of the Institute series. Institute studies and publications fall into two general categories: investigative or exploratory studies intended to further general understanding of life cycle assessment as it applies to building materials and buildings; and individual life cycle inventory studies which deal with specific industries, product groups or building life cycles stages. All studies in this latter category are firmly grounded on the principles and practices of life cycle assessment (LCA), and follow our published Research Guidelines which define boundary or scope conditions and ensure equal treatment of all building materials and products in terms of assumptions, research decisions, estimating methods and other aspects of the work. The integration of all inventory data is a primary function of ATHENA itself. ATHENA also generates various composite measures that can be best described as environmental impact indicators, a step toward the ultimate LCA goal of developing true measures of impacts on human and ecosystem health. We believe this report and others in the series will be of value to people concerned with the environmental implications and sustainability of our built environment. But we caution that individual industry life cycle study reports may not be entirely stand-alone documents in the sense that they tell the whole story about an individual set of products. For example, the report on concrete notes how much steel is used for reinforcing various products, but the life cycle inventory data for those steel products is included in the reports dealing with integrated and mini-mill steel production. There are also transportation and energy production and distribution aspects that are common to many different building projects, and are therefore handled separately within ATHENATM. Please contact us at the address shown on the Disclaimer/Copyright page at the front of this report for more information about the ATHENATM Sustainable Materials Institute, or for other reports in the series. The AthenaTM Project: Gypsum Board and Associated Finishing Products
ACKNOWLEDGMENTS
Forintek Canada Corp. would like to acknowledge Natural Resources Canada for its funding contribution to the ATHENATM Sustainable Materials Project. In addition, Forintek would like to thank all of the research alliance members for their timely work, their assistance and their enthusiasm for the project.
The life cycle study described in this report was carried out by VENTA, GLASER & ASSOCIATES under Forintek Canada Corp. Contract. The author gratefully acknowledges their support. Special thanks go to the managers of the ATHENATM Project, Wayne Trusty of Wayne B. Trusty & Associates Limited and Jamie Meil of JKM Associates for their enthusiasm and guidance. We wish to thank all the major gypsum companies in Canada - CGC INC., DOMTAR GYPSUM, and WESTROC INDUSTRIES LTD. - for their trust and cooperation in providing the necessary data input. Thanks are especially extended to the following individuals for their valuable contributions:
Brian Colbert W.R. Grace & Co. of Canada Ltd. Robert Daly Ontario Hydro Gerry Harlos Domtar Gypsum Mike Hunter CGC Inc. A. Marchand The Beaver Wood Fibre Company Ltd. David Shanahan Westroc Industries Ltd. Francis Vrillaud Domtar Gypsum Rick Weber CGC Inc.
We also want to acknowledge the following provincial and regional authorities and their representatives for their input:
Michel de Spot Greater Vancouver Regional District Serge Goulet Quebec MOE&F Bernard Matlock Nova Scotia DOE Don Murray New Brunswick DOE Jean Van Dusen Manitoba Environment Simon Wong Ontario MOEE
Finally, we want to express our thanks to the GYPSUM ASSOCIATION, to Bob Wessel and Jerry Walker, for their support, willingness to review this study and to provide us with their comments. The AthenaTM Project: Gypsum Board and Associated Finishing Products 1-1
LIFE CYCLE ANALYSIS OF GYPSUM BOARD AND ASSOCIATED FINISHING PRODUCTS
1.0 INTRODUCTION This report presents cradle to gate life cycle inventory estimates for gypsum board and associated finishing products, and explains how the estimates were developed. The work was commissioned by the ATHENATM project as part of the continuing series of life cycle studies being done to support the ATHENATM environmental decision support tool described in the Preface.
ATHENATM relies on life cycle inventory databases, termed unit factors, which include estimates of raw material, energy and water inputs as well as atmospheric emissions, liquid effluents and solid wastes outputs per unit of product. The estimates encompass production activities from raw materials extraction (e.g. gypsum quarrying) through product manufacturing, including related transportation. We have also provided estimates of typical or average transportation modes and distances for the distribution of finished products from relevant manufacturing facilities to the six regions covered by the computer model.
The estimates presented in this report were developed by Venta, Glaser & Associates with the assistance and cooperation of the Gypsum Association and its member companies.
1.1 RESEARCH GUIDELINES To ensure consistent and compatible approaches by the different alliance members, all estimates had to be prepared in accordance with a set of research guidelines first issued in October 1992 and subsequently revised as work proceeded. This research protocol defined information requirements and procedures for the study, such as the following:
¥ the specific building products; ¥ the content of general and detailed industry descriptions; ¥ the specific energy forms, emissions and effluents of potential interest; ¥ the treatment of secondary building components and assemblies; ¥ preferred data types and sources (e.g. actual industry data and data from process studies); ¥ the analysis scope, including system boundaries and limits and the level of detail of the analysis; ¥ geographic divisions; The AthenaTM Project: Gypsum Board and Associated Finishing Products 1-2
¥ transportation factors to be included when estimating transportation energy use; and ¥a set of standard conventions for dealing with such aspects as non-domestic production, process feedstocks, in-plant recycling and multiple products.
In addition, the research guidelines provided a set of conversion factors and tables of standard factors for calculating energy contents and emissions by fuel type.
The analysis limits established for the project in the guidelines are similar to a Level II analysis for energy studies as determined by the International Federation of Institutes of Advanced Studies. These limits typically capture about 90% to 95% of the full impacts of an industry.
The life cycle analysis framework, additional unit factors and related impact studies are discussed in detail in the Phase III Summary Report. The Research Guidelines are available under separate cover as part of the full set of project reports and we have not, in this report, duplicated that material by explaining the rationale for all steps in the research and calculation process. For example, the Research Guidelines require that empty backhauls be included when calculating transportation energy use in certain circumstances. Our calculations therefore show the addition of such backhaul mileages without explaining why backhauls should be included. However, we have provided full explanations wherever our calculations do not conform to the guidelines because of data limitations or for other reasons.
1.2 STUDY STRUCTURE The systems model requires unit factors for the following specific gypsum boards and associated finishing products:
¥ 1/2" regular gypsum board, ¥ 5/8" regular gypsum board, ¥ 1/2" Type X (fire-resistant) gypsum board, ¥ 5/8"" Type X (fire-resistant) gypsum board, ¥ 1/2" moisture-resistant (MR) gypsum board, ¥ 5/8" moisture-resistant (MR) gypsum board, ¥ 5/16" mobile home gypsum board, ¥ 1" shaftliner board, ¥ 1/2" gypsum fiberboard (GFB), ¥ 5/8" gypsum fiberboard (GFB), ¥ drying type ready-mixed joint compound, ¥ setting type dry joint compound, and ¥ paper joint tape. The AthenaTM Project: Gypsum Board and Associated Finishing Products 1-3
Gypsum board and associated jointing products are essential building materials for the Canadian residential, commercial, industrial and institutional housing industries, and we had to fully analyze the gypsum industry before developing unit factors for these products. That fact dictated how our study was structured.
Unit factor estimates for the Canadian gypsum board industry were developed and are expressed in terms of material inputs or waste outputs per unit of product. Similar estimates were then developed for the jointing materials required to apply and finish gypsum board-based systems. These two sets of factors have to be combined in the ATHENATM computer model to develop the desired estimates for a specific board application.
The analysis procedures and calculations are described in detail in the relevant sections of this report. The key point at this stage is that the study was structured as two separate, but obviously related, analysis streams — one for gypsum board and one for the jointing products of interest.
1.3 REPORT STRUCTURE The arrangement of this report basically parallels the study structure. Section 2 of the report provides the background information regarding the industry within the framework of the Canadian economy. It discusses in some detail the industry structure, manufacturing processes, types of gypsum board and associated products manufactured and used in Canada. The fact that gypsum board is a composite material, and that its production consists of three distinct and separate manufacturing steps [i.e. partial dehydration (calcination) of gypsum to stucco, paper (to be used as gypsum board facings) manufacturing, and production of gypsum board itself through combination of stucco and paper] affects the discussion of the manufacturing process. Section 2 also introduces the major aspects of the industry with respect to energy consumption and environment, and highlights some of the achievements in this area. Sections 3 through 9 deal with various aspects of raw material balances, energy consumption and environmental issues of the production of the gypsum board as well as the associated joint finishing products.
As indicated below, the basic progression in each part involves an overview section followed by a series of sections dealing with each of the environmental impact areas (e.g. raw material use, energy use, emissions, etc.) Results are presented to show regional variations and, as necessary, by production stage (e.g. resource extraction, raw materials transportation, manufacturing and finished products transportation).
The following regional breakdown was followed in the study:
¥ West (British Columbia, Alberta and Saskatchewan); ¥ Central (Manitoba and Ontario); and ¥ East (Quebec and Atlantic Provinces). The AthenaTM Project: Gypsum Board and Associated Finishing Products 1-4
The Research Guidelines prefer separate information for the West Coast and Prairie regions. However, we had to combine these two regions into one, West region, in order to maintain the confidentiality of data provided by manufacturers: there are only two plants on the West Coast and two plants on the Prairies.
The report is organized as follows:
Section 2 presents an overview profile of the gypsum industry in Canada, including a description of the different production processes, the industry structure in geographic, process and capacity terms, and the general nature of resource and energy use, emissions and other wastes for both the gypsum board and the associated joint finishing materials.
Section 3 details raw material use by the gypsum board industry on a regional basis, and discusses raw material transportation requirements.
Section 4 describes the gypsum board energy use analysis and presents the results, with sub-divisions by region and by stage of production.
Section 5 describes the energy use analysis for associated finishing products and presents the results, with sub-divisions by region and by stage of production.
Section 6 deals with atmospheric emissions associated with gypsum board production on a regional basis by production stage, including the analysis method and results.
Section 7 deals with atmospheric emissions generated by production of associated finishing products on a regional basis by production stage, including the analysis method and results.
Section 8 focuses on liquid effluents associated with production of gypsum board and associated finishing products.
Section 9 deals with solid wastes generated by production of gypsum board and associated finishing products.
At the end of each section, a summary of all the developed unit factor estimates is presented. The AthenaTM Project: Gypsum Board and Associated Finishing Products 2-1
2.0 GYPSUM INDUSTRY - AN OVERVIEW This section provides an overview of the gypsum board and associated finishing products industry in Canada. It provides basic information on the structure, size, production volumes and geographical distribution of the industry, and its position within the framework of the Canadian minerals as well as construction industries.
The basic manufacturing processes for the production of gypsum board, joint compounds, and joint paper tape, are shown and described. Related energy use and efficiency issues, as well as emissions, effluents and waste outputs are also briefly discussed as an introduction to a more detailed description of these aspects and the development of the appropriate unit factors in subsequent sections.
2.1 INDUSTRY STRUCTURE 2.1.1 Gypsum and Gypsum Board Canada has abundant sources of natural gypsum, a relatively soft rock-like mineral that was
deposited in ancient seas. Chemically, gypsum is calcium sulfate dihydrate (CaSO4¥2H2O) and Canada is the third largest producer of crude gypsum in the world, after the U.S.A. and China, generating about 7.3% of the total annual production of this mineral. In 1994, Canadian shipments of crude gypsum were about 8,110,000 t valued at over $91-million.1 A substantial portion of this production, over 70%, is exported, mainly to the U.S. markets. In Canada, almost 2.5 million tonnes of gypsum were used in 1994. Over 70% of gypsum quarried or mined in Canada comes from Nova Scotia, with the rest originating in Ontario, Manitoba and British Columbia. On the West Coast, some gypsum rock is imported from Domtar Gypsum’s co-owned San Marcos Island deposits in the Baja California area of Mexico.
In the U.S., and we assume in Canada as well, about 71 to 75% of gypsum is used in the production of gypsum board, about 2 to 3% for building and industrial plasters, about 14 to 17% in the cement industry, where it is interground with clinker to control cement set, and the remaining 9% in agriculture.2
While natural gypsum represents at this time the overwhelming portion of the Canadian gypsum supply, chemical gypsums are starting to be considered as options to natural gypsum. Synthetic gypsums are most often a by-product of flue gas scrubbing (desulfurization), although co-products of various chemical processes, such as titanium dioxide (TiO2) gypsum, are possible candidates for gypsum board production as well.
Synthetic gypsums’ availability and use are new to Canada. Although chemical gypsums have been used overseas for some time, the abundant sources of quality gypsum on this continent were not conducive to a similar practice in Canada or the U.S.A.3 In 1995 a major gypsum board operation, Westroc’s Mississauga plant, switched from gypsum rock to FGD gypsum, a by-product of flue gas desulfurization, from Ontario Hydro’s Lambton Thermal Power Generating Station. This was The AthenaTM Project: Gypsum Board and Associated Finishing Products 2-2
the first such conversion in Canada. It is reported that Westroc’s Montreal plant is also supplementing natural gypsum with FGD by-product gypsum originating from the NYSEG’s (New York State Electric & Gas Corporation) operations in upper New York state. Further, about 230,000 tonnes of marketable FGD gypsum/year will be available shortly from New Brunswick Power Corporation’s Belledune Generating Station 3. Recently CGC started to use some TiO2 by- product gypsum in its Montreal plant. It is estimated that up to 8-10% of Canadian gypsum board capacity was poised to use non-traditional, by-product sources of gypsum beginning in early 1996.
Within the last fifty years, gypsum board, also popularly known as drywall or plasterboard, has become the dominant product for finishing interior walls and ceilings in residential, commercial and institutional buildings. More than 95% of interior walls in Canada and the U.S.A. are finished using this inexpensive building material.3 In 1994, more than 267-million m2 of gypsum board were produced in Canada.4 Quoting the Gypsum Association, Canadian board capacity at the 1994 year end was 345-million m2, which would indicate 77% capacity utilization.2 The total annual North American gypsum board production capacity is 2.7 x 109 m2, or 9.8 m2 per capita, the highest in the world.5,2
In Canada, gypsum board is produced in all provinces with the exception of Prince Edward Island and Saskatchewan. There are three major companies producing gypsum board: CGC Inc., Domtar Gypsum, and Westroc Industries Limited. CGC Inc. is about 75% owned by USG Corporation, the largest gypsum products manufacturer in the world, while Westroc is a part of the BPB family of companies, the second largest gypsum products producer in the world. Domtar Inc. recently announced an agreement to sell its gypsum division to Georgia-Pacific Corporation.6 Typically, a substantial share of Canadian board production, especially from the Quebec and Ontario plants, is exported to New England, New York and Michigan, with some occasional exports to countries like Denmark, Czech Republic, Cuba, Hong Kong, and Brazil as well as to the Middle East.
Most of the gypsum board manufacturers are large, vertically integrated operations mining or quarrying their own gypsum rock, and producing not only a range of board products, but most of the associated joint finishing materials as well. While gypsum products manufacturers also often own and operate their own paper mills in the U.S., this is not the case in Canada. Facing papers for gypsum board are made in Canada by only two independent producers, Beaver Wood Fibre Co.’s plant in Thorold, ON, and CPL Paperboard Ltd. in Burnaby, B.C. The rest of the paper needs of the Canadian gypsum board manufacturers are supplied from the U.S.A.
Table 2.1 shows the gypsum mining and gypsum board manufacturing operations, and their locations. The AthenaTM Project: Gypsum Board and Associated Finishing Products 2-3
TABLE 2.1: GYPSUM MINING AND GYPSUM PRODUCTS MANUFACTURING OPERATIONS, 1994
Company Location Operation
Newfoundland Domtar Inc. Flat Bay Open-pit mining, closed in 1994 Atlantic Gypsum Corner Brook Gypsum board manufacture Nova Scotia Domtar Inc. McKay Settlement Open-pit mining Domtar Inc. Windsor Plaster manufacture Fundy Gypsum Company Limited Wentworth and Miller Creek Open-pit mining Georgia-Pacific Corporation Sugar Camp Open-pit mining Little Narrows Gypsum Company Ltd. Little Narrows Open-pit mining National Gypsum (Canada) Ltd. Milford Open-pit mining Louisiana-Pacific Corporation Port Hawkesbury Gypsum fiberboard manufacture New Brunswick Westroc Industries Limited McAdam Gypsum board manufacture Quebec CGC Inc. Montreal Gypsum board manufacture CGC Inc. St. Jerome Gypsum board manufacture Domtar Inc. Montreal Distribution terminal only Westroc Industries Limited Montreal Gypsum board manufacture Ontario CGC Inc. Hagersville Underground mining and gypsum board manufacture Domtar Inc. Caledonia Underground mining and gypsum board manufacture Westroc Industries Limited Drumbo Underground mining, closed in 1995 Westroc Industries Limited Mississauga Gypsum board manufacture Manitoba Domtar Inc. Amaranth Open-pit mining Domtar Inc. Winnipeg Gypsum board manufacture Westroc Industries Limited Amaranth Open-pit mining Westroc Industries Limited Winnipeg Gypsum board manufacture Alberta Domtar Inc. Edmonton Gypsum board manufacture Westroc Industries Limited Calgary Gypsum board manufacture British Columbia Domtar Inc. Canal Flats Open-pit mining Domtar Inc. Vancouver Gypsum products manufacture Westroc Industries Limited Windermere Open-pit mining Westroc Industries Limited Vancouver Gypsum products manufacture
Source: Adapted from Ref. (1) The AthenaTM Project: Gypsum Board and Associated Finishing Products 2-4
2.1.2 Gypsum Fiberboard Gypsum fiberboard (GFB) is a product that is new to the North American markets, being introduced here in about 1990. GFB products were developed over the last 20 years in Germany, where the product has been quite successful, capturing about 20 to 25% of the total gypsum board market. There are a number of competing processing technologies. What all of these have in common is the fact that the finished board is “paperless”, that is, it does not have any paper facings as does the conventional gypsum board. Instead GFB consists of about 18% ground waste newsprint/magazine fibers uniformly dispersed throughout the gypsum matrix. It is this recycled paper fiber that provides the reinforcement of the matrix instead of the paper skins.17
The only North American GFB operating facility is Louisiana-Pacific’s plant in Port Hawkesbury, NS. The rated annual capacity of the plant using Carl Schenck’s AG technology is about 23- million m2 per year, representing about 6.7% of the total gypsum board capacity. The plant’s strategic location allows shipping along the Eastern seaboard of the U.S. Market penetration in Canada appears to be limited at this time, and is perhaps more successful in non-traditional areas (for gypsum-based boards) such as 3/8" thick 4' x 4' sheets of floor underlayment than in competition with conventional gypsum board for wall and ceiling applications. L-P’s literature19 (October 1993) gives production volume as 6.5-million m2, which would indicate capacity utilization of only 28% at that time. The corresponding share of L-P’s FiberBond¨ GFB would be about 2.8% of the total Canadian gypsum board production and, as the bulk of the finished board is being shipped to U.S. destinations, their market share in Canada is expected to be even smaller.
2.1.3 Gypsum Building Plasters Gypsum building plasters applied over lath were used for centuries to finish interior wall and ceiling surfaces. However, about 30 or 40 years ago, gypsum board replaced plaster as the premier wall-cladding material due to its ease of application and economy factors. Plastering of the wall surfaces requires trained, experienced workers. Although plaster can provide a superior wall surface, these days only a fraction of walls are finished that way. Building plasters have been largely replaced by more economical and easier-to-apply gypsum board systems.
Building plasters are formulated products that may contain, in addition to calcined gypsum (stucco), hydrated lime, talc, clay, various chemical additives and admixtures to control product set, handling and application characteristics. Some building plasters may also contain various aggregates: materials such as sand, woodfiber, vermiculite or perlite. While some building plasters are applied over gypsum lath or metal lath, more often veneer plasters are used in thin (1/16" to 3/32") coat applications over a special type of gypsum board for veneer plasters. One-coat as well as two-coat (base and finish coats) systems are available. The AthenaTM Project: Gypsum Board and Associated Finishing Products 2-5
2.1.4 Joint Finishing Products Joint finishing products are an integral part of gypsum board systems. Their role is to finish the joint between the individual sheets of gypsum board in such a manner that even under critical lighting the whole wall (or ceiling) gives an impression of a monolithic surface. Typically a paper joint tape embedded in joint compound is used to “bridge” the joint. (In a relatively new development, some glass mesh tape has been used for the same purpose, especially by the "do-it- yourself" market.) Additional application(s) of joint compounds are required to provide a smooth, uniform joint treatment.
Joint compounds are highly formulated products consisting of 8 to 12 different raw materials to ensure a joint compound with the right application, performance and appearance characteristics. Although the basic composition of each type of compound is common to all brands within that type, different additives and admixtures make these brand formulations proprietary. Basically, there are two types of joint compounds on the market,
¥ drying compounds, and ¥ setting compounds.
Drying compounds are usually calcium carbonate-based. The overwhelming majority are produced as “ready mix”, compounded with other ingredients, such as talc, mica, thickeners, resin/latex, perlite, preservatives, and water to produce creamy, easily spreadable paste. These compounds shrink upon drying, and there is, therefore, a need for further applications of the compound and “feathering” of the joint, with proper drying and sanding in between the applications, to obtain a satisfactory joint. Ready mix joint compound is usually applied in three coats. Gypsum board manufacturers specify about 67.4 kg of joint compound per 100 m2 of board (138 lb/MSF).20 (Similarly about 98 m of joint tape is used for 100 m2 of board (300'/MSF).) These amounts already account for small joint compounds and joint tape wastes during their application.
Setting compounds are usually stucco-based and, therefore, come only in dry form. They are mixed with water only just prior to their application and, depending on their formulation, they typically then have a 45- or 90-minute “pot” life. As the hardening of these compounds is a chemical reaction rather than a physical one (drying), their shrinkage is substantially lower than that of the ready mix joint compounds. Due to their convenience, ready mix joint compounds are much more popular than the dry powder materials. According to Statistics Canada, 131,844 tonnes of ready mix compounds and 11,877 tonnes of dry powder compounds were produced in 1994.4
Joint compounds are produced and marketed by all three major gypsum board manufacturers, CGC Inc., Domtar Gypsum, and Westroc Industries Ltd. Louisiana-Pacific offers fiber filled ready mix compound compatible with their gypsum fiberboard. There are also a number of independent joint compounds producers, among them Synkoloid in Vancouver and Edmonton, Ontario Gypsum and Bondex in Toronto, Rayproc in Montreal, and Maritime Gypsum in New Brunswick. The AthenaTM Project: Gypsum Board and Associated Finishing Products 2-6
2.2 GYPSUM BOARD MANUFACTURING Gypsum board is manufactured in a two step process. In the first step finely crushed and ground
gypsum, calcium sulfate dihydrate (CaSO4¥2H2O), is heated and partially dehydrated (calcined) to calcium sulfate hemihydrate (CaSO4¥1/2H2O), called stucco in the industry, also popularly known as “Plaster of Paris”. A unique characteristic of stucco is that when it is mixed with the proper amount of water, it forms a smooth plastic mass which can be molded into any desired shape. When the hardening has been completed, the mass has been chemically restored to its rock-like state. This characteristic has also been used in the development and production of gypsum board. In the second step of the manufacturing process stucco is mixed with a number of additives, foam and an excess amount of water to prepare gypsum slurry which is extruded on a fast moving, continuous board production line between two layers of special gypsum paper. “Raw” gypsum board is then allowed to fully hydrate - calcium sulfate hemihydrate is converted back to dihydrate - before it is cut to the desired size and before it enters a “gypsum kiln”, where at elevated temperatures the excess water is driven off. The gypsum board is then stacked, ready to be shipped. The process is described in literature from a number of gypsum board manufacturers as well as equipment suppliers.7-12
The basic manufacturing steps are depicted in Figure 2.1 and summarized below:
2.2.1 Extraction Rock mining/quarrying Gypsum rock is open pit quarried or (underground) mined, generally by drilling and blasting, then moved to a primary crusher close to the quarry/mine site. The primary deposits of high quality gypsum in Canada are found in the Atlantic provinces, where open-pit quarrying is used. The quarry process begins by first removing the earth over the deposit. Then gypsum rock is drilled and blasted loose to be carried to the processing plant where it is crushed and screened. The largest quarry in the world, National Gypsum's Milford NS operation produces up to 4.5-million tonnes of gypsum a year. Quarrying is also a primary extraction technique used in Manitoba and British Columbia.
In south-western Ontario, gypsum is mined in underground mines. There, gypsum lies about 80 to 100 feet below ground level. The deposits lie in flat beds approximately 48" thick, interlayed with limestone. Either mine shafts driven straight into the ground or long sloping tunnels leading through the overburden of soil, clay and limestone rock are used to access the gypsum strata. From there extend “streets”, separated from each other by pillars of rock left to support the roof of the mine. Domtar’s #3 mine in Caledonia recently went to a continuous mining technology using electrically powered machines to cut the rock in place, thus eliminating the use of any explosives. Front-end loaders, diesel-powered shuttle cars, trucks, hoists and conveyor belts are all used in various quarrying and mining operations. The AthenaTM Project: Gypsum Board and Associated Finishing Products 2-7
gypsum rock (mined or crusher screen gypsum quarried) bin or hammer mill by-product gypsum (FGD or TiO2)
screen Raymond mill continuous kettle H2O additives calciner
stucco bin back paper board knife
face pin mixer paper
board kiln
stacking, bundling
gypsum board to warehouse & shipping
Fig. 2.1 Flow diagram of a typical gypsum board plant using continuous kettle calcination (adapted from Refs. 7, 8, 9). The AthenaTM Project: Gypsum Board and Associated Finishing Products 2-8
Primary crushing In the primary crusher, gypsum rock is reduced to approximately 2" - 5" or less in size. From here the crushed rock can be sent to secondary crushing and conveyed directly to the mill, it can be stockpiled, or, as is the situation in most cases because quarry and the production facilities are usually not in the same location, it can be shipped by ship, rail or truck to the manufacturing plant. In Canada only CGC’s Hagersville plant and Domtar’s Caledonia one are located directly on the mine.
2.2.2 Calcination Plant Secondary crushing, drying, milling After primary crushing, gypsum rock may be sent through the dryers. Normally gypsum rock has 1-3% free moisture content (quarry water). At this moisture content level, it may by-pass the dryer. However, if the moisture content is higher (typically up to 10%), as is often the case if the material has been stockpiled outside, some drying in directly heated rotary dryers is needed in order to reduce moisture to below the 3% level. Secondary crushers, typically hammermills, reduce the rock further to about 1" in diameter. Baghouses are preferred to collect fine particulate matter, although some plants may use electrostatic precipitators or cyclones. These operations usually take place at the plant site.
In most of the processes the crushed rock is fed to the roller or other type of mill, where its size is further reduced so that 90% will pass through a 150 µm sieve. The resulting form of gypsum is called landplaster, referring to one of its possible uses. In some processes (Imp Mills, for example) calcination and grinding can be accomplished simultaneously and, in such a case, no prior grinding is required. Rock drying/grinding consumes ~6% of the total energy required to produce gypsum board (not counting energy needed to produce paper skins for the board).13
Other sources of gypsum Quarried or mined gypsum represents the bulk of the gypsum supply and consumption. However, there are two additional sources of raw gypsum that can be used: waste gypsum (board) and industrial by-product gypsum.
The term waste gypsum is understood to mean internally generated plant waste and, more recently, also new construction waste collected and brought back to the manufacturing facilities, primarily in the Vancouver and Toronto metropolitan areas. (No gypsum plants accept any demolition waste due to possible contamination.) When waste gypsum board is used, it has to be broken down, chopped and crushed. A variety of different equipment and techniques are used: Norba crushers appear to be the most efficient and favoured ones. In some cases a portion of paper / paper fibers is removed or screened from the waste gypsum stream. Typically, the gypsum board plants that recycle waste gypsum board use up to about 20% waste in their gypsum stream. Unless prevented by some technical reasons, producers like to do so, as it makes not only environmental, but also economic sense. The AthenaTM Project: Gypsum Board and Associated Finishing Products 2-9
Use of by-product, chemical gypsum is new to the North American continent. In the U.S., by-product gypsum represented only 3.6% of the total gypsum supply in 1994.2 In Canada, Westroc is the first gypsum board producer to use FGD gypsum on any significant scale starting in 1995.
Flue gas desulfurization (FGD) gypsum Growing awareness of the environmental damage caused by SO2 emissions and the resulting acid rain, followed by legislative actions, spurred research and development of a large number of FGD processes. Wet FGD processes are the most popular and the only processes that have the potential to produce board-grade gypsum. These processes are well established and have been implemented at many Japanese and German utilities, and increasingly in North American ones as well. Wet FGD processes use lime or limestone and may or may not produce gypsum co-product. The calcium sorbent reacts with SO2 to produce calcium sulfite hemihydrate, which can be oxidized to calcium sulfate dihydrate (gypsum). The production of FGD gypsum has four stages:
Stage 1 — Desulfurization: The dedusted flue gas is sprayed into a washing tower with a limestone suspension in a counterflow operation. The primary purpose of desulfurization is accomplished by eliminating the SO2 from the flue gas. The calcium sulfite thus obtained occurs as a sludge in the quencher of the washing tower.
Stage 2 — Forced Oxidation: Conversion of the calcium sulfite sludge into gypsum is achieved through its oxidation in the quencher of the FGD reaction vessel using atmospheric oxygen. First, the highly insoluble calcium sulfite reacts with further SO2 to produce calcium bisulfite, easily soluble in water, that subsequently reacts spontaneously with atmospheric oxygen blown into the reactor to produce calcium sulfate dihydrate, i.e. gypsum. This second stage is the operation that leads to the conversion of waste sulfite into a product: FGD gypsum. In the course of this stage, the gypsum crystals increase markedly in size, up to an average of 50 µm.
Stage 3 — Gypsum Separation: Large crystals of a desirable size are separated by means of hydrocyclone and collected in a separate vessel.
Stage 4 — Washing and Dewatering: Finally, in the last stage, the gypsum crystal suspension is filtered or centrifuged, and the gypsum cake is washed with clean water to remove water soluble substances, especially chlorides, sodium and magnesium ions. Dewatering to less than 10% moisture is achieved by means of vacuum filters or centrifuges. The FGD gypsum thus obtained is a product chemically identical with natural gypsum. FGD gypsum is a salable, commercial grade gypsum suitable for gypsum board manufacturing or any other applications calling for gypsum. The AthenaTM Project: Gypsum Board and Associated Finishing Products 2-10
Processing of by-product gypsum by gypsum board producers poses challenges of its own. Due to its very fine particle size and residual moisture, handling of by-product gypsum can be difficult. Even if modern filtration presses and centrifuges are used for dewatering, gypsum’s moisture content is in the 8 to 10% range when delivered to the gypsum board plants. Typically, by-product gypsum has to be dried prior to its calcination using a flash dryer or a fluidized bed dryer, requiring a major modification/up-grade of the existing natural gypsum handling operation. Drying of by- product gypsum with 10% moisture content requires about 0.55 GJ of thermal energy and 0.04 GJ of electrical energy per tonne.14
Calcination Calcination is perhaps the most important step of the gypsum processing and gypsum board manufacturing process. During the calcination, gypsum that in its dihydrate form contains 21% by weight of chemically bound water is heated and converted to stucco, calcium sulfate hemihydrate:
heat CaSO4 ¥ 2H2O ———> CaSO4 ¥ 1/2 H2O + 1 1/2 H2O
Although different types of equipment are available for calcination of gypsum, calcination kettles that can be operated in either batch or continuous mode are the most commonly used equipment in North America. To produce gypsum board stucco, continuous calcination kettles are usually used with a throughput of 300 to 500 tonnes a day. Although several designs are available, the basic principle involves an externally heated cylindrical vessel with a height greater than its diameter, enclosed within a refractory shell and complete with stirrer, flues and internal baffles. Kettles can be fired by coal, oil, or gas.
Gypsum (landplaster) is fed into the kettle from the top. Heat is introduced from a firebox below and flows upward around the vessel. In submerged combustion kettles, a modern type of a continuous kettle, a tube is installed so that combustion gases are discharged into the calcining mass. The kettle contents boil violently, as chemically bound water is released as steam at around 120¡C. Heavier stucco tends to settle at the lower section of the kettle from where it is continuously discharged through a plunging tube into a hot pit where cooling occurs. In practice due to the inability to heat all the particles of gypsum uniformly, the dumped stucco will often contain small amounts of uncalcined gypsum as well as of completely dehydrated anhydrite. The modern continuous calcination kettles require about 0.9 GJ to 1.0 GJ of energy per tonne of finished stucco.15 In older, less energy-efficient kettles, the energy consumption can be as high as 1.3 GJ/tonne. Corresponding electrical energy requirements are given as between 0.01 GJ/tonne and 0.03 GJ/tonne. Calcination consumes ~27% of the total energy required to produce gypsum board13, and represents the second most energy-intensive step of the gypsum board manufacturing process.
Other types of calciners can be used, but lag in popularity behind the continuous calcination kettles. At one time, counter-current direct heating rotary kilns, similar to those used in Portland cement manufacturing, were used by the gypsum industry. Due to the improved design and energy The AthenaTM Project: Gypsum Board and Associated Finishing Products 2-11
efficiency of the calcination kettles, most of the rotary kilns in the gypsum industry were replaced. Now only Atlantic Gypsum in Corner Brook is using such a kiln. Domtar Gypsum is using Imp mills (flash calciners with simultaneous impact hammermill grinding) in some of its operations, and Louisiana-Pacific’s gypsum fiberboard operation in Port Hawkesbury employs a Claudius Peters flash calciner that incorporates a ring ball grinder in its design. The energy efficiency of rotary kilns is similar to large continuous kettles, while that of flash calciners is reported to be slightly better.
Raymond mill, stucco bins After stucco has cooled it is elevated to bins from where, in some plants, it is fed to a Raymond Mill for further grinding to get the fineness needed. In the Raymond Mill stucco is ground by rolls running centrifugally against the stationary outer ring.
2.2.3 Gypsum Board Plant The layout of a gypsum board plant is usually U-shaped with the board line from the paper roll stands to the board cut-off knife forming one side of the U, the transfer station its bottom, and the board dryer returning parallel to the board line its other side.11
Mixing Stucco for gypsum board production is blown from the supply bins (or mill) to the board plant. The amount of stucco is metered and fed to the stucco feed system. Dry board additives and admixtures such as starch, accelerator, retarder, and other ingredients depending on the type of board being made, are conveyed and blended with the stucco in a mixing screw conveyor. The blended dry materials, water with premixed liquid additives such as water reducers, and pregenerated foam are fed directly into the pin mixer, and the resulting slurry is deposited in a number of streams on the paper as it starts to form the board. To achieve the right fluidity of the slurry, a volume of water in excess of the amount needed for complete hydration has to be used. (This excess “water of convenience” will later be driven off during the drying process.) Two small edge mixers are often used to prepare and deposit higher density slurry for the board edges, to improve their strength and handling properties.
Paper Gypsum board is frequently described as a sandwich, with gypsum in its core and paper as its facings. Making the paper for gypsum board is as complex a process as making the gypsum board itself.9 The raw materials used are waste paper from newspaper, magazines, and old corrugated cardboard. Waste paper is fed by conveyor into a pulper, a large “blender” that disintegrates and dissolves the old paper into a pulp, a slurry of paper fibers. The paper slurry is then cleaned of various contaminants such as bailing wires, staples, glue and ink, before it is fed into the paper- making machine. Two types of paper making equipment, i.e. rotating cylinders or Fourdrinier flat wire machines, can be used to produce gypsum paper. The AthenaTM Project: Gypsum Board and Associated Finishing Products 2-12
A cylinder machine rotates a large drum through a vat of pulp slurry. A wide felt belt passes over the top of the turning drum of a cylinder. The cylinder pulls the pulp up and presses it against the bottom of the felt, where it sticks to form a single ply of paper. It takes nine cylinder-made plies pressed together to make a single continuous sheet of gypsum board paper.9 The characteristics of the pulp entering the vats determine whether the system produces cream stock, called “ivory”, used for the face of the gypsum board or gray stock, which makes the back side. The Fourdrinier method uses two machines instead of nine to make a two-ply paper with the same performance characteristics as nine-ply, cylinder made paper. The pulp slurry is systematically fed onto a continuously running wire screen (the Fourdrinier). As the screen moves forward, water drains from the pulp to create the paper. One Fourdrinier machine makes the surface (top) ply, which may be cream or gray stock depending on the pulp mixture. The second machine produces the gray (bottom) ply.
From this point, both systems operate in the same way. In the press section, the paper plies are pressed together to squeeze out the excess water. Next, they enter a series of high-temperature dryers where any remaining water is removed. The “bone dry” paper enters what is called a “calender stack”, where different chemicals or treatments are applied to the top and bottom surfaces to create the specific finishes required. For example, a dye and sizing agent will be added to the top surface to produce the moisture-resistant characteristics for the moisture resistant (“green”) board. The face and back paper each weigh about 45 to 55 lb/MSF. On the basis of one source16 that estimates the energy content of gypsum board paper prepared from recycled stock at about 25.4 GJ/tonne, we can extrapolate the related energy input into the finished gypsum board at about 12.4 MJ/m2 of board.
Gypsum board line The paper is placed on racks beside the pin mixer, where stucco slurry has been mixed with water. The racks run above and below the exit of the pin mixer, so that the stucco slurry can be sandwiched between the paper. The stucco slurry is then spread onto the ivory-coloured face paper on a moving belt and covered, or sandwiched, with the top paper, or “gray back”, to be formed into gypsum board at the master roll. As the board passes along the belt line the edges are formed, shaped and sealed. The proper identification is printed on the “gray back”. The long continuous sheet of gypsum board now travels about 200 to 275 meters on moving belts and roller conveyors while setting (hydrating). The long board line is needed to allow the slurry time (about four minutes) to harden before it is cut. By the time the end of the conveyor is approached, the stucco slurry has set; hydrated back to gypsum.
Knife, transfer station An automatic device trips a knife that cuts each board to the correct length. The individual boards are now transferred, inverted, turned over, stacked six or even eight layers high and sent slowly back to the drying kiln. The AthenaTM Project: Gypsum Board and Associated Finishing Products 2-13
Gypsum board drying kiln In the drying kiln, the excess amount of water introduced into the slurry mix in the pin mixer in order to have the slurry of the correct working characteristics, has to be driven off. Oil, gas or even electricity can be used as the source of heat in kilns. Drying of the gypsum board in the kiln consumes more energy than all the other steps of the gypsum board manufacturing process combined, representing ~67% of the total.13 The temperature and humidity in the kiln are closely controlled in three or four separate sections, first a lot of heat, then gradually less. After some 60 minutes of drying the board emerges at the “take-off” end of the machine where it is inspected, taped in two-panel bundles, stacked and taken to the warehouse, ready for shipment.
2.2.4 Types of Gypsum Board Produced The industry has developed and is producing a range of different gypsum boards for different applications. National Standard CAN/CSA-A82.27-M91 covers gypsum board, defines its various types and specifies their composition and special properties. The types of gypsum board covered include: ¥ gypsum board (regular gypsum board) ¥ type X gypsum board (fire-resistant gypsum board) ¥ vinyl-faced gypsum board ¥ foil-backed gypsum board ¥ gypsum backing board ¥ water-resistant gypsum board ¥ gypsum coreboard ¥ gypsum sheathing ¥ gypsum base for veneer plaster ¥ gypsum lath ¥ exterior gypsum soffit board
While some of the above boards, such as regular or type X, are produced in large volume, some of the other materials are specialties only. Furthermore, many of the above boards are made in different thicknesses: 1/2" and 5/8" gypsum board are among the more popular ones. Statistics Canada does not provide a detailed breakdown for the volume of different boards produced, distinguishing only between plain gypsum board, gypsum board covered with vinyl or other substances, and sheathing.4 U.S. statistics are published by USDI Bureau of Mines2, and the breakdown of various boards is more detailed. It states that of the prefabricated products, based on surface area,
¥ 63% was regular gypsum board, ¥ 24% was fire-resistant type X gypsum board, ¥ 5% was 5/16" mobile home board, ¥ 3% was water- and/or moisture-resistant board, and the remaining ¥ 5% covered lath, veneer base, sheathing, predecorated, and other types of board. The AthenaTM Project: Gypsum Board and Associated Finishing Products 2-14
Of the gypsum regular board, ¥ 82% was 1/2", and ¥ 10% was 5/8".
A detailed breakdown of gypsum board consumed in the U.S.A. is given in Table 2.2, and in the absence of similar Canadian data we will assume a similar split for Canada as well.
TABLE 2.2: TYPES OF GYPSUM BOARDS SOLD OR USED IN THE U.S.A., 1994
Product Thousand Thousand Value % square feet tonnes [US $] (based on area)
Lath: 3/8" 6,886 4 1,410 0.0297 1/2" 137 > 0.5 24 0.0006 other 5,867 5 407 0.0253 Total lath 12,890 10 1,841 0.0556
Veneer base 419,149 374 36,667 1.8070
Sheathing 286,166 242 33,544 1.2337 Regular gypsum board: 3/8" 918,125 711 69,102 3.9582 1/2" 11,885,323 9,357 1,487,447 51.2395 5/8" 1,466,834 1,225 57,282 6.3238 1" 172,079 155 31,905 0.7419 other (1/4", 7/16", 3/4") 128,872 101 16,470 0.5556 Total regular board 14,571,233 11,548 1,662,206 62.8189
Type X gypsum board 5,526,219 5,157 460,985 23.8244
Predecorated board 87,066 78 27,872 0.3754
5/16" mobile home board 1,226,687 843 117,345 5.2884
Water-resistant board 658,432 558 84,529 2.8386
Other 407,790 382 27,168 1.7580
Grand total 23,195,632 19,192 2,452,158 100.0000 Source: adapted from Ref. (2) The AthenaTM Project: Gypsum Board and Associated Finishing Products 2-15
2.3 GYPSUM FIBERBOARD 2.3.1 Gypsum Fiberboard Manufacturing The basic raw materials for the production of gypsum fiberboard in Louisiana-Pacific’s plant in Nova Scotia are local natural gypsum, waste newsprint/magazine stock from the U.S./Canadian east coast, and perlite from Greece or New Mexico.18 Various additives and admixtures such as lime, starch, accelerators, etc., are used as well. The board has a 3-layer composition: the surface layers contain paper fibers and stucco, the core layer also contains expanded perlite, which helps to control the board density by reducing its overall weight by 20 to 25%.
Raw materials preparation The basic material flow is shown in Fig. 2.2. The waste paper bales are transported to the plant site by barge. (The barge also takes the finished product back to the consumers in the more populated areas on the east coast.) The waste paper is broken down first in a shredder to 2" x 2" clippings. The hammermill reduces the particle size further to about 1" x 1" pieces, which are subsequently milled down to fibers and wetted. Perlite arrives by truck and is expanded in four parallel lines to about eight times its original volume. In a primary blender, perlite is mixed with water, and in a secondary blender wet fibers are added to wet perlite. Natural gypsum comes to the plant from the local Nova Scotia mine by rail.18 Gypsum rock extraction, preparation and calcination is done in a similar manner as for conventional gypsum board, and as discussed in Sections 2.2.1 and 2.2.2 above.
Board forming and pressing It is in the raw materials streams mixing, board forming and pressing, that GFB processing differs from gypsum board manufacturing. The process is considered to be “semi-dry”, the amount of water added to the raw materials (fibers and perlite) and on the line just before it enters the press is carefully controlled and is close to the theoretical amount needed for stucco hydration. The three layers and related three raw material blends are kept separate in handling and deposition on the line, and can be identified in the finished product.
The forming station consists of three conveyor belts, one for each surface layer and one for the core layer. In each layer a weight-controlled layer of prewetted fibers or prewetted fibers and perlite is formed and a weight controlled layer of stucco is put on the top. Unmixed layers of wet and dry materials are conveyed to the mixing heads in front of the press, and spread onto the press belt. The board is produced in a continuous roller type COE Manufacturing (Washington Iron Works) press. The press is about 30 meters long, and the residence time of the board in the press is about 3 minutes. As the stucco setting characteristics are accelerated by means of additives, the initial board setting is finished before the board leaves the press. The AthenaTM Project: Gypsum Board and Associated Finishing Products 2-16
gypsum rock (mined or crusher screen gypsum quarried) bin or by-product gypsum (FGD or TiO2)
Raymond mill screen Claudius Peters flash waste additives calciner paper perlite
paper perlite shredding expansion
stucco moisture bin fiber blending mills
spreading spreading surface centre layer layers fibres fibres & perlite
mixing mixing
cross cut saw forming belt continuous press
stacking, bundling
GFB to warehouse & shipping board dryer Fig. 2.2 Flow diagram of a gypsum fiberboard (GFB) plant with a Claudius Peters flash calciner (adapted from Refs. 18, 34). The AthenaTM Project: Gypsum Board and Associated Finishing Products 2-17
Board line, kiln dryer After the press, the continuous ribbon of the “green board” is cut to 22- or 24-foot-long pieces using a high pressure water jet, and after about 15 minutes spent moving on the conveyor and completing the hydration in a manner similar to that of conventional gypsum board, GFB enters the first heating zone of an 8-deck Dornier dryer. The dryer has a screen belt as a carrier and jet nozzles to distribute the hot air evenly onto the boards. It has 17 heating zones, each individually controlled. The source of heating energy is propane gas. The residence time of the board in the kiln dryer is about 25 minutes, and the final board moisture content is about 0.8%. A finishing area for final trim and cutting, application of seal coat, stackers etc. follows the dryer.18
2.3.2 Types of Gypsum Fiberboard Produced Louisiana-Pacific is producing three types of gypsum fiberboard:
¥ 1/4" and 3/8" FiberBond¨ GFB floor underlayment, ¥ 1/2" and 5/8" FiberBond¨ GFB exterior wall sheathing, and ¥ 1/2" and 5/8" FiberBond¨ GFB board.
As noted in Section 2.1.2, we estimate that all L-P’s FiberBond¨ GFB products combined have a 2.8% share of the total Canadian gypsum board production.
2.4 GYPSUM BUILDING PLASTERS 2.4.1 Gypsum Building Plasters Manufacturing As noted in Section 2.1.3, gypsum board largely replaced plaster as the premier wall-cladding material. Their market share in Canada is limited, and their manufacturing process is discussed here only briefly.
Extraction, crushing, milling, calcination, stucco milling The gypsum plasters manufacturing process, with the exception of final milling, formulating and bagging, is the same as that of gypsum board. Steps 1 through 5 of the gypsum board production, i.e. extraction and preparation of raw materials, their crushing and milling, and the calcination process with subsequent grinding in a Raymond mill, as described in Section 2.2.1 and 2.2.2 are the same. (However, some gypsum facilities use separate production lines and smaller batch kettle calciners to give them more flexibility in producing plaster stucco. Another reason for a separate line is that the inclusion of paper fibers from the recycled gypsum board construction waste in building plasters is undesirable.) Fig. 2.3 shows a flow diagram of the gypsum plaster manufacturing process. The AthenaTM Project: Gypsum Board and Associated Finishing Products 2-18
gypsum rock (mined or crusher screen gypsum quarried) bin or hammer mill by-product gypsum (FGD or TiO2)
screen tube mill batch kettle calciner
additives
stucco stucco stucco bin bin bin
weighting / mixing belt
mixing & packing stations
building and industrial plasters to warehouse & shipping
Fig. 2.3 Flow diagram of a gypsum building and industrial plasters manufacturing plant with a kettle calciner (adapted from Ref. 7). The AthenaTM Project: Gypsum Board and Associated Finishing Products 2-19
Plaster Manufacturing - Grinding / Tube mill Raymond mill stucco is passed through a tube mill. This is a long tube filled with iron balls of various sizes which grind the stucco to the required fineness. Plasters require stucco of higher surface area than gypsum board stucco.
Additives / Plaster mixer / Packer Plaster additives such as lime, talc, clays, and various admixtures regulating plaster set, are mixed with the tube mill stucco in the plaster mixer to produce plaster of the desired handling, application and performance properties. The building / veneer plasters (or industrial plasters) are then bagged in the packer and taken to the warehouse for shipment.3
2.4.2 Types of Plasters Produced The market for building/veneer plasters is small. Some gypsum manufacturers produce plasters in Canada, others bring them from the U.S. There is little information in the public domain regarding the size and regional distribution of veneer plasters in Canada. In the U.S.A. 553,000 tonnes of plasters were produced in 1994 vs. 19,200,000 tonnes of gypsum board.2 The above tonnage for plasters, however, is the total for building and industrial plasters, which normally split the total production in about a 60 to 40 ratio. Our estimate, based on some Gypsum Association breakdowns between different types of materials, is that in the U.S. the following volumes of different calcined gypsum products were produced in 1994 (Table 2.3).
TABLE 2.3: CALCINED GYPSUM PRODUCTS SOLD OR USED IN THE U.S.A. IN 1994
Product Volume [tonnes] %
Regular Plasters 155,400 0.79 Veneer Plasters 148,900 0.75 Gauging Plaster & Keene's Cement 24,700 0.13 Sub-total Building Plasters 329,000 1.67 Sub total Industrial Plasters 224,000 1.13 Total Building and Industrial Plasters 553,000 2.80 Prefabricated Products (Gypsum board) 19,192,000 97.20 TOTAL CALCINED GYPSUM PRODUCTS 19,745,000 100.00 Source: adapted from Ref. (2)
In the absence of similar Canadian data we will assume that plaster products have a similar share of the market in Canada, athough there are some indications that they are used here even less than in the U.S. However, as the total of all building plasters represents only 1.67% of the total calcined gypsum products, we will omit them from development of detailed unit factor estimates, and concentrate instead on a variety of gypsum boards dominating the gypsum products markets. The AthenaTM Project: Gypsum Board and Associated Finishing Products 2-20
2.5 JOINT FINISHING PRODUCTS MANUFACTURING To apply gypsum board and to finish joints, drywall nails or screws are needed, as well as drywall tape and joint compound. Gypsum board manufacturers20 provide typical usage for these associated finishing products as follows:
¥ ready mixed joint compound: 67.4 kg/100 m2 ¥ setting joint compound: 35.2 kg/100 m2 ¥ paper tape: 98 m/100 m2.
Similarly, the approximate usage for various fasteners is as follows:
¥ drywall nails 1 1/4": 2.20 kg/100 m2 ¥1 5/8": 2.81 kg/100 m2 ¥ drywall screws 1 1/4": 2.07 kg/100 m2 ¥1 5/8": 2.73 kg/100 m2.
2.5.1 Ready Mix Joint Compound Ready mix joint compounds represent over 90% of the total joint finishing materials used in Canada. Their formulas are proprietary, nevertheless they share the same major raw material components, and their development is as much an art as it is a science. An experienced formulator is critical to their success. Generic formulations used in the development of the unit factors in this study are shown later. The two main constituents of ready mix are:
¥ water, acting as a vehicle, and ¥ calcium carbonate (CaCO3), finely ground limestone, functioning as a filler.
These two raw materials represent about 80 to 90% of the total composition. In some formulations a portion of limestone is replaced by gypsum. Other components whose share is above 2% (by weight) of the total can include:
¥ talc, ¥ mica, ¥ specialty clays, such as attapulgite or kaolin, and ¥ resin (latex), usually polyvinyl acetate, functioning as a binder.
Lightweight formulas can contain perlite. The joint compound formulas are completed with different admixtures and additives, such as cellulosic thickeners, starches, surfactants, dispersants, flocculants, and preservatives (antibacterial and antifungal agents); all of these being used in minute quantities only. Typically, ready mix compounds contain about 65% solids. Virtually all of these, as indicated, are industrial minerals that are quarried or mined, crushed and ground to the appropriate fineness. Joint compound manufacturers generally purchase rather than mine the raw materials. The basic manufacturing process is depicted in Fig. 2.4 and summarized below. The AthenaTM Project: Gypsum Board and Associated Finishing Products 2-21
dry raw materials bagged dry raw resin materials & in bulk water additives
ribbon mixer
dry powder mixer
pump discharge
weigh scale pulverizer & inspection station
packer packer
valve bags pails or box containers
palletizer weigh scale & inspection station
warehousing & shipping
Fig. 2.4 Flow diagram of a joint compound producing plant (adapted from Ref.7). The AthenaTM Project: Gypsum Board and Associated Finishing Products 2-22
Industrial minerals extraction & preparation The main component, calcium carbonate, is abundantly available. Limestone is mined by open-pit methods, requiring no special equipment. Overburden is removed using bulldozers, draglines, or hydraulic shovels. The rock is drilled and blasted. The broken stone is loaded into dump trucks and hauled to the primary crushers, or it is loaded onto a conveyor and carried directly to a portable or permanent crusher. For most uses of limestone, it must travel through a secondary crusher and be sized. Where fine particle size is required, as in joint compounds, it has to be ground.16,21 Other industrial minerals used, such as talc, mica and clays are extracted and prepared in a similar manner. The mining and production of gypsum have been discussed under gypsum board (Section 2.2.1).
Latex binder The only raw material accounting for more than 2% of the mass of the ready mix joint compound composition other than industrial minerals is a latex binder, usually polyvinyl acetate (PVA). Polyvinyl acetate is prepared by introducing a benzene solution of vinyl acetate with a catalyst into a jacketed vessel. The mixture boils at 72¡C, and the vapours are returned to the kettle. After about five hours at a gentle boil, the reaction mixture is run to a still and the solvent and unchanged vinyl acetate are removed by steam distillation. The molten resin is run into drums, where it solidifies, or is extruded into rods and sliced into flakes.22 It is usually supplied to the joint compound manufacturers in the form of a 55 to 60% solids emulsion.
The precursor of polyvinyl acetate, vinyl acetate is manufactured by reacting ethylene, derived usually from natural gas, with acetic acid in the vapour phase over a palladium catalyst. The reaction takes place in a fixed-bed tubular reactor and is highly exothermic. When the reaction is conducted under the correct conditions, the only significant by-product is CO2. Enough heat is recovered as steam to perform the recovery distillation. The reaction occurs at 175 to 200¡C under pressure of 475 to 1,000 kPa. 22
Ready mix joint compound manufacturing process Limestone, and sometimes the other larger volume components, are stored in bulk facilities. Limestone is weighed as are the other dry raw materials, and often pre-mixed in a dry blender. Dry premix is fed via weigh hopper and screw conveyor into wet blenders, either a paddle- or a continuous-ribbon-type. Liquid ingredients (water, PVA emulsion) are distributed through a piping system. Following the blending operation, finished ready mix compound is transferred into holding tanks, either by gravity or using Moyno pumps, usually de-aerated under vacuum, and packaged either in pails or in lined boxes.
2.5.2 Dry (Setting) Joint Compound Gypsum stucco accounts for about 70 to 75% of the total formulation in setting compounds. Calcium carbonate and mica are other major ingredients, while clays, starches, gels, hydrated lime, accelerators and retarders are typical additives used in smaller quantities. Perlite can be used in The AthenaTM Project: Gypsum Board and Associated Finishing Products 2-23
lightweight formulas, as well. The main formulation components, gypsum stucco, calcium carbonate and mica are extracted, prepared, and in the case of gypsum, calcined to stucco, as described in detail in previous sections. All the ingredients are weighed and mixed in dry paddle or V-shell blenders. Dry setting compounds are shipped in bags, and they are offered in a range of different set times, 45-minute and 90-minute ones being the most popular. Recently some lightweight setting compounds have become available as well.
2.5.3 Products Statistics Canadian production volumes for joint filler compounds in 1994 are shown in Table. 2.4.4
TABLE 2.4: PRODUCTION OF JOINT FILLER COMPOUNDS, 1994
SCG Code 1994 Production [tonnes]
Ready mix 2520.20.90 131,844 Dry powder 2520.10.13 11,877 Source: adapted from Ref. (4)
2.5.4 Joint Paper Tape Most joint tape is manufactured from paper similar to the “ivory” bleached paper used as facing of the board. Papermaking raw materials and production were discussed in Section 2.2.3 under “paper” for gypsum board. Paper is cut into proper widths (typically 2 1/16"), sanded and buffed, and perforated. All paper joint tape is creased in the middle to accommodate taping of inside corners. Joint tape is sold in rolls, either boxed in bulk, unpackaged, or wrapped in plastic.
Use of paper joint tape is the most widespread, although a small quantity of glass mesh tape pioneered by a Canadian company, Bayex Division of Bay Mills Ltd., is used mainly by the DIY market. Statistics Canada does not provide their relative market share, but it is apparently growing.
2.6 GYPSUM INDUSTRY, ENERGY AND ENVIRONMENT Like any industry, gypsum board manufacturing uses energy resources and emits some pollutants to the atmosphere. It also generates some liquid effluents and solid wastes. At the same time, gypsum board is perhaps one of the more environmentally friendly building products because of:
¥ the long established use of recycled newsprint and cardboard in the production of its paper facings, ¥ essentially 100% recycling of in-plant and increased volume of construction waste gypsum board back into production, and The AthenaTM Project: Gypsum Board and Associated Finishing Products 2-24
¥ the recent development of synthetic (by-product) gypsum replacing some of the natural gypsum.
2.6.1 Energy Use and Efficiency Energy used for drying/grinding of gypsum raw materials (~6% of total energy), gypsum calcination (~27%) and gypsum board drying (~67%) constitutes a major cost in gypsum board production (around 18% of the total direct manufacturing costs).13 As a result, the industry made major, conscientious strides to reduce their energy consumption, especially following the oil cost increases during the 1970’s. A shift from batch kettle calcination to continuous kettle calcination, and optimization of the firing process significantly improved efficiencies and energy consumption. Modern well-designed continuous kettles such as are used in most of the North American facilities require approximately 1 GJ/tonne of hemihydrate.15 Recent development of improved calcination methods, such as kettles with submerged combustion and conical kettles offer further improvements in energy efficiencies. Energy input of 0.65 GJ/tonne was measured for 72% purity gypsum calcined in a conical kettle.23-25 (Table 2.5)
TABLE 2.5 TYPICAL EFFICIENCIES AND ENERGY CONSUMPTION OF DIFFERENT CALCINATION KETTLES
Type of Kettle Energy Efficiency Energy Consumption [GJ/tonne]
@ 72% purity @ 90% purity
Batch 55 0.98 1.21 Continuous 65 0.82 1.02 Continuous with submerged 75 0.71 0.88 combustion Conical 90 0.65 0.70 @ 81.5% Source: adapted from Refs. (23-25)
Judicious selection of fuels as well as insulation, a sophisticated temperature control regime and heat recirculation/recovery on the gypsum board drying kilns implemented following the energy crisis also resulted in energy efficiency improvements.
Industry data indicate an average expenditure of 36.3 GJ/tonne of paper produced.28 This can vary from about 28.2 GJ/tonne if the paper is produced in an integrated mill, to 39.0 GJ/tonne if it is produced in a pulp mill followed by a paper finishing mill. However, the gypsum industry has been using paper made from recycled newspaper and cardboard since the 1950’s; a long time before it became environmentally “popular”. It is estimated that paper products manufactured from recycled material require approximately 27 to 44% less energy than from virgin wood, depending largely upon whether the paper is bleached or unbleached.28 It is assumed that for the gypsum board industry, which uses bleached kraft paper, the energy savings is probably in the 30% range16, bringing the energy content from 36.3 GJ/tonne down to about 25.4 GJ/tonne. As about 100 lb of The AthenaTM Project: Gypsum Board and Associated Finishing Products 2-25
paper is used per MSF of board (0.5 kg/m2), a contribution of about 12.45 MJ/m2 of gypsum board can be attributed to the paper.
2.6.2 Atmospheric Emissions Mining of gypsum, as well as its crushing, grinding, and handling in the plant, including the calcination step of the process, result in particulate emissions. Similarly extraction and processing of other industrial minerals, such as calcium carbonate, talc, mica and clay, used in the joint compound manufacturing, will cause some particulate emissions.
Energy consumed in the extraction process, in the raw materials transportation, as well as gypsum board manufacturing and subsequent shipping to the markets, will result in emissions of CO2, CO, SO2, NOx, CH4 and VOCs, as in any process where energy is used. However, gypsum calcination produces less NOx than production of such materials like cement or lime where high temperatures result in significant thermal NOx. In contrast, gypsum calcination requires relatively low dehydration temperatures, in the 120¡ to 140¡C range. Below 1000¡C no significant thermal NOx is generated.26 As far as CO2 is concerned, during the gypsum calcination there is only fuel CO2 generated. In gypsum processing, there is no dissociation of the calcium sulfate molecule as is the case in the calcium carbonate calcination in the cement and lime manufacturing, and therefore no chemical (calcination) release of CO2.
The handling and blending of dry raw materials for gypsum board in plant operations, as well as the cutting of the finished board result in some particulate release. Bag houses and other emission controls are employed to minimize particulate release.
In the production of a moisture (water) resistant gypsum board, asphalt or wax emulsions are usually used to treat the board (albeit in very small quantities). Their precursors are petroleum products and a variety of pollutants, including VOCs and hydrocarbons are released during the drilling, extraction, and cracking of petroleum. However, the amount of such releases that would be attributable to gypsum board are negligible. Regular or type X gypsum board itself does not contain any VOCs, however, there is some indication in the literature that gypsum board can absorb VOCs released from other building materials used during construction, and then release them at a slower rate back into the indoor air.16 There appears to be a lot of confusion on this subject, with no definitive conclusion at this time.
Like gypsum board manufacturing, joint compounds production contributes to the particulate emissions, as it uses mainly dry powder ingredients. Particulates are released in the extraction and processing of the raw materials (calcium carbonate, gypsum, talc, mica, clays, perlite), and in their handling and blending in the manufacturing stage. Ethylene, the precursor of PVA used as a binder in the ready mix joint compounds, will contribute to emissions of VOCs and benzene, a highly regulated, known carcinogen. But again, only a very small amount of such releases would be ultimately attributable to joint compounds on a per unit basis. The uncontrolled emission factor for VOCs is 8.35 kg/tonne of ethylene, and the uncontrolled emission factor for benzene is 1.11 kg/tonne of ethylene. The controlled emission factor for benzene is 0.0845 kg/tonne of ethylene.16 The AthenaTM Project: Gypsum Board and Associated Finishing Products 2-26
2.6.3 Liquid Effluent In comparison with most of the paper manufacturing, gypsum paper production using recycled paper stock substantially reduces water usage and associated effluent discharges, which could otherwise result in increased turbidity from suspended solids, increased alkalinity, reduced BOD, and increased deoxygenation. Most of the paper used in the production of gypsum board is postindustrial newsprint. When such paper is deinked, residues end up in leftover sludge. About one-fifth of the wastepaper material is drawn off as sludge, which contains not only ink residues, but also fillers, clay, fiber fragments, and other materials. The inks on the newsprint, however, are typically non-toxic, and the sludge from many deinking mills is being used by farmers as clay- heavy soil conditioner.28
While there are closed water-loop process technologies available, and many end-of-pipe control improvements were implemented over the last few decades with respect to effluent releases from the paper mills, some problems still remain. Nevertheless, the paper industry record in general is improving. Canadian paper mills (all combined) reduced their total suspended solids (TSS) discharges from 2,106 tonnes/day in 1978 to 816 tonnes/day in 1985. Discharges of BOD fell from 3,337 to 1,961 tonnes/day during the same period of time, while production increased from about 51,000 tonnes/day to 74,000 tonnes/day.29
In the gypsum board manufacturing process, apart from quarry water and stormwater generated in the extraction of gypsum rock, there is very little liquid effluent. (If by-product gypsum is used, such material may have to be washed by its producer to reduce the soluble salts [Na+, Mg++, Cl-] content for gypsum to be acceptable by the gypsum board plant.).
The paper manufacturing process, including that of gypsum facing paper, is a large generator of liquid effluent containing suspended solids and organic pollutants. (On average, in the production of pulp and paper, each tonne of paper requires about 100 m3 of process water, although the actual amount consumed depends on the production process.29
Ready mix joint compounds manufacturing operates in a closed loop system; consequently no liquid effluent is generated with the exception of a very low, non-measured effluent from the occasional washing of the production equipment and area.
2.6.4 Solid Waste Extraction of gypsum rock, in contrast to many other quarrying and mining operations, generates very little waste, as gypsum rock is usually used in its entirety in the manufacturing process, without any separation of the impurities, refining or smelting of the desired materials from the rock. In the few operations where some beneficiation of the rock is required, the main contaminant is usually limestone, which is resold as aggregate for road building or similar applications. The AthenaTM Project: Gypsum Board and Associated Finishing Products 2-27
A small amount, typically 5% to 10%, of waste gypsum board is generated in its production during the start-ups, due to the production of off-specs board, and due to the cutting and trimming of the board. As already noted, all the in-plant generated solid waste is recycled back into production. Some of the off-specs board is cut and used for sleutters to support pallets of the finished board, thus eliminating the need to use 4" x 4" wood supports.
In joint compound production no other solid waste is generated than the raw materials packaging. Most often, however, the packaging paper bags are shipped back for recycling.
2.6.5 Recycling
The use of industrial by-products (FGD or TiO2 gypsum) and post-industrial waste (waste paper, gypsum board construction waste) as raw materials in the production of gypsum board was already mentioned. In our calculations, energy associated with transport of gypsum board construction waste back to the production facility is accounted for. This recycling and reuse of by-products and wastes is one of the major strengths of the gypsum industry. As noted in Section 2.1.1, in 1995 Westroc’s Mississauga plant became the first Canadian gypsum board plant operating entirely on FGD by-product/waste gypsum, with a number of other operations supplementing their gypsum rock supply with by-product gypsum, or construction waste gypsum.
In at least two Canadian metropolitan areas, Vancouver and Toronto, construction gypsum board waste is banned from landfill sites. It is being collected by recyclers, and supplied back to the gypsum board manufacturing plants. An alternate use for construction waste, according to the Gypsum Association, includes agricultural applications and animal bedding material.16 Beneficial re-use of either by-product or waste construction gypsum reduces pressure on scarce landfill sites.
The availability of free, or very inexpensive by-product gypsum, is changing the gypsum industry. In years to come, it is expected that more and more FGD gypsum will be used where it makes economic and geographic sense.3 In 1992 in the U.S.A. over 25.5 GWe of coal-fired power generating plants were already operating, under construction, or planned to be equipped with wet lime/limestone scrubbers generating FGD gypsum. It is expected that by the end of the decade some 7.3-million tonnes of FGD gypsum could be available.31,32 To put that number in perspective, it represents about one-third of the total U.S. annual consumption and almost one-half of its gypsum mining output. Other sources forecast an eventual U.S. production of synthetic gypsum as high as 32-million tonnes annually.33
In Canada 1.5 GWe power generating capacity already is or soon will be similarly equipped.30 Canadian FGD gypsum production capability, estimated on the basis of Canadian vs. U.S. wet lime/limestone scrubbing capacity, appears to be in the 500,000 tonnes/year area. This figure seems to correspond well with the FGD gypsum generating forecasts expected from the Ontario Hydro’s Lambton and New Brunswick’s Belledune power stations. The AthenaTM Project: Gypsum Board and Associated Finishing Products 2-28
REFERENCES 1. O. Vagt, “Gypsum and Anhydrite”, Canadian Minerals Yearbook, 1994, Natural Resources Canada, Ottawa, 1995. 2. “Gypsum”, Annual Review 1994, Mineral Industry Surveys, U.S. Department of Interior - Bureau of Mines, Washington, DC 20241, August 1995. 3. G.J. Venta, R.T. Hemmings, “FGD Gypsum Utilization: A Strategic Approach to Reuse”, Proceedings , Paper 95-WA80.03, Air & Waste Management Association 88th Annual Meeting & Exhibition, San Antonio, TX, June 18-23, 1995. 4. “Gypsum Products”, December 1994, Statistics Canada Catalogue 44-003/ISSN 0380-7223, Vol. 45, No.12 5. G.J. Venta, R.T. Hemmings, E.E. Berry, “A North American Perspective on Recycling and Reuse of Waste and Industrial By-Products in Building Materials”, Proceedings of ReC’93 International Recycling Congress, Geneva, Switzerland, January 1993. 6. Toronto Star, November 10, 1995. 7. “Gypsum / Magic Mineral”, CGC Inc. 8. “The Story of Gypsum / How Gyproc is made”, Domtar Gypsum. 9. “How Gypsum is made”, Construction Dimensions, February 1991, pp.34-37. 10. “The Gypsum Industry and Flue Gas Desulfurization (FGD) Gypsum Utilization: A Utility Guide”, EPRI Report TR-103652, prepared by NYSEG and ORTECH, February 1994. 11. “Board Machinery”, The COE Manufacturing Company, Bulletin 7000. 12. “Board Production - Plant Design, Operational Layout, Manufacturing”, Combustion Engineering, Inc. Bulletin No. 123. 13. L.M. Luckevich, “Microwave Drying of Gypsum Board”, paper presented at the 81st Annual Meeting and Convention of the Canadian Ceramic Society, Montreal, PQ, February 1983. 14. F. Wirsching, “Calcium Sulfate”, Ullmann’s Encyclopedia of Industrial Chemistry, 5th edition, 1985, Vol. A4, pp. 555-584. 15. R.J. Wenk, P.L. Henkels, “Calcium Compounds (Calcium Sulfate)”, Kirk Othmer Scientific Encyclopedia, 1978 edition, Volume 4, pp.437-448. 16. “Gypsum Board Systems: Technical Report”, Topic I-9250, AIA Environmental Resource Guide, July 1993. 17. G.J. Venta, “Gypsum Fiberboard: A High Performance Specialty Board”, Proceedings of the 3rd International Conference on Inorganic-Bonded Wood and Fiber Composite Materials, Spokane, WA, September 28-30, 1992, pp.66-77. 18. G. Natus, “Gypsum Fiberboard Production in Nova Scotia”, Proceedings of the 2nd International Conference on Inorganic-Bonded Wood and Fiber Composite Materials, Moscow, ID, October 15-17, 1990, pp.85-87. 19. “FiberBond¨ Fiber-Reinforced Gypsum Panels”, Louisiana-Pacific, October 1993. 20. “Gypsum Construction Handbook”, 3rd edition, USG, 1987, p. 61. 21. “Building Materials in the Context of Sustainable Development - Raw Material Balances, Energy Profiles and Environmental Unit Factor Estimates for Cement and Structural Concrete Products”, Report prepared by CANMET and Radian Canada Inc. for Forintek Canada Corp., October 1993. The AthenaTM Project: Gypsum Board and Associated Finishing Products 2-29
22. “Gypsum Board Systems: Technical Report”, Topic I-9250, AIA Environmental Resource Guide, July 1993, p.24, adapted from G.T. Austin, “Shreve’s Chemical Process Industries”, 5th edition, 1984. 23. A.G.T. Ward, “Methods of Reducing Energy Requirements in Kettle Calcination”, Ciments, Betons, Platres, Chaux, No.728 - 1/81, pp. 51-56. 24. R. Lewis, “Improved Methods of Calcination”, Ciments, Betons, Platres, Chaux, No.753 - 2/85, pp. 99-105. 25. R. Lewis, “Improved Calcining Process for Gypsum”, Zement-Kalk-Gips, 38, No 5/1985, pp. 250-255. 26. J. Zelkowski, “Kohleverbrennung”, VGB Technische Vereinigung der Grosskraftwerksbetreiber e.V., Band 8 der Fachbuchreihe “Kraftwerkstechnik”, VGB-B008 1986. 27. American Gas Association, “Industrial Sector Energy Analysis: The Paper Industry”, February 1988. 28. “The Tellus Institute Packaging Study Project: Summary”, Tellus Institute, November 1991. 29. ‘The State of Canada’s Environment”, Chapter 14 - Industries, Pulp and Paper Production, Government of Canada, Ottawa, 1991, pp. 14-18/19. 30. H.N. Soud, M. Takeshita, “FGD Handbook”, Chapter 4 - FGD Installations on Coal-Fired Plants, IEACR/65 Report, IEA Coal Research, London, January 1994. 31. G.J. Venta, R.T. Hemmings, “FGD Gypsum Utilization: Bridging the “Two Solitudes”, Proceedings of 11th International Symposium on Use and Management of Coal Combustion By-Products (CCBs), American Coal Ash Association, Orlando, FL, January 15-19, 1995. 32. W. Ellison, R.A. Kuntze, “Expanding of Markets for Gypsum Byproducts”, Proceedings of Society for Mining, Metallurgy and Exploration, Inc., 1993 Annual Meeting, Reno, NE. 33. J.A. Walker, “Gypsum - The Miracle Mineral: Brief History and Prospects”, Proceedings of the 4th International Conference on Inorganic-Bonded Wood and Fiber Composite Materials, Spokane, WA, September 26-28, 1994, pp.39-40. 34. “Schenck Gypsum Fiberboard Plant Ð Future-Oriented Technologies for Innovative Panels”, Carl Schenck AG bulletin V 0224. The AthenaTM Project: Gypsum Board and Associated Finishing Products 3-1
3.0 RAW MATERIAL REQUIREMENTS AND TRANSPORTATION This section provides a brief overview of raw material requirements for gypsum board and associated products production in Canada on a regional basis. The section also provides an overview of transportation distances and typical modes used to move raw materials to the gypsum plants, again on a regional basis. Transportation data underlying the overview was used to develop corresponding energy estimates presented in Section 4.0.
Data on actual raw material requirements, transportation distances and modes was provided to VG&A by the three major gypsum board producers for all their plants listed in Table 2.1 (preceding section). However, we are treating the individual plant data as confidential and all data presented in this report is therefore shown as averages, typically weighted averages on a regional basis. The weights used to develop these and other estimates presented in later sections are the actual utilized capacities for 1995 as provided directly by the producers.
For the Newfoundland plant which did not provide detailed raw material and transportation data, we estimated transportation distances and modes based on the industry and market general information. For the one GFB plant in Nova Scotia that did not provide this data directly, we made assumptions based on their published information18.
3.1 RAW MATERIAL REQUIREMENTS - GYPSUM BOARD Gypsum board formulations are essentially identical from one region of the country to another, and from one part of the North American continent to another. The differences between raw materials from one producer to another are also rather insignificant. Generally, board formulations consist of 48% to 55% gypsum stucco, around 2% to 5% paper, and 42% to 46% water, on a mass basis.
As discussed in Section 2, gypsum stucco, the primary raw material in the board production, is produced through calcination of gypsum. One tonne of gypsum rock (or by-product) yields about 830 kg of stucco. In other words, 1.2048 tonnes of gypsum is needed for 1 tonne of stucco. Paper used as facings of gypsum board is made from recycled waste paper; it is assumed that 1.1 tonnes of raw materials (waste paper) is needed to produce 1 tonne of gypsum paper. These factors are included in relevant calculations and estimates.
While a number of admixtures and additives, such as accelerators, retarders, plasticizers, glass fibers, potash, dextrose, starch, emulsions, paper pulp, clay and perlite are used, depending on the type of gypsum board produced (standard, fire resistant (type X), or moisture resistant), their aggregate amount is only between 0.9% and 2.5%. None of the individual additives reach the 2% limit recommended as a cut-off level in the ATHENATM project Research Guidelines, and therefore their specific energy and emissions estimates were not developed. The AthenaTM Project: Gypsum Board and Associated Finishing Products 3-2
In contrast to conventional gypsum board, gypsum fiberboard, due to the nature of its process (semi-dry technology), uses substantially less water. To lower the GFB product weight and to approach that of gypsum board, expanded perlite is used in the core layer of the board.
Typical gypsum board formulations for ten (10) different gypsum board products are shown in Table 3.1 in kg of raw materials per m2 of finished board. Table 3.2 provides the same breakdown in percentages. These breakdowns by type of product and board thickness are used throughout the development of the unit factor estimates in all subsequent sections.
TABLE 3.1 GYPSUM BOARD GENERIC FORMULATIONS / AVERAGE RAW MATERIALS USE (KG/M2 OF FINISHED BOARD)
1/2" regular 5/8" regular 1/2" type X 5/8" type X 1/2" MR
Stucco 6.3610 8.3057 6.3329 8.4239 6.9755 Paper 0.4715 0.4773 0.4507 0.4649 0.4847 Water 5.4273 6.8308 5.3773 6.8967 6.6290 Other 0.1108 0.1493 0.2761 0.1523 0.3674 Perlite 0.0000 0.0000 0.0000 0.0000 0.0000 TOTAL (wet weight) 12.3706 15.7632 12.4370 15.9378 14.4566
(dry weight) 8.0632 10.2867 8.1854 10.5066 9.0406
5/8" MR 5/16" mobile 1" shaftliner 1/2" GFB 5/8" GFB home
Stucco 8.9438 4.4665 15.6671 6.8432 8.4911 Paper 0.5070 0.4887 0.4887 1.5207 1.8869 Water 8.4140 4.2246 11.9824 1.4147 1.7554 Other 0.4712 0.1050 0.2118 0.2766 0.3432 Perlite 0.0000 0.0000 0.0000 1.3306 1.6510 TOTAL (wet weight) 18.3360 9.2848 28.3500 11.3859 14.1276
(dry weight) 11.4840 5.8642 19.0585 11.1908 13.9762 The AthenaTM Project: Gypsum Board and Associated Finishing Products 3-3
TABLE 3.2 GYPSUM BOARD GENERIC FORMULATIONS / AVERAGE RAW MATERIALS USE (% BREAKDOWN)
1/2" regular 5/8" regular 1/2" type X 5/8" type X 1/2" MR
Stucco 51.42 52.69 50.92 52.85 48.25 Paper 3.81 3.03 3.62 2.92 3.35 Water 43.87 43.33 43.24 43.27 45.85 Other 0.90 0.95 2.22 0.96 2.54 Perlite 0.00 0.00 0.00 0.00 0.00 TOTAL (wet weight) 100.00 100.00 100.00 100.00 100.00
5/8" MR 5/16" mobile 1" shaftliner 1/2" GFB 5/8" GFB home
Stucco 48.78 48.11 55.26 60.10 60.10 Paper 2.77 5.26 1.72 13.36 13.36 Water 45.89 45.50 42.27 12.43 12.43 Other 2.57 1.13 0.75 2.43 2.43 Perlite 0.00 0.00 0.00 11.69 11.69 TOTAL (wet weight) 100.00 100.00 100.00 100.00 100.00
3.2 RAW MATERIALS TRANSPORTATION - GYPSUM BOARD Gypsum There are major differences in transportation distances between the sources of gypsum and the gypsum board plants for different gypsum operations. Some of the plants, such as the large CGC operations in Hagersville, ON, and Domtar’s plants in Caledonia, ON, are built on sites adjoining their sources of gypsum. All other plants receive gypsum from quarries, mines or sources of by- product gypsum from some distance. Some operations use a combination of different sources of gypsum, most often supplementing natural rock gypsum with synthetic gypsum. Table 3.3 provides weighted average distribution of the sources of gypsum for the three geographical regions as of 1995. As can be seen, natural gypsum is still the dominant source of raw material, with some synthetic being used both in the Central and East regions. In 1996, further expansion of FGD gypsum utilization is expected in the East region. The contribution of the recycled waste board, both of the internally generated waste and construction waste collected in major metropolitan areas and trucked to the plants, is also indicated. Legislative actions preventing landfilling of gypsum board construction waste in the Vancouver and Toronto metropolitan areas are the main reason for the higher “external” recycled content in the West and Central regions.
In the manufacturing process, recycled gypsum board is commingled with other sources of gypsum and handled in the same manner. This source of gypsum does not have to be “extracted”, however, its contribution to the unit factor estimates at all process stages, i.e. to raw materials transportation and manufacturing, is included. The AthenaTM Project: Gypsum Board and Associated Finishing Products 3-4
TABLE 3.3 DISTRIBUTION OF GYPSUM SOURCES BY GEOGRAPHICAL REGION (%)
Natural Synthetic Recycled / Recycled / Gypsum Gypsum external internal
West Avg. 86 0 8 6 Central Avg. 85 7 4 4 East Avg. 81 10 2 7 CANADA 85 6 4 5
There is a wide variability in transportation distances, which in some cases also determine the mode of transportation. In the West region, while most of the natural gypsum is moved by truck, one west coast operation using gypsum from Baja California moves it by ship. Current cost structure does not favour rail transport; there is only one plant in this region (and in Canada) transporting gypsum from the quarry to the plant by rail at this time. In the Central region, all the plants are either adjoining their sources of natural gypsum, in which case they use either electric conveyors or trucks, or are within economic trucking distance of the quarries. In the East region of the country, where most of the natural gypsum comes from the Atlantic provinces, the distance and actual board plant location determines the choice of either truck or marine (or marine/truck combination) of gypsum transportation. All the synthetic and recycled gypsum from external sources is transported, at this point, by truck. Table 3.4 shows weighted average distances by mode of transport for the three sources of gypsum for the three geographical regions. The favourable location of the Central region plants relative to gypsum supplies makes this the most efficient region in terms of raw material transportation energy use, as will be shown in the next section.
TABLE 3.4 WEIGHTED AVERAGE TRANSPORTATION DISTANCES FOR GYPSUM (KM) BY MODE OF TRANSPORT
Natural Gypsum Synthetic Recycled Gypsum Gypsum / external
ship rail road total road road
West Avg. 1436 184 274 1894 0 46 Central Avg. - - 44 44 34 15 East Avg. 656 6 231 893 3 9 CANADA 507 47 144 698 18 21 The AthenaTM Project: Gypsum Board and Associated Finishing Products 3-5
Paper In estimates of distances and modes of transport of gypsum board paper, two items have to be considered:
¥ transportation of waste paper to the paper mill for recycling, and ¥ transportation of finished paper from the mill to the board producer.
Based on information from one of the two Canadian suppliers, and known locations of other paper mills, we assume that an average shipping distance for waste paper to paper mill is 150 km, and that all shipping is exclusively by truck.
Weighted average shipping distances for the finished gypsum paper are shown in Table 3.5. In some cases ivory and gray paper are coming from different paper mills, explaining the differences between the two sets of numbers. All gypsum paper is shipped by road transport, with distances ranging from 50 to 2,500 km.
TABLE 3.5 AVERAGE TRANSPORTATION DISTANCES FOR PAPER (KM)
ivory paper gray paper
West Avg. 654 843 Central Avg. 457 351 East Avg. 835 497 CANADA 594 506
Gypsum Fiberboard Raw Materials Waste paper fibers for reinforcement of GFB are barged along the eastern seaboard from an average distance of 1,100 km. Perlite rock is shipped from Greece from an average distance of 9,500 km.
Backhaul Based on our discussions with the producers, we made the following assumption regarding the backhaul associated with transportation of raw materials:
¥ gypsum: no backhaul, ¥ waste paper to paper mill: no backhaul, ¥ finished paper (truck): 75% backhaul ¥ waste paper to GFB plant (ship): 75% backhaul, ¥ perlite (ship): 75% backhaul
Appropriate multiples of the transportation distances were used in estimates of the energy and atmospheric emissions unit factors. The AthenaTM Project: Gypsum Board and Associated Finishing Products 3-6
3.3 RAW MATERIAL REQUIREMENTS - FINISHING PRODUCTS Joint compound formulations are similar from one manufacturer to another, from one region of the country to another. As indicated in Section 2.5.1, the two main constituents of the ready mix compounds are finely ground limestone and water, with smaller amounts of talc, mica, specialty clays and resin binders. The differences between various proprietary formulas are related to minute additions of various admixtures and additives, and the details of the formulations are closely guarded secrets. Nevertheless, the basic formulations are available from raw materials suppliers, companies such as Dow Chemicals, Nacan Products, Reichhold Chemicals, Lorama Chemicals, and others, and as such are readily available and well known. Typical ready mix joint formulation, based on information from various raw materials suppliers, is shown in Table 3.6, expressed both in per cent (by weight) and in kg per m2 of gypsum board, taking into account standard usage of 0.674 kg of compound per 1 m2 of board.
TABLE 3.6 READY MIX JOINT COMPOUNDS GENERIC FORMULATION / AVERAGE RAW MATERIALS USE
Raw Material [%] [kg/m2 of gypsum board]
Water 34.6 0.23320 Clay 1.7 0.01146 Talc 3.8 0.02561 Mica 3.5 0.02359 Calcium carbonate 52.3 0.35250 PVA resin 4.0 0.02696 Other 0.1 0.00068 Total 100.0 0.67400
Setting joint compounds, as discussed in Section 2.5.2, are comprised primarily of calcium sulfate hemihydrate (plaster), calcium carbonate (limestone) and mica, with small additions of clays, starch, gels, lime and other chemicals. The type of plaster used for production of setting compounds is often calcined under different conditions than the stucco for gypsum board production. This so- called “β plaster” is available only from a few calcination plants across North America, and often it is shipped to the joint compound production facilities over some distance. Typical formulation for the setting joint compound, considering its approximate usage of 0.352 kg/m2 of board, is shown in Table 3.7.
Joint paper tape (see Section 2.5.4) is produced from recycled paper (newspaper, magazines and cardboard) stock, being essentially the same material as the “ivory” bleached paper used for facing of gypsum board. In estimating relevant unit factors, we will therefore use the same assumptions and numbers as for the “ivory” gypsum paper. As already indicated in Section 2.5, approximate usage of paper tape is about 0.98 m/m2 of gypsum board. The AthenaTM Project: Gypsum Board and Associated Finishing Products 3-7
TABLE 3.7 SETTING JOINT COMPOUNDS GENERIC FORMULATION / AVERAGE RAW MATERIALS USE
Raw Material [%] [kg/m2 of gypsum board]
Gypsum plaster 48.5 0.17072 Calcium carbonate 36.5 0.12848 Mica 7.2 0.02534 Clay 5.0 0.01760 Other 2.8 0.00986 Total 100.0 0.35200
3.4 RAW MATERIALS TRANSPORTATION - JOINT FINISHING PRODUCTS Joint compound manufacturing plants are located in all three geographical regions of the country. The raw materials, with the exception of plaster, resin binder and chemical additives, are usually sourced from the local distributors of industrial minerals. However, the particular grades of raw materials are often shipped to the local distributor from some distance. Detailed information regarding the transportation distances are not available. On the basis of rather limited information, we will assume following distances:
TABLE 3.8 ESTIMATED TRANSPORTATION DISTANCES FOR JOINT COMPOUNDS RAW MATERIALS (KM)
West Central East
Water - - - Clay 1200 2000 2000 Talc 3500 800 300 Mica 2000 2000 2000 Calcium carbonate 500 500 100 PVA resin 100 100 100 Gypsum plaster 1800 2000 2000
Calcium carbonate, plaster and resin binder are usually shipped in bulk, and we will assume no backhaul, other materials are shipped in bags, and we will assume 100% backhaul. All transport is by truck, with the exception of plaster, 50% of which is shipped by rail in the Central and East regions. The AthenaTM Project: Gypsum Board and Associated Finishing Products 3-8
For the joint tape raw materials (waste paper) transport, we assume the same average shipping distance of 150 km by truck as for the gypsum paper for board facings discussed in Section 3.2. Further we assume that finished “ivory” paper is shipped to the joint tape producer for its conversion the same average distance as the regular “ivory” paper is shipped to the gypsum board producers (Table 3.5), with a 75% backhaul. The AthenaTM Project: Gypsum Board and Associated Finishing Products 4-1
4.0 ENERGY USE - GYPSUM BOARD In this section, we explain and present the estimates of energy use developed for all manufacturing stages of the gypsum board production from the raw materials extraction and transportation to the gypsum board processing. For completion, the estimates of energy associated with finished board transportation are also shown, although these are fully handled by ATHENATM. All of the results are presented and discussed in terms of weighted regional averages using the 1995 actual gypsum board production levels as weights. Various tables show total energy use by region and process stage and we also show the breakdown by energy type because that information is directly relevant to the estimation of atmospheric emissions in a subsequent section of the report.
4.1 RAW MATERIAL EXTRACTION AND TRANSPORTATION In estimates of energy consumption associated with extraction of gypsum, we had to take a number of factors into consideration:
¥ relative distribution of natural, synthetic and recycled gypsum in the three regions, ¥ use of 1.2048 tonnes of gypsum rock (or by-product) for 1 tonne of stucco, ¥ the fact that some primary processing (primary crushing, drying) usually takes place at the quarry site, ¥ in production of commercial grade synthetic gypsum, the use of steam in the dewatering system, and the need for some additional power (e.g. for effluent treatment) that would not have to be used if by-product gypsum were landfilled.1
The differences between the “extraction” energy of natural and synthetic gypsum, as well as the source of energy in the quarries and mines (diesel fuel (road) vs. electricity), greatly affect the regional weighted averages. We did not receive detailed information from all the quarrying operations; for the missing quarries we assumed that it takes 0.027 GJ to extract one tonne of gypsum.2 (Or, multiplying by the factor 1.2048: it takes 0.0325 GJ to extract a sufficient amount of gypsum to produce 1 tonne of stucco.)
Table 4.1 shows weighted average energy consumption for gypsum extraction and primary processing (crushing, drying) at the source site, expressed in GJ per tonne of stucco.
TABLE 4.1 WEIGHTED AVERAGE ENERGY USE FOR GYPSUM EXTRACTION (GJ/TONNE OF STUCCO)
diesel - road coal oil electric total
West Avg. 0.0293 0.0000 0.0000 0.0118 0.0411 Central Avg. 0.0051 0.0043 0.0000 0.0547 0.0641 East Avg. 0.0293 0.0000 0.0057 0.0145 0.0495 CANADA 0.0177 0.0021 0.0018 0.0332 0.0548 The AthenaTM Project: Gypsum Board and Associated Finishing Products 4-2
The use of diesel-road fuel and a portion of the electric power is directly associated with the actual extraction. Coal, oil, and a portion of electric power usage is due to the primary processing. Most of the mines/quarries process gypsum rock on site prior to its transport to the board manufacturing plants; only few operations ship it “as is” to the plants, where it is crushed. In the absence of detailed information, we will assume that all the primary processing is conducted at the extraction site. In this approach, we will not understate the total energy usage at the gypsum source site, although it will create some distortion in terms of atmospheric emission estimates associated with electricity use, primarily in the East region. The estimates of electricity use developed in this report will be translated in the Sustainable Materials Project calculation model into the mixture of primary energy forms used to generate the electricity at the relevant generating facilities and emission factors will be calculated on that basis. To make this adjustment, the model assumes electricity comes from the relevant regional electrical grid. Therefore, when we assume gypsum from Nova Scotia is used in Quebec, the model will assign those electricity estimates to the Quebec grid and will estimate emissions accordingly. The estimates will likely be different from those that would be made assuming use of electricity from the Nova Scotia grid. Again, the lack of data precludes our doing anything to avoid this problem and we believe it will in any case be relatively minor in terms of the overall atmospheric emission estimates for gypsum production.
As an example, the estimates of gypsum extraction energy use, expressed in MJ per square meter of finished 1/2” regular gypsum board on a weighted average basis by region and for Canada as a whole, are shown in Table 4.2. A complete set of tables for all types of gypsum boards is shown in the summary at the end of this section.
TABLE 4.2 WEIGHTED AVERAGE ENERGY USE FOR GYPSUM EXTRACTION (MJ/M2 OF 1/2" REGULAR GYPSUM BOARD)
diesel - road coal oil electric total
West Avg. 0.1898 0.0000 0.0000 0.0765 0.2662 Central Avg. 0.0331 0.0279 0.0000 0.3538 0.4147 East Avg. 0.1895 0.0000 0.0368 0.0940 0.3203 CANADA 0.1145 0.0134 0.0117 0.2152 0.3546
Transportation - Gypsum The transportation energy use estimates were made by applying the following combustion energy factors from the Research Guidelines:
Energy Consumed Mode Fuel (MJ/tonne-kilometre) Truck Diesel - Road 1.18 Rail Diesel - Rail 0.49 Ship HFO - Marine 0.12 The AthenaTM Project: Gypsum Board and Associated Finishing Products 4-3
The above factors were applied to the individual raw material tonnages required per tonne of stucco on a plant-by-plant basis using haul distance estimates provided by the companies, and those numbers were later converted to per square meter of finished board, using the formulations as shown in Table 3.1. The distances were adjusted for all modes except conveyors (electricity) to account for empty or partial backhauls in accordance with the research guidelines. The weighted regional averages shown in the tables below were then calculated from the individual plant estimates.
TABLE 4.3 WEIGHTED AVERAGE ENERGY USE FOR GYPSUM TRANSPORTATION (GJ/TONNE OF STUCCO)
diesel-road diesel-rail HFO-marine electricity total
West Avg. 0.8851 0.2175 0.4152 0.0000 1.5179 Central Avg. 0.2646 0.0000 0.0000 0.0005 0.2651 East Avg. 0.7088 0.0000 0.1897 0.0000 0.8985 CANADA 0.5212 0.0534 0.1465 0.0002 0.7214
TABLE 4.4 WEIGHTED AVERAGE ENERGY USE FOR GYPSUM TRANSPORTATION (MJ/M2 OF 1/2" REGULAR GYPSUM BOARD)
diesel-road diesel-rail HFO-marine electricity total
West Avg. 5.7281 1.4079 2.6873 0.0000 9.8233 Central Avg. 1.7124 0.0000 0.0000 0.0030 1.7154 East Avg. 4.5872 0.0000 1.2275 0.0000 5.8148 CANADA 3.3733 0.3458 0.9480 0.0015 4.6686
Transportation - Paper Weighted regional averages for energy consumption associated with transportation of both the waste paper as raw material for the paper mill, and of the finished gypsum paper from the paper mill to the gypsum board plant, are shown in Tables 4.5 and 4.6. The AthenaTM Project: Gypsum Board and Associated Finishing Products 4-4
TABLE 4.5 WEIGHTED AVERAGE ENERGY USE FOR PAPER TRANSPORTATION (GJ/TONNE)
Waste Paper Finished Paper diesel-road diesel-road HFO-marine total finished paper
West Avg. 0.3894 1.1040 0.0000 1.1040 Central Avg. 0.3894 0.5959 0.0000 0.5959 East Avg. 0.3894 0.7486 0.0088 0.7574 CANADA 0.3894 0.7565 0.0021 0.7586
TABLE 4.6 WEIGHTED AVERAGE ENERGY USE FOR PAPER TRANSPORTATION (MJ/M2 OF 1/2" REGULAR GYPSUM BOARD)
Waste Paper Finished Paper diesel-road diesel-road HFO-marine total finished paper
West Avg. 0.1836 0.5206 0.0000 0.5206 Central Avg. 0.1836 0.2810 0.0000 0.2810 East Avg. 0.1836 0.3530 0.0041 0.3571 CANADA 0.1836 0.3567 0.0010 0.3577
4.2 GYPSUM BOARD MANUFACTURING As noted in Section 2 during the discussion of the gypsum board production process, board manufacturing consists of three separate processes:
¥ calcination of gypsum to stucco, ¥ gypsum paper manufacturing, and ¥ gypsum board production.
In the development of the energy estimates related to gypsum board manufacturing, we considered all these three production steps separately, before eventually combining them into the total manufacturing energy factors.
Fairly detailed information regarding use of energy in the calcination of gypsum to stucco as well as for the manufacturing of gypsum board was made available from the three major Canadian producers for all their plants. Energy consumption estimates were developed and tabulated by both the processing step and by the type of energy used. Calcination energy consumption data are shown in Tables 4.6 Ð 4.9. The AthenaTM Project: Gypsum Board and Associated Finishing Products 4-5
TABLE 4.6 WEIGHTED AVERAGE ENERGY USE IN STUCCO PREPARATION BY PROCESS STEP (GJ/TONNE OF STUCCO)
secondary drying grinding calcination stucco stucco total crushing grinding transport stucco preparation
West Avg. 0.0510 0.6377 0.0250 1.1631 0.0125 0.0476 1.9369 Central Avg. 0.0401 0.2893 0.0253 0.9145 0.0030 0.0688 1.3412 East Avg. 0.0277 0.5030 0.0201 1.2102 0.0062 0.0464 1.8137 CANADA 0.0399 0.4250 0.0240 1.0449 0.0061 0.0584 1.5984
TABLE 4.7 WEIGHTED AVERAGE ENERGY USE IN STUCCO PREPARATION BY PROCESS STEP (MJ/M2 OF 1/2" REGULAR BOARD)
secondary drying grinding calcination stucco stucco total crushing grinding transport stucco preparation
West Avg. 0.3304 4.1267 0.1618 7.5272 0.0810 0.3081 12.5352 Central Avg. 0.2597 1.8722 0.1640 5.9185 0.0197 0.4455 8.6797 East Avg. 0.1793 3.2553 0.1302 7.8319 0.0404 0.3005 11.7375 CANADA 0.2582 2.7505 0.1555 6.7626 0.0396 0.3778 10.3442
TABLE 4.8 WEIGHTED AVERAGE ENERGY USE IN STUCCO PREPARATION BY ENERGY FORM (GJ/TONNE OF STUCCO)
natural gas oil diesel electricity total stucco preparation
West Avg. 1.3135 0.4591 0.0000 0.1643 1.9369 Central Avg. 0.8198 0.1981 0.1692 0.1540 1.3412 East Avg. 0.7690 0.5191 0.3775 0.1481 1.8137 CANADA 0.9291 0.3375 0.1765 0.1552 1.5984
TABLE 4.9 WEIGHTED AVERAGE ENERGY USE IN STUCCO PREPARATION BY ENERGY FORM (MJ/M2 OF 1/2" REGULAR BOARD)
natural gas oil diesel electricity total stucco preparation
West Avg. 8.5007 2.9714 0.0000 1.0630 12.5352 Central Avg. 5.3055 1.2821 1.0951 0.9970 8.6797 East Avg. 4.9770 3.3592 2.4428 0.9586 11.7375 CANADA 6.0131 2.1844 1.1424 1.0042 10.3442 The AthenaTM Project: Gypsum Board and Associated Finishing Products 4-6
Some data were also obtained from one of the Canadian producers of gypsum paper, which was supplemented with some additional information.3 Nevertheless, there is not sufficient information available to develop regional weighted averages for the gypsum paper production. Therefore we have assumed that the energy use associated with the paper manufacturing is the same in all three regions. (Table 4.10) This brings some error into our estimates, however considering that similar processes and the same energy sources are used by all gypsum paper producers, this distortion will be minimal.
TABLE 4.11 WEIGHTED AVERAGE ENERGY USE IN PAPER PRODUCTION BY ENERGY FORM (GJ/TONNE OF PAPER)
natural gas oil electric total paper
CANADA 11.6047 0.6108 2.9148 15.1302
TABLE 4.11 WEIGHTED AVERAGE ENERGY USE IN PAPER PRODUCTION BY ENERGY FORM (MJ/M2 OF 1/2" REGULAR BOARD)
natural gas oil electric total paper
CANADA 5.4720 0.2880 1.3744 7.1344
Energy associated with the production of gypsum board itself, as per information provided by Canadian gypsum board producers, is shown, as an example, for 1/2" regular gypsum board, in Table 4.12.
TABLE 4.12 WEIGHTED AVERAGE ENERGY USE IN BOARD MANUFACTURING BY ENERGY FORM (MJ/M2 OF 1/2" REGULAR BOARD)
total board natural gas oil electric manufacturing energy
West Avg. 14.6351 3.8536 0.4096 18.8984 Central Avg. 14.4121 2.5886 0.3562 17.3569 East Avg. 10.7640 7.5119 0.4645 18.7404 CANADA 13.6108 4.0546 0.3947 18.0601
Total energy use associated with the three process steps of 1/2" thick regular gypsum board manufacturing is summarized in Tables 4.13 and 4.14. The AthenaTM Project: Gypsum Board and Associated Finishing Products 4-7
TABLE 4.13 TOTAL WEIGHTED AVERAGE ENERGY USE ASSOCIATED WITH PRODUCTION OF GYPSUM BOARD BY PROCESS STEP (MJ/M2 OF 1/2" REGULAR BOARD)
paper stucco board total energy production production production
West Avg. 7.1344 12.5352 18.8984 38.5680 Central Avg. 7.1344 8.6797 17.3569 33.1710 East Avg. 7.1344 11.7375 18.7404 37.6124 CANADA 7.1344 10.3442 18.0601 35.5387
TABLE 4.14 TOTAL WEIGHTED AVERAGE ENERGY USE ASSOCIATED WITH PRODUCTION OF GYPSUM BOARD BY ENERGY FORM (MJ/M2 OF 1/2" REGULAR BOARD)
diesel - road natural gas oil electric total energy
West Avg. 0.0000 28.6079 7.1131 2.8471 38.5680 Central Avg. 1.0951 25.1897 4.1587 2.7276 33.1710 East Avg. 2.4428 21.2130 11.1590 2.7975 37.6124 CANADA 1.1424 25.0959 6.5271 2.7733 35.5387
Detailed tables summarizing energy usage for ten types of gypsum boards under consideration, by process stage and region as well as by energy form and region, are shown at the end of this section, in Tables 4.25 to 4-44.
4.3 FINISHED GYPSUM BOARD TRANSPORTATION The last energy use category covers the transportation of finished gypsum board products from gypsum board plants to Canadian market distribution centres.
As in the case of raw material transportation, information about transportation distances, modes and geographical market distribution was provided by the three major gypsum board producers for all their plants. Based on our knowledge of the Canadian gypsum board markets, some assumptions had to be made regarding the relative share of the market between the various producers, as well as to include the remaining minor regional or specialty manufacturers. The Research Guidelines state that finished product transportation data should be provided in kilometres by mode of transport for average haul distances to Halifax, Montreal, Toronto, Winnipeg, Calgary and Vancouver from the relevant production points. The Guidelines further noted that “relevant production points” would be the facilities typically serving each of the cities.
Based on the information received from the gypsum board manufacturers, we concluded: The AthenaTM Project: Gypsum Board and Associated Finishing Products 4-8
¥ Vancouver is served by local plants by truck, ¥ Calgary is served 90% by the plants located in Alberta by truck, with 10% of the board shipped by rail from the Central region, ¥ Winnipeg is similarly served by local plants (85%), and 15% by rail from the Central region, ¥ Toronto is supplied exclusively by truck from local operations, ¥ Montreal is served mainly (80%) by truck from local plants, with the remaining 20% shipped also by truck from the Central region, and ¥ Halifax is supplied by plants located in Atlantic provinces (40%), either by truck or by ship, as well as by rail from either the Central region or the Quebec part of to East region.
The weighted average transportation distances by mode shown in Table 4.15 were then developed using the distances of each plant from the designated cities. Following discussions with the board producers, we assumed that only 20% backhaul is involved in truck transportation, whereas 100% backhaul is the rule for both the rail and the marine transportation of the finished board. These backhaul assumptions are already reflected in the distance numbers in the Table 4.15.
TABLE 4.15 WEIGHTED AVERAGE TRANSPORTATION DISTANCES BY MODE FOR FINISHED GYPSUM BOARD (KM)
Average Distances & Transport Mode Truck Rail Ship
Vancouver 90 0 0 Calgary 225 300 0 Winnipeg 90 400 0 Toronto 153 0 0 Montreal 288 0 0 Halifax 279 847.5 110
Transport factors [MJ/tonne-km] 1.18 0.49 0.12
note: appropriate backhaul factors included in the distances
The ATHENATM computer model calculates the energy consumption associated with the finished products transportation from the plant gate to the market, taking into consideration distances and transport mode. Here, just for illustration, we show the energy estimates (Tables 4.16 and 4.17 for 1/2" regular board). The distances by mode, as per Table 4-15, were multiplied by the relevant tonne-kilometre energy consumption figures.
We should emphasize that the averages in Tables 4.15, 4.16 and 4.17 only reflect where gypsum board is produced and how it is moved. They do not reflect gypsum board consumption levels in any of the cities. Both tables can be interpreted by thinking in terms of the embodied final transportation mileage and energy in a representative or average tonne of board (or square meter of board) landed in any one of the six cities. The AthenaTM Project: Gypsum Board and Associated Finishing Products 4-9
TABLE 4.16 WEIGHTED AVERAGE TRANSPORTATION ENERGY FOR FINISHED GYPSUM BOARD (GJ/ TONNE)
Truck Rail Ship Total diesel-road diesel-rail HFO-marine
Vancouver 0.1062 0.0000 0.0000 0.1062 Calgary 0.2655 0.1470 0.0000 0.4125 Winnipeg 0.1062 0.1960 0.0000 0.3022 Toronto 0.1805 0.0000 0.0000 0.1805 Montreal 0.3398 0.0000 0.0000 0.3398 Halifax 0.3292 0.4153 0.0132 0.7577
TABLE 4.17 WEIGHTED AVERAGE TRANSPORTATION ENERGY FOR FINISHED GYPSUM BOARD (MJ/ M2 OF 1/2" REGULAR BOARD)
Truck Rail Ship Total diesel-road diesel-rail HFO-marine
Vancouver 0.8563 0.0000 0.0000 0.8563 Calgary 2.1408 1.1853 0.0000 3.3261 Winnipeg 0.8563 1.5804 0.0000 2.4367 Toronto 1.4557 0.0000 0.0000 1.4557 Montreal 2.7402 0.0000 0.0000 2.7402 Halifax 2.6546 3.3485 0.1064 6.1095
We have omitted national averages from Tables 4.15 to 4.17 because national averages would be unduly distorted by the absence of any weights to take into account relative consumption levels in different cities and regions. If consumption is not taken into account, the high transportation energy associated with moving gypsum board to cities like Halifax or Calgary would be given too much implicit weight when calculating national averages. In contrast, the earlier sub-sections deal strictly with aspects of production, and actual production capacities provide an adequate weighting mechanism even at the national level. The omission of national averages at this stage, and subsequently, has no bearing in terms of our ultimate focus which is on unit factors for gypsum board delivered to the individual cities.
4.4 GYPSUM BOARD - ENERGY SUMMARY This section summarizes all the preceding energy estimates associated with the production of gypsum board by processing stage and by energy form in MJ/m2 of board. The summaries are presented for a “cradle to gate” LCA used by the ATHENATM model, as well as, for illustration, for a “cradle to market” LCA. Tables 4.25 and 4.26 cover 1/2" regular gypsum board discussed in detail above. The following tables (4.27 to 4.40) provide the same summary information for other common types and thicknesses of gypsum board, as selected and discussed in Section 2. The AthenaTM Project: Gypsum Board and Associated Finishing Products 4-10
The relative distribution of the energy used in production of gypsum board by the process step is shown as a percentage of the total energy use for the six cities under consideration in Table 4.18 and graphically in Fig. 4.1 for 1/2" regular board as an example. For other types of board, relative energy distribution would be similar. The total manufacturing stage (consisting of the paper production, gypsum calcination and board production itself) is obviously the most significant as far energy consumption is concerned, varying between different areas in the 73% to 89% range. This is followed by the raw materials transportation, showing a rather wide range from about 6% to 21%. This wide range is the result of some plants producing board right at the gypsum source site, whereas other board operations have to ship gypsum from thousands of kilometres away. Gypsum extraction and the initial on-site processing represents the lowest energy expense of the four processing stages.
Of the three manufacturing steps, the gypsum board manufacturing constitutes the highest share of the total manufacturing energy use at around 50%, followed by gypsum calcination (around 30%) and paper production (approximately 20%). This relative distribution of the manufacturing energy use is shown for 1/2" regular gypsum board in Table 4.19 and graphically illustrated in Fig. 4.2.
TABLE 4.18 PER CENT OF ENERGY USE IN GYPSUM BOARD PRODUCTION [1/2" BOARD] BY PROCESS STAGE (%)
Gypsum Total RM Total Board TOTAL Extraction Transportation Manufacturing Transportation
Vancouver 0.53 20.96 76.80 1.71 100.00 Calgary 0.51 19.98 73.20 6.31 100.00 Winnipeg 1.09 5.71 86.83 6.38 100.00 Toronto 1.11 5.86 89.12 3.91 100.00 Montreal 0.68 13.51 79.98 5.83 100.00 Halifax 0.64 12.61 74.63 12.12 100.00
TABLE 4.19 PER CENT OF ENERGY USE IN MANUFACTURING STAGES OF GYPSUM BOARD PRODUCTION [1/2" BOARD] BY PROCESS STAGE (%)
Paper Stucco Board Total Manufacturing Manufacturing Manufacturing Manufacturing
West Region 18.50 32.50 49.00 100.00 Central Region 21.51 26.17 52.33 100.00 East Region 18.97 31.21 49.83 100.00 The AthenaTM Project: Gypsum Board and Associated Finishing Products 4-11
Extraction RM Transport Manufacturing 100 Board Transport
80
60
40
20 % of total energy use
0 Vancouver Calgary Winnipeg Toronto Montreal Halifax City
Fig. 4.1: Breakdown of Energy Use in Gypsum Board Production [1/2" Board] by Process Stage (%)
60
West 50 Central East 40
30
20
10
% of total manufacturing energy 0 Paper Stucco Board Manufacturing of
Fig 4.2Breakdown of Energy Use in Manufacturing Stages of Gypsum Board Production [1/2" Board] by Process Stage (%) The AthenaTM Project: Gypsum Board and Associated Finishing Products 4-12
4.5 ENERGY USE IN GYPSUM FIBERBOARD (GFB) PRODUCTION All of the previous parts of this section discussed primarily conventional, paper faced gypsum boards. Most of what was said is also valid for paperless gypsum fiberboard (GFB), although there are some substantial differences in the formulations and in the raw materials used, as well as in the manufacturing process itself. GFB is manufactured only in one location in all of North America at this time, in Louisiana-Pacific’s plant in Nova Scotia, and this was taken into consideration for both the raw materials and the finished product transportation. As the manufacturer decided not to provide any information for this study, some additional assumptions had to be made based on our knowledge of the process and the published information.
Raw Materials Extraction In GFB production only locally available natural gypsum is used (together with 10% internal waste recycling). Gypsum extraction energy for the Eastern region, expressed per tonne of stucco, was adjusted accordingly. For perlite, the other industrial mineral used, we assumed extraction energy of 0.027 GJ/tonne of rock, in the form of diesel-road fuel, and the electrical energy input based on the gypsum rock extraction.
TABLE 4.20 WEIGHTED AVERAGE EXTRACTION ENERGY FOR GYPSUM AND PERLITE USED IN 1/2" GFB PRODUCTION
Gypsum extraction Perlite extraction Total extraction
diesel electric total diesel electric total diesel electric TOTAL gypsum perlite RMs
[GJ/tonne of stucco] [GJ/tonne of perlite]
0.0305 0.0117 0.0423 0.0270 0.0108 0.0378
[MJ/m2 of board] [MJ/m2 of board] [MJ/m2 of board]
0.2175 0.0834 0.3008 0.0359 0.0144 0.0503 0.2534 0.0977 0.3511
Raw Materials Transportation Specific conditions related to the GFB operation were considered. These include rail transportation of the locally quarried gypsum, marine transportation of the perlite rock from overseas, and both the local transportation by truck of the collected waste paper and its shipping by barge from these collection points along the Eastern seaboard.4 It was assumed that other raw materials are locally available in Nova Scotia, and supplied by truck. Appropriate backhaul assumptions were made as well. The resulting energy estimates for 1/2" GFB are shown in Table 4.21. The AthenaTM Project: Gypsum Board and Associated Finishing Products 4-13
TABLE 4.21 WEIGHTED AVERAGE ENERGY USE FOR 1/2" GFB RAW MATERIALS TRANSPORTATION
Gypsum Waste Paper Perlite Other RMs Transport RMs
diesel- diesel- HFO- waste HFO- diesel diesel diesel- HFO- TOTAL rail road marine paper marine road road rail marine total
[GJ/tonne [GJ/tonne] of stucco]
0.0413 0.3894 0.1650 0.5544 1.4250 0.4720
[MJ/m2 of board]
0.2828 0.5922 0.2509 0.8431 1.8961 0.1306 0.7227 0.2828 2.1471 3.1526
GFB Manufacturing In GFB production four separate manufacturing steps have to be considered:
¥ gypsum calcination, ¥ perlite expansion, ¥ paper defiberization, and ¥ board production.
For gypsum calcination we used the weighted average energy estimate [GJ/tonne of stucco] developed for the East region in Table 4.6. For the rather energy-intensive perlite expansion, W.R. Grace provided an average estimate of 3500 BTU/lb (= 8.1337 GJ/tonne).5 As far as the paper defiberization is concerned, we assumed that this is covered by the electrical energy input into the paper production from Table 4.11. Finally, for the board manufacturing itself, we used factors (developed in a client confidential GFB technical study) of 0.9555 for fuel use and 3.15 for power consumption for production of GFB vs. conventional gypsum board of the same thickness.6 The resulting energy estimates for manufacturing of 1/2" GFB are presented in Tables 4.22 and 4.23.
TABLE 4.22 AVERAGE ENERGY USE IN MANUFACTURING OF 1/2" GFB BY ENERGY FORM
Energy natural gas oil diesel-road electricity TOTAL
[MJ/m2 of board] 33.7609 3.6956 2.6875 6.9504 47.0943 The AthenaTM Project: Gypsum Board and Associated Finishing Products 4-14
TABLE 4.23 AVERAGE ENERGY USE IN MANUFACTURING OF 1/2" GFB BY PROCESS STEP
Gypsum Paper Perlite Board TOTAL calcination defiberization expansion manufacturing manufacturing
[GJ/tonne of [GJ/tonne of paper] [GJ/tonne of perlite] stucco]
1.8137 2.9148 8.1337
[MJ/m2 of board]
12.9129 4.4325 10.8229 18.9259 47.0943
Finished GFB Transportation GFB board produced in L-P’s Nova Scotia plant is intended mainly for the markets along the Eastern seaboard of the U.S.A. Nevertheless, it is also available through local distributors across Canada. In estimating energy embodied in finished GFB transportation, we assumed that to Halifax it is shipped by truck (20% backhaul) and to the rest of the country by rail (100% backhaul). Using the appropriate distances between Port Hawkesbury and the six regional cities under consideration
[km] [mode] Vancouver 5840 rail Calgary 4878 rail Winnipeg 3538 rail Toronto 1816 rail Montreal 1276 rail Halifax 360 road
The ATHENATM model calculates the energy factors associated with the GFB point of manufacture to the market. In the study, we provided the finished product transport energy estimates, based on the above distances and transport modes combined with the relevant transport factors from Table 4.15, just for illustration: The AthenaTM Project: Gypsum Board and Associated Finishing Products 4-15
TABLE 4.24 ENERGY EMBODIED IN TRANSPORTATION OF FINISHED 1/2" GFB
diesel-road diesel-rail [GJ/tonne]
Vancouver - 2.8616 Calgary - 2.3902 Winnipeg - 1.7336 Toronto - 0.8898 Montreal - 0.6252 Halifax 0.4248 -
[GJ/m2 of board]
Vancouver - 32.0235 Calgary - 26.7484 Winnipeg - 19.4005 Toronto - 9.9580 Montreal - 6.9969 Halifax 4.7538 -
GFB Energy Summary Total energy estimates associated with the production of 1/2" and 5/8" thick gypsum fiberboard by processing stage and by energy form in MJ/m2 of board are summarized in Tables 4.41 to 4.44.
REFERENCES 1. Communication from R.S. Daly, Ontario Hydro, dated February 27, 1996. 2. Canadian Industry Program for Energy Conservation (CIPEC), Ministry of Energy, Mines and Resources Canada, 1989. 3. “Gypsum Board Systems: Technical Report”, Topic I-9250, AIA Environmental Resource Guide, July 1993. 4. G. Natus, “Gypsum Fiberboard Production in Nova Scotia”, Proceedings of the 2nd International Conference on Inorganic-Bonded Wood and Fiber Composite Materials, Moscow, ID, October 15-17, 1990, pp.85-87. 5. Oral communication from B. Colbert, W.R. Grace Construction Products Division, August 9, 1996 6. “Gypsum Fiberboard (GFB): Technical Assessment Report”, Venta, Glaser & Associates, confidential client report, October 1991/July 1994.
The Athena East Central W TABLE 4.26B East Central West TABLE 4.26A East Central W ENERGY USE IN 4.25 TABLE Products Finishing Associated and Board Gypsum
est est TM Montreal Winnipeg Vancouver Montreal Winnipeg Vancouver Halifax Toronto Calgary Halifax Toronto Calgary
CRADLE TO MARKET ENERGY USE IN 1/2" REGULAR GYPSUM BOARD BY FORM AND REGION [MJ/M CRADLE TO GATE ENERGY USE IN 1/2" REGULAR GYPSUM BOARD BY FORM AND REGION [MJ/M Project: islra Diesel-rail Diesel-road Diesel-rail Diesel-road ysmRs RMs Gypsum Extract.
.23635 .341.351.4437.6124 33.1710 18.7404 17.3569 11.7375 38.5680 8.6797 7.1344 18.8984 7.1344 6.3555 12.5352 2.1800 7.1344 0.3203 10.5276 0.4147 0.2662 040 .45138 123 .001.982.8916 2.8916 11.1958 11.1958 0.0000 0.0000 21.2130 21.2130 1.3381 1.2317 3.3485 0.0000 10.4107 10.4964
.69000 .002.87007 .573.0843 3.0843 2.9235 4.1587 4.1587 7.1131 0.0279 0.0279 0.0000 25.1897 25.1897 28.6079 0.0000 0.0000 2.6873 0.0000 1.5804 2.5932 4.7609 4.1615 8.7629 .74147 .832.09000 .112.9235 7.1131 0.0000 2.8916 28.6079 3.0843 2.9235 11.1958 2.6873 4.1587 7.1131 0.0000 1.4079 0.0279 0.0000 21.2130 7.4784 25.1897 28.6079 1.2317 0.0000 2.6873 0.0000 0.0000 1.4079 7.7562 3.3051 6.6221 1/2" REGULAR GYPSUM BOARD BY PROCESS STAGE AND REGION [MJ/M Transport ae Stucco Paper Manufacturing marine marine HFO- HFO- Natural gas Natural gas Board olOil Coal Oil Coal Manufact. Total 44.2882 35.7657 49.3618 to Total
Gat e lcrct Total Electricity Total Electricity 2 ]
rnpr to Transport
.0550.3977 47.0284 37.2214 6.1095 38.2024 2.7402 52.6878 1.4557 2.4367 3.3261 .5350.2181 0.8563 Board
To Market
50.3977 47.0284 37.2214 38.2024 52.6878 50.2181 44.2882 35.7657 49.3618 To Gate -16 4- Total 2 Market ] 2 ]
The Athena East Central 6.7165 W TABLE 4.28B East Central West TABLE 4.28A East Central W TABLE 4.27 Products Finishing Associated and Board Gypsum
est est TM Montreal Winnipeg Vancouver Montreal Winnipeg Vancouver Halifax Toronto Calgary Halifax Toronto Calgary
CRADLE TO MARKET ENERGY USE IN 1/2" TYPE X GYPSUM BOARD BY FORM AND REGION [MJ/M CRADLE TO GATE ENERGY USE IN 1/2" TYPE X GYPSUM BOARD BY FORM AND REGION [MJ/M ENERGY USE IN 1/2" TYPE X GYPSUM BOARD BY PROCESS STAGE AND REGION [MJ/M Project: islra Diesel-rail Diesel-road islra Diesel-rail Diesel-road ysmRs RMs Extract. Gypsum
.21645 .171.841.4437.5466 33.0404 18.7404 17.3569 11.9864 38.5191 8.8638 6.8197 18.8984 6.8197 6.4550 12.8010 2.1959 6.8197 0.3271 10.7048 0.4235 0.2719 050 .92135 107 .001.512.8533 2.8533 11.2551 11.2551 0.0000 0.0000 21.0772 21.0772 1.3656 1.2575 3.3992 0.0000 10.5804 10.6673
.27000 .002.68008 .723.0524 3.0524 2.8871 4.1732 4.1732 7.1634 0.0284 0.0284 0.0000 25.0608 25.0608 28.5468 0.0000 0.0000 2.7443 0.0000 1.6043 2.6410 4.8227 4.2142 8.8897 .88147 .432.48000 .642.8871 7.1634 0.0000 2.8533 28.5468 3.0524 11.2551 2.7443 4.1732 0.0000 1.4378 0.0284 21.0772 7.5858 25.0608 1.2575 0.0000 0.0000 0.0000 7.8856 3.3449 Transport .38274 856 .00713 2.8871 7.1634 0.0000 28.5468 2.7443 1.4378 ae Stucco Paper Manufacturing marine marine HFO- HFO- Natural gas Natural gas Board olOil Coal olOil Coal Manufact. Total 44.3287 35.6597 49.4958
to Total G ate 2 ] lcrct Total Electricity lcrct Total Electricity rnpr to Transport .8747.1104 38.1334 2.7817 50.3651 2.4736 0.8693 .0050.5308 37.1375 6.2020 52.8723 1.4778 3.3765 Board to Market
2
50.5308 47.1104 37.1375 38.1334 52.8723 50.3651 44.3287 35.6597 49.4958 to Gate ] -17 4- Total 2 Market ]
The Athena East Central W TABLE 4.30B East Central West TABLE 4.30A 0.3 East Vancouver Central West TABLE 4.29 Products Finishing Associated and Board Gypsum
est TM Montreal Winnipeg Vancouver 0.3635 0.4705 Montreal Winnipeg Halifax Toronto Calgary Halifax Toronto Calgary
CRADLE TO MARKET ENERGY USE IN 1/2" MR GYPSUM BOARD BY FORM AND REGION [MJ/M CRADLE TO GATE ENERGY USE IN 1/2" MR GYPSUM BOARD BY FORM AND REGION [MJ/M ENERGY USE IN 1/2" MR GYPSUM BOARD BY PROCESS STAGE AND REGION [MJ/M Project: islra Diesel-rail Diesel-road islra Diesel-rail Diesel-road
ysmRs RMs Extract. Gypsum
179 .53156 206 .001.603.0718 3.0718 11.6610 11.6610 0.0000 0.0000 22.0363 22.0363 1.5164 1.3970 3.7543 0.0000 11.7194 11.8154
.37000 .002.52001 .333.3051 3.3051 3.1155 4.3393 4.3393 7.5211 0.0316 0.0316 0.0000 26.0572 26.0572 29.9055 0.0000 0.0000 3.0491 0.0000 1.7720 2.9264 5.3327 4.6606 9.8387 .95157 .412.05000 .213.1155 7.5211 0.0000 3.0718 29.9055 3.3051 3.1155 11.6610 3.0491 4.3393 7.5211 0.0000 1.5974 0.0316 0.0000 22.0363 8.3985 26.0572 29.9055 1.3970 0.0000 3.0491 0.0000 0.0000 1.5974 8.7430 3.7005 7.4384 2 189 .341.261.9440.4553 18.8984 14.2226 7.3344 11.8696 021 Transport .54734 337 870 39.3923 34.5393 18.7404 17.3569 13.3175 9.8481 7.3344 7.3344 7.1534 2.4239 ae Stucco Paper Manufacturing marine marine HFO- HFO- Natural gas Natural gas Board olOil Coal olOil Coal Manufact. Total 52.6270 46.9092 37.4338 to Total 2
] Gat e lcrct Total Electricity lcrct Total Electricity rnpr to Transport .6153.5871 0.9601 .7449.9816 40.1658 3.0724 2.7321 .5053.7592 39.0660 6.8500 56.3563 1.6322 3.7292 Board 2 ] 2
to Market
]
53.7592 49.9816 39.0660 40.1658 56.3563 53.5871 46.9092 37.4338 52.6270 to Gate -18 4- Total Market
The Athena East Central W H TABLE 4.32B East Central W TABLE 4.32A East Central W ENERGY USE IN 4.31 TABLE Products Finishing Associated and Board Gypsum
est est est TM Montreal Winnipeg Vancouver Winnipeg Vancouver Montreal Winnipeg Vancouver Halifax Toronto Calgary Halifax Toronto Calgary
CRADLE TO MARKET ENERGY USE IN 5/8" REGULAR GYPSUM BOARD BY FORM AND REGION [MJ/M CRADLE TO GATE ENERGY USE IN 5/8" REGULAR GYPSUM BOARD BY FORM AND REGION [MJ/M alifax Project: islra Diesel-rail Diesel-road Diesel-rail Diesel-road ysmRs RMs Gypsum Extract.
.15814 .231.362.2645.9824 23.4256 40.2580 15.3346 21.6961 47.2220 11.3397 7.2223 23.6229 7.2223 8.1442 16.3767 2.7114 7.2223 0.4185 13.5467 0.5418 0.3478 331 .78173 546 .001.113.3472 3.3472 14.1181 14.1181 3.3921 0.0000 0.0000 8.9906 25.4966 25.4966 0.0000 1.7437 1.6079 34.9391 4.2718 0.0000 3.5109 13.3619 13.4711 3.3515 11.1754
.35000 .003.80006 .033.6051 3.6051 5.2023 5.2023 0.0364 0.0364 30.4860 30.4860 0.0000 0.0000 0.0000 2.0162 6.0385 5.2738 .38189 .193.31000 .963.3921 8.9906 0.0000 3.3472 34.9391 3.6051 3.3921 14.1181 3.5109 5.2023 8.9906 0.0000 1.8394 0.0364 0.0000 25.4966 9.5368 30.4860 34.9391 1.6079 0.0000 3.5109 0.0000 0.0000 1.8394 9.9753 4.1814 8.4443 5/8" REGULAR GYPSUM BOARD BY PROCESS STAGE AND REGION [MJ/M Transport ae Stucco Paper Manufacturing marine marine HFO- HFO- Natural gas Natural gas Board olOil Coal Oil Coal Manufact. Total to 54.5451 43.5112 61.1164 to Total
Gat e lcrct Total Electricity Total Electricity 2 ] rnpr to Transport .9858.0409 46.6199 3.4958 62.2089 3.1086 1.0924 .9262.3393 45.3684 7.7942 65.3597 1.8572 4.2433 Board
to Market
62.3393 58.0409 65.3597 45.3684 46.6199 62.2089 54.5451 43.5112 61.1164 to Gate -19 4- Total 2 Market ] 2 ]
The Athena East Central W TABLE 4.34B East Central West TABLE 4.34A East Central W TABLE 4.33 Products Finishing Associated and Board Gypsum
est est TM Montreal Winnipeg Vancouver Montreal Winnipeg Vancouver Halifax Toronto Calgary Halifax Toronto Calgary
CRADLE TO MARKET ENERGY USE IN 5/8" TYPE X GYPSUM BOARD BY FORM AND REGION [MJ/M CRADLE TO GATE ENERGY USE IN 5/8" TYPE X GYPSUM BOARD BY FORM AND REGION [MJ/M ENERGY USE IN 5/8" TYPE X GYPSUM BOARD BY PROCESS STAGE AND REGION [MJ/M Project: islra Diesel-rail Diesel-road islra Diesel-rail Diesel-road ysmRs RMs Extract. Gypsum
.25828 .391.522.2646.0137 23.4256 40.2321 15.5542 21.6961 47.2682 11.5021 7.0339 23.6229 7.0339 8.2387 16.6113 2.7312 7.0339 0.4245 13.7119 0.5496 0.3528
355 .61179 545 .001.703.3306 3.3306 14.1740 14.1740 0.0000 0.0000 25.4453 25.4453 1.7695 1.6308 4.3631 0.0000 13.5552 13.6668 136 .12351 493 .00908 3.3771 9.0386 0.0000 34.9538 3.3306 3.5611 14.1740 3.4102 0.0000 11.3260 25.4453 1.6308 0.0000 10.0962
.11000 .003.49006 .173.5942 3.5942 5.2187 5.2187 0.0369 0.0369 30.4409 30.4409 0.0000 0.0000 0.0000 2.0593 6.1191 5.3381 .53185 .613.58000 .363.3771 9.0386 0.0000 34.9538 3.5942 3.3771 3.5611 5.2187 9.0386 1.8657 0.0369 0.0000 9.6523 30.4409 34.9538 0.0000 3.5611 0.0000 1.8657 4.2223 8.5365 Transport ae Stucco Paper Manufacturing marine marine HFO- HFO- Natural gas Natural gas Board olOil Coal olOil Coal manufact. Total 54.6769 43.5129 61.3329 to Total
Gat 2 e ] lcrct Total Electricity lcrct Total Electricity rnpr to Transport .7658.2475 46.6880 3.5706 62.4487 3.1751 1.1158 .6862.6377 45.4098 7.9608 65.6669 1.8969 4.3340 Board to Market
2
62.6377 58.2475 65.6669 45.4098 46.6880 62.4487 54.6769 43.5129 61.3329 to Gate ] -20 4- Total 2 Market ]
The Athena East Central W TABLE 4.36B East Central West TABLE 4.36A East Central W TABLE 4.35 Products Finishing Associated and Board Gypsum
est est TM Montreal Winnipeg Vancouver Montreal Winnipeg Vancouver Halifax Toronto Calgary Halifax Toronto Calgary
CRADLE TO MARKET ENERGY USE IN 5/8" MR GYPSUM BOARD BY FORM AND REGION [MJ/M CRADLE TO GATE ENERGY USE IN 5/8" MR GYPSUM BOARD BY FORM AND REGION [MJ/M ENERGY USE IN 5/8" MR GYPSUM BOARD BY PROCESS STAGE AND REGION [MJ/M Project: islra Diesel-rail Diesel-road islra Diesel-rail Diesel-road ysmRs RMs Gypsum Extrac.
.60900 .731.762.2648.1724 23.4256 41.9945 17.0756 21.6961 49.5303 12.6271 7.6713 23.6229 7.6713 9.0407 18.2360 2.9951 7.6713 0.4660 15.0480 0.6033 0.3873
480 .60191 659 .001.393.5898 3.5898 14.6399 14.6399 3.6476 0.0000 0.0000 9.4495 26.5792 26.5792 0.0000 1.9418 1.7902 36.5444 4.7690 0.0000 3.9095 14.8606 14.9826 3.7364 12.4154 056 .42399 654 .00949 3.6476 9.4495 0.0000 3.5898 36.5444 14.6399 3.9095 0.0000 2.0482 26.5792 10.5860 1.7902 0.0000 11.0799
.02000 .003.14000 .163.8924 5.4106 0.0405 31.6174 0.0000 0.0000 6.7052 .55220 .003.14000 .163.8924 5.4106 0.0405 31.6174 3.8924 0.0000 3.6476 5.4106 2.2509 9.4495 0.0405 5.8515 0.0000 31.6174 36.5444 0.0000 3.9095 0.0000 2.0482 4.6319 9.3664 Transport ae Stucco Paper Manufacturing marine marine HFO- HFO- Natural gas Natural gas Board olOil Coal olOil Coal Manufact. Total 57.6791 45.5928 64.9656 to Total 2
] Gat e lcrct Total Electricity lcrct Total Electricity rnpr to Transport .0761.5818 49.0633 3.9027 66.1852 3.4705 1.2196 .0466.3804 47.6662 8.7014 69.7027 2.0733 4.7371 Board 2 ] 2
to Market
]
66.3804 61.5818 69.7027 66.1852 47.6662 49.0633 57.6791 45.5928 64.9656 to Gate -21 4- Total Market
The Athena East Central W H TABLE 4.38B East Central W CRADLE TO GATE E 4.38A TABLE East Central W TABLE 4.37 Products Finishing Associated and Board Gypsum
est est est TM Montreal Winnipeg Vancouver Winnipeg Vancouver Montreal Winnipeg Vancouver Halifax Toronto Calgary Halifax Toronto Calgary
CRADLE TO MARKET ENERGY USE IN 5/16" MOBILE HOME BOARD BY FORM AND REGION [MJ/M ENERGY USE IN 5/16" MOBILE HOME GYPSUM BOARD BY PROCESS STAGE AND REGION [MJ/M alifax Project: islra Diesel-rail Diesel-road islra Diesel-rail Diesel-road ysmRs RMs Gypsum Extract.
.23467 .98821 172 27.3977 11.7128 24.3730 10.8480 28.0599 8.2911 11.8115 6.1312 7.3938 8.8546 7.3938 4.6678 7.3938 1.6932 0.2263 7.6688 0.2929 0.1881
.85245 .481.11000 .922.4583 2.4583 2.6032 7.3922 2.6032 7.3922 2.4853 2.8220 0.0000 2.8220 0.0000 4.8059 0.0197 15.9141 0.0197 15.9141 0.0000 18.4263 0.9488 18.4263 0.8714 20.8227 0.0000 2.4352 0.0000 0.0000 1.8983 0.0000 7.5865 1.1494 7.6487 1.8566 3.5467 3.1108 6.4670 .38094 .932.27000 .092.4853 4.8059 0.0000 2.4583 20.8227 2.6032 2.4853 7.3922 1.8983 2.8220 4.8059 0.0000 0.9945 0.0197 0.0000 15.9141 5.5328 18.4263 20.8227 0.8714 0.0000 1.8983 0.0000 0.0000 0.9945 5.6559 2.4880 4.9101 NERGY USE IN 5/16" MOBILE HOME GYPSUM BOARD BY ENERGY FORM AND REGION [MJ/M Transport ae Stucco Paper Manufacturing marine marine HFO- HFO- Natural gas Natural gas Board olOil Coal olOil Coal Manufact. Total 32.2919 26.3592 35.9168 to Total
Gat e lcrct Total Electricity lcrct Total Electricity rnpr to Transport .9934.2847 28.1313 1.9929 36.5396 1.7721 0.6228 .4236.7351 27.4179 4.4432 38.3358 1.0587 2.4190 Board 2 ]
to Market
36.7351 34.2847 27.4179 28.1313 38.3358 36.5396 32.2919 26.3592 35.9168 to Gate -22 4- 2 Total ] Market 2 ]
The Athena East Central W TABLE 4.40B East Central West TABLE 4.40A East Central W TABLE 4.39 Products Finishing Associated and Board Gypsum
est est TM Montreal Winnipeg Vancouver Montreal Winnipeg Vancouver Halifax Toronto Calgary Halifax Toronto Calgary
CRADLE TO MARKET ENERGY USE IN 1" SHAFTLINER BOARD BY FORM AND REGION [MJ/M CRADLE TO GATE ENERGY USE IN 1" SHAFTLINER BOARD BY FORM AND REGION [MJ/M ENERGY USE IN 1" SHAFTLINER BOARD BY PROCESS STAGE AND REGION [MJ/M Project: islra Diesel-rail Diesel-road islra Diesel-rail Diesel-road ysmRs RMs Extract. Gypsum
.801.23733 878 740 73.6736 63.4038 37.4809 34.7137 28.7989 75.9466 21.2962 7.3938 37.7967 7.3938 30.7560 14.8273 4.6903 7.3938 0.7860 24.8321 1.0175 0.6532
454 .15327 940 .002.554.9361 4.9361 5.4582 23.6545 23.6545 5.0395 8.6214 0.0000 0.0000 15.2963 0.0683 39.4103 39.4103 0.0000 47.5128 3.2677 3.0161 55.7984 0.0000 7.9145 0.0000 6.5935 0.0000 24.5443 24.7467 6.2560 10.8918 20.3098 723 .54653 578 .001.935.0395 15.2963 0.0000 4.9361 55.7984 5.0395 23.6545 6.5935 15.2963 0.0000 3.4544 0.0000 39.4103 17.2737 55.7984 3.0161 6.5935 0.0000 3.4544 18.2698 15.2497 .70375 .004.18008 .245.4582 8.6214 0.0683 47.5128 5.4582 0.0000 8.6214 3.7355 0.0683 9.4750 47.5128 0.0000 0.0000 7.4509 Transport ae Stucco Paper Manufacturing marine marine HFO- HFO- Natural gas Natural gas Board olOil Coal olOil Coal Manufact. Total 101.4319 89.2869 69.1116 2 to ] Total
Gat e lcrct Total Electricity lcrct Total Electricity rnpr to Transport 440 103.7274 14.4405 .20103.4559 2.0240 .7895.7637 74.8711 6.4768 5.7595 .4872.5524 3.4408 109.2935 7.8616 Board 2 ] 2 ]
to Market
103.7274 109.2935 103.4559 101.4319
95.7637 72.5524 74.8711 89.2869 69.1116 to Gate -23 4- Total Market
The Athena East Central W TABLE 4.42B East Central West TABLE 4.42A East Central W TABLE 4.41 Products Finishing Associated and Board Gypsum est est
Halifax Montreal Toronto Winnipeg Calgary Vancouver TM Montreal Winnipeg Vancouver Halifax Toronto Calgary
CRADLE TO MARKET ENERGY USE IN 1/2" GFB BY FORM AND REGION [MJ/M CRADLE TO GATE ENERGY USE IN 1/2" GFB BY FORM AND REGION [MJ/M ENERGY USE IN 1/2" GFB BY PROCESS STAGE AND REGION [MJ/M Project: Extract. .51312 .351.291.191.2947.0943 47.0943 18.9259 47.0943 18.9259 47.0943 12.9129 18.9259 47.0943 12.9129 18.9259 47.0943 10.8229 12.9129 18.9259 10.8229 12.9129 18.9259 4.4325 10.8229 12.9129 4.4325 10.8229 12.9129 4.4325 10.8229 3.1526 4.4325 10.8229 3.1526 4.4325 3.1526 0.3511 4.4325 3.1526 0.3511 3.1526 0.3511 3.1526 0.3511 0.3511 0.3511 M RMs RMs
islra Diesel-rail Diesel-road Diesel-rail Diesel-road
.14022 .413.69365 7.0482 7.0482 7.0482 7.0482 3.6956 7.0482 3.6956 3.6956 3.6956 33.7609 3.6956 33.7609 33.7609 33.7609 2.1471 33.7609 2.1471 2.1471 2.1471 0.2828 2.1471 7.2797 10.2408 19.6833 8.4174 27.0312 3.6636 3.6636 3.6636 3.6636 .663.03217 370 .967.0482 3.6956 33.7609 7.0482 7.0482 7.0482 2.1471 3.6956 3.6956 3.6956 32.3063 33.7609 33.7609 33.7609 3.6636 2.1471 2.1471 2.1471 0.2828 0.2828 0.2828 3.6636 3.6636 3.6636 Transport
Paper
Manufacturing Perlite marine marine HFO- HFO- Stucco Natural Natural Gas Gas Board 2 ] Manufact Total Oil Oil 2 50.5980 50.5980 50.5980 50.5980 50.5980 50.5980 to ] Total
2 Gat lcrct Total Electricity Total Electricity ] e rnpr to Transport 940 69.9985 77.3464 19.4005 82.6215 26.7484 32.0235 .5855.3518 57.5949 60.5560 4.7538 6.9969 9.9580 Board
to Market
57.5949 77.3464 55.3518 60.5560 69.9985 82.6215 50.5980 50.5980 50.5980 to Gate -24 4- Market Total
The Athena East Central W TABLE 4.44B H East Central W TABLE 4.44A East Central W TABLE 4.43 Products Finishing Associated and Board Gypsum est est est Halifax Montreal Toronto Winnipeg Calgary Vancouver
Montreal Winnipeg Winnipeg Vancouver Vancouver Halifax Toronto Calgary TM alifax
CRADLE TO MARKET ENERGY USE IN 5/8" GFB BY FORM AND REGION [MJ/M CRADLE TO GATE ENERGY USE IN 5/8" GFB BY FORM AND REGION [MJ/M ENERGY USE IN 5/8" GFB BY PROCESS STAGE AND REGION [MJ/M Project: Extract. .37391 .991.211.242.5458.6088 58.6088 23.6574 58.6088 23.6574 58.6088 16.0224 23.6574 58.6088 16.0224 23.6574 13.4291 58.6088 16.0224 23.6574 13.4291 16.0224 5.4999 23.6574 13.4291 16.0224 5.4999 13.4291 16.0224 5.4999 13.4291 3.9117 5.4999 13.4291 3.9117 5.4999 3.9117 0.4357 5.4999 3.9117 0.4357 3.9117 0.4357 3.9117 0.4357 0.4357 0.4357 M RMs RMs
islra Diesel-rail Diesel-road islra Diesel-rail Diesel-road
042 .59264 201 .848.7588 4.5854 42.0512 2.6641 0.3509 10.4829
.48909 .614.52455 8.7588 8.7588 8.7588 8.7588 4.5854 4.5854 4.5854 4.5854 42.0512 42.0512 42.0512 42.0512 2.6641 2.6641 2.6641 2.6641 9.0894 12.7875 24.5804 33.7572 4.5458 4.5458 4.5458 4.5458 .484.43264 201 .848.7588 4.5854 42.0512 8.7588 2.6641 4.5854 40.3453 42.0512 4.5458 2.6641 0.3509 4.5458 .48030 .614.52455 8.7588 8.7588 4.5854 4.5854 42.0512 42.0512 2.6641 2.6641 0.3509 0.3509 4.5458 4.5458 Transport
ae P Paper
Manufacturing erlite marine marine HFO- HFO- Stucco Natural Natural Gas Gas Board 2 ] Manufact Total Oil Oil 2 62.9562 62.9562 62.9562 62.9562 62.9562 62.9562 to ] Total
2 lcrct Total Electricity lcrct Total Electricity Gat ] e rnpr to Transport 246 75.3928 87.1857 12.4366 96.3625 24.2295 102.9506 33.4063 39.9944
.3168.8933 71.6947 5.9371 8.7385 Board
102.9506 to Market
75.3928 96.3625 68.8933 71.6947 87.1857 62.9562 62.9562 62.9562 to Gate -25 4- Market Total The AthenaTM Project: Gypsum Board and Associated Finishing Products 5-1
5.0 ENERGY USE - FINISHING PRODUCTS In this section, we provide the estimates of energy consumption for the raw materials extraction and transportation, manufacturing and finished products transportation of the gypsum board joint finishing compounds and joint paper tape. All of the estimates are developed essentially in the same manner as the energy unit factors estimated in Section 4 for gypsum board.
5.1 JOINT FINISHING PRODUCTS RAW MATERIAL EXTRACTION AND TRANSPORTATION In Section 3.3 generic formulations for both ready mix drying and dry setting compounds were given. While both types of joint compounds are comprised of a number of different raw materials, most of these (limestone, mica, talc, gypsum and clays) are industrial minerals quarried in open pits. We will therefore assume that it takes 0.027 GJ/tonne1 for extraction of these materials, and that all this energy is in the form of diesel fuel (road), as specified in the Sustainable Materials Project Research Guidelines. For gypsum, we take into account the fact that 1.2048 tonnes of gypsum are needed to produce 1 tonne of calcined plaster. (For water and PVA resin we assume no embodied extraction energy, whereas for “other” materials we assume the same energy loading as for the other industrial minerals.) As no detailed regional data are available, we will assume that the same amount of energy is required to extract the required quantities of raw materials all across Canada. Table 5.1 shows average energy consumption for applicable industrial minerals and their primary on site processing for both types of joint compounds, expressed in MJ/kg of compound as well as in MJ/m2 of board (typical usage of joint compound per m2 of gypsum board was shown in Section 2.5).
TABLE 5.1 AVERAGE ENERGY USE FOR JOINT COMPOUNDS RAW MATERIALS EXTRACTION
Ready Mix Compound Setting (Dry) Compound
[MJ/kg of [MJ/m2 of board] [MJ/kg of [MJ/m2 of board] compound] compound]
Water 0.00000 0.00000 - - Calcium carbonate 0.01412 0.00952 0.00986 0.00347 Gypsum plaster - - 0.01578 0.00555 Mica 0.00095 0.00064 0.00194 0.00068 Talc 0.00103 0.00069 - - Clay 0.00046 0.00031 0.00135 0.00048 PVA resin 0.00000 0.00000 - - Other 0.00003 0.00002 0.00076 0.00027 Total 0.01658 0.01117 0.02968 0.01045 The AthenaTM Project: Gypsum Board and Associated Finishing Products 5-2
Joint Compounds Raw Materials Transportation The transportation energy use estimates were made by applying the appropriate combustion energy factors shown earlier (Section 4.1) to the formulations for both the ready mix and setting joint compounds, as shown in Tables 3.6 and 3.7 respectively, taking into account the average raw materials transportation distances, backhaul assumptions, and modes of transport (Table 3.8). Resulting estimates of energy usage associated with the transportation of the ready mix joint compounds raw materials are shown in Tables 5.2 and 5.3, and of the setting compounds in Tables 5.4 and 5.5.
TABLE 5.2 AVERAGE ENERGY USE FOR READY MIX JOINT COMPOUNDS RAW MATERIALS TRANSPORTATION (MJ/KG OF COMPOUND)
West Region Central Region East Region
Water 0.00000 0.00000 0.00000 Clay 0.02285 0.03808 0.03808 Talc 0.14896 0.03405 0.01277 Mica 0.07840 0.07840 0.07840 Calcium carbonate 0.58576 0.58576 0.11715 PVA resin 0.00896 0.00896 0.00896 Other 0.00280 0.00280 0.00280 Total 0.84773 0.74805 0.25816 note: all energy in form of diesel (road)
TABLE 5.3 AVERAGE ENERGY USE FOR READY MIX JOINT COMPOUNDS RAW MATERIALS TRANSPORTATION (MJ/M2 OF BOARD)
West Region Central Region East Region
Water 0.00000 0.00000 0.00000 Clay 0.01540 0.02567 0.02567 Talc 0.10040 0.02295 0.00861 Mica 0.05284 0.05284 0.05284 Calcium carbonate 0.39480 0.39480 0.07896 PVA resin 0.00604 0.00604 0.00604 Other 0.00189 0.00189 0.00189 Total 0.57137 0.50418 0.17400 note: all energy in form of diesel (road) The AthenaTM Project: Gypsum Board and Associated Finishing Products 5-3
TABLE 5.4 AVERAGE ENERGY USE FOR SETTING JOINT COMPOUNDS RAW MATERIALS TRANSPORTATION (MJ/KG OF COMPOUND)
West Central East
total total total (diesel road) diesel road diesel rail diesel road diesel rail
Gypsum plaster 1.95552 1.56170 1.08640 0.47530 1.56170 1.08640 0.47530 Calcium carbonate 0.40880 0.40880 0.40880 0.00000 0.08176 0.08176 0.00000 Mica 0.16128 0.16128 0.16128 0.00000 0.16128 0.16128 0.00000 Clay 0.06720 0.11200 0.11200 0.00000 0.11200 0.11200 0.00000 Other 0.07840 0.07840 0.07840 0.00000 0.07840 0.07840 0.00000 Total 2.67120 2.32218 1.84688 0.47530 1.99514 1.51984 0.47530
TABLE 5.5 AVERAGE ENERGY USE FOR SETTING JOINT COMPOUNDS RAW MATERIALS TRANSPORTATION (MJ/M2 OF BOARD)
West Central East
total total total (diesel road) diesel road diesel rail diesel road diesel rail
Gypsum plaster 0.68834 0.54972 0.38241 0.16731 0.54972 0.38241 0.16731 Calcium carbonate 0.14390 0.14390 0.14390 0.00000 0.02878 0.02878 0.00000 Mica 0.05677 0.05677 0.05677 0.00000 0.05677 0.05677 0.00000 Clay 0.02365 0.03942 0.03942 0.00000 0.03942 0.03942 0.00000 Other 0.02760 0.02760 0.02760 0.00000 0.02760 0.02760 0.00000 Total 0.94026 0.81741 0.65010 0.16731 0.70229 0.53498 0.16731
Joint Paper Tape Raw Materials Transportation As already noted, joint paper tape is essentially the same product as “ivory” paper for gypsum board facings. The average energy consumption associated with the transportation of waste paper as raw material for the paper mill and of the paper stock from the paper mill to the producer to be converted to the joint tape is therefore estimated in a similar manner as for the “ivory” paper for the board production in Section 4.1. Table 5.6 provides resulting estimates in GJ per tonne of paper. The AthenaTM Project: Gypsum Board and Associated Finishing Products 5-4
TABLE 5.6 AVERAGE ENERGY USE FOR JOINT PAPER TAPE RAW MATERIALS TRANSPORTATION (GJ/TONNE OF PAPER)
Waste Paper Finished Paper for Joint Tape diesel-road diesel-road HFO-marine total finished paper
West Avg. 0.3894 0.9652 0.0000 0.9652 Central Avg. 0.3894 0.6735 0.0000 0.6735 East Avg. 0.3894 0.8501 0.0087 0.8588
The above estimates are then converted to MJ/m of joint tape (52 mm wide) assuming paper weight of 0.2358 kg/m2 (Table 5.7). [For example, for waste paper transportation: 0.3894 GJ/tonne (=MJ/kg) x 0.2358 kg/m2 = 0.09182 MJ/m2 of paper stock for joint tape; m2 of such paper provides 19.23 lineal meters of paper tape 52 mm wide; 0.09182 MJ/m2 / 19.23 m = 0.477 MJ/m of tape.] Taking into consideration typical usage of 0.98 m of tape per m2 of gypsum board, unit factors can be expressed also per m2 of the board (Table 5.8).
TABLE 5.7 AVERAGE ENERGY USE FOR JOINT PAPER TAPE RAW MATERIALS TRANSPORTATION (MJ/M OF JOINT TAPE)
Waste Paper Finished Paper for Joint Tape diesel-road diesel-road HFO-marine total finished paper
West Avg. 0.00477 0.01183 0.00000 0.01183 Central Avg. 0.00477 0.00826 0.00000 0.00826 East Avg. 0.00477 0.01042 0.00011 0.01053
TABLE 5.8 AVERAGE ENERGY USE FOR JOINT PAPER TAPE RAW MATERIALS TRANSPORTATION (MJ/M2 OF BOARD)
Waste Paper Finished Paper for Joint Tape diesel-road diesel-road HFO-marine total finished paper
West Avg. 0.00468 0.01160 0.00000 0.01160 Central Avg. 0.00468 0.00809 0.00000 0.00809 East Avg. 0.00468 0.01022 0.00010 0.01032 The AthenaTM Project: Gypsum Board and Associated Finishing Products 5-5
5.2 JOINT FINISHING PRODUCTS MANUFACTURING Joint compounds manufacturing consists of a number of separate steps, namely through:
¥ industrial minerals processing, ¥ resin binder production, and ¥ joint compound compounding (processing).
Limestone, talc, mica and clays are subjected to secondary crushing, drying and grinding. Gypsum goes through the same processing, followed by calcination and stucco (plaster) grinding. While we had detailed information regarding energy inputs associated with the production of gypsum / plaster (Section 4.2, Table 4.6), similar detailed data for other industrial minerals used in joint compound production is not readily available. We therefore assumed that energy embodied in secondary crushing, drying and grinding of limestone, mica, talc and clays is the same as that of the weighted Canadian average for gypsum. As all of these industrial minerals are indeed handled and processed in a similar manner, we believe that any error introduced into our estimates by this assumption is negligible.
One of the leading PVA resin suppliers to the ready mix joint compound producers provided the total energy associated with the manufacturing of the binder as 200 BTU/lb (0.464 MJ/kg) of resin, with a 20/80 split between electricity and natural gas use.2 Typical electrical power usage needed for compounding / processing (mixing, pumping, resin heating) of the joint compounds was provided by the Canadian producers. Total energy consumption estimates for manufacturing of ready mix and setting (dry) joint compounds were developed and tabulated by both the processing step and the type of energy used. For ease of use, these estimates are presented both in MJ per kg of compound and MJ per m2 of gypsum board. Tables 5.9 to 5.12 show the unit factors for the ready mix compounds, Tables 5.13 to 5.16 do the same for the setting compounds.
TABLE 5.9 WEIGHTED AVERAGE ENERGY USE IN READY MIX JOINT COMPOUND MANUFACTURING BY PROCESS STEP (MJ/KG OF COMPOUND)
secondary drying grinding total resin processing total crushing minerals production processing
Water ------Clay 0.00056 0.00600 0.00034 0.00690 - - 0.00690 Talc 0.00126 0.01340 0.00076 0.01542 - - 0.01542 Mica 0.00116 0.01235 0.00070 0.01420 - - 0.01420 Calcium carbonate 0.01732 0.18449 0.01043 0.21224 - - 0.21224 PVA resin ----0.01855 - 0.01855 Other 0.00003 0.00035 0.00002 0.00041 - - 0.00041 Processing -----0.05400 0.05400 TOTAL 0.02033 0.21659 0.01225 0.24917 0.01855 0.05400 0.32172 The AthenaTM Project: Gypsum Board and Associated Finishing Products 5-6
TABLE 5.10 WEIGHTED AVERAGE ENERGY USE IN READY MIX JOINT COMPOUND MANUFACTURING BY PROCESS STEP (MJ/M2 OF GYPSUM BOARD)
secondary drying grinding total resin processing total crushing minerals production processing
Water ------Clay 0.00038 0.00404 0.00023 0.00465 - - 0.00465 Talc 0.00085 0.00903 0.00051 0.01039 - - 0.01039 Mica 0.00078 0.00832 0.00047 0.00957 - - 0.00957 Calcium carbonate 0.01167 0.12435 0.00703 0.14305 - - 0.14305 PVA resin ----0.01250 - 0.01250 Other 0.00002 0.00024 0.00001 0.00027 - - 0.00027 Processing -----0.03640 0.03640 TOTAL 0.01370 0.14598 0.00825 0.16794 0.01250 0.03640 0.21684
TABLE 5.11 WEIGHTED AVERAGE ENERGY USE IN READY MIX JOINT COMPOUND MANUFACTURING BY ENERGY FORM (MJ/KG OF COMPOUND)
natural gas oil diesel road electric total
Water ----- Clay 0.00340 0.00004 0.00249 0.00097 0.00690 Talc 0.00760 0.00008 0.00557 0.00217 0.01542 Mica 0.00700 0.00007 0.00513 0.00200 0.01420 Calcium carbonate 0.10465 0.00108 0.07663 0.02988 0.21224 PVA resin 0.00371 - - 0.01484 0.01855 Other 0.00020 0.00000 0.00015 0.00006 0.00041 Total raw mat. 0.12657 0.00127 0.08996 0.04992 0.26772 Processing - - - 0.05400 0.05400 TOTAL 0.12657 0.00127 0.08996 0.10392 0.32172 The AthenaTM Project: Gypsum Board and Associated Finishing Products 5-7
TABLE 5.12 WEIGHTED AVERAGE ENERGY USE IN READY MIX JOINT COMPOUND MANUFACTURING BY ENERGY FORM (MJ/M2 OF GYPSUM BOARD)
natural gas oil diesel road electric total
Water ----- Clay 0.00229 0.00002 0.00168 0.00065 0.00465 Talc 0.00512 0.00005 0.00375 0.00146 0.01039 Mica 0.00472 0.00005 0.00346 0.00135 0.00957 Calcium carbonate 0.07054 0.00073 0.05165 0.02014 0.14305 PVA resin 0.00250 - - 0.01000 0.01250 Other 0.00013 0.00000 0.00010 0.00004 0.00027 Total raw mat. 0.08531 0.00086 0.06063 0.03364 0.18044 Processing - - - 0.03640 0.03640 TOTAL 0.08531 0.00086 0.06063 0.07004 0.21684
TABLE 5.13 WEIGHTED AVERAGE ENERGY USE IN SETTING JOINT COMPOUND MANUFACTURING BY PROCESS STEP (MJ/KG OF COMPOUND)
secondary drying grinding calcination stucco processing total crushing grinding
Gypsum plaster 0.01935 0.20612 0.01166 0.50680 0.00297 - 0.74690 Calcium carbonate 0.01209 0.12876 0.00728 - - - 0.14812 Mica 0.00238 0.02540 0.00144 - - - 0.02922 Clay 0.00166 0.01764 0.00100 - - - 0.02029 Other 0.00093 0.00988 0.00056 - - - 0.01136 Compounding - - - - - 0.04320 0.04320 TOTAL 0.03640 0.38779 0.02193 0.50680 0.00297 0.04320 0.99909
TABLE 5.14 WEIGHTED AVERAGE ENERGY USE IN SETTING JOINT COMPOUND MANUFACTURING BY PROCESS STEP (MJ/M2 OF GYPSUM BOARD)
secondary drying grinding calcination stucco processing total crushing grinding
Gypsum plaster 0.00681 0.07256 0.00410 0.17839 0.00105 - 0.26291 Calcium carbonate 0.00425 0.04532 0.00256 - - - 0.05214 Mica 0.00084 0.00894 0.00051 - - - 0.01028 Clay 0.00058 0.00621 0.00035 - - - 0.00714 Other 0.00033 0.00348 0.00020 - - - 0.00400 Compounding ---- - 0.01521 0.01521 TOTAL 0.01281 0.13650 0.00772 0.17839 0.00105 0.01521 0.35168 The AthenaTM Project: Gypsum Board and Associated Finishing Products 5-8
TABLE 5.15 WEIGHTED AVERAGE ENERGY USE IN SETTING JOINT COMPOUND MANUFACTURING BY ENERGY FORM (MJ/KG OF COMPOUND)
natural gas oil diesel road electric total
Gypsum plaster 0.45063 0.16370 0.08561 0.04694 0.74690 Calcium carbonate 0.07304 0.00076 0.05348 0.02085 0.14812 Mica 0.01441 0.00015 0.01055 0.00411 0.02922 Clay 0.01000 0.00010 0.00733 0.00286 0.02029 Other 0.00560 0.00006 0.00410 0.00160 0.01136 Compounding - - - 0.04320 0.04320 TOTAL 0.55368 0.16477 0.16107 0.11956 0.99909
TABLE 5.16 WEIGHTED AVERAGE ENERGY USE IN SETTING JOINT COMPOUND MANUFACTURING BY ENERGY FORM (MJ/M2 OF GYPSUM BOARD)
natural gas oil diesel road electric total
Gypsum plaster 0.15863 0.05763 0.03014 0.01653 0.26291 Calcium carbonate 0.02571 0.00027 0.01882 0.00734 0.05214 Mica 0.00507 0.00005 0.00371 0.00145 0.01028 Clay 0.00352 0.00004 0.00258 0.00101 0.00714 Other 0.00197 0.00002 0.00144 0.00056 0.00400 Compounding - - - 0.01521 0.01521 TOTAL 0.19490 0.05800 0.05670 0.04209 0.35168
Weighted average energy use in gypsum paper production was discussed in Section 4.2, and shown in Table 4.11. Due to the already noted similarity between the paper used for joint tape and the gypsum facings, we will assume that the embodied manufacturing energy for both types of paper is the same. The only other energy input in the joint tape manufacturing is the power needed to lightly sand the paper and to slit the large paper rolls into the rolls of paper tape. In comparison with the other paper manufacturing energy inputs, this is negligible, and we will not consider it in our totals.
The energy estimates expressed per mass of paper in Table 4.11 are converted to MJ/m of joint tape (52 mm wide) assuming paper weight of 0.2358 kg/m2, and taking into consideration typical usage of 0.98 m of tape per m2 of gypsum board, unit factors are also expressed per m2 of the board (Table 5.17). The AthenaTM Project: Gypsum Board and Associated Finishing Products 5-9
TABLE 5.17 WEIGHTED AVERAGE ENERGY USE IN MANUFACTURING OF JOINT PAPER TAPE BY ENERGY FORM
natural gas oil electric total paper
GJ/tonne of paper 11.60470 0.61080 2.91480 15.13020 MJ/m of tape 0.14229 0.00749 0.03574 0.18552 MJ/m2 of gypsum board 0.13945 0.00734 0.03503 0.18181
5.3 JOINT FINISHING PRODUCTS TRANSPORTATION This subsection provides information regarding the distances and modes of the transportation of joint finishing products from their point of manufacture to the distribution centres across Canada. The ATHENATM computer model uses these data to calculate the energy consumption associated with the finished products transportation from the plant gate to the market. Here, in the study, we show some estimates just for illustration. Information regarding transportation distances and modes obtained from some of the individual producers was supplemented by other known geographical market distribution data. Based on our knowledge of the Canadian gypsum board and associated finishing products markets, we made some assumptions regarding the relative market share between the various national as well as regional producers.
Based on the information received from the joint compounds producers, we concluded that:
¥ Vancouver is served 70% by a local producer, 30% from Calgary, all by truck, ¥ Calgary is served 50% by a local producer, 40% from Edmonton, both by truck, and the remaining 10% from Ontario by rail, ¥ Winnipeg is supplied 40% from Calgary, 60% from Ontario, both by rail, with remaining local transport by truck, ¥ Toronto is served 70% by Ontario producers, with the remaining 30% coming from Montreal, all by truck, ¥ Montreal is served 100% by local producers, all by truck, ¥ Halifax is supplied 90% from plants in Montreal, shipped by rail and locally distributed by truck, with the remaining 10% served by a smaller regional supplier.
Further, it was assumed that only 20% backhaul is involved in the local truck transport, 50% backhaul in the long distance (inter-city) truck transport, and 100% backhaul in the rail transport of the finished goods. The weighted average transportation distances by mode were then developed using the distances of each production facilities from the designated cities, and are shown in Table 5.18. For joint paper tape we assumed the same transportation distances and modes of transport as for the joint compounds, as in most cases it is produced and shipped from the same production facility as the joint compounds. The AthenaTM Project: Gypsum Board and Associated Finishing Products 5-10
TABLE 5.18 WEIGHTED AVERAGE TRANSPORTATION DISTANCES BY MODE FOR JOINT FINISHING PRODUCTS (KM)
Average Distances & Transport Mode
Truck Rail
Vancouver 490.5 0 Calgary 234 300 Winnipeg 90 1740 Toronto 372 0 Montreal 90 0 Halifax 126 1125
Transport factors [MJ/tonne-km] 1.18 0.49 note: appropriate backhaul factors included in the distances
The weighted average distances from table 5.18 were converted to the energy estimates by applying the appropriate energy per tonne-km consumption factors. The resulting estimates of the finished products transportation energy unit factors are shown in Tables 5.20 to 5.24.
TABLE 5.20 WEIGHTED AVERAGE TRANSPORTATION ENERGY FOR FINISHED JOINT COMPOUNDS (MJ/KG OF COMPOUND)
Truck Rail Total diesel-road diesel-rail
Vancouver 0.57879 0.00000 0.57879 Calgary 0.27612 0.14700 0.42312 Winnipeg 0.10620 0.85260 0.95880 Toronto 0.43896 0.00000 0.43896 Montreal 0.10620 0.00000 0.10620 Halifax 0.14868 0.55125 0.69993
TABLE 5.21 WEIGHTED AVERAGE TRANSPORTATION ENERGY FOR FINISHED READY MIX JOINT COMPOUNDS (MJ/M2 OF BOARD)
Truck Rail Total diesel-road diesel-rail
Vancouver 0.39010 0.00000 0.39010 Calgary 0.18610 0.09908 0.28518 Winnipeg 0.07158 0.57465 0.64623 Toronto 0.29586 0.00000 0.29586 Montreal 0.07158 0.00000 0.07158 Halifax 0.10021 0.37154 0.47175 The AthenaTM Project: Gypsum Board and Associated Finishing Products 5-11
TABLE 5.22 WEIGHTED AVERAGE TRANSPORTATION ENERGY FOR FINISHED SETTING JOINT COMPOUNDS (MJ/M2 OF BOARD)
Truck Rail Total diesel-road diesel-rail
Vancouver 0.20373 0.00000 0.20373 Calgary 0.09719 0.05174 0.14894 Winnipeg 0.03738 0.30012 0.33750 Toronto 0.15451 0.00000 0.15451 Montreal 0.03738 0.00000 0.03738 Halifax 0.05234 0.19404 0.24638
TABLE 5.23 WEIGHTED AVERAGE TRANSPORTATION ENERGY FOR FINISHED JOINT PAPER TAPE (MJ/M OF TAPE)
Truck Rail Total diesel-road diesel-rail
Vancouver 0.00710 0.00000 0.00710 Calgary 0.00339 0.00180 0.00519 Winnipeg 0.00130 0.01045 0.01176 Toronto 0.00538 0.00000 0.00538 Montreal 0.00130 0.00000 0.00130 Halifax 0.00182 0.00676 0.00858
TABLE 5.24 WEIGHTED AVERAGE TRANSPORTATION ENERGY FOR FINISHED JOINT PAPER TAPE (MJ/M2 OF BOARD)
Truck Rail Total diesel-road diesel-rail
Vancouver 0.00695 0.00000 0.00695 Calgary 0.00332 0.00177 0.00508 Winnipeg 0.00128 0.01025 0.01152 Toronto 0.00527 0.00000 0.00527 Montreal 0.00128 0.00000 0.00128 Halifax 0.00179 0.00662 0.00841
5.4 JOINT FINISHING PRODUCTS - ENERGY SUMMARY In this section we summarize all the preceding energy estimates associated with production of ready mix joint compounds, setting joint compounds, and joint paper tape by processing stage and by energy form. In the following tables (5.25 to 5.30), all these unit factors are expressed in both the customary units that the products are marketed in, i.e. in MJ per kg for joint compounds and in MJ The AthenaTM Project: Gypsum Board and Associated Finishing Products 5-12
per lineal meter for tape, as well as per m2 of gypsum board, so that their usage (and associated energy) can be directly related to the gypsum board that it complements and finishes.
The relative distribution of energy used in production of associated finishing products by process step is shown in Table 5.31 and Fig. 5.1. In a sharp contrast with gypsum board, where the manufacturing step represents the biggest share of the embodied energy, for joint compounds it is the raw materials transportation that contributes most to the total energy consumption. Combined raw materials and finished goods transportation represents almost 75% of the total energy use.
TABLE 5.31 AVERAGE DISTRIBUTION OF ENERGY USE IN JOINT FINISHING PRODUCTS PRODUCTION BY PROCESS STAGE [%]
Extraction Raw Materials Manufacturing Finished Transport Goods Transport ready mix joint compounds 1.25 40.50 24.27 33.98 setting (dry) joint compounds 0.77 59.95 25.98 13.30 joint paper tape - 7.24 89.62 3.14
Extraction RM Transport 100 Manufacturing Finished Transport 80
60
40
% of total energy use 20
0 Ready Mix Setting Compound Joint Tape
Fig. 5.1: Breakdown of Energy Use in Joint Finishing Products Production by Process Stage The AthenaTM Project: Gypsum Board and Associated Finishing Products 5-13
TABLE 5.25 ENERGY USE IN READY MIX JOINT COMPOUNDS PRODUCTION BY PROCESS STAGE AND REGION
Ex- Raw Manufacturing Total Finished Total traction Materials to Products to Transport Gate Transport Market
minerals resin pro- total pro- pro- cessing manu- cessing duction facturing
[MJ/kg of compound]
Vancouver 0.01658 0.84773 0.24917 0.01855 0.05400 0.32172 1.18603 0.57879 1.76482 Calgary 0.01658 0.84773 0.24917 0.01855 0.05400 0.32172 1.18603 0.42312 1.60915 Winnipeg 0.01658 0.74805 0.24917 0.01855 0.05400 0.32172 1.08635 0.95880 2.04515 Toronto 0.01658 0.74805 0.24917 0.01855 0.05400 0.32172 1.08635 0.43896 1.52531 Montreal 0.01658 0.25816 0.24917 0.01855 0.05400 0.32172 0.59646 0.10620 0.70266 Halifax 0.01658 0.25816 0.24917 0.01855 0.05400 0.32172 0.59646 0.69993 1.29639
[MJ/m2 of board]
Vancouver 0.01117 0.57137 0.16794 0.01250 0.03640 0.21684 0.79938 0.39010 1.18949 Calgary 0.01117 0.57137 0.16794 0.01250 0.03640 0.21684 0.79938 0.28518 1.08457 Winnipeg 0.01117 0.50418 0.16794 0.01250 0.03640 0.21684 0.73220 0.64623 1.37843 Toronto 0.01117 0.50418 0.16794 0.01250 0.03640 0.21684 0.73220 0.29586 1.02806 Montreal 0.01117 0.17400 0.16794 0.01250 0.03640 0.21684 0.40201 0.07158 0.47359 Halifax 0.01117 0.17400 0.16794 0.01250 0.03640 0.21684 0.40201 0.47175 0.87377 The AthenaTM Project: Gypsum Board and Associated Finishing Products 5-14
TABLE 5.26A CRADLE TO GATE ENERGY USE IN READY MIX JOINT COMPOUNDS PRODUCTION BY ENERGY FORM AND REGION
diesel-road diesel-rail natural gas oil electric TOTAL
[MJ/kg of compound]
Vancouver 0.95427 0.00000 0.12657 0.00127 0.10392 1.18603 Calgary 0.95427 0.00000 0.12657 0.00127 0.10392 1.18603 Winnipeg 0.85459 0.00000 0.12657 0.00127 0.10392 1.08635 Toronto 0.85459 0.00000 0.12657 0.00127 0.10392 1.08635 Montreal 0.36470 0.00000 0.12657 0.00127 0.10392 0.59646 Halifax 0.36470 0.00000 0.12657 0.00127 0.10392 0.59646
[MJ/m2 of board]
Vancouver 0.64318 0.00000 0.08531 0.00086 0.07004 0.79938 Calgary 0.64318 0.00000 0.08531 0.00086 0.07004 0.79938 Winnipeg 0.57599 0.00000 0.08531 0.00086 0.07004 0.73220 Toronto 0.57599 0.00000 0.08531 0.00086 0.07004 0.73220 Montreal 0.24581 0.00000 0.08531 0.00086 0.07004 0.40201 Halifax 0.24581 0.00000 0.08531 0.00086 0.07004 0.40201
TABLE 5.26B CRADLE TO MARKET ENERGY USE IN READY MIX JOINT COMPOUNDS PRODUCTION BY ENERGY FORM AND REGION
diesel-road diesel-rail natural gas oil electric TOTAL
[MJ/kg of compound]
Vancouver 1.53306 0.00000 0.12657 0.00127 0.10392 1.76482 Calgary 1.23039 0.14700 0.12657 0.00127 0.10392 1.60915 Winnipeg 0.96079 0.85260 0.12657 0.00127 0.10392 2.04515 Toronto 1.29355 0.00000 0.12657 0.00127 0.10392 1.52531 Montreal 0.47090 0.00000 0.12657 0.00127 0.10392 0.70266 Halifax 0.51338 0.55125 0.12657 0.00127 0.10392 1.29639
[MJ/m2 of board]
Vancouver 1.03328 0.00000 0.08531 0.00086 0.07004 1.18949 Calgary 0.82928 0.09908 0.08531 0.00086 0.07004 1.08457 Winnipeg 0.64757 0.57465 0.08531 0.00086 0.07004 1.37843 Toronto 0.87185 0.00000 0.08531 0.00086 0.07004 1.02806 Montreal 0.31739 0.00000 0.08531 0.00086 0.07004 0.47359 Halifax 0.34602 0.37154 0.08531 0.00086 0.07004 0.87377 The AthenaTM Project: Gypsum Board and Associated Finishing Products 5-15
TABLE 5.27 ENERGY USE IN SETTING JOINT COMPOUNDS PRODUCTION BY PROCESS STAGE AND REGION
Extraction Raw Manufacturing Total Finished Total Materials to Products to Transport Gate Transport Market
minerals pro- total pro- cessing manu- cessing facturing
[MJ/kg of compound]
Vancouver 0.02968 2.67120 0.95589 0.04320 0.99909 3.69997 0.57879 4.27876 Calgary 0.02968 2.67120 0.95589 0.04320 0.99909 3.69997 0.42312 4.12309 Winnipeg 0.02968 2.32218 0.95589 0.04320 0.99909 3.35095 0.95880 4.30975 Toronto 0.02968 2.32218 0.95589 0.04320 0.99909 3.35095 0.43896 3.78991 Montreal 0.02968 1.99514 0.95589 0.04320 0.99909 3.02391 0.10620 3.13011 Halifax 0.02968 1.99514 0.95589 0.04320 0.99909 3.02391 0.69993 3.72384
[MJ/m2 of board]
Vancouver 0.01045 0.94026 0.33647 0.01521 0.35168 1.30239 0.20373 1.50612 Calgary 0.01045 0.94026 0.33647 0.01521 0.35168 1.30239 0.14894 1.45133 Winnipeg 0.01045 0.81741 0.33647 0.01521 0.35168 1.17953 0.33750 1.51703 Toronto 0.01045 0.81741 0.33647 0.01521 0.35168 1.17953 0.15451 1.33405 Montreal 0.01045 0.70229 0.33647 0.01521 0.35168 1.06442 0.03738 1.10180 Halifax 0.01045 0.70229 0.33647 0.01521 0.35168 1.06442 0.24638 1.31079 The AthenaTM Project: Gypsum Board and Associated Finishing Products 5-16
TABLE 5.28A CRADLE TO GATE ENERGY USE IN SETTING JOINT COMPOUNDS PRODUCTION BY ENERGY FORM AND REGION
diesel-road diesel-rail natural gas oil electric TOTAL
[MJ/kg of compound]
Vancouver 2.86195 0.00000 0.55368 0.16477 0.11956 3.69997 Calgary 2.86195 0.00000 0.55368 0.16477 0.11956 3.69997 Winnipeg 2.03763 0.47530 0.55368 0.16477 0.11956 3.35095 Toronto 2.03763 0.47530 0.55368 0.16477 0.11956 3.35095 Montreal 1.71059 0.47530 0.55368 0.16477 0.11956 3.02391 Halifax 1.71059 0.47530 0.55368 0.16477 0.11956 3.02391
[MJ/m2 of board]
Vancouver 1.00741 0.00000 0.19490 0.05800 0.04209 1.30239 Calgary 1.00741 0.00000 0.19490 0.05800 0.04209 1.30239 Winnipeg 0.71725 0.16731 0.19490 0.05800 0.04209 1.17953 Toronto 0.71725 0.16731 0.19490 0.05800 0.04209 1.17953 Montreal 0.60213 0.16731 0.19490 0.05800 0.04209 1.06442 Halifax 0.60213 0.16731 0.19490 0.05800 0.04209 1.06442
TABLE 5.28B CRADLE TO MARKET ENERGY USE IN SETTING JOINT COMPOUNDS PRODUCTION BY ENERGY FORM AND REGION
diesel-road diesel-rail natural gas oil electric TOTAL
[MJ/kg of compound]
Vancouver 3.44074 0.00000 0.55368 0.16477 0.11956 4.27876 Calgary 3.13807 0.14700 0.55368 0.16477 0.11956 4.12309 Winnipeg 2.14383 1.32790 0.55368 0.16477 0.11956 4.30975 Toronto 2.47659 0.47530 0.55368 0.16477 0.11956 3.78991 Montreal 1.81679 0.47530 0.55368 0.16477 0.11956 3.13011 Halifax 1.85927 1.02655 0.55368 0.16477 0.11956 3.72384
[MJ/m2 of board]
Vancouver 1.21114 0.00000 0.19490 0.05800 0.04209 1.50612 Calgary 1.10460 0.05174 0.19490 0.05800 0.04209 1.45133 Winnipeg 0.75463 0.46742 0.19490 0.05800 0.04209 1.51703 Toronto 0.87176 0.16731 0.19490 0.05800 0.04209 1.33405 Montreal 0.63951 0.16731 0.19490 0.05800 0.04209 1.10180 Halifax 0.65446 0.36135 0.19490 0.05800 0.04209 1.31079 The AthenaTM Project: Gypsum Board and Associated Finishing Products 5-17
TABLE 5.29 ENERGY USE IN JOINT PAPER TAPE PRODUCTION BY PROCESS STAGE AND REGION
Raw Materials Transport Manu- Total Finished Total facturing to Joint to Gate Tape Market Transport
waste finished total RMs paper paper transport
[MJ/kg]
Vancouver 0.38940 0.96520 1.35460 15.13020 16.48480 0.57879 17.06359 Calgary 0.38940 0.96520 1.35460 15.13020 16.48480 0.42312 16.90792 Winnipeg 0.38940 0.67350 1.06290 15.13020 16.19310 0.95880 17.15190 Toronto 0.38940 0.67350 1.06290 15.13020 16.19310 0.43896 16.63206 Montreal 0.38940 0.85880 1.24820 15.13020 16.37840 0.10620 16.48460 Halifax 0.38940 0.85880 1.24820 15.13020 16.37840 0.69993 17.07833
[MJ/m of tape]
Vancouver 0.00477 0.01183 0.01661 0.18552 0.20213 0.00710 0.20923 Calgary 0.00477 0.01183 0.01661 0.18552 0.20213 0.00519 0.20732 Winnipeg 0.00477 0.00826 0.01303 0.18552 0.19855 0.01176 0.21031 Toronto 0.00477 0.00826 0.01303 0.18552 0.19855 0.00538 0.20394 Montreal 0.00477 0.01053 0.01530 0.18552 0.20083 0.00130 0.20213 Halifax 0.00477 0.01053 0.01530 0.18552 0.20083 0.00858 0.20941
[MJ/m2 of board]
Vancouver 0.00468 0.01160 0.01628 0.18181 0.19809 0.00695 0.20504 Calgary 0.00468 0.01160 0.01628 0.18181 0.19809 0.00508 0.20317 Winnipeg 0.00468 0.00809 0.01277 0.18181 0.19458 0.01152 0.20610 Toronto 0.00468 0.00809 0.01277 0.18181 0.19458 0.00527 0.19986 Montreal 0.00468 0.01032 0.01500 0.18181 0.19681 0.00128 0.19809 Halifax 0.00468 0.01032 0.01500 0.18181 0.19681 0.00841 0.20522 The AthenaTM Project: Gypsum Board and Associated Finishing Products 5-18
TABLE 5.30A CRADLE TO GATE ENERGY USE IN JOINT PAPER TAPE PRODUCTION BY ENERGY FORM AND REGION
diesel- diesel- HFO- natural oil electric TOTAL road rail marine gas
[MJ/kg]
Vancouver 1.35460 0.00000 0.00000 11.60470 0.61080 2.91480 16.48490 Calgary 1.35460 0.00000 0.00000 11.60470 0.61080 2.91480 16.48490 Winnipeg 1.06290 0.00000 0.00000 11.60470 0.61080 2.91480 16.19320 Toronto 1.06290 0.00000 0.00000 11.60470 0.61080 2.91480 16.19320 Montreal 1.23950 0.00000 0.00870 11.60470 0.61080 2.91480 16.37850 Halifax 1.23950 0.00000 0.00870 11.60470 0.61080 2.91480 16.37850
[MJ/m of tape]
Vancouver 0.01661 0.00000 0.00000 0.14229 0.00749 0.03574 0.20213 Calgary 0.01661 0.00000 0.00000 0.14229 0.00749 0.03574 0.20213 Winnipeg 0.01303 0.00000 0.00000 0.14229 0.00749 0.03574 0.19855 Toronto 0.01303 0.00000 0.00000 0.14229 0.00749 0.03574 0.19855 Montreal 0.01520 0.00000 0.00011 0.14229 0.00749 0.03574 0.20083 Halifax 0.01520 0.00000 0.00011 0.14229 0.00749 0.03574 0.20083
[MJ/m2 of board]
Vancouver 0.01628 0.00000 0.00000 0.13945 0.00734 0.03503 0.19809 Calgary 0.01628 0.00000 0.00000 0.13945 0.00734 0.03503 0.19809 Winnipeg 0.01277 0.00000 0.00000 0.13945 0.00734 0.03503 0.19458 Toronto 0.01277 0.00000 0.00000 0.13945 0.00734 0.03503 0.19458 Montreal 0.01489 0.00000 0.00010 0.13945 0.00734 0.03503 0.19681 Halifax 0.01489 0.00000 0.00010 0.13945 0.00734 0.03503 0.19681 The AthenaTM Project: Gypsum Board and Associated Finishing Products 5-19
TABLE 5.30B CRADLE TO MARKET ENERGY USE IN JOINT PAPER TAPE PRODUCTION BY ENERGY FORM AND REGION
diesel- diesel- HFO- natural oil electric TOTAL road rail marine gas
[MJ/kg]
Vancouver 1.93339 0.00000 0.00000 11.60470 0.61080 2.91480 17.06369 Calgary 1.63072 0.14700 0.00000 11.60470 0.61080 2.91480 16.90802 Winnipeg 1.16910 0.85260 0.00000 11.60470 0.61080 2.91480 17.15200 Toronto 1.50186 0.00000 0.00000 11.60470 0.61080 2.91480 16.63216 Montreal 1.34570 0.00000 0.00870 11.60470 0.61080 2.91480 16.48470 Halifax 1.38818 0.55125 0.00870 11.60470 0.61080 2.91480 17.07843
[MJ/m of tape]
Vancouver 0.02371 0.00000 0.00000 0.14229 0.00749 0.03574 0.20923 Calgary 0.02000 0.00180 0.00000 0.14229 0.00749 0.03574 0.20732 Winnipeg 0.01434 0.01045 0.00000 0.14229 0.00749 0.03574 0.21031 Toronto 0.01842 0.00000 0.00000 0.14229 0.00749 0.03574 0.20394 Montreal 0.01650 0.00000 0.00011 0.14229 0.00749 0.03574 0.20213 Halifax 0.01702 0.00676 0.00011 0.14229 0.00749 0.03574 0.20941
[MJ/m2 of board]
Vancouver 0.02323 0.00000 0.00000 0.13945 0.00734 0.03503 0.20504 Calgary 0.01960 0.00177 0.00000 0.13945 0.00734 0.03503 0.20317 Winnipeg 0.01405 0.01025 0.00000 0.13945 0.00734 0.03503 0.20610 Toronto 0.01805 0.00000 0.00000 0.13945 0.00734 0.03503 0.19986 Montreal 0.01617 0.00000 0.00010 0.13945 0.00734 0.03503 0.19809 Halifax 0.01668 0.00662 0.00010 0.13945 0.00734 0.03503 0.20522
REFERENCES 1. Canadian Industry Program for Energy Conservation (CIPEC), Ministry of Energy, Mines and Resources Canada, 1989. 2. Confidential information from the leading PVA resin manufacturer, January 1996. The AthenaTM Project: Gypsum Board and Associated Finishing Products 6-1
6.0 ATMOSPHERIC EMISSIONS - GYPSUM BOARD This section addresses atmospheric emissions associated with the production of gypsum board in all its processing stages, from the extraction and transportation of raw materials through manufacturing and final transportation to markets.
Like any energy-burning production process, gypsum board production generates common air pollutants including carbon dioxide (CO2), sulfur oxides (SOx ) — primarily sulfur dioxide (SO2) — nitrogen oxides (NOx ), volatile organic compounds (VOC), methane (CH4), and carbon monoxide (CO) as well as total particulate matter (TPM). These energy-related emissions are termed “fuel emissions”.
In a major contrast between gypsum-based products and those based on limestone, there is no additional CO2 released during the calcination of gypsum. In processing of limestone in the cement or lime industries, a substantial amount of CO2 (about 60% of the total) is released due to its dissociation (calcination) at high temperatures. Calcination of gypsum that occurs at much lower temperatures releases only some of the molecular water. The relatively low gypsum calcination temperatures (at about 120¡ to 160¡C as opposed to about 1,450¡C for cement clinker processing) has another “positive” effect as far as the atmospheric emissions are concerned: no “thermal” NOx is generated. Therefore in a marked contrast to some other inorganic building materials industries, apart from the particulate emissions, fuel emissions are the only emissions generated in the production of gypsum board.
As in the energy section of the report, all results are presented in terms of weighted averages developed for the three geographical regions (West, Central and East), and adjusted to take into account transportation of the gypsum board to the six cities (Vancouver, Calgary, Winnipeg, Toronto, Montreal and Halifax), following the same assumptions regarding shipping distances and modes of transportation, as shown and discussed in Section 4.3.
Essentially no data on measured atmospheric emissions is publicly available from the gypsum industry. In developing our atmospheric emission estimates, therefore, energy consumption unit factors developed in Section 4 were used as a base to calculate CO2, SO2, NOx, CO, CH4 and VOC releases. Contributions to atmospheric emissions by both the gypsum board production process stages and source of energy/fuel are tabulated and discussed in some detail, including the assumptions made and the reasoning for them.
6.1 APPROACH With the exception of those related to electricity, energy-related atmospheric emission estimates were developed using the energy estimates by process stage from Section 4 and energy emission factors as given in Tables 3 and 6 of the Research Guidelines, based on factors developed by Natural Resources Canada’s “Ad Hoc Committee on Emission Factors”.1 Applicable energy emission factors used throughout this work are summarized in Table 6.1. The AthenaTM Project: Gypsum Board and Associated Finishing Products 6-2
Emissions related to the generation of electricity used by the gypsum board industry are not included in the tables that follow in this section. These emissions are being calculated separately within the Sustainable Materials Project calculation model for all of the products under consideration (i.e. concrete, steel, wood, gypsum board, and other materials under development). The estimates of electricity use in gypsum board production presented in this report will be translated into the mix of primary energy forms used to generate the electricity for the relevant regional electrical systems. Corresponding atmospheric emissions will then be added in the model to the other emissions estimated in this study.
TABLE 6.1 ENERGY EMISSION FACTORS (KG/GJ)
CO2 SO2 NOx VOC CH4 CO
Natural gas 49.700 0.0002 0.0590 0.00120 0.00130 0.01500 Diesel road 70.700 0.1020 0.8070 0.08690 0.02170 0.44300 Diesel rail 70.700 0.1020 1.4000 0.07000 0.00780 0.05700 H.F. oil marine 74.000 0.4500 0.2000 0.36000 0.04000 0.00740 H.F. oil industrial. 74.000 0.8375 0.1600 0.00290 0.00082 0.01440 Coal - Central 87.600 0.8360 0.2500 0.00150 0.00054 0.09300
6.2 ATMOSPHERIC EMISSION ESTIMATES 6.2.1 Raw Materials Extraction Raw materials extraction (usually quarrying in open pit operations) involves drilling and blasting, with fractured rock handled and loaded onto trucks using front-end loaders, mechanical shovels and traxcavators. Most of this equipment uses diesel fuel, although some sites use electrical power only. Some heavy fuel oil and coal (for steam generation) are also used for on-site drying of both the natural and by-product gypsum. Atmospheric emissions were estimated using the weighted average energy estimates for raw materials extraction and on-site processing (Section 4.1) together with appropriate diesel-road, heavy fuel oil, and coal emission factors.
Drilling, blasting and loading operations also create dust emissions. Environment Canada’s report entitled A Nationwide Inventory of Emissions of Air Contaminants 2 quotes particulate emission factors taken from a U.S. Environmental Protection Agency (EPA) paper.3 For open-pit mining, a particulate emission factor of 0.51 kg/tonne is given, whereas for underground mining a factor of 0.05 kg/tonne is shown. As in some areas gypsum from both underground mines and quarries is used, weighted average particulate emission factors per tonne of rock were developed for the Canadian gypsum industry. We also have to take into account that natural rock represents a different percentage of the total gypsum supply in various regions of the country. Based on the limited amount of data from some gypsum quarries and mines, we assumed that on average 0.373 tonnes of solid waste is generated per tonne of extracted gypsum. Applying this multiplier (1.373), as well as another for conversion of gypsum to stucco (1.2048), as discussed in Section 3.1, we obtain the following TPM factors: The AthenaTM Project: Gypsum Board and Associated Finishing Products 6-3
TABLE 6.2 WEIGHTED AVERAGE TPM EXTRACTION FACTORS APPLICABLE TO CANADIAN GYPSUM INDUSTRY
Natural gypsum as TPM emissions TPM emissions % of total supply (kg/tonne of rock) (kg/tonne of stucco)
West 86.50 0.5100 0.7297 Central 85.33 0.0970 0.1369 East 81.26 0.3662 0.4922
(As an example: weighted average TPM factor for the East region = 0.3662 (weighted average of 0.05 for underground mines and 0.51 for quarries, reflecting their relative contribution in the region) multiplied by 0.8126 (share of the natural gypsum in the total gypsum supply) times 1.373 (to account for mining solid waste) times 1.2048 (to convert to per tonnes of stucco units) = TPM East = 0.3662 x 0.8126 x 1.373 x 1.2048 = 0.4922.)
For estimates of extraction TPM of gypsum fiberboard, we considered the fact that only locally quarried natural gypsum is used in its production. The contribution of perlite quarrying to the total particulate emissions was also taken into account.
These factors were used to estimate weighted averages for total particulate (TPM) emissions due to raw materials extraction. It should be noted that the EPA extraction emissions factors also include particulate emissions due to raw materials transportation. However, as the transportation particulate emissions are rather small in comparison to the extraction dust emissions, we felt that using the EPA numbers results in only a small error in the allocation of particulate emissions and, what is more important, both particulate emissions are still captured in the totals. Although blasting agents also generate some nitrogen oxides and some hydrocarbons, these emissions do not contribute significantly to the pollution burden, and are considered to be negligible.1
Total estimated atmospheric emissions due to gypsum board raw materials extraction, for a 1/2" thick regular gypsum board, are shown in Table 6.3. The emissions for the other types of gypsum boards are tabulated in the summary part of this section.
TABLE 6.3 ATMOSPHERIC EMISSIONS DUE TO GYPSUM BOARD RAW MATERIALS EXTRACTION (G/M2 OF 1/2" REGULAR GYPSUM BOARD)
CO2 SO2 NOx VOC CH4 CO TPM
West Avg. 13.42 0.0194 0.1531 0.0165 0.0041 0.0841 4.6419 Central Avg. 4.78 0.0267 0.0336 0.0029 0.0007 0.0172 0.8709 East Avg. 16.12 0.0502 0.1588 0.0166 0.0041 0.0845 3.1312 CANADA 10.13 0.0326 0.0976 0.0100 0.0025 0.0521 2.3275 The AthenaTM Project: Gypsum Board and Associated Finishing Products 6-4
6.2.2 Raw Materials Transportation Raw materials transportation energy unit factors based on information provided directly by most gypsum board manufacturing operations were shown in Section 4.1, Tables 4.4 and 4.6 for 1/2" regular gypsum board. These factors were multiplied by the appropriate emission factors from Table 6.1. The resulting raw materials transportation emissions estimates for such a board are presented in Table 6.4. As noted above, particulate emissions related to raw material transportation are included in Table 6.3. Again, the emissions for the other gypsum board products are shown in the summary part of this section.
TABLE 6.4 ATMOSPHERIC EMISSIONS DUE TO GYPSUM BOARD RAW MATERIALS TRANSPORTATION (G/M2 OF 1/2" REGULAR GYPSUM BOARD)
CO2 SO2 NOx VOC CH4 CO
West Avg. 753.17 2.0090 7.6994 1.6250 0.2581 2.9497 Central Avg. 153.92 0.2221 1.7569 0.1892 0.0472 0.9644 East Avg. 453.40 1.0769 4.3813 0.8887 0.1605 2.2790 CANADA 371.37 0.8615 3.8322 0.7059 0.1256 1.7605
6.2.3 Gypsum Board Manufacturing Atmospheric emissions are generated in all steps of the gypsum board manufacturing process described in Section 2 of this report, i.e. in gypsum calcination, in the paper making process, and in the gypsum board manufacturing itself. Use of energy to drive the crushers, screens, hammer mills, Raymond mills, the various conveyors, and especially fuel combustion in the calcination step, generates all the common air pollutants (i.e. CO2, SO2, NOx, VOCs, CH4 and CO) usually associated with energy consumption. Similarly the paper manufacturing process energy use in all the processing steps, from waste paper defiberization through paper formation, pressing, drying and calendering, generates atmospheric fuel emissions.
Of the three board processing steps, the gypsum board manufacturing, due to the board drying in heated board kilns, uses about the same amount of energy as the other two steps combined (Table 4.35). Fossil fuels providing the kiln heat produce the common atmospheric emissions.
Particulate matter is also generated as rock gypsum is dried and reduced to fine particles through crushing and milling, and as gypsum is conveyed and processed in the calcination kettles to stucco, and eventually into the board. A nationwide emissions inventory (1978)2 offers uncontrolled particulate emission factors (Table 6.5) based on the U.S. EPA 1977 data, and in calculation of the actual TPM emissions it assumes 90% control efficiency. Considering the advances in the particulate emissions controls and their implementation, these data appear to be somewhat obsolete now. Particulate emissions from paper board production are considered to be negligible.2 The AthenaTM Project: Gypsum Board and Associated Finishing Products 6-5
As any industry, the gypsum industry has been under some pressure to control its particulate emissions. High efficiency baghouses and some electrostatic precipitators are installed and used in all modern gypsum operations, and this is reflected in updated U.S. EPA 1983 controlled particulate emission factors.4 The EPA controlled emissions indicate 99.7% control efficiency. At the same time, however, the large spread in the factor estimates is an indication that there is relatively little actual measured data available, mainly due to the fact that the gypsum industry does not present any substantial particulates problem. This is best summarized in a response from one of the provincial authorities: “Based on site inspections, which demonstrated no visible particulate emissions, the Company was not required to do particulate stack testing.”
Estimates of particulate emissions were obtained from provincial environmental ministries in Quebec, Ontario and from GVRD (Greater Vancouver Regional District). Ontario data cover all producers, and as such appear to be representative of the situation in the province. The reported weighted average TPM emissions of 0.2109 g/m2 are substantially better than even EPA assumed controlled emission. This is not surprising, considering that the Ontario plants are the flagship operations of the respective producers, and as such their emissions controls will be close to the state-of-the-art. As Ontario represents close to 90% of the Central region, we will use this factor for the entire region. For the East we received data concerning only one plant. At 0.7546 g/m2 of board, it is close to the EPA estimate, and we will assume that it is representative of the whole region. The GVRD data are permit data giving the maximum allowable annual emissions, but providing only scant measured data. From this limited actual emission monitoring, it would appear that the performance at 1.7494 g/m2 is substantially better than maximum potential assessment, although not as good as in the other regions. The above discussed gypsum board manufacturing TPM factors are summarized in Table 6.6.
TABLE 6.5 ENVIRONMENT CANADA AND U.S. EPA PARTICULATE EMISSION FACTORS FOR GYPSUM PROCESSING (KG/TONNE)
Environment Canada 1978 U.S. EPA AP-42 19854 Inventory2 uncontrolled controlled uncontrolled controlled emissions emissions* emissions emissions**
raw material drying 20.0 2.0 5 Ð 60 0.02 primary grinding 0.5 0.05 1.3 0.06 calcining 45.0 4.5 21 0.003 conveying 0.35 0.035 - - board sawing - - 0.005 - TOTAL 65.85 6.585 27.305 Ð 82.305 0.083
TOTAL g/m2 for 1/2" 504.66 50.47 209.26 Ð 630.76 0.636 board; gypsum use 7.6637 kg/m2 of board notes: * assuming 90% control efficiencies, ** with baghouse / fabric filter The AthenaTM Project: Gypsum Board and Associated Finishing Products 6-6
TABLE 6.6 ESTIMATES OF PARTICULATE EMISSION FACTORS FOR GYPSUM PROCESSING BY REGION (G/M2 OF 1/2" BOARD)
Weighted TPM Emissions
West Region 1.7494 Central Region 0.2109 East Region 0.7546
Processing (expansion) of perlite used in manufacturing of gypsum fiberboard also generates particulate emissions. According to U.S. EPA, uncontrolled emissions for perlite expansion are 10.5 kg/tonne.5 For our estimates, we will use the same particulate emissions as for gypsum (assuming that perlite expansion generates about the same TPM as gypsum calcination) in the East region adjusted for relative usage of gypsum and perlite in GFB.
Weighted averages of estimates for atmospheric emissions due to all three manufacturing stages of gypsum board production, as well as the total, are summarized in Tables 6.7 to 6.10 for 1/2" regular gypsum board. The emissions for the other board products are shown in the summary part of this section.
TABLE 6.7 ATMOSPHERIC EMISSIONS DUE TO STUCCO CALCINATION (G/M2 OF 1/2” REGULAR GYPSUM BOARD)
CO2 SO2 NOx VOC CH4 CO TPM
West 642.37 2.4903 0.9770 0.0188 0.0135 0.1703 1.7494 Central 435.98 1.1865 1.4019 0.1052 0.0317 0.5832 0.2109 East 668.64 3.0635 2.8025 0.2280 0.0622 1.2052 0.7546 CANADA 541.27 1.9472 1.6262 0.1128 0.0344 0.6277 0.7163
TABLE 6.8 ATMOSPHERIC EMISSIONS DUE TO GYPSUM PAPER PRODUCTION (G/M2 OF 1/2” REGULAR GYPSUM BOARD)
CO2 SO2 NOx VOC CH4 CO
West 293.27 0.2423 0.3689 0.0074 0.0073 0.0862 Central 293.27 0.2423 0.3689 0.0074 0.0073 0.0862 East 293.27 0.2423 0.3689 0.0074 0.0073 0.0862 CANADA 293.27 0.2423 0.3689 0.0074 0.0073 0.0862 The AthenaTM Project: Gypsum Board and Associated Finishing Products 6-7
TABLE 6.9 ATMOSPHERIC EMISSIONS DUE TO BOARD MANUFACTURING (G/M2 OF 1/2” REGULAR GYPSUM BOARD)
CO2 SO2 NOx VOC CH4 CO
West 1012.53 3.2303 1.4801 0.0287 0.0222 0.2750 Central 907.84 2.1708 1.2645 0.0248 0.0209 0.2535 East 1090.85 6.2933 1.8370 0.0347 0.0202 0.2696 CANADA 976.50 3.3985 1.4518 0.0281 0.0210 0.2625
TABLE 6.10 SUBTOTAL OF ATMOSPHERIC EMISSIONS FROM ALL THREE MANUFACTURING STEPS (G/M2 OF 1/2” REGULAR GYPSUM BOARD)
CO2 SO2 NOx VOC CH4 CO TPM
West 1948.18 5.9629 2.8260 0.0550 0.0430 0.5315 1.7494 Central 1637.09 3.5996 3.0353 0.1374 0.0599 0.9228 0.2109 East 2052.76 9.5991 5.0084 0.2701 0.0897 1.5611 0.7546 CANADA 1811.04 5.5880 3.4469 0.1483 0.0628 0.9765 0.7163
Permissible levels of SO2, NOx and TPM emissions are regulated by the provinces. However, as gypsum board plants, in comparison with many other operations, generate relatively low emissions, there are no known monitoring data of such operations for either SO2 and NOx. According to industry sources, monitoring of air quality with respect to TPM near board plants indicates that the current emission limits are not exceeded.
6.2.4 Finished Gypsum Board Transportation The ATHENATM computer model calculates atmospheric emissions associated with the finished products transportation from the plant gate to the market, taking into consideration distances and transport modes, as tabulated in Table 4.15. To better recall this information, it is shown in this subsection again.
To provide a picture of atmospheric emissions associated with finished products transportation in this study as well, the weighted average emissions related to finished 1/2" gypsum board transportation to market distribution centres were calculated by combining transportation energy emission factors from Table 6.1 with the estimates of transportation energy use by fuel type developed and presented in Table 4.17. The results are shown in Table 6.11, while the finished board transportation emissions for the other gypsum board products are tabulated in the summary part of this section. The AthenaTM Project: Gypsum Board and Associated Finishing Products 6-8
TABLE 4.15 WEIGHTED AVERAGE TRANSPORTATION DISTANCES BY MODE FOR FINISHED GYPSUM BOARD (KM)
Average Distances & Transport Mode Truck Rail Ship
Vancouver 90 0 0 Calgary 225 300 0 Winnipeg 90 400 0 Toronto 153 0 0 Montreal 288 0 0 Halifax 279 847.5 110
Transport factors [MJ/tonne-km] 1.18 0.49 0.12 note: appropriate backhaul factors included in the distances
TABLE 6.11 ATMOSPHERIC EMISSIONS DUE TO TRANSPORTATION OF FINISHED GYPSUM BOARD (G/M2 OF 1/2" REGULAR GYPSUM BOARD)
CO2 SO2 NOx VOC CH4 CO
West Vancouver 60.54 0.0873 0.6910 0.0744 0.0186 0.3793 Calgary 235.15 0.3393 3.3870 0.2690 0.0557 1.0159 Central Winnipeg 172.28 0.2485 2.9036 0.1850 0.0309 0.4694 Toronto 102.92 0.1485 1.1748 0.1265 0.0316 0.6449 East Montreal 193.73 0.2795 2.2113 0.2381 0.0595 1.2139 Halifax 432.29 0.6602 6.8514 0.5034 0.0880 1.3676 The AthenaTM Project: Gypsum Board and Associated Finishing Products 6-9
6.3 ATMOSPHERIC EMISSIONS SUMMARY Total atmospheric emissions due to the production of 1/2" regular gypsum board are shown in Table 6.12. Comprehensive tables of atmospheric emissions by process stage for all gypsum board products under consideration are shown as Tables 6.13 to 6.20.
TABLE 6.12 TOTAL ATMOSPHERIC EMISSIONS DUE TO GYPSUM BOARD PRODUCTION - FROM CRADLE TO MARKET (G/M2 OF 1/2" REGULAR GYPSUM BOARD)
CO2 SO2 NOx VOC CH4 CO TPM
West Vancouver 2775.30 8.0786 11.3696 1.7708 0.3238 3.9446 6.3913 Calgary 2949.91 8.3305 14.0655 1.9654 0.3609 4.5812 6.3913 Central Winnipeg 1968.06 4.0969 7.7294 0.5146 0.1388 2.3739 1.0818 Toronto 1898.70 3.9968 6.0006 0.4560 0.1395 2.5494 1.0818 East Montreal 2716.01 11.0056 11.7598 1.4135 0.3138 5.1384 3.8858 Halifax 2954.57 11.3863 16.3998 1.6787 0.3423 5.2921 3.8858 The AthenaTM Project: Gypsum Board and Associated Finishing Products 6-10
TABLE 6.13 ATMOSPHERIC EMISSIONS DUE TO PRODUCTION OF 1/2" REGULAR GYPSUM BOARD (G/M2)
CO2 SO2 NOx VOC CH4 CO TPM
Gypsum extraction & processing emissions West 13.42 0.0194 0.1531 0.0165 0.0041 0.0841 4.6419 Central 4.78 0.0267 0.0336 0.0029 0.0007 0.0172 0.8709 East 16.13 0.0502 0.1588 0.0166 0.0041 0.0845 3.1312 CANADA 10.13 0.0326 0.0976 0.0100 0.0025 0.0521 2.3275 Total raw materials transportation emissions West 753.17 2.0090 7.6994 1.6250 0.2581 2.9497 Central 153.92 0.2221 1.7569 0.1892 0.0472 0.9644 East 453.40 1.0769 4.3813 0.8887 0.1605 2.2790 CANADA 371.37 0.8615 3.8322 0.7059 0.1256 1.7605 Total manufacturing emissions West 1948.18 5.9629 2.8260 0.0550 0.0430 0.5315 1.7494 Central 1637.09 3.5996 3.0353 0.1374 0.0599 0.9228 0.2109 East 2052.76 9.5991 5.0084 0.2701 0.0897 1.5611 0.7546 CANADA 1811.04 5.5880 3.4469 0.1483 0.0628 0.9765 0.7163 Cradle to gate emissions West 2714.76 7.9913 10.6785 1.6964 0.3052 3.5653 6.3913 Central 1795.78 3.8483 4.8258 0.3295 0.1079 1.9045 1.0818 East 2522.28 10.7261 9.5485 1.1753 0.2543 3.9245 3.8858 CANADA 2192.53 6.4821 7.3767 0.8643 0.1909 2.7891 3.0438 Transportation emissions for the finished product West Vancouver 60.54 0.0873 0.6910 0.0744 0.0186 0.3793 Calgary 235.15 0.3393 3.3870 0.2690 0.0557 1.0159 Central Winnipeg 172.28 0.2485 2.9036 0.1850 0.0309 0.4694 Toronto 102.92 0.1485 1.1748 0.1265 0.0316 0.6449 East Montreal 193.73 0.2795 2.2113 0.2381 0.0595 1.2139 Halifax 432.29 0.6602 6.8514 0.5034 0.0880 1.3676 Total emissions associated with 1/2" regular board West Vancouver 2775.30 8.0786 11.3696 1.7708 0.3238 3.9446 6.3913 Calgary 2949.91 8.3305 14.0655 1.9654 0.3609 4.5812 6.3913 Central Winnipeg 1968.06 4.0969 7.7294 0.5146 0.1388 2.3739 1.0818 Toronto 1898.70 3.9968 6.0006 0.4560 0.1395 2.5494 1.0818 East Montreal 2716.01 11.0056 11.7598 1.4135 0.3138 5.1384 3.8858 Halifax 2954.57 11.3863 16.3998 1.6787 0.3423 5.2921 3.8858 The AthenaTM Project: Gypsum Board and Associated Finishing Products 6-11
TABLE 6.14 ATMOSPHERIC EMISSIONS DUE TO PRODUCTION OF 1/2" TYPE X FIRE RESISTANT GYPSUM BOARD (G/M2)
CO2 SO2 NOx VOC CH4 CO TPM
Gypsum extraction & processing emissions West 13.70 0.0198 0.1564 0.0168 0.0042 0.0858 4.6214 Central 4.88 0.0272 0.0344 0.0030 0.0007 0.0176 0.8671 East 16.46 0.0512 0.1622 0.0169 0.0042 0.0863 3.1173 CANADA 10.34 0.0333 0.0996 0.0102 0.0026 0.0532 2.3172 Total raw materials transportation emissions West 765.89 2.0469 7.8256 1.6554 0.2625 2.9918 Central 155.03 0.2237 1.7696 0.1906 0.0476 0.9714 East 460.52 1.0960 4.4458 0.9044 0.1631 2.3118 CANADA 376.74 0.8762 3.8849 0.7178 0.1275 1.7822 Total manufacturing emissions West 1948.86 6.0050 2.8304 0.0550 0.0430 0.5314 1.7417 Central 1633.40 3.6141 3.0488 0.1394 0.0603 0.9314 0.2100 East 2054.01 9.6534 5.0515 0.2746 0.0907 1.5828 0.7513 CANADA 1809.58 5.6186 3.4651 0.1504 0.0632 0.9860 0.7132 Cradle to gate emissions West 2728.45 8.0717 10.8124 1.7273 0.3097 3.6090 6.3631 Central 1793.31 3.8650 4.8527 0.3329 0.1086 1.9204 1.0771 East 2530.99 10.8006 9.6596 1.1959 0.2580 3.9809 3.8686 CANADA 2196.66 6.5280 7.4497 0.8784 0.1932 2.8214 3.0303 Transportation emissions for the finished product West Vancouver 61.46 0.0887 0.7015 0.0755 0.0189 0.3851 Calgary 238.72 0.3444 3.4383 0.2731 0.0565 1.0313 Central Winnipeg 174.89 0.2523 2.9476 0.1878 0.0314 0.4765 Toronto 104.48 0.1507 1.1926 0.1284 0.0321 0.6547 East Montreal 196.67 0.2837 2.2449 0.2417 0.0604 1.2323 Halifax 438.84 0.6702 6.9552 0.5110 0.0893 1.3883 Total emissions associated with 1/2" type X board West Vancouver 2789.91 8.1604 11.5139 1.8028 0.3286 3.9941 6.3631 Calgary 2967.17 8.4161 14.2507 2.0004 0.3663 4.6404 6.3631 Central Winnipeg 1968.20 4.1173 7.8003 0.5207 0.1400 2.3970 1.0771 Toronto 1897.79 4.0157 6.0453 0.4613 0.1407 2.5751 1.0771 East Montreal 2727.65 11.0844 11.9044 1.4376 0.3184 5.2132 3.8686 Halifax 2969.83 11.4708 16.6147 1.7069 0.3474 5.3692 3.8686 The AthenaTM Project: Gypsum Board and Associated Finishing Products 6-12
TABLE 6.15 ATMOSPHERIC EMISSIONS DUE TO PRODUCTION OF 1/2" MR MOISTURE RESISTANT GYPSUM BOARD (G/M2)
CO2 SO2 NOx VOC CH4 CO TPM
Gypsum extraction & processing emissions West 15.22 0.0220 0.1737 0.0187 0.0047 0.0954 5.0903 Central 5.42 0.0302 0.0382 0.0033 0.0008 0.0196 0.9551 East 18.29 0.0569 0.1802 0.0188 0.0047 0.0959 3.4336 CANADA 11.49 0.0370 0.1107 0.0113 0.0028 0.0591 2.5523 Total raw materials transportation emissions West 849.24 2.2718 8.6753 1.8372 0.2912 3.3135 Central 171.13 0.2469 1.9534 0.2103 0.0525 1.0723 East 510.36 1.2158 4.9248 1.0032 0.1808 2.5604 CANADA 417.28 0.9716 4.3015 0.7959 0.1412 1.9719 Total manufacturing emissions West 2042.87 6.3049 2.9678 0.0577 0.0450 0.5569 1.9184 Central 1704.00 3.7661 3.2343 0.1518 0.0644 1.0038 0.2313 East 2150.99 10.0183 5.3960 0.3010 0.0983 1.7257 0.8275 CANADA 1892.12 5.8569 3.6762 0.1637 0.0676 1.0634 0.7855 Cradle to gate emissions West 2907.33 8.5986 11.8168 1.9136 0.3409 3.9657 7.0087 Central 1880.55 4.0433 5.2259 0.3655 0.1178 2.0956 1.1863 East 2679.64 11.2910 10.5010 1.3230 0.2838 4.3820 4.2611 CANADA 2320.89 6.8655 8.0884 0.9710 0.2117 3.0945 3.3378 Transportation emissions for the finished product West Vancouver 67.88 0.0979 0.7748 0.0834 0.0208 0.4253 Calgary 263.66 0.3804 3.7976 0.3016 0.0625 1.1391 Central Winnipeg 193.16 0.2787 3.2555 0.2075 0.0347 0.5263 Toronto 115.40 0.1665 1.3172 0.1418 0.0354 0.7231 East Montreal 217.22 0.3134 2.4794 0.2670 0.0667 1.3611 Halifax 484.69 0.7402 7.6818 0.5644 0.0986 1.5334 Total emissions associated with 1/2" MR board West Vancouver 2975.21 8.6966 12.5916 1.9970 0.3617 4.3911 7.0088 Calgary 3170.99 8.9790 15.6144 2.2152 0.4033 5.1048 7.0088 Central Winnipeg 2073.71 4.3220 8.4814 0.5729 0.1524 2.6220 1.1863 Toronto 1995.95 4.2098 6.5431 0.5073 0.1532 2.8187 1.1863 East Montreal 2896.85 11.6044 12.9803 1.5899 0.3505 5.7430 4.2611 Halifax 3164.32 12.0312 18.1828 1.8874 0.3825 5.9154 4.2611 The AthenaTM Project: Gypsum Board and Associated Finishing Products 6-13
TABLE 6.16 ATMOSPHERIC EMISSIONS DUE TO PRODUCTION OF 5/8" REGULAR GYPSUM BOARD (G/M2)
CO2 SO2 NOx VOC CH4 CO TPM
Gypsum extraction & processing emissions West 17.53 0.0253 0.2001 0.0215 0.0054 0.1098 6.0610 Central 6.24 0.0348 0.0440 0.0038 0.0010 0.0225 1.1372 East 21.06 0.0655 0.2075 0.0217 0.0054 0.1104 4.0884 CANADA 13.23 0.0426 0.1275 0.0131 0.0033 0.0681 3.0390 Total raw materials transportation emissions West 969.33 2.6035 9.8918 2.1049 0.3326 3.7618 Central 191.42 0.2762 2.1850 0.2353 0.0588 1.1994 East 581.10 1.3903 5.5963 1.1468 0.2062 2.9075 CANADA 473.96 1.1092 4.8782 0.9084 0.1606 2.2296 Total manufacturing emissions West 2401.78 7.5366 3.4999 0.0680 0.0528 0.6536 2.2842 Central 2001.27 4.5089 3.7856 0.1760 0.0749 1.1660 0.2754 East 2534.00 12.1142 6.3310 0.3487 0.1139 1.9989 0.9853 CANADA 2224.65 7.0373 4.3128 0.1900 0.0787 1.2356 0.9353 Cradle to gate emissions West 3388.64 10.1655 13.5918 2.1945 0.3908 4.5252 8.3453 Central 2198.94 4.8199 6.0145 0.4151 0.1347 2.3879 1.4126 East 3136.16 13.5700 12.1348 1.5172 0.3255 5.0167 5.0737 CANADA 2711.80 8.1891 9.3185 1.1114 0.2425 3.5332 3.9743 Transportation emissions for the finished product West Vancouver 77.24 0.1114 0.8816 0.0949 0.0237 0.4840 Calgary 300.00 0.4328 4.3210 0.3432 0.0711 1.2961 Central Winnipeg 219.78 0.3171 3.7043 0.2361 0.0394 0.5989 Toronto 131.30 0.1894 1.4987 0.1614 0.0403 0.8227 East Montreal 247.16 0.3566 2.8211 0.3038 0.0759 1.5487 Halifax 551.50 0.8423 8.7407 0.6422 0.1122 1.7448 Total emissions associated with 5/8" regular board West Vancouver 3465.88 10.2769 14.4734 2.2894 0.4145 5.0092 8.3453 Calgary 3688.64 10.5983 17.9128 2.5377 0.4619 5.8213 8.3453 Central Winnipeg 2418.72 5.1370 9.7188 0.6512 0.1741 2.9868 1.4126 Toronto 2330.24 5.0094 7.5132 0.5765 0.1750 3.2107 1.4126 East Montreal 3383.31 13.9266 14.9560 1.8210 0.4014 6.5653 5.0737 Halifax 3687.65 14.4123 20.8755 2.1594 0.4377 6.7614 5.0737 The AthenaTM Project: Gypsum Board and Associated Finishing Products 6-14
TABLE 6.17 ATMOSPHERIC EMISSIONS DUE TO PRODUCTION OF 5/8" TYPE X FIRE RESISTANT GYPSUM BOARD (G/M2)
CO2 SO2 NOx VOC CH4 CO TPM
Gypsum extraction & processing emissions West 17.78 0.0256 0.2029 0.0219 0.0055 0.1114 6.1473 Central 6.33 0.0353 0.0446 0.0039 0.0010 0.0228 1.1534 East 21.36 0.0665 0.2105 0.0220 0.0055 0.1119 4.1466 CANADA 13.42 0.0432 0.1293 0.0133 0.0033 0.0691 3.0823 Total raw materials transportation emissions West 981.18 2.6379 10.0103 2.1326 0.3368 3.8030 Central 192.82 0.2782 2.2009 0.2370 0.0592 1.2082 East 587.86 1.4079 5.6587 1.1613 0.2086 2.9394 CANADA 479.14 1.1228 4.9303 0.9194 0.1624 2.2517 Total manufacturing emissions West 2406.06 7.5768 3.5085 0.0682 0.0529 0.6545 2.3167 Central 2001.69 4.5247 3.8021 0.1778 0.0753 1.1746 0.2793 East 2538.77 12.1652 6.3737 0.3528 0.1149 2.0191 0.9993 CANADA 2227.04 7.0674 4.3335 0.1919 0.0791 1.2451 0.9486 Cradle to gate emissions West 3405.02 10.2404 13.7216 2.2226 0.3951 4.5688 8.4640 Central 2200.84 4.8383 6.0476 0.4186 0.1355 2.4057 1.4327 East 3147.99 13.6395 12.2429 1.5361 0.3290 5.0705 5.1459 CANADA 2719.60 8.2334 9.3930 1.1246 0.2448 3.5658 4.0309 Transportation emissions for the finished product West Vancouver 78.89 0.1138 0.9005 0.0970 0.0242 0.4943 Calgary 306.41 0.4421 4.4134 0.3505 0.0726 1.3238 Central Winnipeg 224.48 0.3239 3.7835 0.2411 0.0403 0.6117 Toronto 134.11 0.1935 1.5308 0.1648 0.0412 0.8403 East Montreal 252.44 0.3642 2.8814 0.3103 0.0775 1.5818 Halifax 563.29 0.8603 8.9275 0.6559 0.1146 1.7821 Total emissions associated with 5/8" type X board West Vancouver 3483.91 10.3542 14.6221 2.3196 0.4193 5.0631 8.4640 Calgary 3711.43 10.6824 18.1350 2.5731 0.4677 5.8926 8.4640 Central Winnipeg 2425.32 5.1621 9.8311 0.6597 0.1758 3.0173 1.4327 Toronto 2334.95 5.0317 7.5784 0.5835 0.1767 3.2460 1.4327 East Montreal 3400.43 14.0037 15.1243 1.8464 0.4065 6.6522 5.1459 Halifax 3711.27 14.4998 21.1704 2.1920 0.4437 6.8525 5.1459 The AthenaTM Project: Gypsum Board and Associated Finishing Products 6-15
TABLE 6.18 ATMOSPHERIC EMISSIONS DUE TO PRODUCTION OF 5/8" MR MOISTURE RESISTANT GYPSUM BOARD (G/M2)
CO2 SO2 NOx VOC CH4 CO TPM
Gypsum extraction & processing emissions West 19.52 0.0282 0.2228 0.0240 0.0060 0.1223 6.5267 Central 6.95 0.0388 0.0489 0.0042 0.0011 0.0251 1.2246 East 23.45 0.0730 0.2310 0.0241 0.0060 0.1229 4.4025 CANADA 14.73 0.0474 0.1419 0.0145 0.0036 0.0758 3.2725 Total raw materials transportation emissions West 1076.80 2.8954 10.9853 2.3407 0.3696 4.1727 Central 211.45 0.3051 2.4135 0.2599 0.0649 1.3249 East 645.08 1.5452 6.2091 1.2745 0.2289 3.2252 CANADA 525.73 1.2322 5.4094 1.0090 0.1782 2.4702 Total manufacturing emissions West 2515.52 7.9213 3.6680 0.0713 0.0553 0.6842 2.4597 Central 2084.40 4.7002 4.0167 0.1921 0.0801 1.2579 0.2965 East 2651.63 12.5839 6.7699 0.3830 0.1236 2.1831 1.0610 CANADA 2323.40 7.3414 4.5772 0.2072 0.0842 1.3341 1.0072 Cradle to gate emissions West 3611.83 10.8448 14.8761 2.4360 0.4309 4.9792 8.9864 Central 2302.79 5.0440 6.4792 0.4562 0.1461 2.6079 1.5211 East 3320.17 14.2020 13.2101 1.6817 0.3586 5.5311 5.4635 CANADA 2863.85 8.6211 10.1286 1.2308 0.2661 3.8802 4.2797 Transportation emissions for the finished product West Vancouver 86.23 0.1244 0.9842 0.1060 0.0265 0.5403 Calgary 334.92 0.4832 4.8239 0.3831 0.0793 1.4469 Central Winnipeg 245.36 0.3540 4.1354 0.2635 0.0440 0.6686 Toronto 146.58 0.2115 1.6732 0.1802 0.0450 0.9185 East Montreal 275.92 0.3981 3.1495 0.3391 0.0847 1.7289 Halifax 615.69 0.9403 9.7580 0.7170 0.1253 1.9478 Total emissions associated with 5/8" MR board West Vancouver 3698.06 10.9692 15.8603 2.5420 0.4573 5.5195 8.9864 Calgary 3946.75 11.3280 19.7001 2.8191 0.5102 6.4262 8.9864 Central Winnipeg 2548.16 5.3980 10.6146 0.7198 0.1901 3.2765 1.5211 Toronto 2449.38 5.2555 8.1524 0.6364 0.1911 3.5264 1.5211 East Montreal 3596.09 14.6001 16.3596 2.0208 0.4433 7.2600 5.4635 Halifax 3935.85 15.1423 22.9681 2.3986 0.4839 7.4790 5.4635 The AthenaTM Project: Gypsum Board and Associated Finishing Products 6-16
TABLE 6.19 ATMOSPHERIC EMISSIONS DUE TO PRODUCTION OF 5/16" MOBILE HOME GYPSUM BOARD (G/M2)
CO2 SO2 NOx VOC CH4 CO TPM
Gypsum extraction & processing emissions West 9.48 0.0137 0.1082 0.0116 0.0029 0.0594 3.2594 Central 3.37 0.0188 0.0238 0.0021 0.0005 0.0122 0.6115 East 11.39 0.0354 0.1122 0.0117 0.0029 0.0597 2.1986 CANADA 7.15 0.0230 0.0689 0.0071 0.0018 0.0368 1.6343 Total raw materials transportation emissions West 548.45 1.4428 5.6262 1.1680 0.1873 2.1865 Central 119.56 0.1725 1.3647 0.1470 0.0367 0.7492 East 332.89 0.7794 3.2380 0.6436 0.1172 1.6883 CANADA 274.96 0.6269 2.8509 0.5143 0.0926 1.3225 Total manufacturing emissions West 1390.53 4.0291 1.9975 0.0389 0.0310 0.3815 1.2284 Central 1179.30 2.4460 2.1629 0.0975 0.0431 0.6597 0.1481 East 1458.03 6.3484 3.5101 0.1904 0.0642 1.1092 0.5299 CANADA 1296.59 3.7506 2.4384 0.1049 0.0451 0.6969 0.5030 Cradle to gate emissions West 1948.45 5.4856 7.7319 1.2186 0.2212 2.6274 4.4878 Central 1302.24 2.6373 3.5514 0.2465 0.0803 1.4210 0.7596 East 1802.31 7.1632 6.8603 0.8457 0.1843 2.8572 2.7285 CANADA 1578.69 4.4005 5.3583 0.6263 0.1394 2.0562 2.1373 Transportation emissions for the finished product West Vancouver 44.03 0.0635 0.5026 0.0541 0.0135 0.2759 Calgary 171.02 0.2467 2.4633 0.1956 0.0405 0.7389 Central Winnipeg 125.29 0.1808 2.1117 0.1346 0.0225 0.3414 Toronto 74.85 0.1080 0.8544 0.0920 0.0230 0.4690 East Montreal 140.90 0.2033 1.6083 0.1732 0.0432 0.8828 Halifax 314.39 0.4801 4.9828 0.3661 0.0640 0.9946 Total emissions associated with 5/16" mobile home board West Vancouver 1992.48 5.5491 8.2345 1.2727 0.2348 2.9033 4.4878 Calgary 2119.47 5.7324 10.1952 1.4142 0.2618 3.3663 4.4878 Central Winnipeg 1427.53 2.8181 5.6631 0.3811 0.1027 1.7624 0.7596 Toronto 1377.09 2.7453 4.4058 0.3385 0.1032 1.8901 0.7596 East Montreal 1943.21 7.3665 8.4685 1.0189 0.2276 3.7400 2.7285 Halifax 2116.70 7.6433 11.8431 1.2118 0.2483 3.8518 2.7285 The AthenaTM Project: Gypsum Board and Associated Finishing Products 6-17
TABLE 6.20 ATMOSPHERIC EMISSIONS DUE TO PRODUCTION OF 1" SHAFTLINER GYPSUM BOARD (G/M2)
CO2 SO2 NOx VOC CH4 CO TPM
Gypsum extraction & processing emissions West 32.92 0.0475 0.3757 0.0405 0.0101 0.2063 11.4330 Central 11.72 0.0654 0.0826 0.0072 0.0018 0.0423 2.1451 East 39.56 0.1231 0.3897 0.0407 0.0102 0.2073 7.7120 CANADA 24.84 0.0800 0.2394 0.0245 0.0061 0.1279 5.7325 Total raw materials transportation emissions West 1777.39 4.8274 18.0857 3.9002 0.6115 6.7951 Central 331.09 0.4777 3.7792 0.4070 0.1016 2.0746 East 1058.25 2.5620 10.1349 2.1122 0.3769 5.2547 CANADA 856.93 2.0351 8.7842 1.6650 0.2915 3.9802 Total manufacturing emissions West 3905.11 12.8218 5.7395 0.1113 0.0851 1.0572 4.3088 Central 3189.32 7.5040 6.3509 0.3155 0.1271 2.0271 0.5194 East 4126.19 20.3542 10.9323 0.6365 0.2006 3.5857 1.8586 CANADA 3584.98 11.8257 7.2760 0.3407 0.1341 2.1547 1.7643 Cradle to gate emissions West 5715.41 17.6967 24.2009 4.0520 0.7067 8.0586 15.7417 Central 3532.13 8.0470 10.2127 0.7296 0.2306 4.1440 2.6645 East 5223.99 23.0393 21.4569 2.7893 0.5877 9.0476 9.5706 CANADA 4466.75 13.9407 16.2996 2.0303 0.4316 6.2627 7.4968 Transportation emissions for the finished product West Vancouver 143.10 0.2064 1.6334 0.1759 0.0439 0.8966 Calgary 555.82 0.8019 8.0057 0.6358 0.1317 2.4013 Central Winnipeg 407.20 0.5875 6.8630 0.4374 0.0731 1.1096 Toronto 243.27 0.3510 2.7767 0.2990 0.0747 1.5243 East Montreal 457.91 0.6606 5.2268 0.5628 0.1405 2.8692 Halifax 1021.78 1.5605 16.1941 1.1898 0.2080 3.2326 Total emissions associated with 1" shaftliner board West Vancouver 5858.51 17.9032 25.8343 4.2279 0.7506 8.9552 15.7418 Calgary 6271.23 18.4986 32.2066 4.6878 0.8383 10.4598 15.7418 Central Winnipeg 3939.33 8.6345 17.0757 1.1670 0.3036 5.2535 2.6645 Toronto 3775.40 8.3980 12.9894 1.0286 0.3052 5.6682 2.6645 East Montreal 5681.91 23.6999 26.6837 3.3522 0.7283 11.9169 9.5706 Halifax 6245.77 24.5998 37.6510 3.9792 0.7957 12.2802 9.5706 The AthenaTM Project: Gypsum Board and Associated Finishing Products 6-18
TABLE 6.21 ATMOSPHERIC EMISSIONS DUE TO PRODUCTION OF 1/2" GYPSUM FIBERBOARD (GFB) (G/M2)
CO2 SO2 NOx VOC CH4 CO TPM
Gypsum extraction & processing emissions 17.91 0.0258 0.2045 0.0220 0.0055 0.1122 6.1276 Total raw materials transportation emissions 229.97 1.069 1.409 0.856 0.104 0.352 Total manufacturing emissions 2141.39 3.376 4.752 0.285 0.105 1.750 0.9697 Cradle to gate emissions 2389.28 4.4705 6.3650 1.1623 0.2145 2.2146 7.0973 Transportation emissions for the finished product Vancouver 2264.06 3.266 44.833 2.242 0.250 1.825 Calgary 1891.11 2.728 37.448 1.872 0.209 1.525 Winnipeg 1371.62 1.979 27.161 1.358 0.151 1.106 Toronto 704.03 1.016 13.941 0.697 0.078 0.568 Montreal 494.68 0.714 9.796 0.490 0.055 0.399 Halifax 336.10 0.485 3.836 0.413 0.103 2.106 Total emissions associated with 1/2" GFB West Vancouver 4653.34 7.7369 51.1979 3.4040 0.4643 4.0399 7.0973 Calgary 4280.39 7.1988 43.8128 3.0347 0.4231 3.7393 7.0973 Central Winnipeg 3760.90 6.4493 33.5258 2.5204 0.3658 3.3204 7.0973 Toronto 3093.31 5.4862 20.3062 1.8594 0.2922 2.7822 7.0973 East Montreal 2883.96 5.1842 16.1607 1.6521 0.2691 2.6134 7.0973 Halifax 2725.37 4.9554 10.2013 1.5754 0.3177 4.3205 7.0973 The AthenaTM Project: Gypsum Board and Associated Finishing Products 6-19
TABLE 6.22 ATMOSPHERIC EMISSIONS DUE TO PRODUCTION OF 5/8" GYPSUM FIBERBOARD (GFB) (G/M2)
CO2 SO2 NOx VOC CH4 CO TPM
Gypsum extraction & processing emissions 22.23 0.0321 0.2537 0.0273 0.0068 0.1393 7.6031 Total raw materials transportation emissions 285.35 1.326 1.748 1.062 0.129 0.437 Total manufacturing emissions 2665.02 4.189 5.906 0.354 0.131 2.174 1.2031 Cradle to gate emissions 2972.60 5.5470 7.9072 1.4424 0.2664 2.7503 8.8062 Transportation emissions for the finished product West Vancouver 2827.61 4.079 55.992 2.800 0.312 2.280 Calgary 2361.83 3.407 46.769 2.338 0.261 1.904 Central Winnipeg 1713.03 2.471 33.921 1.696 0.189 1.381 Toronto 879.27 1.269 17.411 0.871 0.097 0.709 East Montreal 617.81 0.891 12.234 0.612 0.068 0.498 Halifax 419.75 0.606 4.791 0.516 0.129 2.630 Total emissions associated with 5/8" GFB West Vancouver 5800.21 9.6264 63.8994 4.2420 0.5783 5.0300 8.8062 Calgary 5334.43 8.9545 54.6760 3.7809 0.5269 4.6544 8.8062 Central Winnipeg 4685.63 8.0184 41.8285 3.1385 0.4554 4.1314 8.8062 Toronto 3851.87 6.8155 25.3184 2.3130 0.3634 3.4592 8.8062 East Montreal 3590.41 6.4383 20.1411 2.0541 0.3345 3.2484 8.8062 Halifax 3392.35 6.1526 12.6984 1.9583 0.3952 5.3804 8.8062 The AthenaTM Project: Gypsum Board and Associated Finishing Products 6-20
REFERENCES
1. “Emission Factors for Greenhouse and Other Gases by Fuel Type: An Inventory”, Energy, Mines and Resources Canada, Ad Hoc Committee on Emissions Factors, December 1990. 2. “A Nationwide Inventory of Emissions of Air Contaminants”, Environment Canada, Report EPS 3-EP-83-10, December 1983. 3. “Metals Mining and Milling Process Profiles with Environmental Aspects, U.S. Environmental Protection Agency, EPA-600/2-76-167, Washington, USA, 1976. 4. “Compilation of Air Pollutant Emission Factors”, Section 8.14 “Gypsum Manufacturing” (May 1983), U.S. Environmental Protection Agency, EPA AP-42, 4th edition, September 1985. 5. “Compilation of Air Pollutant Emission Factors”, Section 8.17 “Gypsum Manufacturing” (February 1972), U.S. Environmental Protection Agency, EPA AP-42, 4th edition, September 1985. The AthenaTM Project: Gypsum Board and Associated Finishing Products 7-1
7.0 ATMOSPHERIC EMISSIONS - JOINT FINISHING PRODUCTS In this section atmospheric emission estimates for joint finishing products are developed using the same approach employed in the development of estimates for emissions associated with gypsum board production, as was described in some detail in Section 6.0.
To calculate CO2, SO2, NOx, CO, CH4 and VOC releases, energy consumption unit factors developed in Section 5 were used as a base, combined with the energy emission factors as given in Tables 3 and 6 of the Research Guidelines, based on factors developed by Natural Resources Canada’s “Ad Hoc Committee on Emission Factors”.1 Applicable energy emission factors used throughout this work were summarized in Section 6, Table 6.1. Contributions to atmospheric emissions, with the exception of those related to electricity, were developed for all three types of finishing products under consideration (ready mix joint compound, setting (dry) compound, and joint paper tape). They are tabulated and discussed in the individual subsections below.
The emissions related to the generation of electricity are being calculated separately within the Sustainable Materials Project calculation model for all of the products under consideration (i.e. concrete, steel, wood, gypsum board, and other materials under development). The estimates of electricity use in gypsum board and associated finishing products production presented in this report will be translated into the mix of primary energy forms used to generate the electricity for the relevant regional electrical systems. Corresponding atmospheric emissions will then be added in the model to the other emissions estimated in this study.
7.1 ATMOSPHERIC EMISSION ESTIMATES 7.1.1 Raw Materials Extraction As noted in Section 5.1, while both types of joint compounds are comprised of a number of different raw materials, all of those with embodied extraction energy are industrial minerals quarried in open pits. Quarrying involves drilling and blasting, with fractured rock handled and loaded onto trucks using front-end loaders, mechanical shovels and traxcavators. In agreement with the Sustainable Materials Project Research Guidelines, we assumed that it takes 0.027 GJ/tonne2 for extraction of all of these materials, including gypsum, and that all this energy is in the form of diesel fuel - road. (As far as gypsum is concerned, this assumption is slightly different from those discussed for gypsum extraction for gypsum board production. However, as indicated in Section 5, gypsum used in production of setting compound is often calcined in a different manner, and it is always natural gypsum of as high a purity as possible.) Furthermore we assumed that the same amount of energy is required to extract the required quantities of raw materials in all geographical regions, and that consequently the same emissions are generated all across Canada. Atmospheric emissions were estimated using the average energy estimates for joint compounds raw materials extraction (Table 5.1) together with appropriate diesel-road emission factors from Table 6.1. The AthenaTM Project: Gypsum Board and Associated Finishing Products 7-2
For the estimates of particulate emissions due to the drilling, blasting and loading in open-pit mining operations, a factor of 0.51 kg/tonne is used.3,4 For gypsum, we have assumed a high grade quality gypsum deposit, and considered the requirement of 1.2048 tonnes of gypsum for a tonne of stucco.
Resulting estimates of atmospheric emissions due to the extraction of raw materials for the production of ready mix joint compound are presented in Table 7.1, and those for setting joint compounds in Table 7.2. As the joint paper tape is made entirely from recycled paper, we assume no raw materials extraction or emissions there.
7.1.2 Raw Materials Transportation In estimating raw materials transportation emissions factors, average raw materials energy transportation estimates (by energy form) developed in Section 5.1 (Tables 5.2 and 5.3 for ready mix compound, 5.4 and 5.5 for setting compound, and 5.6-5.8 for joint paper tape) were multiplied by appropriate emission energy factors from Table 6.1. The resulting atmospheric emissions estimates are shown in Tables 7.3 - 7.5. As already noted in Section 5, the specific grades of industrial minerals needed to produce joint compounds often have to be brought over from distant locations. Consequently the raw materials transportation contribution to the total energy, and therefore also to the atmospheric emissions total is rather high.
TABLE 7.1 ATMOSPHERIC EMISSIONS DUE TO READY MIX JOINT COMPOUND RAW MATERIALS EXTRACTION
CO2 SO2 NOx VOC CH4 CO TPM
g/kg of compound
Vancouver 1.17206 0.00169 0.01338 0.00144 0.00036 0.00734 0.31314 Calgary 1.17206 0.00169 0.01338 0.00144 0.00036 0.00734 0.31314 Winnipeg 1.17206 0.00169 0.01338 0.00144 0.00036 0.00734 0.31314 Toronto 1.17206 0.00169 0.01338 0.00144 0.00036 0.00734 0.31314 Montreal 1.17206 0.00169 0.01338 0.00144 0.00036 0.00734 0.31314 Halifax 1.17206 0.00169 0.01338 0.00144 0.00036 0.00734 0.31314
g/m2 of board
Vancouver 0.78997 0.00114 0.00902 0.00097 0.00024 0.00495 0.21106 Calgary 0.78997 0.00114 0.00902 0.00097 0.00024 0.00495 0.21106 Winnipeg 0.78997 0.00114 0.00902 0.00097 0.00024 0.00495 0.21106 Toronto 0.78997 0.00114 0.00902 0.00097 0.00024 0.00495 0.21106 Montreal 0.78997 0.00114 0.00902 0.00097 0.00024 0.00495 0.21106 Halifax 0.78997 0.00114 0.00902 0.00097 0.00024 0.00495 0.21106 The AthenaTM Project: Gypsum Board and Associated Finishing Products 7-3
TABLE 7.2 ATMOSPHERIC EMISSIONS DUE TO SETTING JOINT COMPOUND RAW MATERIALS EXTRACTION
CO2 SO2 NOx VOC CH4 CO TPM g/kg of compound
Vancouver 2.09851 0.00303 0.02395 0.00258 0.00064 0.01315 0.56066 Calgary 2.09851 0.00303 0.02395 0.00258 0.00064 0.01315 0.56066 Winnipeg 2.09851 0.00303 0.02395 0.00258 0.00064 0.01315 0.56066 Toronto 2.09851 0.00303 0.02395 0.00258 0.00064 0.01315 0.56066 Montreal 2.09851 0.00303 0.02395 0.00258 0.00064 0.01315 0.56066 Halifax 2.09851 0.00303 0.02395 0.00258 0.00064 0.01315 0.56066 g/m2 of board
Vancouver 0.73867 0.00107 0.00843 0.00091 0.00023 0.00463 0.19735 Calgary 0.73867 0.00107 0.00843 0.00091 0.00023 0.00463 0.19735 Winnipeg 0.73867 0.00107 0.00843 0.00091 0.00023 0.00463 0.19735 Toronto 0.73867 0.00107 0.00843 0.00091 0.00023 0.00463 0.19735 Montreal 0.73867 0.00107 0.00843 0.00091 0.00023 0.00463 0.19735 Halifax 0.73867 0.00107 0.00843 0.00091 0.00023 0.00463 0.19735
TABLE 7.3 ATMOSPHERIC EMISSIONS DUE TO READY MIX JOINT COMPOUND RAW MATERIALS TRANSPORTATION
CO2 SO2 NOx VOC CH4 CO g/kg of compound
Vancouver 59.93437 0.08647 0.68412 0.07367 0.01840 0.37554 Calgary 59.93437 0.08647 0.68412 0.07367 0.01840 0.37554 Winnipeg 52.88699 0.07630 0.60367 0.06501 0.01623 0.33139 Toronto 52.88699 0.07630 0.60367 0.06501 0.01623 0.33139 Montreal 18.25191 0.02633 0.20834 0.02243 0.00560 0.11436 Halifax 18.25191 0.02633 0.20834 0.02243 0.00560 0.11436 g/m2 of board
Vancouver 40.39577 0.05828 0.46109 0.04965 0.01240 0.25312 Calgary 40.39577 0.05828 0.46109 0.04965 0.01240 0.25312 Winnipeg 35.64583 0.05143 0.40688 0.04381 0.01094 0.22335 Toronto 35.64583 0.05143 0.40688 0.04381 0.01094 0.22335 Montreal 12.30179 0.01775 0.14042 0.01512 0.00378 0.07708 Halifax 12.30179 0.01775 0.14042 0.01512 0.00378 0.07708 The AthenaTM Project: Gypsum Board and Associated Finishing Products 7-4
TABLE 7.4 ATMOSPHERIC EMISSIONS DUE TO SETTING JOINT COMPOUND RAW MATERIALS TRANSPORTATION CO2 SO2 NOx VOC CH4 CO g/kg of compound
Vancouver 188.85384 0.27246 2.15566 0.23213 0.05797 1.18334 Calgary 188.85384 0.27246 2.15566 0.23213 0.05797 1.18334 Winnipeg 164.17813 0.23686 2.15585 0.19376 0.04378 0.84526 Toronto 164.17813 0.23686 2.15585 0.19376 0.04378 0.84526 Montreal 141.05640 0.20350 1.89193 0.16535 0.03669 0.70038 Halifax 141.05640 0.20350 1.89193 0.16535 0.03669 0.70038 g/m2 of board
Vancouver 66.47655 0.09591 0.75879 0.08171 0.02040 0.41654 Calgary 66.47655 0.09591 0.75879 0.08171 0.02040 0.41654 Winnipeg 57.79070 0.08338 0.75886 0.06821 0.01541 0.29753 Toronto 57.79070 0.08338 0.75886 0.06821 0.01541 0.29753 Montreal 49.65185 0.07163 0.66596 0.05820 0.01291 0.24653 Halifax 49.65185 0.07163 0.66596 0.05820 0.01291 0.24653
TABLE 7.5 ATMOSPHERIC EMISSIONS DUE TO JOINT PAPER TAPE RAW MATERIALS TRANSPORTATION CO2 SO2 NOx VOC CH4 CO kg/tonne of paper
Vancouver 95.77022 0.13817 1.09316 0.11771 0.02939 0.60009 Calgary 95.77022 0.13817 1.09316 0.11771 0.02939 0.60009 Winnipeg 75.14703 0.10842 0.85776 0.09237 0.02306 0.47086 Toronto 75.14703 0.10842 0.85776 0.09237 0.02306 0.47086 Montreal 88.27645 0.13034 1.00202 0.11084 0.02725 0.54916 Halifax 88.27645 0.13034 1.00202 0.11084 0.02725 0.54916 g/meter of tape
Vancouver 1.17430 0.00169 0.01340 0.00144 0.00036 0.00736 Calgary 1.17430 0.00169 0.01340 0.00144 0.00036 0.00736 Winnipeg 0.92142 0.00133 0.01052 0.00113 0.00028 0.00577 Toronto 0.92142 0.00133 0.01052 0.00113 0.00028 0.00577 Montreal 1.08241 0.00160 0.01229 0.00136 0.00033 0.00673 Halifax 1.08241 0.00160 0.01229 0.00136 0.00033 0.00673 g/m2 of board Vancouver 1.15081 0.00166 0.01314 0.00141 0.00035 0.00721 Calgary 1.15081 0.00166 0.01314 0.00141 0.00035 0.00721 Winnipeg 0.90299 0.00130 0.01031 0.00111 0.00028 0.00566 Toronto 0.90299 0.00130 0.01031 0.00111 0.00028 0.00566 Montreal 1.06076 0.00157 0.01204 0.00133 0.00033 0.00660 Halifax 1.06076 0.00157 0.01204 0.00133 0.00033 0.00660 The AthenaTM Project: Gypsum Board and Associated Finishing Products 7-5
7.1.3 Joint Finishing Products Manufacturing Atmospheric emissions are generated in all steps of the finishing products manufacturing process where energy is used. Industrial raw minerals have to be processed - dried and reduced to proper size through secondary grinding and milling. Furthermore, gypsum used in the setting compounds has to be calcined. The processing of joint compounds involves compounding and mixing of all the raw materials together, pumping and packaging of the finished materials. Use of energy in all these processing steps results in generation of common air pollutants, although as most of the processing is done at room temperatures, in comparison with many other processes, the energy used and the resulting emissions are relatively low.
Particulate emissions are released in handling and processing of industrial minerals used in joint compound production. We assumed that drying and secondary processing (grinding, milling) of all industrial minerals will generate similar TPM emissions. Gypsum plaster processing, of course, includes the calcining caused TPM emission as well. Based on Environment Canada nationwide emission inventory (1978)3 data for gypsum processing (Table 5.5), we arrived at the following controlled emission factors:
¥ limestone, mica, talc, clay 2.085 kg/tonne ¥ gypsum plaster 6.585 kg/tonne
In Section 6 while discussing gypsum paper processing, in agreement with the EC nationwide emission inventory (1978) we assumed that the particulate emissions associated with paper production are negligible. Despite all the similarities between the gypsum paper and paper used for joint tape production, however, we believe that in the case of joint tape some particulate emissions are generated due to the sanding, buffing and cutting operations, that have to be taken into consideration. Based on U.S. EPA AP-425, the following particulate emission factors for paper tape manufacturing was used:
¥ paper tape 0.3 kg/tonne.
The resulting estimates of atmospheric emissions associated with manufacturing of the three relevant joint finishing materials are shown in Tables 7.6, 7.7 and 7.8. As we assumed the same energy inputs (Section 5.2) into these products’ manufacture in all production facilities across Canada, atmospheric emissions assigned to the manufacturing are the same in all six cities under consideration. The AthenaTM Project: Gypsum Board and Associated Finishing Products 7-6
TABLE 7.6 ATMOSPHERIC EMISSIONS DUE TO MANUFACTURING OF READY MIX JOINT COMPOUND AND ITS CONSTITUENTS
CO2 SO2 NOx VOC CH4 CO TPM g/kg of compound
Vancouver 12.74505 0.01027 0.08027 0.00797 0.00212 0.04177 1.28019 Calgary 12.74505 0.01027 0.08027 0.00797 0.00212 0.04177 1.28019 Winnipeg 12.74505 0.01027 0.08027 0.00797 0.00212 0.04177 1.28019 Toronto 12.74505 0.01027 0.08027 0.00797 0.00212 0.04177 1.28019 Montreal 12.74505 0.01027 0.08027 0.00797 0.00212 0.04177 1.28019 Halifax 12.74505 0.01027 0.08027 0.00797 0.00212 0.04177 1.28019 g/m2 of board
Vancouver 8.59016 0.00692 0.05410 0.00537 0.00143 0.02815 0.86285 Calgary 8.59016 0.00692 0.05410 0.00537 0.00143 0.02815 0.86285 Winnipeg 8.59016 0.00692 0.05410 0.00537 0.00143 0.02815 0.86285 Toronto 8.59016 0.00692 0.05410 0.00537 0.00143 0.02815 0.86285 Montreal 8.59016 0.00692 0.05410 0.00537 0.00143 0.02815 0.86285 Halifax 8.59016 0.00692 0.05410 0.00537 0.00143 0.02815 0.86285
TABLE 7.7 ATMOSPHERIC EMISSIONS DUE TO MANUFACTURING OF SETTING JOINT COMPOUND AND ITS CONSTITUENTS
CO2 SO2 NOx VOC CH4 CO TPM g/kg of compound
Vancouver 51.09884 0.15454 0.18902 0.01514 0.00435 0.08203 4.92157 Calgary 51.09884 0.15454 0.18902 0.01514 0.00435 0.08203 4.92157 Winnipeg 51.09884 0.15454 0.18902 0.01514 0.00435 0.08203 4.92157 Toronto 51.09884 0.15454 0.18902 0.01514 0.00435 0.08203 4.92157 Montreal 51.09884 0.15454 0.18902 0.01514 0.00435 0.08203 4.92157 Halifax 51.09884 0.15454 0.18902 0.01514 0.00435 0.08203 4.92157 g/m2 of board
Vancouver 17.98679 0.05440 0.06653 0.00533 0.00153 0.02888 1.73239 Calgary 17.98679 0.05440 0.06653 0.00533 0.00153 0.02888 1.73239 Winnipeg 17.98679 0.05440 0.06653 0.00533 0.00153 0.02888 1.73239 Toronto 17.98679 0.05440 0.06653 0.00533 0.00153 0.02888 1.73239 Montreal 17.98679 0.05440 0.06653 0.00533 0.00153 0.02888 1.73239 Halifax 17.98679 0.05440 0.06653 0.00533 0.00153 0.02888 1.73239 The AthenaTM Project: Gypsum Board and Associated Finishing Products 7-7
TABLE 7.8 ATMOSPHERIC EMISSIONS DUE TO MANUFACTURING OF PAPER JOINT TAPE
CO2 SO2 NOx VOC CH4 CO TPM
[kg/tonne of paper]
Vancouver 621.95279 0.51387 0.78241 0.01570 0.01559 0.18287 0.30000 Calgary 621.95279 0.51387 0.78241 0.01570 0.01559 0.18287 0.30000 Winnipeg 621.95279 0.51387 0.78241 0.01570 0.01559 0.18287 0.30000 Toronto 621.95279 0.51387 0.78241 0.01570 0.01559 0.18287 0.30000 Montreal 621.95279 0.51387 0.78241 0.01570 0.01559 0.18287 0.30000 Halifax 621.95279 0.51387 0.78241 0.01570 0.01559 0.18287 0.30000
[g/meter of tape]
Vancouver 7.62614 0.00630 0.00959 0.00019 0.00019 0.00224 0.00368 Calgary 7.62614 0.00630 0.00959 0.00019 0.00019 0.00224 0.00368 Winnipeg 7.62614 0.00630 0.00959 0.00019 0.00019 0.00224 0.00368 Toronto 7.62614 0.00630 0.00959 0.00019 0.00019 0.00224 0.00368 Montreal 7.62614 0.00630 0.00959 0.00019 0.00019 0.00224 0.00368 Halifax 7.62614 0.00630 0.00959 0.00019 0.00019 0.00224 0.00368
[g/m2 of board]
Vancouver 7.47361 0.00617 0.00940 0.00019 0.00019 0.00220 0.00360 Calgary 7.47361 0.00617 0.00940 0.00019 0.00019 0.00220 0.00360 Winnipeg 7.47361 0.00617 0.00940 0.00019 0.00019 0.00220 0.00360 Toronto 7.47361 0.00617 0.00940 0.00019 0.00019 0.00220 0.00360 Montreal 7.47361 0.00617 0.00940 0.00019 0.00019 0.00220 0.00360 Halifax 7.47361 0.00617 0.00940 0.00019 0.00019 0.00220 0.00360
7.1.4 Finished Associated Products Transportation The ATHENATM computer model calculates the finished products transportation emissions from the distances and modes of transport, as shown in Table 5.18. For an illustration, some finished associated products transportation emissions are shown in this study as well. The average atmospheric emissions due to transportation of finished associated products to the markets were calculated by combining energy emission factors from Table 6.1 with the estimates of finished products transportation energy use by fuel type developed and shown in Tables 5.20 to 5.24. The results are shown in Tables 7.9 for ready mix compound, 7.10 for setting compound, and 7.11 for joint paper tape. The AthenaTM Project: Gypsum Board and Associated Finishing Products 7-8
TABLE 7.9 ATMOSPHERIC EMISSIONS DUE TO TRANSPORTATION OF FINISHED READY MIX JOINT COMPOUND
CO2 SO2 NOx VOC CH4 CO g/kg of compound
Vancouver 40.92045 0.05904 0.46708 0.05030 0.01256 0.25640 Calgary 29.91458 0.04316 0.42863 0.03428 0.00714 0.13070 Winnipeg 67.78716 0.09780 1.27934 0.06891 0.00895 0.09564 Toronto 31.03447 0.04477 0.35424 0.03815 0.00953 0.19446 Montreal 7.50834 0.01083 0.08570 0.00923 0.00230 0.04705 Halifax 49.48505 0.07139 0.89173 0.05151 0.00753 0.09729 g/m2 of board
Vancouver 27.58039 0.03979 0.31481 0.03390 0.00847 0.17282 Calgary 20.16243 0.02909 0.28890 0.02311 0.00481 0.08809 Winnipeg 45.68855 0.06592 0.86228 0.04645 0.00604 0.06446 Toronto 20.91723 0.03018 0.23876 0.02571 0.00642 0.13107 Montreal 5.06062 0.00730 0.05776 0.00622 0.00155 0.03171 Halifax 33.35292 0.04812 0.60103 0.03472 0.00507 0.06557
TABLE 7.10 ATMOSPHERIC EMISSIONS DUE TO TRANSPORTATION OF FINISHED SETTING JOINT COMPOUND
CO2 SO2 NOx VOC CH4 CO g/kg of compound
Vancouver 40.92045 0.05904 0.46708 0.05030 0.01256 0.25640 Calgary 29.91458 0.04316 0.42863 0.03428 0.00714 0.13070 Winnipeg 67.78716 0.09780 1.27934 0.06891 0.00895 0.09564 Toronto 31.03447 0.04477 0.35424 0.03815 0.00953 0.19446 Montreal 7.50834 0.01083 0.08570 0.00923 0.00230 0.04705 Halifax 49.48505 0.07139 0.89173 0.05151 0.00753 0.09729 g/m2 of board
Vancouver 14.40400 0.02078 0.16441 0.01770 0.00442 0.09025 Calgary 10.52993 0.01519 0.15088 0.01207 0.00251 0.04601 Winnipeg 23.86108 0.03442 0.45033 0.02426 0.00315 0.03367 Toronto 10.92413 0.01576 0.12469 0.01343 0.00335 0.06845 Montreal 2.64294 0.00381 0.03017 0.00325 0.00081 0.01656 Halifax 17.41874 0.02513 0.31389 0.01813 0.00265 0.03424 The AthenaTM Project: Gypsum Board and Associated Finishing Products 7-9
TABLE 7.11 ATMOSPHERIC EMISSIONS DUE TO TRANSPORTATION OF FINISHED PAPER JOINT TAPE
CO2 SO2 NOx VOC CH4 CO
[kg/tonne of paper]
Vancouver 40.92045 0.00000 0.46708 1.48283 0.04195 0.00000 Calgary 29.91458 0.02999 0.54726 1.47959 0.03653 0.07350 Winnipeg 67.78716 0.17393 1.96739 1.55018 0.03202 0.42630 Toronto 31.03447 0.00000 0.35424 1.44533 0.03259 0.00000 Montreal 7.50834 0.00000 0.08570 1.43251 0.02920 0.00000 Halifax 49.48505 0.11246 1.33659 1.52269 0.03442 0.27563
[g/meter of tape]
Vancouver 0.50175 0.00072 0.00573 0.00062 0.00015 0.00314 Calgary 0.36680 0.00053 0.00526 0.00042 0.00009 0.00160 Winnipeg 0.83118 0.00120 0.01569 0.00084 0.00011 0.00117 Toronto 0.38053 0.00055 0.00434 0.00047 0.00012 0.00238 Montreal 0.09206 0.00013 0.00105 0.00011 0.00003 0.00058 Halifax 0.60677 0.00088 0.01093 0.00063 0.00009 0.00119
[g/m2 of board]
Vancouver 0.49172 0.00071 0.00561 0.00060 0.00015 0.00308 Calgary 0.35946 0.00052 0.00515 0.00041 0.00009 0.00157 Winnipeg 0.81456 0.00118 0.01537 0.00083 0.00011 0.00115 Toronto 0.37292 0.00054 0.00426 0.00046 0.00011 0.00234 Montreal 0.09022 0.00013 0.00103 0.00011 0.00003 0.00057 Halifax 0.59463 0.00086 0.01072 0.00062 0.00009 0.00117
7.2 JOINT FINISHING PRODUCTS ATMOSPHERIC EMISSIONS - SUMMARY Total atmospheric emissions due to the production of ready mix joint compounds, setting joint compounds, and joint paper tape, are summarized and shown in Tables 7.12, 7.13 and 7.14, respectively. The emission unit factors are expressed in both grams per unit of production and in grams per m2 of gypsum board. More detailed summary tables showing breakdown due to process stage and region are shown in Tables 7.15 to 7.21. The AthenaTM Project: Gypsum Board and Associated Finishing Products 7-10
TABLE 7.12 TOTAL ATMOSPHERIC EMISSIONS DUE TO PRODUCTION OF READY MIX JOINT COMPOUND
CO2 SO2 NOx VOC CH4 CO TPM g/kg of compound
Vancouver 114.77194 0.15746 1.24485 0.13338 0.03343 0.68106 1.59333 Calgary 103.76607 0.14158 1.20639 0.11737 0.02801 0.55536 1.59333 Winnipeg 134.59127 0.18606 1.97667 0.14333 0.02766 0.47614 1.59333 Toronto 97.83858 0.13303 1.05156 0.11256 0.02824 0.57496 1.59333 Montreal 39.67737 0.04912 0.38769 0.04108 0.01038 0.21053 1.59333 Halifax 81.65408 0.10968 1.19372 0.08336 0.01561 0.26077 1.59333 g/m2 of board
Vancouver 77.35629 0.10613 0.83903 0.08990 0.02253 0.45904 1.07390 Calgary 69.93833 0.09543 0.81311 0.07910 0.01888 0.37431 1.07390 Winnipeg 90.71452 0.12540 1.33227 0.09660 0.01865 0.32092 1.07390 Toronto 65.94320 0.08966 0.70875 0.07587 0.01903 0.38752 1.07390 Montreal 26.74255 0.03311 0.26130 0.02769 0.00700 0.14189 1.07390 Halifax 55.03485 0.07393 0.80457 0.05618 0.01052 0.17576 1.07390
TABLE 7.13 TOTAL ATMOSPHERIC EMISSIONS DUE TO PRODUCTION OF SETTING JOINT COMPOUND
CO2 SO2 NOx VOC CH4 CO TPM g/kg of compound
Vancouver 282.97164 0.48906 2.83571 0.30014 0.07552 1.53493 5.48223 Calgary 271.96577 0.47318 2.79726 0.28413 0.07010 1.40922 5.48223 Winnipeg 285.16264 0.49222 3.64816 0.28039 0.05773 1.03609 5.48223 Toronto 248.40995 0.43920 2.72306 0.24963 0.05830 1.13490 5.48223 Montreal 201.76209 0.37190 2.19060 0.19229 0.04399 0.84261 5.48223 Halifax 243.73880 0.43246 2.99663 0.23457 0.04921 0.89285 5.48223 g/m2 of board
Vancouver 99.60602 0.17215 0.99817 0.10565 0.02658 0.54029 1.92975 Calgary 95.73195 0.16656 0.98463 0.10001 0.02467 0.49605 1.92975 Winnipeg 100.37725 0.17326 1.28415 0.09870 0.02032 0.36470 1.92975 Toronto 87.44030 0.15460 0.95852 0.08787 0.02052 0.39949 1.92975 Montreal 71.02025 0.13091 0.77109 0.06769 0.01548 0.29660 1.92975 Halifax 85.79606 0.15223 1.05482 0.08257 0.01732 0.31428 1.92975 The AthenaTM Project: Gypsum Board and Associated Finishing Products 7-11
TABLE 7.14 TOTAL ATMOSPHERIC EMISSIONS DUE TO PRODUCTION OF PAPER JOINT TAPE
CO2 SO2 NOx VOC CH4 CO TPM
[kg/tonne of paper]
Vancouver 758.64346 0.71107 2.34265 0.18371 0.05754 1.03936 0.30000 Calgary 747.63759 0.69519 2.30420 0.16770 0.05212 0.91365 0.30000 Winnipeg 764.88698 0.72008 2.91951 0.17697 0.04761 0.74938 0.30000 Toronto 728.13429 0.66706 1.99441 0.14621 0.04818 0.84819 0.30000 Montreal 717.73758 0.65504 1.87013 0.13577 0.04514 0.77908 0.30000 Halifax 759.71429 0.71560 2.67616 0.17805 0.05036 0.82932 0.30000
[g/meter of tape]
Vancouver 9.30218 0.00872 0.02872 0.00225 0.00071 0.01274 0.00368 Calgary 9.16723 0.00852 0.02825 0.00206 0.00064 0.01120 0.00368 Winnipeg 9.37874 0.00883 0.03580 0.00217 0.00058 0.00919 0.00368 Toronto 8.92809 0.00818 0.02445 0.00179 0.00059 0.01040 0.00368 Montreal 8.80061 0.00803 0.02293 0.00166 0.00055 0.00955 0.00368 Halifax 9.31531 0.00877 0.03281 0.00218 0.00062 0.01017 0.00368
[MJ/m2 of board]
Vancouver 9.11614 0.00854 0.02815 0.00221 0.00069 0.01249 0.00360 Calgary 8.98389 0.00835 0.02769 0.00202 0.00063 0.01098 0.00360 Winnipeg 9.19116 0.00865 0.03508 0.00213 0.00057 0.00900 0.00360 Toronto 8.74953 0.00802 0.02397 0.00176 0.00058 0.01019 0.00360 Montreal 8.62460 0.00787 0.02247 0.00163 0.00054 0.00936 0.00360 Halifax 9.12901 0.00860 0.03216 0.00214 0.00061 0.00997 0.00360 The AthenaTM Project: Gypsum Board and Associated Finishing Products 7-12
TABLE 7.15 ATMOSPHERIC EMISSIONS DUE TO PRODUCTION OF READY MIX JOINT COMPOUND BY PROCESS STAGE AND REGION (G/KG OF COMPOUND)
CO2 SO2 NOx VOC CH4 CO TPM
Extraction Vancouver 1.17206 0.00169 0.01338 0.00144 0.00036 0.00734 0.31314 Calgary 1.17206 0.00169 0.01338 0.00144 0.00036 0.00734 0.31314 Winnipeg 1.17206 0.00169 0.01338 0.00144 0.00036 0.00734 0.31314 Toronto 1.17206 0.00169 0.01338 0.00144 0.00036 0.00734 0.31314 Montreal 1.17206 0.00169 0.01338 0.00144 0.00036 0.00734 0.31314 Halifax 1.17206 0.00169 0.01338 0.00144 0.00036 0.00734 0.31314 Raw Materials Transport Vancouver 59.93437 0.08647 0.68412 0.07367 0.01840 0.37554 Calgary 59.93437 0.08647 0.68412 0.07367 0.01840 0.37554 Winnipeg 52.88699 0.07630 0.60367 0.06501 0.01623 0.33139 Toronto 52.88699 0.07630 0.60367 0.06501 0.01623 0.33139 Montreal 18.25191 0.02633 0.20834 0.02243 0.00560 0.11436 Halifax 18.25191 0.02633 0.20834 0.02243 0.00560 0.11436 Manufacturing Vancouver 12.74505 0.01027 0.08027 0.00797 0.00212 0.04177 1.28019 Calgary 12.74505 0.01027 0.08027 0.00797 0.00212 0.04177 1.28019 Winnipeg 12.74505 0.01027 0.08027 0.00797 0.00212 0.04177 1.28019 Toronto 12.74505 0.01027 0.08027 0.00797 0.00212 0.04177 1.28019 Montreal 12.74505 0.01027 0.08027 0.00797 0.00212 0.04177 1.28019 Halifax 12.74505 0.01027 0.08027 0.00797 0.00212 0.04177 1.28019 Cradle to Gate Emissions Vancouver 73.85148 0.09843 0.77777 0.08308 0.02087 0.42466 1.59333 Calgary 73.85148 0.09843 0.77777 0.08308 0.02087 0.42466 1.59333 Winnipeg 66.80411 0.08826 0.69732 0.07442 0.01871 0.38050 1.59333 Toronto 66.80411 0.08826 0.69732 0.07442 0.01871 0.38050 1.59333 Montreal 32.16903 0.03829 0.30198 0.03185 0.00808 0.16348 1.59333 Halifax 32.16903 0.03829 0.30198 0.03185 0.00808 0.16348 1.59333 Finished Products Transport Vancouver 40.92045 0.05904 0.46708 0.05030 0.01256 0.25640 Calgary 29.91458 0.04316 0.42863 0.03428 0.00714 0.13070 Winnipeg 67.78716 0.09780 1.27934 0.06891 0.00895 0.09564 Toronto 31.03447 0.04477 0.35424 0.03815 0.00953 0.19446 Montreal 7.50834 0.01083 0.08570 0.00923 0.00230 0.04705 Halifax 49.48505 0.07139 0.89173 0.05151 0.00753 0.09729 TOTAL Vancouver 114.77194 0.15746 1.24485 0.13338 0.03343 0.68106 1.59333 Calgary 103.76607 0.14158 1.20639 0.11737 0.02801 0.55536 1.59333 Winnipeg 134.59127 0.18606 1.97667 0.14333 0.02766 0.47614 1.59333 Toronto 97.83858 0.13303 1.05156 0.11256 0.02824 0.57496 1.59333 Montreal 39.67737 0.04912 0.38769 0.04108 0.01038 0.21053 1.59333 Halifax 81.65408 0.10968 1.19372 0.08336 0.01561 0.26077 1.59333 The AthenaTM Project: Gypsum Board and Associated Finishing Products 7-13
TABLE 7.16 ATMOSPHERIC EMISSIONS DUE TO PRODUCTION OF READY MIX JOINT COMPOUND BY PROCESS STAGE AND REGION (G/M2 OF BOARD)
CO2 SO2 NOx VOC CH4 CO TPM
Extraction Vancouver 0.78997 0.00114 0.00902 0.00097 0.00024 0.00495 0.21106 Calgary 0.78997 0.00114 0.00902 0.00097 0.00024 0.00495 0.21106 Winnipeg 0.78997 0.00114 0.00902 0.00097 0.00024 0.00495 0.21106 Toronto 0.78997 0.00114 0.00902 0.00097 0.00024 0.00495 0.21106 Montreal 0.78997 0.00114 0.00902 0.00097 0.00024 0.00495 0.21106 Halifax 0.78997 0.00114 0.00902 0.00097 0.00024 0.00495 0.21106 Raw Materials Transport Vancouver 40.39577 0.05828 0.46109 0.04965 0.01240 0.25312 Calgary 40.39577 0.05828 0.46109 0.04965 0.01240 0.25312 Winnipeg 35.64583 0.05143 0.40688 0.04381 0.01094 0.22335 Toronto 35.64583 0.05143 0.40688 0.04381 0.01094 0.22335 Montreal 12.30179 0.01775 0.14042 0.01512 0.00378 0.07708 Halifax 12.30179 0.01775 0.14042 0.01512 0.00378 0.07708 Manufacturing Vancouver 8.59016 0.00692 0.05410 0.00537 0.00143 0.02815 0.86285 Calgary 8.59016 0.00692 0.05410 0.00537 0.00143 0.02815 0.86285 Winnipeg 8.59016 0.00692 0.05410 0.00537 0.00143 0.02815 0.86285 Toronto 8.59016 0.00692 0.05410 0.00537 0.00143 0.02815 0.86285 Montreal 8.59016 0.00692 0.05410 0.00537 0.00143 0.02815 0.86285 Halifax 8.59016 0.00692 0.05410 0.00537 0.00143 0.02815 0.86285 Cradle to Gate Emissions Vancouver 49.77590 0.06634 0.52421 0.05600 0.01407 0.28622 1.07390 Calgary 49.77590 0.06634 0.52421 0.05600 0.01407 0.28622 1.07390 Winnipeg 45.02597 0.05949 0.47000 0.05016 0.01261 0.25646 1.07390 Toronto 45.02597 0.05949 0.47000 0.05016 0.01261 0.25646 1.07390 Montreal 21.68192 0.02581 0.20354 0.02147 0.00545 0.11018 1.07390 Halifax 21.68192 0.02581 0.20354 0.02147 0.00545 0.11018 1.07390 Finished Products Transport Vancouver 27.58039 0.03979 0.31481 0.03390 0.00847 0.17282 Calgary 20.16243 0.02909 0.28890 0.02311 0.00481 0.08809 Winnipeg 45.68855 0.06592 0.86228 0.04645 0.00604 0.06446 Toronto 20.91723 0.03018 0.23876 0.02571 0.00642 0.13107 Montreal 5.06062 0.00730 0.05776 0.00622 0.00155 0.03171 Halifax 33.35292 0.04812 0.60103 0.03472 0.00507 0.06557 TOTAL Vancouver 77.35629 0.10613 0.83903 0.08990 0.02253 0.45904 1.07390 Calgary 69.93833 0.09543 0.81311 0.07910 0.01888 0.37431 1.07390 Winnipeg 90.71452 0.12540 1.33227 0.09660 0.01865 0.32092 1.07390 Toronto 65.94320 0.08966 0.70875 0.07587 0.01903 0.38752 1.07390 Montreal 26.74255 0.03311 0.26130 0.02769 0.00700 0.14189 1.07390 Halifax 55.03485 0.07393 0.80457 0.05618 0.01052 0.17576 1.07390 The AthenaTM Project: Gypsum Board and Associated Finishing Products 7-14
TABLE 7.17 ATMOSPHERIC EMISSIONS DUE TO PRODUCTION OF SETTING JOINT COMPOUND BY PROCESS STAGE AND REGION (G/KG OF COMPOUND)
CO2 SO2 NOx VOC CH4 CO TPM
Extraction Vancouver 2.09851 0.00303 0.02395 0.00258 0.00064 0.01315 0.56066 Calgary 2.09851 0.00303 0.02395 0.00258 0.00064 0.01315 0.56066 Winnipeg 2.09851 0.00303 0.02395 0.00258 0.00064 0.01315 0.56066 Toronto 2.09851 0.00303 0.02395 0.00258 0.00064 0.01315 0.56066 Montreal 2.09851 0.00303 0.02395 0.00258 0.00064 0.01315 0.56066 Halifax 2.09851 0.00303 0.02395 0.00258 0.00064 0.01315 0.56066 Raw Materials Transport Vancouver 188.85384 0.27246 2.15566 0.23213 0.05797 1.18334 Calgary 188.85384 0.27246 2.15566 0.23213 0.05797 1.18334 Winnipeg 164.17813 0.23686 2.15585 0.19376 0.04378 0.84526 Toronto 164.17813 0.23686 2.15585 0.19376 0.04378 0.84526 Montreal 141.05640 0.20350 1.89193 0.16535 0.03669 0.70038 Halifax 141.05640 0.20350 1.89193 0.16535 0.03669 0.70038 Manufacturing Vancouver 51.09884 0.15454 0.18902 0.01514 0.00435 0.08203 4.92157 Calgary 51.09884 0.15454 0.18902 0.01514 0.00435 0.08203 4.92157 Winnipeg 51.09884 0.15454 0.18902 0.01514 0.00435 0.08203 4.92157 Toronto 51.09884 0.15454 0.18902 0.01514 0.00435 0.08203 4.92157 Montreal 51.09884 0.15454 0.18902 0.01514 0.00435 0.08203 4.92157 Halifax 51.09884 0.15454 0.18902 0.01514 0.00435 0.08203 4.92157 Cradle to Gate Emissions Vancouver 242.05119 0.43003 2.36863 0.24985 0.06296 1.27852 5.48223 Calgary 242.05119 0.43003 2.36863 0.24985 0.06296 1.27852 5.48223 Winnipeg 217.37548 0.39443 2.36882 0.21148 0.04878 0.94044 5.48223 Toronto 217.37548 0.39443 2.36882 0.21148 0.04878 0.94044 5.48223 Montreal 194.25375 0.36107 2.10490 0.18306 0.04168 0.79556 5.48223 Halifax 194.25375 0.36107 2.10490 0.18306 0.04168 0.79556 5.48223 Finished Products Transport Vancouver 40.92045 0.05904 0.46708 0.05030 0.01256 0.25640 Calgary 29.91458 0.04316 0.42863 0.03428 0.00714 0.13070 Winnipeg 67.78716 0.09780 1.27934 0.06891 0.00895 0.09564 Toronto 31.03447 0.04477 0.35424 0.03815 0.00953 0.19446 Montreal 7.50834 0.01083 0.08570 0.00923 0.00230 0.04705 Halifax 49.48505 0.07139 0.89173 0.05151 0.00753 0.09729 TOTAL Vancouver 282.97164 0.48906 2.83571 0.30014 0.07552 1.53493 5.48223 Calgary 271.96577 0.47318 2.79726 0.28413 0.07010 1.40922 5.48223 Winnipeg 285.16264 0.49222 3.64816 0.28039 0.05773 1.03609 5.48223 Toronto 248.40995 0.43920 2.72306 0.24963 0.05830 1.13490 5.48223 Montreal 201.76209 0.37190 2.19060 0.19229 0.04399 0.84261 5.48223 Halifax 243.73880 0.43246 2.99663 0.23457 0.04921 0.89285 5.48223 The AthenaTM Project: Gypsum Board and Associated Finishing Products 7-15
TABLE 7.18 ATMOSPHERIC EMISSIONS DUE TO PRODUCTION OF SETTING JOINT COMPOUND BY PROCESS STAGE AND REGION (G/M2 OF BOARD)
CO2 SO2 NOx VOC CH4 CO TPM
Extraction Vancouver 0.73867 0.00107 0.00843 0.00091 0.00023 0.00463 0.19735 Calgary 0.73867 0.00107 0.00843 0.00091 0.00023 0.00463 0.19735 Winnipeg 0.73867 0.00107 0.00843 0.00091 0.00023 0.00463 0.19735 Toronto 0.73867 0.00107 0.00843 0.00091 0.00023 0.00463 0.19735 Montreal 0.73867 0.00107 0.00843 0.00091 0.00023 0.00463 0.19735 Halifax 0.73867 0.00107 0.00843 0.00091 0.00023 0.00463 0.19735 Raw Materials Transport Vancouver 66.47655 0.09591 0.75879 0.08171 0.02040 0.41654 Calgary 66.47655 0.09591 0.75879 0.08171 0.02040 0.41654 Winnipeg 57.79070 0.08338 0.75886 0.06821 0.01541 0.29753 Toronto 57.79070 0.08338 0.75886 0.06821 0.01541 0.29753 Montreal 49.65185 0.07163 0.66596 0.05820 0.01291 0.24653 Halifax 49.65185 0.07163 0.66596 0.05820 0.01291 0.24653 Manufacturing Vancouver 17.98679 0.05440 0.06653 0.00533 0.00153 0.02888 1.73239 Calgary 17.98679 0.05440 0.06653 0.00533 0.00153 0.02888 1.73239 Winnipeg 17.98679 0.05440 0.06653 0.00533 0.00153 0.02888 1.73239 Toronto 17.98679 0.05440 0.06653 0.00533 0.00153 0.02888 1.73239 Montreal 17.98679 0.05440 0.06653 0.00533 0.00153 0.02888 1.73239 Halifax 17.98679 0.05440 0.06653 0.00533 0.00153 0.02888 1.73239 Cradle to Gate Emissions Vancouver 85.20202 0.15137 0.83376 0.08795 0.02216 0.45004 1.92975 Calgary 85.20202 0.15137 0.83376 0.08795 0.02216 0.45004 1.92975 Winnipeg 76.51617 0.13884 0.83382 0.07444 0.01717 0.33104 1.92975 Toronto 76.51617 0.13884 0.83382 0.07444 0.01717 0.33104 1.92975 Montreal 68.37732 0.12710 0.74092 0.06444 0.01467 0.28004 1.92975 Halifax 68.37732 0.12710 0.74092 0.06444 0.01467 0.28004 1.92975 Finished Products Transport Vancouver 14.40400 0.02078 0.16441 0.01770 0.00442 0.09025 Calgary 10.52993 0.01519 0.15088 0.01207 0.00251 0.04601 Winnipeg 23.86108 0.03442 0.45033 0.02426 0.00315 0.03367 Toronto 10.92413 0.01576 0.12469 0.01343 0.00335 0.06845 Montreal 2.64294 0.00381 0.03017 0.00325 0.00081 0.01656 Halifax 17.41874 0.02513 0.31389 0.01813 0.00265 0.03424 TOTAL Vancouver 99.60602 0.17215 0.99817 0.10565 0.02658 0.54029 1.92975 Calgary 95.73195 0.16656 0.98463 0.10001 0.02467 0.49605 1.92975 Winnipeg 100.37725 0.17326 1.28415 0.09870 0.02032 0.36470 1.92975 Toronto 87.44030 0.15460 0.95852 0.08787 0.02052 0.39949 1.92975 Montreal 71.02025 0.13091 0.77109 0.06769 0.01548 0.29660 1.92975 Halifax 85.79606 0.15223 1.05482 0.08257 0.01732 0.31428 1.92975 The AthenaTM Project: Gypsum Board and Associated Finishing Products 7-16
TABLE 7.19 ATMOSPHERIC EMISSIONS DUE TO PRODUCTION OF JOINT PAPER TAPE BY PROCESS STAGE AND REGION (KG/TONNE OF PAPER)
CO2 SO2 NOx VOC CH4 CO TPM
Raw Materials Transport Vancouver 95.77022 0.13817 1.09316 0.11771 0.02939 0.60009 Calgary 95.77022 0.13817 1.09316 0.11771 0.02939 0.60009 Winnipeg 75.14703 0.10842 0.85776 0.09237 0.02306 0.47086 Toronto 75.14703 0.10842 0.85776 0.09237 0.02306 0.47086 Montreal 88.27645 0.13034 1.00202 0.11084 0.02725 0.54916 Halifax 88.27645 0.13034 1.00202 0.11084 0.02725 0.54916 Manufacturing Vancouver 621.95279 0.51387 0.78241 0.01570 0.01559 0.18287 0.30000 Calgary 621.95279 0.51387 0.78241 0.01570 0.01559 0.18287 0.30000 Winnipeg 621.95279 0.51387 0.78241 0.01570 0.01559 0.18287 0.30000 Toronto 621.95279 0.51387 0.78241 0.01570 0.01559 0.18287 0.30000 Montreal 621.95279 0.51387 0.78241 0.01570 0.01559 0.18287 0.30000 Halifax 621.95279 0.51387 0.78241 0.01570 0.01559 0.18287 0.30000 Cradle to Gate Emissions Vancouver 717.72301 0.65204 1.87557 0.13341 0.04498 0.78295 0.30000 Calgary 717.72301 0.65204 1.87557 0.13341 0.04498 0.78295 0.30000 Winnipeg 697.09982 0.62228 1.64017 0.10806 0.03865 0.65373 0.30000 Toronto 697.09982 0.62228 1.64017 0.10806 0.03865 0.65373 0.30000 Montreal 710.22924 0.64421 1.78442 0.12654 0.04283 0.73203 0.30000 Halifax 710.22924 0.64421 1.78442 0.12654 0.04283 0.73203 0.30000 Finished Materials Transport Vancouver 40.92045 0.05904 0.46708 0.05030 0.01256 0.25640 Calgary 29.91458 0.04316 0.42863 0.03428 0.00714 0.13070 Winnipeg 67.78716 0.09780 1.27934 0.06891 0.00895 0.09564 Toronto 31.03447 0.04477 0.35424 0.03815 0.00953 0.19446 Montreal 7.50834 0.01083 0.08570 0.00923 0.00230 0.04705 Halifax 49.48505 0.07139 0.89173 0.05151 0.00753 0.09729 TOTAL Vancouver 758.64346 0.71107 2.34265 0.18371 0.05754 1.03936 0.30000 Calgary 747.63759 0.69519 2.30420 0.16770 0.05212 0.91365 0.30000 Winnipeg 764.88698 0.72008 2.91951 0.17697 0.04761 0.74938 0.30000 Toronto 728.13429 0.66706 1.99441 0.14621 0.04818 0.84819 0.30000 Montreal 717.73758 0.65504 1.87013 0.13577 0.04514 0.77908 0.30000 Halifax 759.71429 0.71560 2.67616 0.17805 0.05036 0.82932 0.30000 The AthenaTM Project: Gypsum Board and Associated Finishing Products 7-17
TABLE 7.20 ATMOSPHERIC EMISSIONS DUE TO PRODUCTION OF JOINT PAPER TAPE BY PROCESS STAGE AND REGION (G/METER OF TAPE)
CO2 SO2 NOx VOC CH4 CO TPM
Raw Materials Transport Vancouver 1.17430 0.00169 0.01340 0.00144 0.00036 0.00736 Calgary 1.17430 0.00169 0.01340 0.00144 0.00036 0.00736 Winnipeg 0.92142 0.00133 0.01052 0.00113 0.00028 0.00577 Toronto 0.92142 0.00133 0.01052 0.00113 0.00028 0.00577 Montreal 1.08241 0.00160 0.01229 0.00136 0.00033 0.00673 Halifax 1.08241 0.00160 0.01229 0.00136 0.00033 0.00673 Manufacturing Vancouver 7.62614 0.00630 0.00959 0.00019 0.00019 0.00224 0.00368 Calgary 7.62614 0.00630 0.00959 0.00019 0.00019 0.00224 0.00368 Winnipeg 7.62614 0.00630 0.00959 0.00019 0.00019 0.00224 0.00368 Toronto 7.62614 0.00630 0.00959 0.00019 0.00019 0.00224 0.00368 Montreal 7.62614 0.00630 0.00959 0.00019 0.00019 0.00224 0.00368 Halifax 7.62614 0.00630 0.00959 0.00019 0.00019 0.00224 0.00368 Cradle to Gate Emissions Vancouver 8.80043 0.00799 0.02300 0.00164 0.00055 0.00960 0.00368 Calgary 8.80043 0.00799 0.02300 0.00164 0.00055 0.00960 0.00368 Winnipeg 8.54756 0.00763 0.02011 0.00133 0.00047 0.00802 0.00368 Toronto 8.54756 0.00763 0.02011 0.00133 0.00047 0.00802 0.00368 Montreal 8.70855 0.00790 0.02188 0.00155 0.00053 0.00898 0.00368 Halifax 8.70855 0.00790 0.02188 0.00155 0.00053 0.00898 0.00368 Finished Materials Transport Vancouver 0.50175 0.00072 0.00573 0.00062 0.00015 0.00314 Calgary 0.36680 0.00053 0.00526 0.00042 0.00009 0.00160 Winnipeg 0.83118 0.00120 0.01569 0.00084 0.00011 0.00117 Toronto 0.38053 0.00055 0.00434 0.00047 0.00012 0.00238 Montreal 0.09206 0.00013 0.00105 0.00011 0.00003 0.00058 Halifax 0.60677 0.00088 0.01093 0.00063 0.00009 0.00119 TOTAL Vancouver 9.30218 0.00872 0.02872 0.00225 0.00071 0.01274 0.00368 Calgary 9.16723 0.00852 0.02825 0.00206 0.00064 0.01120 0.00368 Winnipeg 9.37874 0.00883 0.03580 0.00217 0.00058 0.00919 0.00368 Toronto 8.92809 0.00818 0.02445 0.00179 0.00059 0.01040 0.00368 Montreal 8.80061 0.00803 0.02293 0.00166 0.00055 0.00955 0.00368 Halifax 9.31531 0.00877 0.03281 0.00218 0.00062 0.01017 0.00368 The AthenaTM Project: Gypsum Board and Associated Finishing Products 7-18
TABLE 7.21 ATMOSPHERIC EMISSIONS DUE TO PRODUCTION OF JOINT PAPER TAPE BY PROCESS STAGE AND REGION (G/M2 OF BOARD)
CO2 SO2 NOx VOC CH4 CO TPM
Raw Materials Transport Vancouver 1.15081 0.00166 0.01314 0.00141 0.00035 0.00721 Calgary 1.15081 0.00166 0.01314 0.00141 0.00035 0.00721 Winnipeg 0.90299 0.00130 0.01031 0.00111 0.00028 0.00566 Toronto 0.90299 0.00130 0.01031 0.00111 0.00028 0.00566 Montreal 1.06076 0.00157 0.01204 0.00133 0.00033 0.00660 Halifax 1.06076 0.00157 0.01204 0.00133 0.00033 0.00660 Manufacturing Vancouver 7.47361 0.00617 0.00940 0.00019 0.00019 0.00220 0.00360 Calgary 7.47361 0.00617 0.00940 0.00019 0.00019 0.00220 0.00360 Winnipeg 7.47361 0.00617 0.00940 0.00019 0.00019 0.00220 0.00360 Toronto 7.47361 0.00617 0.00940 0.00019 0.00019 0.00220 0.00360 Montreal 7.47361 0.00617 0.00940 0.00019 0.00019 0.00220 0.00360 Halifax 7.47361 0.00617 0.00940 0.00019 0.00019 0.00220 0.00360 Cradle to Gate Emissions Vancouver 8.62442 0.00784 0.02254 0.00160 0.00054 0.00941 0.00360 Calgary 8.62442 0.00784 0.02254 0.00160 0.00054 0.00941 0.00360 Winnipeg 8.37661 0.00748 0.01971 0.00130 0.00046 0.00786 0.00360 Toronto 8.37661 0.00748 0.01971 0.00130 0.00046 0.00786 0.00360 Montreal 8.53438 0.00774 0.02144 0.00152 0.00051 0.00880 0.00360 Halifax 8.53438 0.00774 0.02144 0.00152 0.00051 0.00880 0.00360 Finished Materials Transport Vancouver 0.49172 0.00071 0.00561 0.00060 0.00015 0.00308 Calgary 0.35946 0.00052 0.00515 0.00041 0.00009 0.00157 Winnipeg 0.81456 0.00118 0.01537 0.00083 0.00011 0.00115 Toronto 0.37292 0.00054 0.00426 0.00046 0.00011 0.00234 Montreal 0.09022 0.00013 0.00103 0.00011 0.00003 0.00057 Halifax 0.59463 0.00086 0.01072 0.00062 0.00009 0.00117 TOTAL Vancouver 9.11614 0.00854 0.02815 0.00221 0.00069 0.01249 0.00360 Calgary 8.98389 0.00835 0.02769 0.00202 0.00063 0.01098 0.00360 Winnipeg 9.19116 0.00865 0.03508 0.00213 0.00057 0.00900 0.00360 Toronto 8.74953 0.00802 0.02397 0.00176 0.00058 0.01019 0.00360 Montreal 8.62460 0.00787 0.02247 0.00163 0.00054 0.00936 0.00360 Halifax 9.12901 0.00860 0.03216 0.00214 0.00061 0.00997 0.00360 The AthenaTM Project: Gypsum Board and Associated Finishing Products 7-19
REFERENCES 1. “Emission Factors for Greenhouse and Other Gases by Fuel Type: An Inventory”, Energy, Mines and Resources Canada, Ad Hoc Committee on Emissions Factors, December 1990. 2. Canadian Industry Program for Energy Conservation (CIPEC), Ministry of Energy, Mines and Resources Canada, 1989. 3. “A Nationwide Inventory of Emissions of Air Contaminants”, Environment Canada, Report EPS 3-EP-83-10, December 1983. 4. “Metals Mining and Milling Process Profiles with Environmental Aspects, U.S. Environmental Protection Agency, EPA-600/2-76-167, Washington, USA, 1976. 5. “Compilation of Air Pollutant Emission Factors”, U.S. Environmental Protection Agency, EPA AP-42, 4th edition, Research Triangle Park, NC, September 1985. The AthenaTM Project: Gypsum Board and Associated Finishing Products 8-1
8.0 LIQUID EFFLUENTS This section addresses liquid effluents associated with gypsum board production, namely in its raw materials extraction and manufacturing stages. The gypsum board manufacturing process itself generates hardly any process effluent. While a large amount of water is mixed with gypsum stucco to prepare slurry, in the case of 1/2" regular gypsum board, for example, representing about 44% of the total raw materials weight, this water is partially chemically bonded in the re-hydration of calcium sulfate hemihydrate back to calcium sulfate dihydrate, with the rest of the “water of convenience” driven off during the drying process. However, gypsum board plants do use some water to clean equipment and yards. In addition, rainwater washes away gypsum dust into containment areas and this “gypsum board plant” effluent is regularly discharged. As a result, some plant liquid effluents are associated with the gypsum board production and associated operations despite the absence of process effluents. While perhaps negligible in comparison to the atmospheric emissions, these effluents should not be ignored.
Furthermore, gypsum board raw materials extraction and preparation is associated with effluent discharges. Mining or quarrying of gypsum rock generates regular and often fairly substantial volumes of “minewater” or “quarry effluent”. Sudden storms can also create “stormwater effluent” at quarries. Preparation of a commercial grade by-product gypsum often requires additional washing of the “gypsum cake” that would not be necessary if the by-product were stacked or landfilled. The paper manufacturing process is well known to use large volumes of water, although modern near “zero discharge” paper-making operations have reduced the amount of effluent drastically.
We were not able to find any information or references in the literature regarding liquid effluents associated with gypsum operations. However, we were able to obtain some detailed monitoring data from the Water Resources Branch of the Ontario Ministry of the Environment and Energy from their MISA program1, as well as some additional limited information of similar numbers from the Nova Scotia Department of the Environment.2 Further valuable data were supplied by the Greater Vancouver Regional Authority3 and Ontario Hydro.4
8.1 LIQUID EFFLUENT ESTIMATES - GYPSUM BOARD 8.1.1 Raw Materials Extraction The detailed MOEE information on “minewater” effluent characteristics both in grams per liter of discharge, as well as annual loading in kilograms per year, are summarized in Table 8.1. These numbers represent weighted averages of four mining operations. Cursory comparison with limited data from Nova Scotia quarries indicate that “quarry effluent” is fairly similar to the “minewater”, and therefore in the absence of more detailed information from various quarries across the country, we will use the Ontario data as representative of gypsum mines and quarries for all regions. Also shown in table 6.1 are the monitoring data representing FGD blowdown wastewater treated effluent from sand filters at the Ontario Hydro’s Lambton Generating Station before discharging into the equalization ponds. We are assuming that effluent from other by-product gypsum washing would have similar characteristics. The AthenaTM Project: Gypsum Board and Associated Finishing Products 8-2
TABLE 8.1 GYPSUM EXTRACTION LIQUID EFFLUENT CHARACTERISTICS1,2,4
Natural gypsum FGD gypsum treated effluent from sand filters minewater before discharge to equalization pond weighted weighted avg. average average average annual loading annual loading
Flow [m3/day] 199 - 4010 300 Hydrogen ion [pH] 7.78 - 7.94 Specific conductance [microS/cm] 1600 - 3100
[mg/L] [kg/yr] [mg/L] [kg/yr]
Total suspended solids 28.378 31207.94 Aluminum 0.672 891.33 0.050 5.48 Zinc 0.008 10.70 0.015 1.64 Phenolics 0.002 0.41 0.001 0.11 Sulfide 0.017 6.29 0.002 0.22 Oil & grease 1.034 1085.62 Ammonia & ammonium 0.358 315.16 4.280 468.66 Nitrate & nitrite 2.686 2622.88 Dissolved Organic Compounds (DOC) 3.615 2781.66 Chlorides 42.282 34497.04 Sulfates 1044.831 1157168.98
Taking then into consideration the relative use of natural, by-product, and recycled gypsum (see Table 3.3 in Section 3) in the respective region of the country, Table 8.2 shows, as an example, weighted average effluent loading due to the gypsum extraction by region in g/m2 of 1/2" regular gypsum board. (Data for other types of gypsum board are shown in the summary of this section.)
TABLE 8.2 WEIGHTED AVERAGE EFFLUENT LOADING DUE TO GYPSUM EXTRACTION BY REGION (G/M2 OF 1/2" REGULAR GYPSUM BOARD)
West Region Central Region East Region (Vancouver, Calgary) Winnipeg, Toronto) (Montreal, Halifax)
Total suspended solids 0.25371 0.25028 0.23834 Aluminum 0.00725 0.00749 0.00726 Zinc 0.00009 0.00019 0.00022 Phenolics 0.00000 0.00001 0.00001 Sulfide 0.00005 0.00006 0.00007 Oil & grease 0.00883 0.00871 0.00829 Ammonia & ammonium 0.00256 0.03182 0.04120 Nitrate & nitrite 0.02132 0.02103 0.02003 Dissolved Organic Compounds (DOC) 0.02261 0.02231 0.02124 Chlorides 0.28045 0.27666 0.26346 Sulfates 9.40744 9.28019 8.83755 The AthenaTM Project: Gypsum Board and Associated Finishing Products 8-3
8.1.2 Gypsum Board Manufacturing In developing estimates for effluents associated with gypsum board manufacturing, two parts of the process have to be factored in:
¥ gypsum paper production, and ¥ manufacturing of gypsum board itself.
Table 6.3 provides average characteristics of gypsum paper producing mill effluent. Major effluent categories are expressed in both milligrams per liter as well as in kg per day, taking average effluent flow at the time of monitoring sampling into account. To be able to provide, later, effluent loading per area of gypsum board, Table 8.3 also shows effluent estimates expressed in grams per tonne of finished paper. In our calculations, it was assumed that a paper mill operates six days a week, 52 weeks a year, for a total of 312 days per year.
Liquid effluent generated in gypsum board manufacturing operations and its characteristics are shown in Table 8.4. These estimates represent weighted averages of a number of Ontario operations, and due to the general similarities of gypsum board plants across the industry, it will be assumed that it is representative of all Canadian gypsum board plants.
TABLE 8.3 GYPSUM PAPER PLANT LIQUID EFFLUENT CHARACTERISTICS 3,1
Gypsum Paper Production (averages)
Flow [m3/day] 203.00 Hydrogen ion [pH] 4.9 - 8.4 Specific conductance [microS/cm] 362.60
[mg/L] [kg/day] [g/tonne of paper]
Total suspended solids 243.40 46.30 270.44089 Biochemical Oxygen Demand (BOD) 270.70 55.00 321.25807 Aluminum 1.38 0.27 1.57709 Zinc 0.36 0.07 0.40887 Iron 2.14 0.45 2.62848 Copper 1.07 0.24 1.40185 Boron 1.72 0.34 1.98596 Cyanides 0.10 0.00 0.00000 Oil & grease 13.50 2.80 16.35496 Manganese 0.12 0.02 0.11682 Lead 0.02 0.00 0.00000 Molybdenum 0.01 0.00 0.00000 Nickel 0.01 0.00 0.00000 Silver 0.01 0.00 0.00000 Cobalt 0.00 0.00 0.00000 Cadmium 0.00 0.00 0.00000 Chromium 0.01 0.00 0.00000 The AthenaTM Project: Gypsum Board and Associated Finishing Products 8-4
TABLE 8.4 GYPSUM BOARD PLANT LIQUID EFFLUENT CHARACTERISTICS 1
Gypsum Board Plant (weighted averages)
annual loading Flow [m3/day] 4330 - 5500 Hydrogen ion [pH] 7.89 - 7.96 Specific conductance [microS/cm] 2050 - 2500
[mg/L] [kg/yr]
Total suspended solids 35.85 75063.91 Aluminum 0.32 923.51 Zinc 0.00 0.00 Phenolics 0.00 0.00 Sulfide 0.05 134.92 Oil & grease 0.76 1376.26 Ammonia & ammonium 0.40 397.22 Nitrate & nitrite 1.70 1780.66 Dissolved Organic Compounds (DOC) 2.62 6976.95 Chlorides 41.39 84293.61 Sulfates 1219.60 1156065.79
From the manufacturing effluent monitoring data shown in Tables 8.3 and 8.4, unit factors for effluent loading expressed in grams per square meter of gypsum board can be estimated. In the development of these estimates, paper content in various types of gypsum boards was taken into consideration (see Table 3.1 in Section 3). As an example, weighted average effluent loading due to gypsum board manufacturing steps for 1/2" regular gypsum board is shown in Table 8.5.
The manufacturing effluent estimates can be combined with those for the raw materials extraction effluent to yield total effluent loading per m2 of 1/2" regular gypsum board, as shown in Table 8.6 below. Similar effluent estimates for other types of gypsum board are shown in the summary of this section. The AthenaTM Project: Gypsum Board and Associated Finishing Products 8-5
TABLE 8.5 WEIGHTED AVERAGE EFFLUENT LOADING DUE TO GYPSUM BOARD MANUFACTURING (G/M2 OF 1/2" REGULAR GYPSUM BOARD)
Paper Gypsum board Total manufacturing manufacturing manufacturing
Total suspended solids 0.12752 0.70549 0.83301 Biochemical Oxygen Demand (BOD) 0.15148 0.15148 Aluminum 0.00074 0.00868 0.00942 Zinc 0.00019 0.00000 0.00019 Iron 0.00124 0.00124 Copper 0.00066 0.00066 Boron 0.00094 0.00094 Phenolics 0.00000 0.00000 Sulfide 0.00127 0.00127 Cyanides 0.00000 0.00000 Oil & grease 0.00771 0.01293 0.02065 Ammonia & ammonium 0.00373 0.00373 Nitrate & nitrite 0.01674 0.01674 Dissolved Organic Compounds (DOC) 0.06557 0.06557 Chlorides 0.79223 0.79223 Sulfates 10.86528 10.86528
TABLE 8.6 TOTAL WEIGHTED AVERAGE EFFLUENT LOADING DUE TO GYPSUM BOARD PRODUCTION (G/M2 OF 1/2" REGULAR GYPSUM BOARD)
West Region Central Region East Region (Vancouver, Calgary) Winnipeg, Toronto) (Montreal, Halifax)
Total suspended solids 1.08672 1.08329 1.07135 Biochemical Oxygen Demand (BOD) 0.15148 0.15148 0.15148 Aluminum 0.01667 0.01691 0.01668 Zinc 0.00028 0.00038 0.00041 Iron 0.00124 0.00124 0.00124 Copper 0.00066 0.00066 0.00066 Boron 0.00094 0.00094 0.00094 Phenolics 0.00000 0.00001 0.00001 Sulfide 0.00132 0.00133 0.00133 Oil & grease 0.02947 0.02935 0.02894 Ammonia & ammonium 0.00630 0.03555 0.04493 Nitrate & nitrite 0.03806 0.03777 0.03677 Dissolved Organic Compounds (DOC) 0.08819 0.08788 0.08682 Chlorides 1.07268 1.06889 1.05569 Sulfates 20.27272 20.14547 19.70283 The AthenaTM Project: Gypsum Board and Associated Finishing Products 8-6
8.2 LIQUID EFFLUENT - GYPSUM BOARD SUMMARY Effluent estimates associated with the extraction and manufacturing stages, as well as total effluent unit factors for all ten different types of gypsum boards considered in this study, are summarized in Tables 8.7 to 8.11.
8.3 LIQUID EFFLUENT ESTIMATES - FINISHING PRODUCTS 8.3.1 Joint Compounds According to joint compounds manufacturers, there is no liquid effluent associated with the production of either ready mix or setting (dry) joint compounds. Although water is used as a major component of the ready mix compounds, as the manufacturing process operates as a closed loop system, no liquid waste is generated.
Consequently, the only liquid effluent associated with the joint compounds is generated in the extraction (open pit mining) of industrial minerals used as raw materials in their production. Mine/quarry water characteristics for natural gypsum were shown in Table 8.1 above, and we will assume the same effluent characteristics also for gypsum used for production of gypsum plaster for setting compounds. For the effluent parameters of other industrial minerals used in joint compounds, mainly calcium carbonate (limestone), we used the numbers provided by the “Water Resources Branch of the Ontario Ministry of the Environment and Energy”,5 and used in the “Cement and Structural Concrete Products” part of the ATHENATM Sustainable Development Project.6 We will assume that mica, talc and clay have the same effluent loading as limestone. Table 8.11 shows the relevant effluent characteristics for gypsum and limestone quarry water, expressed both in g/mL and in g/tonne of a mineral.
Gypsum and limestone quarry effluent loadings from Table 8.11 were combined with joint compounds formulations as shown in Tables 3.6 for ready mix compound and 3.7 for the setting compound to provide the unit factor estimates for effluent loadings associated with these two types of joint finishing compounds. The results are shown in Table 8.12, expressed in both grams per kg of compound and grams per m2 of board.
8.3.2 Joint Paper Tape As noted earlier, joint paper tape is produced from the same recycled paper stock as paper for gypsum board facings. Liquid effluent generated in the manufacturing of gypsum paper was discussed in detail above, in Section 8.1.2 (Table 8.3). In this subsection, we will use the same paper effluent data as derived there, but in addition to mg/L and kg/tonne of paper units we will express the liquid effluent also in grams per lineal meter of tape and grams per m2 of gypsum board (Table 8.13). The AthenaTM Project: Gypsum Board and Associated Finishing Products 8-7
TABLE 8.7 WEIGHTED AVERAGE EFFLUENT LOADING DUE TO GYPSUM BOARD PRODUCTION BY PROCESS STAGE (G/M2) - 1/2" REGULAR & TYPE X
1/2" Regular Gypsum Board 1/2" Type X Gypsum Board West Central East West Central East
Gypsum Extraction
Total suspended solids 0.25371 0.25028 0.23834 0.25259 0.24917 0.23729 Aluminum 0.00725 0.00749 0.00726 0.00721 0.00746 0.00723 Zinc 0.00009 0.00019 0.00022 0.00009 0.00019 0.00022 Phenolics 0.00000 0.00001 0.00001 0.00000 0.00001 0.00001 Sulfide 0.00005 0.00006 0.00007 0.00005 0.00006 0.00007 Oil & grease 0.00883 0.00871 0.00829 0.00879 0.00867 0.00825 Ammonia & ammonium 0.00256 0.03182 0.04120 0.00255 0.03168 0.04102 Nitrate & nitrite 0.02132 0.02103 0.02003 0.02123 0.02094 0.01994 DOC 0.02261 0.02231 0.02124 0.02251 0.02221 0.02115 Chlorides 0.28045 0.27666 0.26346 0.27921 0.27544 0.26230 Sulfates 9.40744 9.28019 8.83755 9.36588 9.23920 8.79851 Paper and Gypsum Board Production Total suspended solids 0.83301 0.82427 BOD 0.15148 0.14480 Aluminum 0.00942 0.00935 Zinc 0.00019 0.00018 Iron 0.00124 0.00118 Copper 0.00066 0.00063 Boron 0.00094 0.00090 Phenolics 0.00000 0.00000 Sulfide 0.00127 0.00126 Oil & grease 0.02065 0.02025 Ammonia & ammonium 0.00373 0.00372 Nitrate & nitrite 0.01674 0.01666 DOC 0.06557 0.06528 Chlorides 0.79223 0.78873 Sulfates 10.86528 10.81728 TOTAL EFFLUENT Total suspended solids 1.08672 1.08329 1.07135 1.07686 1.07344 1.06156 BOD 0.15148 0.15148 0.15148 0.14480 0.14480 0.14480 Aluminum 0.01667 0.01691 0.01668 0.01657 0.01681 0.01658 Zinc 0.00028 0.00038 0.00041 0.00027 0.00037 0.00040 Iron 0.00124 0.00124 0.00124 0.00118 0.00118 0.00118 Copper 0.00066 0.00066 0.00066 0.00063 0.00063 0.00063 Boron 0.00094 0.00094 0.00094 0.00090 0.00090 0.00090 Phenolics 0.00000 0.00001 0.00001 0.00000 0.00001 0.00001 Sulfide 0.00132 0.00133 0.00133 0.00131 0.00133 0.00133 Oil & grease 0.02947 0.02935 0.02894 0.02904 0.02892 0.02850 Ammonia & ammonium 0.00630 0.03555 0.04493 0.00627 0.03539 0.04474 Nitrate & nitrite 0.03806 0.03777 0.03677 0.03789 0.03760 0.03660 DOC 0.08819 0.08788 0.08682 0.08780 0.08749 0.08643 Chlorides 1.07268 1.06889 1.05569 1.06795 1.06417 1.05103 Sulfates 20.27272 20.14547 19.70283 20.18316 20.05648 19.61579 The AthenaTM Project: Gypsum Board and Associated Finishing Products 8-8
TABLE 8.8 WEIGHTED AVERAGE EFFLUENT LOADING DUE TO GYPSUM BOARD PRODUCTION BY PROCESS STAGE (G/M2) - 1/2" MR & 5/8" REGULAR
1/2" Moisture Resistant Board 5/8" Regular Gypsum Board West Central East West Central East
Gypsum Extraction
Total suspended solids 0.27822 0.27446 0.26137 0.33128 0.32680 0.31121 Aluminum 0.00795 0.00821 0.00796 0.00946 0.00978 0.00948 Zinc 0.00010 0.00021 0.00024 0.00011 0.00025 0.00028 Phenolics 0.00000 0.00001 0.00001 0.00000 0.00001 0.00002 Sulfide 0.00006 0.00007 0.00007 0.00007 0.00008 0.00009 Oil & grease 0.00968 0.00955 0.00909 0.01152 0.01137 0.01083 Ammonia & ammonium 0.00281 0.03489 0.04518 0.00335 0.04155 0.05380 Nitrate & nitrite 0.02338 0.02307 0.02197 0.02784 0.02747 0.02616 DOC 0.02480 0.02446 0.02330 0.02953 0.02913 0.02774 Chlorides 0.30754 0.30338 0.28891 0.36619 0.36124 0.34401 Sulfates 10.31623 10.17670 9.69130 12.28350 12.11735 11.53939 Paper and Gypsum Board Production Total suspended solids 0.90474 1.05026 BOD 0.15573 0.15335 Aluminum 0.01028 0.01209 Zinc 0.00020 0.00020 Iron 0.00127 0.00125 Copper 0.00068 0.00067 Boron 0.00096 0.00095 Phenolics 0.00000 0.00000 Sulfide 0.00139 0.00166 Oil & grease 0.02211 0.02470 Ammonia & ammonium 0.00409 0.00487 Nitrate & nitrite 0.01835 0.02185 DOC 0.07191 0.08562 Chlorides 0.86877 1.03444 Sulfates 11.91491 14.18704 TOTAL EFFLUENT Total suspended solids 1.18296 1.17919 1.16610 1.38154 1.37706 1.36147 BOD 0.15573 0.15573 0.15573 0.15335 0.15335 0.15335 Aluminum 0.01823 0.01850 0.01824 0.02155 0.02187 0.02157 Zinc 0.00029 0.00040 0.00044 0.00031 0.00044 0.00048 Iron 0.00127 0.00127 0.00127 0.00125 0.00125 0.00125 Copper 0.00068 0.00068 0.00068 0.00067 0.00067 0.00067 Boron 0.00096 0.00096 0.00096 0.00095 0.00095 0.00095 Phenolics 0.00000 0.00001 0.00001 0.00000 0.00001 0.00002 Sulfide 0.00145 0.00146 0.00146 0.00172 0.00174 0.00174 Oil & grease 0.03179 0.03166 0.03120 0.03622 0.03606 0.03552 Ammonia & ammonium 0.00690 0.03899 0.04928 0.00822 0.04642 0.05867 Nitrate & nitrite 0.04174 0.04142 0.04032 0.04969 0.04932 0.04801 DOC 0.09671 0.09637 0.09520 0.11515 0.11475 0.11336 Chlorides 1.17631 1.17215 1.15768 1.40063 1.39567 1.37844 Sulfates 22.23115 22.09161 21.60621 26.47054 26.30439 25.72643 The AthenaTM Project: Gypsum Board and Associated Finishing Products 8-9
TABLE 8.9 WEIGHTED AVERAGE EFFLUENT LOADING DUE TO GYPSUM BOARD PRODUCTION BY PROCESS STAGE (G/M2) - 5/8" TYPE X AND MR
5/8" Type X Gypsum Board 5/8" Moisture Resistant Board West Central East West Central East
Gypsum Extraction
Total suspended solids 0.33599 0.33145 0.31564 0.35673 0.35190 0.33512 Aluminum 0.00960 0.00992 0.00962 0.01019 0.01053 0.01021 Zinc 0.00012 0.00025 0.00029 0.00012 0.00026 0.00031 Phenolics 0.00000 0.00001 0.00002 0.00000 0.00001 0.00002 Sulfide 0.00007 0.00008 0.00009 0.00007 0.00009 0.00009 Oil & grease 0.01169 0.01153 0.01098 0.01241 0.01224 0.01166 Ammonia & ammonium 0.00339 0.04214 0.05456 0.00360 0.04474 0.05793 Nitrate & nitrite 0.02824 0.02786 0.02653 0.02998 0.02958 0.02817 DOC 0.02995 0.02954 0.02813 0.03180 0.03137 0.02987 Chlorides 0.37140 0.36638 0.34890 0.39432 0.38899 0.37044 Sulfates 12.45831 12.28980 11.70361 13.22720 13.04829 12.42592 Paper and Gypsum Board Production Total suspended solids 1.06001 1.12906 BOD 0.14935 0.16288 Aluminum 0.01223 0.01300 Zinc 0.00019 0.00021 Iron 0.00122 0.00133 Copper 0.00065 0.00071 Boron 0.00092 0.00101 Phenolics 0.00000 0.00000 Sulfide 0.00168 0.00178 Oil & grease 0.02473 0.02648 Ammonia & ammonium 0.00494 0.00525 Nitrate & nitrite 0.02216 0.02353 DOC 0.08684 0.09220 Chlorides 1.04916 1.11391 Sulfates 14.38894 15.27698 TOTAL EFFLUENT Total suspended solids 1.39600 1.39145 1.37564 1.48579 1.48096 1.46418 BOD 0.14935 0.14935 0.14935 0.16288 0.16288 0.16288 Aluminum 0.02182 0.02215 0.02184 0.02319 0.02354 0.02321 Zinc 0.00031 0.00044 0.00048 0.00033 0.00047 0.00051 Iron 0.00122 0.00122 0.00122 0.00133 0.00133 0.00133 Copper 0.00065 0.00065 0.00065 0.00071 0.00071 0.00071 Boron 0.00092 0.00092 0.00092 0.00101 0.00101 0.00101 Phenolics 0.00000 0.00001 0.00002 0.00000 0.00001 0.00002 Sulfide 0.00175 0.00176 0.00177 0.00185 0.00187 0.00188 Oil & grease 0.03642 0.03626 0.03571 0.03889 0.03872 0.03814 Ammonia & ammonium 0.00834 0.04708 0.05951 0.00885 0.04999 0.06318 Nitrate & nitrite 0.05040 0.05002 0.04869 0.05351 0.05311 0.05170 DOC 0.11679 0.11638 0.11497 0.12399 0.12356 0.12207 Chlorides 1.42056 1.41554 1.39806 1.50823 1.50290 1.48435 Sulfates 26.84725 26.67873 26.09255 28.50418 28.32527 27.70291 The AthenaTM Project: Gypsum Board and Associated Finishing Products 8-10
TABLE 8.10 WEIGHTED AVERAGE EFFLUENT LOADING DUE TO GYPSUM BOARD PRODUCTION BY PROCESS STAGE (G/M2) - 5/16" MH AND 1" SL
5/16" Mobile Home Board 1" Shaftliner West Central East West Central East
Gypsum Extraction
Total suspended solids 0.17815 0.17574 0.16736 0.62489 0.61644 0.58703 Aluminum 0.00509 0.00526 0.00510 0.01785 0.01845 0.01788 Zinc 0.00006 0.00013 0.00015 0.00021 0.00046 0.00054 Phenolics 0.00000 0.00001 0.00001 0.00001 0.00002 0.00003 Sulfide 0.00004 0.00005 0.00005 0.00013 0.00016 0.00016 Oil & grease 0.00620 0.00611 0.00582 0.02174 0.02144 0.02042 Ammonia & ammonium 0.00180 0.02234 0.02893 0.00631 0.07837 0.10148 Nitrate & nitrite 0.01497 0.01477 0.01407 0.05252 0.05181 0.04934 DOC 0.01588 0.01566 0.01492 0.05570 0.05494 0.05232 Chlorides 0.19692 0.19426 0.18499 0.69075 0.68140 0.64890 Sulfates 6.60561 6.51627 6.20546 23.17045 22.85705 21.76683 Paper and Gypsum Board Production Total suspended solids 0.62753 1.86977 BOD 0.15699 0.15699 Aluminum 0.00687 0.02215 Zinc 0.00020 0.00020 Iron 0.00128 0.00128 Copper 0.00069 0.00069 Boron 0.00097 0.00097 Phenolics 0.00000 0.00000 Sulfide 0.00089 0.00312 Oil & grease 0.01707 0.03985 Ammonia & ammonium 0.00262 0.00920 Nitrate & nitrite 0.01175 0.04122 DOC 0.04604 0.16151 Chlorides 0.55628 1.95126 Sulfates 7.62927 26.76111 TOTAL EFFLUENT Total suspended solids 0.80568 0.80327 0.79489 2.49466 2.48621 2.45681 BOD 0.15699 0.15699 0.15699 0.15699 0.15699 0.15699 Aluminum 0.01195 0.01212 0.01196 0.04000 0.04060 0.04003 Zinc 0.00026 0.00033 0.00035 0.00041 0.00066 0.00074 Iron 0.00128 0.00128 0.00128 0.00128 0.00128 0.00128 Copper 0.00069 0.00069 0.00069 0.00069 0.00069 0.00069 Boron 0.00097 0.00097 0.00097 0.00097 0.00097 0.00097 Phenolics 0.00000 0.00001 0.00001 0.00001 0.00002 0.00003 Sulfide 0.00093 0.00094 0.00094 0.00325 0.00328 0.00329 Oil & grease 0.02327 0.02319 0.02290 0.06159 0.06129 0.06027 Ammonia & ammonium 0.00442 0.02496 0.03155 0.01551 0.08756 0.11067 Nitrate & nitrite 0.02672 0.02652 0.02582 0.09374 0.09303 0.09056 DOC 0.06192 0.06171 0.06096 0.21720 0.21645 0.21383 Chlorides 0.75321 0.75054 0.74128 2.64201 2.63267 2.60017 Sulfates 14.23488 14.14553 13.83473 49.93156 49.61816 48.52794 The AthenaTM Project: Gypsum Board and Associated Finishing Products 8-11
TABLE 8.11 WEIGHTED AVERAGE EFFLUENT LOADING DUE TO GYPSUM BOARD PRODUCTION BY PROCESS STAGE (G/M2) - 1/2" AND 5/8" GFB
1/2" Gypsum Fiberboard 5/8" Gypsum Fiberboard East East
Gypsum Extraction
Total suspended solids 0.32602 0.40452 Aluminum 0.00931 0.01155 Zinc 0.00011 0.00014 Phenolics 0.00000 0.00001 Sulfide 0.00007 0.00008 Oil & grease 0.01134 0.01407 Ammonia & ammonium 0.00329 0.00409 Nitrate & nitrite 0.02740 0.03400 DOC 0.02906 0.03606 Chlorides 0.36038 0.44716 Sulfates 12.08843 14.99940 GFB Production Total suspended solids 0.90654 1.12484 BOD 0.00000 0.00000 Aluminum 0.01115 0.01384 Zinc 0.00000 0.00000 Iron 0.00000 0.00000 Copper 0.00000 0.00000 Boron 0.00000 0.00000 Phenolics 0.00000 0.00000 Sulfide 0.00163 0.00202 Oil & grease 0.01662 0.02062 Ammonia & ammonium 0.00480 0.00595 Nitrate & nitrite 0.02150 0.02668 DOC 0.08426 0.10455 Chlorides 1.01801 1.26315 Sulfates 13.96174 17.32381 TOTAL EFFLUENT Total suspended solids 1.23256 1.52937 BOD 0.00000 0.00000 Aluminum 0.02046 0.02539 Zinc 0.00011 0.00014 Iron 0.00000 0.00000 Copper 0.00000 0.00000 Boron 0.00000 0.00000 Phenolics 0.00000 0.00001 Sulfide 0.00170 0.00210 Oil & grease 0.02796 0.03470 Ammonia & ammonium 0.00809 0.01004 Nitrate & nitrite 0.04890 0.06068 DOC 0.11332 0.14061 Chlorides 1.37838 1.71031 Sulfates 26.05017 32.32321 The AthenaTM Project: Gypsum Board and Associated Finishing Products 8-12
TABLE 8.12 WEIGHTED AVERAGE EFFLUENT LOADING DUE TO GYPSUM AND LIMESTONE EXTRACTION
Gypsum mine/quarry water Limestone quarry water
[mg/L of g/tonne of [mg/L of g/tonne of effluent] gypsum effluent] CaCO3
Total suspended solids [TSS] 24.22 29.04387 103.70 80.17464 Aluminum 0.57 0.82952 0.76 0.26055 Zinc 0.01 0.00996 0.00 0.02077 Phenolics 0.00 0.00038 0.01 0.00713 Sulfide 0.01 0.00585 0.04 0.04669 Oil & grease 0.88 1.01034 1.77 2.19849 Ammonia & ammonium 0.31 0.29330 1.41 0.73995 Nitrate & nitrite 2.29 2.44100 2.90 3.38014 Dissolved organic compounds [DOC] 3.08 2.58877 2.49 3.73075 Chlorides 36.08 32.10489 1290.03 449.11891 Sulfates 891.55 1076.92658 217.71 261.46478
TABLE 8.13 AVERAGE EFFLUENT LOADING DUE TO JOINT COMPOUNDS PRODUCTION
Ready Mix Compounds Setting Compounds
[g/kg of [g/m2 of [g/kg of [g/m2 of compound] board] compound] board]
Total suspended solids [TSS] 0.049227 0.033179 0.058261 0.020508 Aluminum 0.000160 0.000108 0.000619 0.000218 Zinc 0.000013 0.000009 0.000017 0.000006 Phenolics 0.000004 0.000003 0.000004 0.000001 Sulfide 0.000029 0.000019 0.000027 0.000010 Oil & grease 0.001350 0.000910 0.001723 0.000606 Ammonia & ammonium 0.000454 0.000306 0.000552 0.000194 Nitrate & nitrite 0.002075 0.001399 0.003167 0.001115 Dissolved organic compounds [DOC] 0.002291 0.001544 0.003434 0.001209 Chlorides 0.275759 0.185862 0.250056 0.088020 Sulfates 0.160539 0.108204 0.763933 0.268904 The AthenaTM Project: Gypsum Board and Associated Finishing Products 8-13
TABLE 8.14 AVERAGE EFFLUENT LOADING DUE TO PAPER JOINT TAPE PRODUCTION
Flow [m3/day] 203.00 Hydrogen ion [pH] 4.9 - 8.4 Conductance [microS/cm] 362.60
[mg/L] [kg/day] [g/tonne [g/meter of [g/m2 of of paper] tape] board]
Biochemical Oxygen Demand (BOD) 270.70 55.00 321.25807 0.003939 0.003860 Total suspended solids [TSS] 243.40 46.30 270.44089 0.003316 0.003250 Oil&grease 13.50 2.80 16.35496 0.000201 0.000197 Aluminum 1.38 0.27 1.57709 0.000019 0.000019 Boron 1.72 0.34 1.98596 0.000024 0.000024 Copper 1.07 0.24 1.40185 0.000017 0.000017 Iron 2.14 0.45 2.62848 0.000032 0.000032 Manganese 0.12 0.02 0.11682 0.000001 0.000001 Zinc 0.36 0.07 0.40887 0.000005 0.000005
REFERENCES 1. Communication from S. Wong / K. Donyina, Ontario Ministry of Environment and Energy (MOEE), re. MISA water effluent discharge data for gypsum plants in Ontario, February 7, 1996. 2. Communication from B. Matlock, Nova Scotia Department of the Environment, February 22, 1996. 3. Communication from M. de Spot, Greater Vancouver Regional District (GVRD), March 4, 1996. 4. Communication from R.S. Daly, Ontario Hydro, February 27, 1996. 5. Communication from G. Rees, Ontario Ministry of Environment and Energy (MOEE), re. MISA water effluent discharge data for cement plants in Ontario, April 19, 1993. 6. “Building Materials in the Context of Sustainable Development - Raw Material Balances, Energy Profiles and Cement and Structural Concrete Products”, CANMET and Radian Canada Inc. for Forintek Canada Corp., February 1994, pp. 36-37. The AthenaTM Project: Gypsum Board and Associated Finishing Products 9-1
9.0 SOLID WASTES In this section we discuss solid wastes associated with gypsum board and related materials. The gypsum board industry generates remarkably little solid waste. The only production stage where the gypsum board industry generates some measurable solid wastes, as any other industry that mines and quarries its raw materials, is from the raw materials extraction. Essentially, all the waste generated in the manufacturing stage is internally recycled back as raw materials or used as sleutters to support gypsum board pallets.
To balance the picture, the growing trend in using by-product gypsum as a replacement for mined/quarried gypsum, as well as the beneficial role of the board industry in recycling and reuse of collected construction gypsum board waste are discussed.
9.1 SOLID WASTES ESTIMATES - GYPSUM BOARD 9.1.1 Raw Materials Extraction Overburden, top soil, and subsoil have to be removed before a new quarry can commence operation. The soil used to be resold, but in modern operations it is stockpiled for eventual quarry reclamation and is not considered waste. In general, quarrying and mining operations can create large amounts of mine spoil — rock material that is not used, but is moved to get to the desired mineral resource. Mine spoils are usually deposited in old surface-mine pits or in mounds. These materials can be physically stabilized and protected from runoff or leaching to varying degrees, but have nevertheless been frequent sources of environmental problems.
In contrast to most mining operations, however, gypsum rock is fairly widely available and mining/quarrying it generates relatively little waste. In comparison with metals mining, for example, there is little or no separating (depending on the amount and nature of impurities), no refining or smelting of the desired materials from the rock. In the gypsum industry, it is the rock itself that is quite often used in its entirety. In mines or quarries where gypsum rock is contaminated with larger volumes of limestone or dolomite, and it is separated from them, limestone or dolomite is resold and used in road bases or in similar applications. In general, the extraction of gypsum, like other structural materials extracted from mines, pits and quarries, results in little environmental contamination although the degree of land disturbance can be substantial.1
Based on information obtained from six different gypsum mines or quarries located in all three regions of Canada, weighted average solid waste, including mine/quarry soil/subsoil overlay, overburden, minespoil and separated impurities (limestone, dolomite, salt, shale), was estimated to be 336.5 kg/tonne of gypsum rock. (Excluding stripped overlay and overburden, solid waste impurities on their own were estimated to be 142.8 kg/tonne of gypsum. This is in good agreement with U.S. EPA numbers.2) Taking into consideration the fact that 1.2048 tonnes of gypsum are needed to produce one tonne of stucco (Section 3.1), and the difference in regional usage of natural gypsum versus the other sources (Table 3.3, Section 3), solid waste unit factors expressed per tonne of stucco were developed for all three regions, and are shown in Table 9.1. The AthenaTM Project: Gypsum Board and Associated Finishing Products 9-2
TABLE 9.1 GYPSUM EXTRACTION SOLID WASTE BY REGION
natural gypsum solid waste as percentage of total gypsum supply [%]
Solid waste [kg/tonne of natural gypsum] 336.51
Solid waste [kg/tonne of stucco] * 405.43
West Region (Vancouver, Calgary) [kg/tonne of stucco] 86.50 350.68 Central region (Winnipeg, Toronto) [kg/tonne of stucco] 85.33 345.94 East region (Montreal, Halifax) [kg/tonne of stucco] 81.26 329.44 Note: * if stucco produced from natural gypsum only
As more by-product gypsum will enter the gypsum board production stream replacing some of the natural gypsum, these solid waste unit factors will undoubtedly diminish in the years to come.
9.1.2 Gypsum Board Manufacturing During the gypsum board manufacturing stage about 2 to 5% of the production is culled due to some operation problems or material being off specifications. However, in contrast to many other manufacturing processes, the rejected gypsum board is not wasted; virtually all of it is reused. Most of the off-spec board is broken down, shredded and recycled back as a part of the raw materials stream into the production. As shown in Table 3.3 in Section 3, such internal gypsum board waste recycling accounts for about 6%, 4% and 7% of the gypsum sources in the West, Central and East regions respectively.
Some of the waste gypsum board is also cut into strips and used as sleutters to support gypsum board pallets during storage and transportation, thus eliminating the need to use 4"x4" wood support for the same purpose. Any off-spec paper or damaged paper is also recycled, as is the paper that is on some occasions stripped from the waste gypsum board before it is broken, shredded and fed back into the calciner.
Consequently, there is no solid waste that is associated with the gypsum board manufacturing stage. The only solid waste generated by the gypsum board production is that already identified and estimated above for gypsum mining / quarrying.
9.1.3 Total Solid Waste Due to Gypsum Board Production The unit factors from Table 7.1, now considered the total solid waste factor estimates, can then be combined with typical average mass of stucco used in formulations of different gypsum board products (Table 3.1, Section 3) to develop estimates for solid waste associated with gypsum board production expressed per m2 of board. (For gypsum fiberboard, it was assumed that use of perlite generates about the same amount of solid waste as gypsum.) These estimates are presented in Table 9.2. The AthenaTM Project: Gypsum Board and Associated Finishing Products 9-3
TABLE 9.2 TOTAL SOLID WASTE ASSOCIATED WITH GYPSUM BOARD PRODUCTION BY REGION [KG/M2 OF BOARD]
[kg of [kg of solid waste/m2] stucco/m2]
West Central East
1/2" regular gypsum board 6.3610 2.2307 2.2005 2.0955 1/2" Type X gypsum board 6.3329 2.2208 2.1908 2.0863 1/2" MR gypsum board 6.9755 2.4462 2.4131 2.2980 5/8" regular gypsum board 8.3057 2.9126 2.8733 2.7362 5/8" type X gypsum board 8.4239 2.9541 2.9141 2.7751 5/8" MR gypsum board 8.9438 3.1364 3.0940 2.9464 5/16" mobile home board 4.4665 1.5663 1.5451 1.4714 1" shaftliner 15.6671 5.4941 5.4198 5.1613 1/2" gypsum fiberboard (GFB)* 8.1738** - - 2.6928 5/8" gypsum fiberboard (GFB)* 10.1421** - - 3.3412
notes: * includes perlite ** GFB is produced only in the East region
9.2 THE USE OF WASTES IN GYPSUM BOARD PROCESSING It has been already noted (Section 2.6.5) that the gypsum board industry is in a rather unique position in that it can use industrial by-products, construction waste and products made from post- consumers waste paper as a part of its raw materials stream. This recycling and reuse of by- products and wastes is one of the major strengths of the gypsum industry. Westroc’s Mississauga plant became the first Canadian gypsum board plant operating entirely on FGD by-product/waste gypsum, with a number of other operations supplementing their gypsum rock supply with by- product gypsum, or construction waste gypsum. This trend to increased utilization of by-product gypsum appears to be especially strong in East region plants. It is entirely feasible that both CGC’s and Westroc’s Montreal gypsum board plants will be operating on 100% by-product / recycled gypsum before the end of 1996.
The availability of free, or very inexpensive by-product gypsum, is changing the gypsum industry. In years to come, it is expected that where it will make economic and geographic sense, more and more FGD gypsum will be used.3 In 1992 in the U.S.A. over 25.5 GWe of coal-fired power generating plants were already operating, under construction, or planned to be equipped with wet lime/limestone scrubbers generating FGD gypsum. It is expected that by the end of the decade some 7.3-million tonnes of FGD gypsum could be available.6,7 To put that number in perspective, it represents about one-third of the total U.S. annual consumption and almost one-half of its gypsum mining output. Other sources forecast an eventual U.S. production of synthetic gypsum as high as 32-million tonnes annually.8 The AthenaTM Project: Gypsum Board and Associated Finishing Products 9-4
Increased generation and use of FGF gypsum is a worldwide phenomenon. In Great Britain, FGD gypsum output of just one power station, of the National Power’s Drax station, when fully operational in late 1996, will have the capability to supply up to 1,000,000 tonnes of gypsum annually, representing more than one third of the total UK gypsum industry needs.
In Canada 1.5 GWe power generating capacity already is or will soon be similarly equipped with flue gas desulfurization scrubbers capable of generating commercial grade gypsum.5 Canadian FGD gypsum production capability, estimated on the basis of Canadian vs. U.S. wet lime/limestone scrubbing capacity, appears to be in the 500,000 tonnes/year area. This figure seems to correspond well with the FGD gypsum generating forecasts expected from Ontario Hydro’s Lambton and New Brunswick’s Belledune power stations.
In at least two Canadian metropolitan areas, Vancouver and Toronto, construction gypsum board waste has been banned from landfill sites since the early 1990s. In these areas, the gypsum board producers entered into partnership arrangements with recycling companies such as New West Gypsum. Gypsum construction waste is being collected and processed by recyclers, and supplied back to the gypsum board manufacturing plants. An alternate use for construction waste, according to the Gypsum Association, includes agricultural applications and animal bedding material.4 Beneficial re-use of either by-product or waste construction gypsum eliminates some of the pressure on scarce landfill sites.
One leading gypsum board producer certifies that over 20% (by weight) of all gypsum board manufactured consisted of recycled material, and that 100% of gypsum waste generated at that particular manufacturing facility is recycled.9 The same operation was recognized for its environmental leadership by the Recycling Council of Ontario when it was awarded the 1991 Ontario Waste Minimization Award for Outstanding Industrial 3-R’s Initiative.
Table 9.3 summarizes the current distribution of gypsum sources used by Canadian gypsum board manufacturers.
TABLE 9.3 DISTRIBUTION OF GYPSUM SOURCES BY GEOGRAPHICAL REGION (%)
Natural Synthetic Recycled / Recycled / Gypsum Gypsum external internal
West Avg. 86 0 8 6 Central Avg. 85 7 4 4 East Avg. 81 10 2 7 CANADA 85 6 4 5
Furthermore, as already noted in Section 2.2.3, paper used as facings of gypsum board is made entirely f rom waste paper (old newspaper, magazines and corrugated cardboard). Therefore, The AthenaTM Project: Gypsum Board and Associated Finishing Products 9-5
gypsum board from at least some of the operations is, or can be, 100% recycled or by-products- derived building material.
9.3 SOLID WASTES ESTIMATES - FINISHING PRODUCTS According to industry sources, there is no solid waste generated in the manufacturing steps of joint compounds production, other than bagged raw materials packaging. Paper bags packaging, however, is collected, compacted and sent back to the paper producers for recycling, and is not therefore considered to be a waste.
Consequently, the only solid waste assignable to the joint compounds production, is the portion of the solid waste generated in extraction of industrial minerals used as their constituents. In Table 9.1, solid waste of 336.51 kg/tonne of gypsum and 405.43 kg/tonne of stucco (plaster) were shown. As a rough approximation, we will use the “gypsum” solid waste number for limestone, mica, talc and clay as well. Combining the content of industrial minerals in the joint compound formulations (Tables 3.6 and 3.7) with these factors, we can provide some indication of the solid waste associated with joint compounds production (Table 9.4).
TABLE 9.4 SOLID WASTE ASSOCIATED WITH JOINT COMPOUNDS PRODUCTION
Ready Mix Joint Compound Setting Joint Compound
[g/kg of compound] [g/m2 of board] [g/kg of compound] [g/m2 of board]
206.62 139.26 369.94 130.22
REFERENCES 1. “The State of Canada’s Environment”, Environment Canada, Ottawa 1991, p. 11-20. 2. U.S. Environmental Protection Agency (EPA), Industrial Process Profiles for Environmental Use: Chapter 17, The Gypsum and Board Industry, 1977. 3. G.J. Venta, R.T. Hemmings, “FGD Gypsum Utilization: A Strategic Approach to Reuse”, Proceedings, Paper 95-WA80.03, Air & Waste Management Association 88th Annual Meeting & Exhibition, San Antonio, TX, June 18-23, 1995. 4. “Gypsum Board Systems: Technical Report”, Topic I-9250, AIA Environmental Resource Guide, July 1993. 5. H.N. Soud, M. Takeshita, “FGD Handbook”, Chapter 4 - FGD Installations on Coal-Fired Plants, IEACR/65 Report, IEA Coal Research, London, January 1994. 6. G.J. Venta, R.T. Hemmings, “FGD Gypsum Utilization: Bridging the “Two Solitudes”, Proceedings of 11th International Symposium on Use and Management of Coal Combustion By-Products (CCBs), American Coal Ash Association, Orlando, FL, January 15-19, 1995. The AthenaTM Project: Gypsum Board and Associated Finishing Products 9-6
7. W. Ellison, R.A. Kuntze, “Expanding of Markets for Gypsum Byproducts”, Proceedings of Society for Mining, Metallurgy and Exploration, Inc., 1993 Annual Meeting, Reno, NE. 8. J.A. Walker, “Gypsum - The Miracle Mineral: Brief History and Prospects”, Proceedings of the 4th International Conference on Inorganic-Bonded Wood and Fiber Composite Materials, Spokane, WA, September 26-28, 1994, pp.39-40. 9. “Certificate of Recycling”, Westroc Industries Limited, June 1993.