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See detailUse of a bio-based binder in the building sector
Gerbinet, Saïcha ULg; Briard, Vincent; Pigeolet, Jean-Pierre et al

Poster (2017, May 15)

A binder is a material or a substance that holds materials together, like a glue. In the building sector, binders have several applications: they can be used in producing wood panels such as MDF to paste ... [more ▼]

A binder is a material or a substance that holds materials together, like a glue. In the building sector, binders have several applications: they can be used in producing wood panels such as MDF to paste together the wood particles and give the panels their stabil-ity. They are also used in insulation materials, such as glass wool or stone wool to bind the fibers together. Traditional binders are mostly fossil-based (phenol-formaldehyde, urea-formaldehyde, etc.), and previous Life Cycle Assessments (LCA) [1-3] show that these binders, even if they are a minor component on a mass basis, can have a major contribution to the environmental impact of the material, especially in wood panels. In addition, the use of these binders has raised some sanitary questions, especially con-cerning indoor air quality. Therefore alternative binders are being investigated, namely bio-based binders. In this presentation, we focus on the ECOSE binder, developed by Knauf Insulation, a global building insulation manufacturer. It has the particularity of being based on plant starch and it is currently used in glass wool products, while other applications are being developed. We underline that using biomass as raw materials instead of fossil-based ma-terials could have several benefits on the environment, especially fossil resources deple-tion and CO2 emissions, but that this is not necessarily the case for all environmental as-pects, for instance land use, even if only the direct land use is included in this study. The presentation will first underline the differences in term of environmental impact be-tween the traditional binder and ECOSE applied in glass mineral wool. Indeed, a compar-ison on a mass basis is not totally relevant: two binders can have different application conditions; therefore, we can only compare them at the application level. But the main focus of the presentation will be on the hypothesis made in the modeling of the biomass part and their influence on the results. For example, the influence of the use of bio-based raw materials instead of traditional ones will be studied, but also the influence of the dis-tance between farm and factory where the starch is produced. The use of local data will be compared with the use of databases. All these results will highlight the difficulties in studying bio-based products and to compare them with fossil-based ones. The use of LCA and a complete analysis of the results are essential to better understand the chal-lenges related to binder technology modification. ________________________________________ 1. Rivela, B., et al., Life cycle inventory of particleboard: A case study in the wood sector. International Journal of Life Cycle Assessment, 2006. 11(2): p. 106-113. 2. Wilson, J.B., Particleboard: A Life-Cycle Inventory of Manufacturing Panels from Resource through Product, in CORRIM: Phase II Final Report. 2008, Department of Wood Science and Engineering, Oregon State University. 3. Silva, D.A.L., et al., Environmental performance assessment of the melamine-urea-formaldehy (MUF) resin manufacture: a case study in Brazil. Journal of Cleaner Production, 2015. 96. [less ▲]

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See detailPARTNERSHIP with a glass wool producer for accurate LCA
Gerbinet, Saïcha ULg; Briard, Vincent; Pigeolet, Jean-Pierre et al

Conference (2016, October 08)

This presentation aims to illustrate how a partnership with the private sector can progressively become a win-win collaboration. Taking into account the environmental aspects in the building sector has ... [more ▼]

This presentation aims to illustrate how a partnership with the private sector can progressively become a win-win collaboration. Taking into account the environmental aspects in the building sector has become unavoidable. Knauf Insulation, a glass wool producer, has started to evaluate the environmental impacts of it manufacturing processes for drafting Environmental Product Declarations (EPD). This first objective was mainly intended to respond to a market demand for EPDs of their products. Our first contact with Knauf Insulation was for drawing up EPDs of 10 of their products. This first work has shown the need for a more flexible tool to allow rapid life cycle analyze of a product and publication of an EPD, and thus respond quickly to market demands. The need of a better understanding of the environmental impact of the process is also underline to allow to follow the evolution of the impact and to reduce it. All the glass wool products are manufactured in a similar way, only a few parameters, such as density or thickness, are modified in the process to produce a given product. We have therefore chosen to develop a generic model that can be used for all glass wool products produced by Knauf Insulation, in any of their plants. The LCA model was developed in GaBi, and thanks to a positive collaboration with Thinkstep, the software editor, and Knauf Insulation, the model is finetuned for the production plants. Knauf Insulation can use this model for EPDs as well as for Ecoconception. The model is built to be user-friendly: the user sets the product characteristics and dimensions, and in which plant (or combination of plants) it is produced. The data collection is performed by Knauf Insulation with our support. When new data are available, the model is easily updated. Therefore the model is easy to use, easy to update and accurate. Thanks to this positive experience the collaboration is ongoing. The same modelling aspects have been adapted to another insulation product from Knauf Insulation, stone wool. Furthermore, Knauf Insulation has developed a new binder for its products called ECOSE and produced from renewable materials (biomass), and is formaldehyde-free. The previous LCA underline the need of a better characterization of ECOSE in a LCA perspective. Therefore, a PhD is underway to evaluate the impacts of this binder and its applications (glass wool products) as well as its future applications. This story underlines how the partnership between the university and private sector is a win-win situation, staring from EPD and leading to much needed fundamental research, more accurate EPDs and better awareness of the environmental impacts in general, when the private sector is convinced with the interest of the demarche. [less ▲]

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See detailEnvironmental impact assessment of bio-based binders: from production to industrial applications
Gerbinet, Saïcha ULg; Belboom, Sandra ULg; Briard, Vincent et al

Poster (2015, October 15)

A binder is used to hold together the fibers forming the mineral wool products (see figure 1). These fibers can be produced from sand and recycled glass for glass wool products (see figure 2) or from rock ... [more ▼]

A binder is used to hold together the fibers forming the mineral wool products (see figure 1). These fibers can be produced from sand and recycled glass for glass wool products (see figure 2) or from rock (volcanic rock, typically basalt or dolomite) for stone wool products. Traditionally, the binders used in mineral wool products are based on phenol-formaldehyde. Due to sanitary and environmental considerations and increased focus on indoor air quality, the producers developed new alternative binders. Especially, Knauf Insulation, a worldwide building insulation manufacturer, developed a binder based on plant starch and called ECOSE. In addition of not using added phenol-formaldehyde , this new binder is also supposed to reduce the environmental impacts of Knauf Insulation mineral wools. Moreover, due to its properties, others applications are now considered for ECOSE such as composite wood panels [1]. The aim of this study is to determine the environmental impact of ECOSE and to compare it with more traditional binders using Life Cycle Assessment (LCA) methodology. LCA analyzes the environmental aspects and potential impacts associated with all the stages of a product's life. In this type of environmental assessment the energy and material flows for the entire life-cycle are surveyed and analyzed with special attention to possible environmental hazards or human health problems. The ISO 14040 and 14044 norms [2, 3] provide the general guidance for performing an LCA. The LCA methodology is first applied to ECOSE main component: glucose. The presentation will present results for glucose production from cereals starches After that, first ECOSE application, glass mineral wool products will be presented in details, including production process (see figure 3). The modelling of the glass mineral wool production process in LCA software GaBi 6 [4] is then described. One of the model specificity is that it allows to perform LCA of any glass wool products produced in Knauf Insulation plants in Europe. The adaptations to the model to allow studying former glass wool product when using phenol-formaldehyde binders will also be presented such as the advantages of this model. Moreover, preliminary results about ECOSE and phenol-formaldehyde glass wool products are explained. Références [1] Knauf Insulation. [cited 2014; Available from: http://www.knaufinsulation.ua/en. [2] ISO 14044, Environmental management - Life cycle assessment - Requirements and guidelines. 2006. [3] ISO 14040, Environmental management - Life cycle assessment - Principles and framework. 2006. [4] LBP, University of Stuttgart, and PE INTERNATIONAL AG, GaBI 6. 2012: Leinfelden-Echterdingen. p. GaBi 6: Software and database for life cycle engineering. [less ▲]

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See detailModeling of a glass mineral wool process in view of Life Cycle Analysis
Gerbinet, Saïcha ULg; Briard, Vincent; Léonard, Angélique ULg

in Matériaux et Techniques (2014), 102(502),

In line with the growing concern about the environmental impact of materials in the building sector, Knauf Insulation, a glass wool producer, is performing environmental impact assessment of its products ... [more ▼]

In line with the growing concern about the environmental impact of materials in the building sector, Knauf Insulation, a glass wool producer, is performing environmental impact assessment of its products through LCA. Knauf Insulation has several glass wool factories in Europe that produce various products, and for a specific market, the same product can be produced in several factories. As the plants that produce glass wool work with similar pathways, a generic model for LCA usable for every plant and every glass wool product has been designed. The general principle of glass wool production is the following: the raw materials, sand, limestone, soda ash, borax, sodium carbonate, as well as recycled off-cuts from the production process, are weighed and mixed. Knauf Insulation also uses a large amount of recycled glass (cullet). The mix is sent to a furnace at high temperature (1350°C). The melted material is then fiberized and the binder is added, a process called forming. Knauf Insulation uses a special binder with ECOSE Technology, a new and formaldehyde-free binder. The wool fibers are collected, by suction, on a conveyor belt, and the mattress then goes through the curing oven. For some products a facing is added. Finally the product is compressed and packed. Specific attention is put in certain LCA aspects, such as allocations procedures, and we have used ISO 14040 and 14044 along with the ILCD handbook as guides during the model development. LCA is performed from raw materials extraction to end-of-life. Nevertheless, the impacts of the insulation system use phase are not included, as they strongly depend on parameters such as construction systems, etc. The functional unit is defined as 1 m3 of specific glass mineral wool product. The model, implemented in GaBi 6, is made as generic as possible by including, for each step, all the raw materials that can be used in one of the factories as well as all the energy sources. Parameters allow to define the amount of each raw material consumed, therefore the model can be adapted to any factory simply by setting these parameters accordingly. Moreover, the transport distances are also parameters and the origin of the energies (electricity or heat) can also be selected. This simplifies the data collection, since the template is the same for all the factories, it can be supported by data collection tools already existing. A part of the model is dedicated to weighting between factories, so a combination of factories can also be studied. This allows to study products sold on a specific market. The model can also be adapted to almost all Knauf Insulation products by using parameters where necessary: for example, several products have different binder contents, so a parameter defines the amount of binder. As some materials can be recycled between several parts of the process, special attention has been paid to recycling loops inside the model. The model is flexible enough to be used for Environmental Product Declaration (EPD) as well as for Eco-Design purposes. [less ▲]

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See detailModeling of a glass mineral wool process in view of Life Cycle Analysis
Gerbinet, Saïcha ULg; Léonard, Angélique ULg; Briard, Vincent

Conference (2014, May 20)

In line with the growing concern about the environmental impact of materials in the building sector, Knauf Insulation, a glass wool producer, is performing environmental impact assessment of its products ... [more ▼]

In line with the growing concern about the environmental impact of materials in the building sector, Knauf Insulation, a glass wool producer, is performing environmental impact assessment of its products through LCA. Knauf Insulation has several glass wool factories in Europe that produce various products, and for a specific market, the same product can be produced in several factories. As the plants that produce glass wool work with similar pathways, a generic model for LCA usable for every plant and every glass wool product has been designed. The general principle of glass wool production is the following: the raw materials, sand, limestone, soda ash, borax, sodium carbonate, as well as recycled off-cuts from the production process, are weighed and mixed. Knauf Insulation also uses a large amount of recycled glass (cullet). The mix is sent to a furnace at high temperature (1350°C). The melted material is then fiberized and the binder is added, a process called forming. Knauf Insulation uses a special binder with ECOSE Technology, a new and formaldehyde-free binder. The wool fibers are collected, by suction, on a conveyor belt, and the mattress then goes through the curing oven. For some products a facing is added. Finally the product is compressed and packed. Specific attention is put in certain LCA aspects, such as allocations procedures, and we have used ISO 14040 and 14044 along with the ILCD handbook as guides dur-ing the model development. LCA is performed from raw materials extraction to end-of-life. Nevertheless, the impacts of the insulation system use phase are not included, as they strongly depend on parameters such as construction systems, etc. The functional unit is defined as 1 m3 of specific glass mineral wool product. The model, implemented in GaBi 6, is made as generic as possible by including, for each step, all the raw materials that can be used in one of the factories as well as all the energy sources. Parameters allow to define the amount of each raw material consumed, therefore the model can be adapted to any factory simply by setting these parameters accordingly. Moreover, the transport distances are also parameters and the origin of the energies (electricity or heat) can also be selected. This simplifies the data collection, since the template is the same for all the factories, it can be supported by data collection tools already existing. A part of the model is dedicated to weighting between factories, so a combination of factories can also be studied. This allows to study products sold on a specific market. The model can also be adapted to almost all Knauf Insulation products by using parameters where necessary: for example, several products have different binder contents, so a parameter defines the amount of binder. As some materials can be recycled between several parts of the process, special attention has been paid to recycling loops inside the model. The model is flexible enough to be used for Environmental Product Declaration (EPD) as well as for Eco-Design purposes. [less ▲]

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See detailModeling of a glass mineral wool process in view of Life Cycle Analysis
Gerbinet, Saïcha ULg; Léonard, Angélique ULg; Briard, Vincent

Poster (2014, May 12)

In line with the growing concern about the environmental impact of materials in the building sector, Knauf Insulation, a glass wool producer, is performing environmental impact assessment of its products ... [more ▼]

In line with the growing concern about the environmental impact of materials in the building sector, Knauf Insulation, a glass wool producer, is performing environmental impact assessment of its products through LCA. Knauf Insulation has several glass wool factories in Europe that produce various products, and for a specific market, the same product can be produced in several factories. As the plants that produce glass wool work with similar pathways, a generic model for LCA usable for every plant and every glass wool product has been designed. Moreover, combination of different factories is also possible. The general principle of glass wool production is the following: the raw materials, sand, limestone, soda ash, borax, sodium carbonate, as well as recycled off-cuts from the production process, are weighed and mixed. Knauf Insulation also uses a large amount of recycled glass (cullet). The mix is sent to a furnace at high temperature (1350°C). The melted material is then fiberized and the binder is added, a process called forming. Knauf Insulation uses a special binder with ECOSE Technology, a new and formaldehyde-free binder. The wool fibers are collected, by suction, on a conveyor belt, and the mattress then goes through the curing oven. For some product a facing is added. Finally the product is compressed and packed. The model, implemented in GaBi 6, is made as generic as possible by including, for each step, all the raw materials that can be used in one of the factories as well as all the energy sources. Parameters allow to define the amount of each raw material consumed, therefore the model can be adapted to any factory simply by setting these parameters accordingly. This also simplifies the data collection, since the template is the same for all the factories, it can be supported by data collection tools already existing. A part of the model is dedicated to weighting between factories, so a combination of factories can also be studied. The model can also be adapted to almost all Knauf Insulation products by using parameters where necessary: for example, several products have different binder contents, so a parameter defines the amount of binder. As some materials can be recycled between several parts of the process, special attention has been paid to recycling loops inside the model. The model is flexible enough to be used for Environmental Product Declaration (EPD) as well as for Eco-Design purposes. [less ▲]

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See detailUse of Life Cycle Assessment to support in the Eco-Design of a glass-wool process
Gerbinet, Saïcha ULg; Renzoni, Roberto ULg; Briard, Vincent et al

Poster (2013, November 15)

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See detailUse of Life Cycle Assessment in view of Eco-Design for a glass wool process
Gerbinet, Saïcha ULg; Renzoni, Roberto ULg; Briard, Vincent et al

Conference (2013, April 25)

Detailed reference viewed: 45 (5 ULg)
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See detailACV et Ecoconception: illustration de la démarche au sein de Knauf Insulation.
Gerbinet, Saïcha ULg; Briard, Vincent; Léonard, Angélique ULg

Conference (2013, March 22)

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See detailMODELING OF A GLASS WOOL PROCESS IN VIEW OF LIFE CYCLE ASSESSMENT (L.C.A.)
Gerbinet, Saïcha ULg; Renzoni, Roberto ULg; Briard, Vincent et al

Poster (2012, November)

Taking into account the environmental aspects in the building sector has become unavoidable. In France, environmental and sanitary statements for building products (“Fiches de Déclarations ... [more ▼]

Taking into account the environmental aspects in the building sector has become unavoidable. In France, environmental and sanitary statements for building products (“Fiches de Déclarations Environnementales et Sanitaires” (FDE&S)) have been developed. The environmental part of the statement is based on Life Cycle Assessment. So, KnaufInsulation, glass wool producer for the French market, has started to evaluated the environmental impacts of it process in view of FDE&S realization. The process has been modeling in GaBi with industrial data. Adjustable parameters have been introduced to allow to study the environmental impacts of almost all the KnaufInsulation products. So the FDE&S can be easily done for the different products. This model is also used for eco-conception. The LCA results allow to show the life cycle leaks. More, in modifying the model, the impact of a change in the process on its environmental performances will be highlighted. So relevant improvement will be brought out. The model and the mains results as the eco-conception strategy will be presented. The interest of making a modeling based on the step and process of the life cycle of a product or a product range will be clearly understood. [less ▲]

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See detailMODELING OF A GLASS WOOL PROCESS IN VIEW OF LIFE CYCLE ASSESSMENT (L.C.A.)
Gerbinet, Saïcha ULg; Renzoni, Roberto ULg; Briard, Vincent et al

in LCA conference 2012 - Proceeding of the 2nd international conference on life cycle approaches (2012, November)

Taking into account the environmental aspects in the building sector has become unavoidable. In France, environmental and sanitary statements for building products (“Fiches de Déclarations ... [more ▼]

Taking into account the environmental aspects in the building sector has become unavoidable. In France, environmental and sanitary statements for building products (“Fiches de Déclarations Environnementales et Sanitaires” (FDE&S)) have been developed. The environmental part of the statement is based on Life Cycle Assessment. So, KnaufInsulation, glass wool producer for the French market, has started to evaluated the environmental impacts of it process in view of FDE&S realization. The process has been modeling in GaBi with industrial data. Adjustable parameters have been introduced to allow to study the environmental impacts of almost all the KnaufInsulation products. So the FDE&S can be easily done for the different products. This model is also used for eco-conception. The LCA results allow to show the life cycle leaks. More, in modifying the model, the impact of a change in the process on its environmental performances will be highlighted. So relevant improvement will be brought out. The model and the mains results as the eco-conception strategy will be presented. The interest of making a modeling based on the step and process of the life cycle of a product or a product range will be clearly understood. [less ▲]

Detailed reference viewed: 102 (7 ULg)