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 Athena TM 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 Athena TM 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 Athena TM 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 Athena TM 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
Robert Daly
Gerry Harlos
Mike Hunter
A. Marchand
David Shanahan
Francis Vrillaud
Rick Weber
W.R. Grace & Co. of Canada Ltd.
Ontario Hydro
Domtar Gypsum
CGC Inc.
The Beaver Wood Fibre Company Ltd.
Westroc Industries Ltd.
Domtar Gypsum
CGC Inc.
We also want to acknowledge the following provincial and regional authorities and their
representatives for their input:
Michel de Spot
Serge Goulet
Bernard Matlock
Don Murray
Jean Van Dusen
Simon Wong
Greater Vancouver Regional District
Quebec MOE&F
Nova Scotia DOE
New Brunswick DOE
Manitoba Environment
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 Athena TM 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 Athena TM 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.
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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).
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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 Athena TM Project:
Gypsum Board and Associated Finishing Products
2.0
2-1
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 Athena TM Project:
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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 byproduct 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.
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TABLE 2.1: GYPSUM MINING AND GYPSUM PRODUCTS MANUFACTURING
OPERATIONS, 1994
Company
Newfoundland
Domtar Inc.
Atlantic Gypsum
Nova Scotia
Domtar Inc.
Domtar Inc.
Fundy Gypsum Company Limited
Georgia-Pacific Corporation
Little Narrows Gypsum Company Ltd.
National Gypsum (Canada) Ltd.
Louisiana-Pacific Corporation
New Brunswick
Westroc Industries Limited
Quebec
CGC Inc.
CGC Inc.
Domtar Inc.
Westroc Industries Limited
Ontario
CGC Inc.
Location
Operation
Flat Bay
Corner Brook
Open-pit mining, closed in 1994
Gypsum board manufacture
McKay Settlement
Windsor
Wentworth and Miller Creek
Sugar Camp
Little Narrows
Milford
Port Hawkesbury
Open-pit mining
Plaster manufacture
Open-pit mining
Open-pit mining
Open-pit mining
Open-pit mining
Gypsum fiberboard manufacture
McAdam
Gypsum board manufacture
Montreal
St. Jerome
Montreal
Montreal
Gypsum board manufacture
Gypsum board manufacture
Distribution terminal only
Gypsum board manufacture
Hagersville
Domtar Inc.
Caledonia
Westroc Industries Limited
Westroc Industries Limited
Manitoba
Domtar Inc.
Domtar Inc.
Westroc Industries Limited
Westroc Industries Limited
Alberta
Domtar Inc.
Westroc Industries Limited
British Columbia
Domtar Inc.
Domtar Inc.
Westroc Industries Limited
Westroc Industries Limited
Drumbo
Mississauga
Underground mining and gypsum board
manufacture
Underground mining and gypsum board
manufacture
Underground mining, closed in 1995
Gypsum board manufacture
Amaranth
Winnipeg
Amaranth
Winnipeg
Open-pit mining
Gypsum board manufacture
Open-pit mining
Gypsum board manufacture
Edmonton
Calgary
Gypsum board manufacture
Gypsum board manufacture
Canal Flats
Vancouver
Windermere
Vancouver
Open-pit mining
Gypsum products manufacture
Open-pit mining
Gypsum products manufacture
Source: Adapted from Ref. (1)
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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 23million 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.
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Gypsum Board and Associated Finishing Products
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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-ityourself" 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 Athena TM Project:
Gypsum Board and Associated Finishing Products
2.2
2-6
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 Athena TM Project:
Gypsum Board and Associated Finishing Products
gypsum rock
(mined or
quarried)
crusher
2-7
screen
gypsum
bin
or
hammer
mill
by-product
gypsum
(FGD or TiO2)
screen
Raymond mill
continuous
kettle
calciner
H2O
additives
stucco
bin
face
paper
back
paper
board
knife
pin mixer
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).
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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.
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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 SO 2 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 SO 2 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 SO 2 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.
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Gypsum Board and Associated Finishing Products
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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 byproduct 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 Athena TM 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 papermaking machine. Two types of paper making equipment, i.e. rotating cylinders or Fourdrinier flat
wire machines, can be used to produce gypsum paper.
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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.
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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 Athena TM Project:
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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
Lath:
3/8"
1/2"
other
Thousand
square feet
Thousand
tonnes
Value
[US $]
%
(based on
area)
6,886
137
5,867
4
> 0.5
5
1,410
24
407
0.0297
0.0006
0.0253
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"
1/2"
5/8"
1"
other (1/4", 7/16", 3/4")
918,125
11,885,323
1,466,834
172,079
128,872
711
9,357
1,225
155
101
69,102
1,487,447
57,282
31,905
16,470
3.9582
51.2395
6.3238
0.7419
0.5556
Total regular board
14,571,233
11,548
1,662,206
62.8189
5,526,219
5,157
460,985
23.8244
87,066
78
27,872
0.3754
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
23,195,632
19,192
2,452,158
100.0000
Total lath
Type X gypsum board
Predecorated board
5/16" mobile home board
Grand total
Source: adapted from Ref. (2)
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Gypsum Board and Associated Finishing Products
2.3
2-15
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 Athena TM Project:
Gypsum Board and Associated Finishing Products
gypsum rock
(mined or
quarried)
or
crusher
2-16
screen
gypsum
bin
by-product
gypsum
(FGD or TiO2)
Raymond mill
waste
paper
paper
shredding
screen
additives
Claudius
Peters
flash
calciner
perlite
perlite
expansion
moisture
stucco
bin
fiber
mills
blending
spreading
surface
layers fibres
spreading
centre layer
fibres & perlite
mixing
mixing
cross cut
saw
forming belt
continuous press
stacking,
bundling
GFB to warehouse & shipping
Fig. 2.2
board dryer
Flow diagram of a gypsum fiberboard (GFB) plant with a Claudius Peters flash
calciner (adapted from Refs. 18, 34).
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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 Athena TM Project:
Gypsum Board and Associated Finishing Products
gypsum rock
(mined or
quarried)
crusher
2-18
screen
gypsum
bin
or
hammer
mill
by-product
gypsum
(FGD or TiO2)
screen
tube mill
batch
kettle
calciner
additives
stucco
bin
stucco
bin
stucco
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).
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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]
%
155,400
148,900
24,700
0.79
0.75
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
Regular Plasters
Veneer Plasters
Gauging Plaster & Keene's Cement
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.
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Gypsum Board and Associated Finishing Products
2.5
2-20
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:
setting joint compound:
paper tape:
67.4 kg/100 m2
35.2 kg/100 m2
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 Athena TM Project:
Gypsum Board and Associated Finishing Products
dry raw
materials
in bulk
2-21
bagged dry raw
materials &
additives
resin
water
ribbon mixer
dry powder
mixer
pump discharge
weigh scale
& inspection
station
pulverizer
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).
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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 Athena TM Project:
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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
Ready mix
Dry powder
SCG Code
1994 Production
[tonnes]
2520.20.90
2520.10.13
131,844
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 Athena TM 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
Batch
Continuous
Continuous with submerged
combustion
Conical
Energy Efficiency
Energy Consumption [GJ/tonne]
@ 72% purity
@ 90% purity
55
65
0.98
0.82
1.21
1.02
75
0.71
0.88
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
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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
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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 clayheavy 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 Athena TM Project:
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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.
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1.
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4.
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7.
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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”,
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Zelkowski,
“Kohleverbrennung”,
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Vereinigung
der
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1986.
27. American Gas Association, “Industrial Sector Energy Analysis: The Paper Industry”,
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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 – Future-Oriented Technologies for Innovative Panels”,
Carl Schenck AG bulletin V 0224.
The Athena TM Project:
Gypsum Board and Associated Finishing Products
3.0
3-1
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 Athena TM 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/M 2 OF FINISHED BOARD)
1/2" regular
5/8" regular
1/2" type X
5/8" type X
1/2" MR
Stucco
Paper
Water
Other
Perlite
6.3610
0.4715
5.4273
0.1108
0.0000
8.3057
0.4773
6.8308
0.1493
0.0000
6.3329
0.4507
5.3773
0.2761
0.0000
8.4239
0.4649
6.8967
0.1523
0.0000
6.9755
0.4847
6.6290
0.3674
0.0000
TOTAL (wet weight)
12.3706
15.7632
12.4370
15.9378
14.4566
8.0632
10.2867
8.1854
10.5066
9.0406
5/8" MR
5/16" mobile
home
1" shaftliner
1/2" GFB
5/8" GFB
Stucco
Paper
Water
Other
Perlite
8.9438
0.5070
8.4140
0.4712
0.0000
4.4665
0.4887
4.2246
0.1050
0.0000
15.6671
0.4887
11.9824
0.2118
0.0000
6.8432
1.5207
1.4147
0.2766
1.3306
8.4911
1.8869
1.7554
0.3432
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
(dry weight)
The Athena TM Project:
Gypsum Board and Associated Finishing Products
3-3
TABLE 3.2 GYPSUM BOARD GENERIC FORMULATIONS / AVERAGE RAW
MATERIALS USE (% BREAKDOWN)
Stucco
Paper
Water
Other
Perlite
TOTAL (wet weight)
Stucco
Paper
Water
Other
Perlite
TOTAL (wet weight)
3.2
1/2" regular
5/8" regular
1/2" type X
5/8" type X
1/2" MR
51.42
3.81
43.87
0.90
0.00
52.69
3.03
43.33
0.95
0.00
50.92
3.62
43.24
2.22
0.00
52.85
2.92
43.27
0.96
0.00
48.25
3.35
45.85
2.54
0.00
100.00
100.00
100.00
100.00
100.00
5/8" MR
5/16" mobile
home
1" shaftliner
1/2" GFB
5/8" GFB
48.78
2.77
45.89
2.57
0.00
48.11
5.26
45.50
1.13
0.00
55.26
1.72
42.27
0.75
0.00
60.10
13.36
12.43
2.43
11.69
60.10
13.36
12.43
2.43
11.69
100.00
100.00
100.00
100.00
100.00
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 byproduct 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 Athena TM Project:
Gypsum Board and Associated Finishing Products
TABLE 3.3
West Avg.
Central Avg.
East Avg.
CANADA
3-4
DISTRIBUTION OF GYPSUM SOURCES BY GEOGRAPHICAL REGION (%)
Natural
Gypsum
Synthetic
Gypsum
Recycled /
external
Recycled /
internal
86
85
81
85
0
7
10
6
8
4
2
4
6
4
7
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
West Avg.
Central Avg.
East Avg.
CANADA
Synthetic
Gypsum
Recycled
Gypsum /
external
ship
rail
road
total
road
road
1436
656
507
184
6
47
274
44
231
144
1894
44
893
698
0
34
3
18
46
15
9
21
The Athena TM 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)
West Avg.
Central Avg.
East Avg.
CANADA
ivory paper
gray paper
654
457
835
594
843
351
497
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:
waste paper to paper mill:
finished paper (truck):
waste paper to GFB plant (ship):
perlite (ship):
no backhaul,
no backhaul,
75% backhaul
75% backhaul,
75% backhaul
Appropriate multiples of the transportation distances were used in estimates of the energy and
atmospheric emissions unit factors.
The Athena TM Project:
Gypsum Board and Associated Finishing Products
3.3
3-6
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/m 2 of gypsum board]
Water
Clay
Talc
Mica
Calcium carbonate
PVA resin
Other
34.6
1.7
3.8
3.5
52.3
4.0
0.1
0.23320
0.01146
0.02561
0.02359
0.35250
0.02696
0.00068
100.0
0.67400
Total
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 socalled “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 Athena TM Project:
Gypsum Board and Associated Finishing Products
3-7
TABLE 3.7 SETTING JOINT COMPOUNDS GENERIC FORMULATION / AVERAGE
RAW MATERIALS USE
Raw Material
[%]
[kg/m 2 of gypsum board]
Gypsum plaster
Calcium carbonate
Mica
Clay
Other
48.5
36.5
7.2
5.0
2.8
0.17072
0.12848
0.02534
0.01760
0.00986
100.0
0.35200
Total
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)
Water
Clay
Talc
Mica
Calcium carbonate
PVA resin
Gypsum plaster
West
Central
East
1200
3500
2000
500
100
1800
2000
800
2000
500
100
2000
2000
300
2000
100
100
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 Athena TM 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 Athena TM Project:
Gypsum Board and Associated Finishing Products
4.0
4-1
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)
West Avg.
Central Avg.
East Avg.
CANADA
diesel - road
coal
oil
electric
total
0.0293
0.0051
0.0293
0.0177
0.0000
0.0043
0.0000
0.0021
0.0000
0.0000
0.0057
0.0018
0.0118
0.0547
0.0145
0.0332
0.0411
0.0641
0.0495
0.0548
The Athena TM 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/M 2 OF 1/2" REGULAR GYPSUM BOARD)
West Avg.
Central Avg.
East Avg.
CANADA
diesel - road
coal
oil
electric
total
0.1898
0.0331
0.1895
0.1145
0.0000
0.0279
0.0000
0.0134
0.0000
0.0000
0.0368
0.0117
0.0765
0.3538
0.0940
0.2152
0.2662
0.4147
0.3203
0.3546
Transportation - Gypsum
The transportation energy use estimates were made by applying the following combustion energy
factors from the Research Guidelines:
Mode
Fuel
Energy Consumed
(MJ/tonne-kilometre)
Truck
Rail
Ship
Diesel - Road
Diesel - Rail
HFO - Marine
1.18
0.49
0.12
The Athena TM 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)
West Avg.
Central Avg.
East Avg.
CANADA
diesel-road
diesel-rail
HFO-marine
electricity
total
0.8851
0.2646
0.7088
0.5212
0.2175
0.0000
0.0000
0.0534
0.4152
0.0000
0.1897
0.1465
0.0000
0.0005
0.0000
0.0002
1.5179
0.2651
0.8985
0.7214
TABLE 4.4 WEIGHTED AVERAGE ENERGY USE FOR GYPSUM TRANSPORTATION
(MJ/M 2 OF 1/2" REGULAR GYPSUM BOARD)
West Avg.
Central Avg.
East Avg.
CANADA
diesel-road
diesel-rail
HFO-marine
electricity
total
5.7281
1.7124
4.5872
3.3733
1.4079
0.0000
0.0000
0.3458
2.6873
0.0000
1.2275
0.9480
0.0000
0.0030
0.0000
0.0015
9.8233
1.7154
5.8148
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 Athena TM Project:
Gypsum Board and Associated Finishing Products
4-4
TABLE 4.5 WEIGHTED AVERAGE ENERGY USE FOR PAPER TRANSPORTATION
(GJ/TONNE)
Waste Paper
West Avg.
Central Avg.
East Avg.
CANADA
Finished Paper
diesel-road
diesel-road
HFO-marine
total finished
paper
0.3894
0.3894
0.3894
0.3894
1.1040
0.5959
0.7486
0.7565
0.0000
0.0000
0.0088
0.0021
1.1040
0.5959
0.7574
0.7586
TABLE 4.6 WEIGHTED AVERAGE ENERGY USE FOR PAPER TRANSPORTATION
(MJ/M 2 OF 1/2" REGULAR GYPSUM BOARD)
Waste Paper
West Avg.
Central Avg.
East Avg.
CANADA
4.2
Finished Paper
diesel-road
diesel-road
HFO-marine
total finished
paper
0.1836
0.1836
0.1836
0.1836
0.5206
0.2810
0.3530
0.3567
0.0000
0.0000
0.0041
0.0010
0.5206
0.2810
0.3571
0.3577
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 – 4.9.
The Athena TM 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)
West Avg.
Central Avg.
East Avg.
CANADA
secondary
crushing
drying
grinding
calcination
stucco
grinding
stucco
transport
total
stucco
preparation
0.0510
0.0401
0.0277
0.0399
0.6377
0.2893
0.5030
0.4250
0.0250
0.0253
0.0201
0.0240
1.1631
0.9145
1.2102
1.0449
0.0125
0.0030
0.0062
0.0061
0.0476
0.0688
0.0464
0.0584
1.9369
1.3412
1.8137
1.5984
TABLE 4.7 WEIGHTED AVERAGE ENERGY USE IN STUCCO PREPARATION BY
PROCESS STEP (MJ/M 2 OF 1/2" REGULAR BOARD)
West Avg.
Central Avg.
East Avg.
CANADA
secondary
crushing
drying
grinding
calcination
stucco
grinding
stucco
transport
total
stucco
preparation
0.3304
0.2597
0.1793
0.2582
4.1267
1.8722
3.2553
2.7505
0.1618
0.1640
0.1302
0.1555
7.5272
5.9185
7.8319
6.7626
0.0810
0.0197
0.0404
0.0396
0.3081
0.4455
0.3005
0.3778
12.5352
8.6797
11.7375
10.3442
TABLE 4.8 WEIGHTED AVERAGE ENERGY USE IN STUCCO PREPARATION BY
ENERGY FORM (GJ/TONNE OF STUCCO)
West Avg.
Central Avg.
East Avg.
CANADA
natural gas
oil
diesel
electricity
total stucco
preparation
1.3135
0.8198
0.7690
0.9291
0.4591
0.1981
0.5191
0.3375
0.0000
0.1692
0.3775
0.1765
0.1643
0.1540
0.1481
0.1552
1.9369
1.3412
1.8137
1.5984
TABLE 4.9 WEIGHTED AVERAGE ENERGY USE IN STUCCO PREPARATION BY
ENERGY FORM (MJ/M 2 OF 1/2" REGULAR BOARD)
West Avg.
Central Avg.
East Avg.
CANADA
natural gas
oil
diesel
electricity
total stucco
preparation
8.5007
5.3055
4.9770
6.0131
2.9714
1.2821
3.3592
2.1844
0.0000
1.0951
2.4428
1.1424
1.0630
0.9970
0.9586
1.0042
12.5352
8.6797
11.7375
10.3442
The Athena TM 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)
CANADA
natural gas
oil
electric
total paper
11.6047
0.6108
2.9148
15.1302
TABLE 4.11 WEIGHTED AVERAGE ENERGY USE IN PAPER PRODUCTION BY
ENERGY FORM (MJ/M 2 OF 1/2" REGULAR BOARD)
CANADA
natural gas
oil
electric
total paper
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/M 2 OF 1/2" REGULAR BOARD)
West Avg.
Central Avg.
East Avg.
CANADA
natural gas
oil
electric
total board
manufacturing
energy
14.6351
14.4121
10.7640
13.6108
3.8536
2.5886
7.5119
4.0546
0.4096
0.3562
0.4645
0.3947
18.8984
17.3569
18.7404
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 Athena TM 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/M 2 OF 1/2" REGULAR BOARD)
West Avg.
Central Avg.
East Avg.
CANADA
paper
production
stucco
production
board
production
total energy
7.1344
7.1344
7.1344
7.1344
12.5352
8.6797
11.7375
10.3442
18.8984
17.3569
18.7404
18.0601
38.5680
33.1710
37.6124
35.5387
TABLE 4.14 TOTAL WEIGHTED AVERAGE ENERGY USE ASSOCIATED WITH
PRODUCTION OF GYPSUM BOARD BY ENERGY FORM
(MJ/M 2 OF 1/2" REGULAR BOARD)
West Avg.
Central Avg.
East Avg.
CANADA
diesel - road
natural gas
oil
electric
total energy
0.0000
1.0951
2.4428
1.1424
28.6079
25.1897
21.2130
25.0959
7.1131
4.1587
11.1590
6.5271
2.8471
2.7276
2.7975
2.7733
38.5680
33.1710
37.6124
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 Athena TM 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
Calgary
Winnipeg
Toronto
Montreal
Halifax
90
225
90
153
288
279
0
300
400
0
0
847.5
0
0
0
0
0
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 Athena TM Project:
Gypsum Board and Associated Finishing Products
4-9
TABLE 4.16 WEIGHTED AVERAGE TRANSPORTATION ENERGY FOR FINISHED
GYPSUM BOARD (GJ/ TONNE)
Vancouver
Calgary
Winnipeg
Toronto
Montreal
Halifax
Truck
Rail
Ship
diesel-road
diesel-rail
HFO-marine
0.1062
0.2655
0.1062
0.1805
0.3398
0.3292
0.0000
0.1470
0.1960
0.0000
0.0000
0.4153
0.0000
0.0000
0.0000
0.0000
0.0000
0.0132
Total
0.1062
0.4125
0.3022
0.1805
0.3398
0.7577
TABLE 4.17 WEIGHTED AVERAGE TRANSPORTATION ENERGY FOR FINISHED
GYPSUM BOARD (MJ/ M 2 OF 1/2" REGULAR BOARD)
Vancouver
Calgary
Winnipeg
Toronto
Montreal
Halifax
Truck
Rail
Ship
diesel-road
diesel-rail
HFO-marine
0.8563
2.1408
0.8563
1.4557
2.7402
2.6546
0.0000
1.1853
1.5804
0.0000
0.0000
3.3485
0.0000
0.0000
0.0000
0.0000
0.0000
0.1064
Total
0.8563
3.3261
2.4367
1.4557
2.7402
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 Athena TM 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
Extraction
Vancouver
Calgary
Winnipeg
Toronto
Montreal
Halifax
Total RM
Total
Board
Transportation Manufacturing Transportation
0.53
0.51
1.09
1.11
0.68
0.64
20.96
19.98
5.71
5.86
13.51
12.61
76.80
73.20
86.83
89.12
79.98
74.63
1.71
6.31
6.38
3.91
5.83
12.12
TOTAL
100.00
100.00
100.00
100.00
100.00
100.00
TABLE 4.19 PER CENT OF ENERGY USE IN MANUFACTURING STAGES OF GYPSUM
BOARD PRODUCTION [1/2" BOARD] BY PROCESS STAGE (%)
West Region
Central Region
East Region
Paper
Manufacturing
Stucco
Manufacturing
Board
Manufacturing
Total
Manufacturing
18.50
21.51
18.97
32.50
26.17
31.21
49.00
52.33
49.83
100.00
100.00
100.00
The Athena TM Project:
Gypsum Board and Associated Finishing Products
4-11
Extraction
RM Transport
Manufacturing
% of total energy use
100
Board Transport
80
60
40
20
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 (%)
% of total manufacturing energy
60
50
40
West
Central
East
30
20
10
0
Paper
Stucco
Manufacturing
Board
of
Fig 4.2Breakdown of Energy Use in Manufacturing Stages of Gypsum Board Production
[1/2" Board] by Process Stage (%)
The Athena TM Project:
Gypsum Board and Associated Finishing Products
4.5
4-12
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
diesel
electric
Perlite extraction
total
gypsum
diesel
[GJ/tonne of stucco]
0.0305
0.0117
0.0834
0.0423
0.3008
total
perlite
diesel
electric
TOTAL
RMs
[GJ/tonne of perlite]
0.0270
[MJ/m2 of board]
0.2175
electric
Total extraction
0.0108
0.0378
[MJ/m2 of board]
0.0359
0.0144
0.0503
[MJ/m2 of board]
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 Athena TM Project:
Gypsum Board and Associated Finishing Products
4-13
TABLE 4.21 WEIGHTED AVERAGE ENERGY USE FOR 1/2" GFB RAW MATERIALS
TRANSPORTATION
Gypsum
dieselrail
Waste Paper
dieselroad
Perlite
Other
RMs
RMs Transport
HFOmarine
waste
paper
total
HFOmarine
diesel
road
0.1650
0.5544
1.4250
0.4720
0.2509
0.8431
1.8961
0.1306
diesel
road
dieselrail
HFOmarine
TOTAL
0.7227
0.2828
2.1471
3.1526
[GJ/tonne [GJ/tonne]
of stucco]
0.0413
0.3894
[MJ/m2 of board]
0.2828
0.5922
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
[MJ/m2 of board]
natural gas
oil
diesel-road
electricity
TOTAL
33.7609
3.6956
2.6875
6.9504
47.0943
The Athena TM 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
calcination
Paper
defiberization
Perlite
expansion
[GJ/tonne of
stucco]
[GJ/tonne of paper]
[GJ/tonne of perlite]
1.8137
2.9148
8.1337
4.4325
10.8229
Board
manufacturing
TOTAL
manufacturing
18.9259
47.0943
[MJ/m2 of board]
12.9129
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
Vancouver
Calgary
Winnipeg
Toronto
Montreal
Halifax
[km]
[mode]
5840
4878
3538
1816
1276
360
rail
rail
rail
rail
rail
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 Athena TM 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
Calgary
Winnipeg
Toronto
Montreal
Halifax
0.4248
2.8616
2.3902
1.7336
0.8898
0.6252
[GJ/m2 of board]
Vancouver
Calgary
Winnipeg
Toronto
Montreal
Halifax
4.7538
32.0235
26.7484
19.4005
9.9580
6.9969
-
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.
2.
3.
4.
5.
6.
Communication from R.S. Daly, Ontario Hydro, dated February 27, 1996.
Canadian Industry Program for Energy Conservation (CIPEC), Ministry of Energy, Mines and
Resources Canada, 1989.
“Gypsum Board Systems: Technical Report”, Topic I-9250, AIA Environmental Resource
Guide, July 1993.
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.
Oral communication from B. Colbert, W.R. Grace Construction Products Division, August 9,
1996
“Gypsum Fiberboard (GFB): Technical Assessment Report”, Venta, Glaser & Associates,
confidential client report, October 1991/July 1994.
The Athena TM Project:
Gypsum Board and Associated Finishing Products
TABLE 4.25
West
Central
East
4- 16
ENERGY USE IN 1/2" REGULAR GYPSUM BOARD BY PROCESS STAGE AND REGION [MJ/M 2 ]
Vancouver
Calgary
Winnipeg
Toronto
Montreal
Halifax
Gypsum
Extract.
RMs
Transport
Manufacturing
Paper
Stucco
Board
Total
Manufact.
0.2662
Total
to Gate
Board
Transport
Total
to Market
10.5276
7.1344
12.5352
18.8984
38.5680
49.3618
17.3569
33.1710
35.7657
18.7404
37.6124
44.2882
0.8563
3.3261
2.4367
1.4557
2.7402
6.1095
50.2181
52.6878
38.2024
37.2214
47.0284
50.3977
0.4147
2.1800
7.1344
8.6797
0.3203
6.3555
7.1344
11.7375
TABLE 4.26A CRADLE TO GATE ENERGY USE IN 1/2" REGULAR GYPSUM BOARD BY ENERGY FORM AND REGION [MJ/M2 ]
West
Central
East
Diesel-road
Diesel-rail
HFOmarine
Natural gas
Coal
Oil
Electricity
Total
To Gate
6.6221
3.3051
7.7562
1.4079
0.0000
0.0000
2.6873
0.0000
1.2317
28.6079
25.1897
21.2130
0.0000
0.0279
0.0000
7.1131
4.1587
11.1958
2.9235
3.0843
2.8916
49.3618
35.7657
44.2882
TABLE 4.26B CRADLE TO MARKET ENERGY USE IN 1/2" REGULAR GYPSUM BOARD BY ENERGY FORM AND REGION [MJ/M2 ]
West
Central
East
Vancouver
Calgary
Winnipeg
Toronto
Montreal
Halifax
Diesel-road
Diesel-rail
HFOmarine
Natural gas
Coal
Oil
Electricity
Total
To Market
7.4784
8.7629
4.1615
4.7609
10.4964
10.4107
1.4079
2.5932
1.5804
0.0000
0.0000
3.3485
2.6873
2.6873
0.0000
0.0000
1.2317
1.3381
28.6079
28.6079
25.1897
25.1897
21.2130
21.2130
0.0000
0.0000
0.0279
0.0279
0.0000
0.0000
7.1131
7.1131
4.1587
4.1587
11.1958
11.1958
2.9235
2.9235
3.0843
3.0843
2.8916
2.8916
50.2181
52.6878
38.2024
37.2214
47.0284
50.3977
The Athena TM Project:
Gypsum Board and Associated Finishing Products
TABLE 4.27
West
Central
East
4- 17
ENERGY USE IN 1/2" TYPE X GYPSUM BOARD BY PROCESS STAGE AND REGION [MJ/M 2 ]
Vancouver
Calgary
Winnipeg
Toronto
Montreal
Halifax
Gypsum
Extract.
RMs
Transport
Manufacturing
Paper
Stucco
Board
Total
Manufact.
0.2719
Total
to Gate
Board
Transport
Total
to Market
10.7048
6.8197
12.8010
18.8984
38.5191
49.4958
17.3569
33.0404
35.6597
18.7404
37.5466
44.3287
0.8693
3.3765
2.4736
1.4778
2.7817
6.2020
50.3651
52.8723
38.1334
37.1375
47.1104
50.5308
0.4235
2.1959
6.8197
8.8638
0.3271
6.4550
6.8197
11.9864
TABLE 4.28A CRADLE TO GATE ENERGY USE IN 1/2" TYPE X GYPSUM BOARD BY ENERGY FORM AND REGION [MJ/M 2 ]
West
Central
East
Diesel-road
Diesel-rail
HFOmarine
Natural gas
Coal
Oil
Electricity
Total
to Gate
6.7165
3.3449
7.8856
1.4378
0.0000
0.0000
2.7443
0.0000
1.2575
28.5468
25.0608
21.0772
0.0000
0.0284
0.0000
7.1634
4.1732
11.2551
2.8871
3.0524
2.8533
49.4958
35.6597
44.3287
TABLE 4.28B CRADLE TO MARKET ENERGY USE IN 1/2" TYPE X GYPSUM BOARD BY ENERGY FORM AND REGION [MJ/M 2 ]
West
Central
East
Vancouver
Calgary
Winnipeg
Toronto
Montreal
Halifax
Diesel-road
Diesel-rail
HFOmarine
Natural gas
Coal
Oil
Electricity
Total
to Market
7.5858
8.8897
4.2142
4.8227
10.6673
10.5804
1.4378
2.6410
1.6043
0.0000
0.0000
3.3992
2.7443
2.7443
0.0000
0.0000
1.2575
1.3656
28.5468
28.5468
25.0608
25.0608
21.0772
21.0772
0.0000
0.0000
0.0284
0.0284
0.0000
0.0000
7.1634
7.1634
4.1732
4.1732
11.2551
11.2551
2.8871
2.8871
3.0524
3.0524
2.8533
2.8533
50.3651
52.8723
38.1334
37.1375
47.1104
50.5308
The Athena TM Project:
Gypsum Board and Associated Finishing Products
TABLE 4.29
West
Central
East
4- 18
ENERGY USE IN 1/2" MR GYPSUM BOARD BY PROCESS STAGE AND REGION [MJ/M 2 ]
Vancouver
Calgary
Winnipeg
Toronto
Montreal
Halifax
Gypsum
Extract.
RMs
Transport
Manufacturing
Paper
Stucco
Board
Total
Manufact.
0.3021
Total
to Gate
Board
Transport
Total
to Market
11.8696
7.3344
14.2226
18.8984
40.4553
52.6270
17.3569
34.5393
37.4338
18.7404
39.3923
46.9092
0.9601
3.7292
2.7321
1.6322
3.0724
6.8500
53.5871
56.3563
40.1658
39.0660
49.9816
53.7592
0.4705
2.4239
7.3344
9.8481
0.3635
7.1534
7.3344
13.3175
TABLE 4.30A CRADLE TO GATE ENERGY USE IN 1/2" MR GYPSUM BOARD BY ENERGY FORM AND REGION [MJ/M2 ]
West
Central
East
Diesel-road
Diesel-rail
HFOmarine
Natural gas
Coal
Oil
Electricity
Total
to Gate
7.4384
3.7005
8.7430
1.5974
0.0000
0.0000
3.0491
0.0000
1.3970
29.9055
26.0572
22.0363
0.0000
0.0316
0.0000
7.5211
4.3393
11.6610
3.1155
3.3051
3.0718
52.6270
37.4338
46.9092
TABLE 4.30B CRADLE TO MARKET ENERGY USE IN 1/2" MR GYPSUM BOARD BY ENERGY FORM AND REGION [MJ/M2 ]
West
Central
East
Vancouver
Calgary
Winnipeg
Toronto
Montreal
Halifax
Diesel-road
Diesel-rail
HFOmarine
Natural gas
Coal
Oil
Electricity
Total
to Market
8.3985
9.8387
4.6606
5.3327
11.8154
11.7194
1.5974
2.9264
1.7720
0.0000
0.0000
3.7543
3.0491
3.0491
0.0000
0.0000
1.3970
1.5164
29.9055
29.9055
26.0572
26.0572
22.0363
22.0363
0.0000
0.0000
0.0316
0.0316
0.0000
0.0000
7.5211
7.5211
4.3393
4.3393
11.6610
11.6610
3.1155
3.1155
3.3051
3.3051
3.0718
3.0718
53.5871
56.3563
40.1658
39.0660
49.9816
53.7592
The Athena TM Project:
Gypsum Board and Associated Finishing Products
TABLE 4.31
West
Central
East
4- 19
ENERGY USE IN 5/8" REGULAR GYPSUM BOARD BY PROCESS STAGE AND REGION [MJ/M 2 ]
Vancouver
Calgary
Winnipeg
Toronto
Montreal
Halifax
Gypsum
Extract.
RMs
Transport
Manufacturing
Paper
Stucco
Board
Total to
Manufact.
0.3478
Total
to Gate
Board
Transport
Total
to Market
13.5467
7.2223
16.3767
23.6229
47.2220
61.1164
21.6961
40.2580
43.5112
23.4256
45.9824
54.5451
1.0924
4.2433
3.1086
1.8572
3.4958
7.7942
62.2089
65.3597
46.6199
45.3684
58.0409
62.3393
0.5418
2.7114
7.2223
11.3397
0.4185
8.1442
7.2223
15.3346
TABLE 4.32A CRADLE TO GATE ENERGY USE IN 5/8" REGULAR GYPSUM BOARD BY ENERGY FORM AND REGION [MJ/M2 ]
West
Central
East
Vancouver
Winnipeg
Halifax
Diesel-road
Diesel-rail
HFOmarine
Natural gas
Coal
Oil
Electricity
Total
to Gate
8.4443
4.1814
9.9753
1.8394
0.0000
0.0000
3.5109
0.0000
1.6079
34.9391
30.4860
25.4966
0.0000
0.0364
0.0000
8.9906
5.2023
14.1181
3.3921
3.6051
3.3472
61.1164
43.5112
54.5451
TABLE 4.32B CRADLE TO MARKET ENERGY USE IN 5/8" REGULAR GYPSUM BOARD BY ENERGY FORM AND REGION [MJ/M2 ]
West
Central
East
Vancouver
Calgary
Winnipeg
Toronto
Montreal
Halifax
Diesel-road
Diesel-rail
HFOmarine
Natural gas
Coal
Oil
Electricity
Total
to Market
9.5368
11.1754
5.2738
6.0385
13.4711
13.3619
1.8394
3.3515
2.0162
0.0000
0.0000
4.2718
3.5109
3.5109
0.0000
0.0000
1.6079
1.7437
34.9391
34.9391
30.4860
30.4860
25.4966
25.4966
0.0000
0.0000
0.0364
0.0364
0.0000
0.0000
8.9906
8.9906
5.2023
5.2023
14.1181
14.1181
3.3921
3.3921
3.6051
3.6051
3.3472
3.3472
62.2089
65.3597
46.6199
45.3684
58.0409
62.3393
The Athena TM Project:
Gypsum Board and Associated Finishing Products
TABLE 4.33
West
Central
East
4- 20
ENERGY USE IN 5/8" TYPE X GYPSUM BOARD BY PROCESS STAGE AND REGION [MJ/M 2 ]
Vancouver
Calgary
Winnipeg
Toronto
Montreal
Halifax
Gypsum
Extract.
RMs
Transport
Manufacturing
Paper
Stucco
Board
Total
manufact.
0.3528
Total
to Gate
Board
Transport
Total
to Market
13.7119
7.0339
16.6113
23.6229
47.2682
61.3329
21.6961
40.2321
43.5129
23.4256
46.0137
54.6769
1.1158
4.3340
3.1751
1.8969
3.5706
7.9608
62.4487
65.6669
46.6880
45.4098
58.2475
62.6377
0.5496
2.7312
7.0339
11.5021
0.4245
8.2387
7.0339
15.5542
TABLE 4.34A CRADLE TO GATE ENERGY USE IN 5/8" TYPE X GYPSUM BOARD BY ENERGY FORM AND REGION [MJ/M 2 ]
West
Central
East
Diesel-road
Diesel-rail
HFOmarine
Natural gas
Coal
Oil
Electricity
Total
to Gate
8.5365
4.2223
10.0962
1.8657
0.0000
0.0000
3.5611
0.0000
1.6308
34.9538
30.4409
25.4453
0.0000
0.0369
0.0000
9.0386
5.2187
14.1740
3.3771
3.5942
3.3306
61.3329
43.5129
54.6769
TABLE 4.34B CRADLE TO MARKET ENERGY USE IN 5/8" TYPE X GYPSUM BOARD BY ENERGY FORM AND REGION [MJ/M 2 ]
West
Central
East
Vancouver
Calgary
Winnipeg
Toronto
Montreal
Halifax
Diesel-road
Diesel-rail
HFOmarine
Natural gas
Coal
Oil
Electricity
Total
to Market
9.6523
11.3260
5.3381
6.1191
13.6668
13.5552
1.8657
3.4102
2.0593
0.0000
0.0000
4.3631
3.5611
3.5611
0.0000
0.0000
1.6308
1.7695
34.9538
34.9538
30.4409
30.4409
25.4453
25.4453
0.0000
0.0000
0.0369
0.0369
0.0000
0.0000
9.0386
9.0386
5.2187
5.2187
14.1740
14.1740
3.3771
3.3771
3.5942
3.5942
3.3306
3.3306
62.4487
65.6669
46.6880
45.4098
58.2475
62.6377
The Athena TM Project:
Gypsum Board and Associated Finishing Products
TABLE 4.35
West
Central
East
4- 21
ENERGY USE IN 5/8" MR GYPSUM BOARD BY PROCESS STAGE AND REGION [MJ/M 2 ]
Vancouver
Calgary
Winnipeg
Toronto
Montreal
Halifax
Gypsum
Extrac.
RMs
Transport
Manufacturing
Paper
Stucco
Board
Total
Manufact.
0.3873
Total
to Gate
Board
Transport
Total
to Market
15.0480
7.6713
18.2360
23.6229
49.5303
64.9656
21.6961
41.9945
45.5928
23.4256
48.1724
57.6791
1.2196
4.7371
3.4705
2.0733
3.9027
8.7014
66.1852
69.7027
49.0633
47.6662
61.5818
66.3804
0.6033
2.9951
7.6713
12.6271
0.4660
9.0407
7.6713
17.0756
TABLE 4.36A CRADLE TO GATE ENERGY USE IN 5/8" MR GYPSUM BOARD BY ENERGY FORM AND REGION [MJ/M2 ]
West
Central
East
Diesel-road
Diesel-rail
HFOmarine
Natural gas
Coal
Oil
Electricity
Total
to Gate
9.3664
4.6319
11.0799
2.0482
0.0000
0.0000
3.9095
0.0000
1.7902
36.5444
31.6174
26.5792
0.0000
0.0405
0.0000
9.4495
5.4106
14.6399
3.6476
3.8924
3.5898
64.9656
45.5928
57.6791
TABLE 4.36B CRADLE TO MARKET ENERGY USE IN 5/8" MR GYPSUM BOARD BY ENERGY FORM AND REGION [MJ/M2 ]
West
Central
East
Vancouver
Calgary
Winnipeg
Toronto
Montreal
Halifax
Diesel-road
Diesel-rail
HFOmarine
Natural gas
Coal
Oil
Electricity
Total
to Market
10.5860
12.4154
5.8515
6.7052
14.9826
14.8606
2.0482
3.7364
2.2509
0.0000
0.0000
4.7690
3.9095
3.9095
0.0000
0.0000
1.7902
1.9418
36.5444
36.5444
31.6174
31.6174
26.5792
26.5792
0.0000
0.0000
0.0405
0.0405
0.0000
0.0000
9.4495
9.4495
5.4106
5.4106
14.6399
14.6399
3.6476
3.6476
3.8924
3.8924
3.5898
3.5898
66.1852
69.7027
49.0633
47.6662
61.5818
66.3804
The Athena TM Project:
Gypsum Board and Associated Finishing Products
TABLE 4.37
West
Central
East
4- 22
ENERGY USE IN 5/16" MOBILE HOME GYPSUM BOARD BY PROCESS STAGE AND REGION [MJ/M 2 ]
Vancouver
Calgary
Winnipeg
Toronto
Montreal
Halifax
Gypsum
Extract.
RMs
Transport
Manufacturing
Paper
Stucco
Board
Total
Manufact.
0.1881
Total
to Gate
Board
Transport
Total
to Market
7.6688
7.3938
8.8546
11.8115
28.0599
35.9168
10.8480
24.3730
26.3592
11.7128
27.3977
32.2919
0.6228
2.4190
1.7721
1.0587
1.9929
4.4432
36.5396
38.3358
28.1313
27.4179
34.2847
36.7351
0.2929
1.6932
7.3938
6.1312
0.2263
4.6678
7.3938
8.2911
TABLE 4.38A CRADLE TO GATE ENERGY USE IN 5/16" MOBILE HOME GYPSUM BOARD BY ENERGY FORM AND REGION [MJ/M 2 ]
West
Central
East
Vancouver
Winnipeg
Halifax
Diesel-road
Diesel-rail
HFOmarine
Natural gas
Coal
Oil
Electricity
Total
to Gate
4.9101
2.4880
5.6559
0.9945
0.0000
0.0000
1.8983
0.0000
0.8714
20.8227
18.4263
15.9141
0.0000
0.0197
0.0000
4.8059
2.8220
7.3922
2.4853
2.6032
2.4583
35.9168
26.3592
32.2919
TABLE 4.38B CRADLE TO MARKET ENERGY USE IN 5/16" MOBILE HOME BOARD BY ENERGY FORM AND REGION [MJ/M2 ]
West
Central
East
Vancouver
Calgary
Winnipeg
Toronto
Montreal
Halifax
Diesel-road
Diesel-rail
HFOmarine
Natural gas
Coal
Oil
Electricity
Total
to Market
5.5328
6.4670
3.1108
3.5467
7.6487
7.5865
0.9945
1.8566
1.1494
0.0000
0.0000
2.4352
1.8983
1.8983
0.0000
0.0000
0.8714
0.9488
20.8227
20.8227
18.4263
18.4263
15.9141
15.9141
0.0000
0.0000
0.0197
0.0197
0.0000
0.0000
4.8059
4.8059
2.8220
2.8220
7.3922
7.3922
2.4853
2.4853
2.6032
2.6032
2.4583
2.4583
36.5396
38.3358
28.1313
27.4179
34.2847
36.7351
The Athena TM Project:
Gypsum Board and Associated Finishing Products
TABLE 4.39
West
Central
East
4- 23
ENERGY USE IN 1" SHAFTLINER BOARD BY PROCESS STAGE AND REGION [MJ/M 2 ]
Vancouver
Calgary
Winnipeg
Toronto
Montreal
Halifax
Gypsum
Extract.
RMs
Transport
Manufacturing
Paper
Stucco
Board
Total
Manufact.
0.6532
Total
to Gate
Board
Transport
Total
to Market
24.8321
7.3938
30.7560
37.7967
75.9466
101.4319
34.7137
63.4038
69.1116
37.4809
73.6736
89.2869
2.0240
7.8616
5.7595
3.4408
6.4768
14.4405
103.4559
109.2935
74.8711
72.5524
95.7637
103.7274
1.0175
4.6903
7.3938
21.2962
0.7860
14.8273
7.3938
28.7989
TABLE 4.40A CRADLE TO GATE ENERGY USE IN 1" SHAFTLINER BOARD BY ENERGY FORM AND REGION [MJ/M 2 ]
West
Central
East
Diesel-road
Diesel-rail
HFOmarine
Natural gas
Coal
Oil
Electricity
Total
to Gate
15.2497
7.4509
18.2698
3.4544
0.0000
0.0000
6.5935
0.0000
3.0161
55.7984
47.5128
39.4103
0.0000
0.0683
0.0000
15.2963
8.6214
23.6545
5.0395
5.4582
4.9361
101.4319
69.1116
89.2869
TABLE 4.40B CRADLE TO MARKET ENERGY USE IN 1" SHAFTLINER BOARD BY ENERGY FORM AND REGION [MJ/M 2 ]
West
Central
East
Vancouver
Calgary
Winnipeg
Toronto
Montreal
Halifax
Diesel-road
Diesel-rail
HFOmarine
Natural gas
Coal
Oil
Electricity
Total
to Market
17.2737
20.3098
9.4750
10.8918
24.7467
24.5443
3.4544
6.2560
3.7355
0.0000
0.0000
7.9145
6.5935
6.5935
0.0000
0.0000
3.0161
3.2677
55.7984
55.7984
47.5128
47.5128
39.4103
39.4103
0.0000
0.0000
0.0683
0.0683
0.0000
0.0000
15.2963
15.2963
8.6214
8.6214
23.6545
23.6545
5.0395
5.0395
5.4582
5.4582
4.9361
4.9361
103.4559
109.2935
74.8711
72.5524
95.7637
103.7274
The Athena TM Project:
Gypsum Board and Associated Finishing Products
TABLE 4.41
West
Central
East
4- 24
ENERGY USE IN 1/2" GFB BY PROCESS STAGE AND REGION [MJ/M2 ]
RMs
Extract.
RMs
Transport
0.3511
0.3511
0.3511
0.3511
0.3511
0.3511
3.1526
3.1526
3.1526
3.1526
3.1526
3.1526
Vancouver
Calgary
Winnipeg
Toronto
Montreal
Halifax
Manufacturing
Paper
Perlite
Stucco
Board
Total
Manufact
4.4325
4.4325
4.4325
4.4325
4.4325
4.4325
12.9129
12.9129
12.9129
12.9129
12.9129
12.9129
18.9259
18.9259
18.9259
18.9259
18.9259
18.9259
47.0943
47.0943
47.0943
47.0943
47.0943
47.0943
10.8229
10.8229
10.8229
10.8229
10.8229
10.8229
Total
to Gate
Board
Transport
Total
to
Market
50.5980
50.5980
50.5980
50.5980
50.5980
50.5980
32.0235
26.7484
19.4005
9.9580
6.9969
4.7538
82.6215
77.3464
69.9985
60.5560
57.5949
55.3518
TABLE 4.42A CRADLE TO GATE ENERGY USE IN 1/2" GFB BY ENERGY FORM AND REGION [MJ/M2 ]
West
Central
East
Diesel-road
Diesel-rail
HFOmarine
Natural
Gas
Oil
Electricity
Total
to Gate
3.6636
3.6636
3.6636
0.2828
0.2828
0.2828
2.1471
2.1471
2.1471
33.7609
33.7609
33.7609
3.6956
3.6956
3.6956
7.0482
7.0482
7.0482
50.5980
50.5980
50.5980
TABLE 4.42B CRADLE TO MARKET ENERGY USE IN 1/2" GFB BY ENERGY FORM AND REGION [MJ/M2 ]
West
Central
East
Vancouver
Calgary
Winnipeg
Toronto
Montreal
Halifax
Diesel-road
Diesel-rail
HFOmarine
Natural
Gas
Oil
Electricity
Total
to Market
3.6636
3.6636
3.6636
3.6636
3.6636
8.4174
32.3063
27.0312
19.6833
10.2408
7.2797
0.2828
2.1471
2.1471
2.1471
2.1471
2.1471
2.1471
33.7609
33.7609
33.7609
33.7609
33.7609
33.7609
3.6956
3.6956
3.6956
3.6956
3.6956
3.6956
7.0482
7.0482
7.0482
7.0482
7.0482
7.0482
82.6215
77.3464
69.9985
60.5560
57.5949
55.3518
The Athena TM Project:
Gypsum Board and Associated Finishing Products
TABLE 4.43
West
Central
East
4- 25
ENERGY USE IN 5/8" GFB BY PROCESS STAGE AND REGION [MJ/M2 ]
Vancouver
Calgary
Winnipeg
Toronto
Montreal
Halifax
Manufacturing
RMs
Extract.
RMs
Transport
Paper
Perlite
Stucco
Board
Total
Manufact
0.4357
0.4357
0.4357
0.4357
0.4357
0.4357
3.9117
3.9117
3.9117
3.9117
3.9117
3.9117
5.4999
5.4999
5.4999
5.4999
5.4999
5.4999
13.4291
13.4291
13.4291
13.4291
13.4291
13.4291
16.0224
16.0224
16.0224
16.0224
16.0224
16.0224
23.6574
23.6574
23.6574
23.6574
23.6574
23.6574
58.6088
58.6088
58.6088
58.6088
58.6088
58.6088
Total
to Gate
Board
Transport
Total
to
Market
62.9562
62.9562
62.9562
62.9562
62.9562
62.9562
39.9944
33.4063
24.2295
12.4366
8.7385
5.9371
102.9506
96.3625
87.1857
75.3928
71.6947
68.8933
TABLE 4.44A CRADLE TO GATE ENERGY USE IN 5/8" GFB BY ENERGY FORM AND REGION [MJ/M2 ]
West
Central
East
Vancouver
Winnipeg
Halifax
Diesel-road
Diesel-rail
HFOmarine
Natural
Gas
Oil
Electricity
Total
to Gate
4.5458
4.5458
4.5458
0.3509
0.3509
0.3509
2.6641
2.6641
2.6641
42.0512
42.0512
42.0512
4.5854
4.5854
4.5854
8.7588
8.7588
8.7588
62.9562
62.9562
62.9562
TABLE 4.44B CRADLE TO MARKET ENERGY USE IN 5/8" GFB BY ENERGY FORM AND REGION [MJ/M2 ]
West
Central
East
Vancouver
Calgary
Winnipeg
Toronto
Montreal
Halifax
Diesel-road
Diesel-rail
HFOmarine
Natural
Gas
Oil
Electricity
Total
to Market
4.5458
4.5458
4.5458
4.5458
4.5458
10.4829
40.3453
33.7572
24.5804
12.7875
9.0894
0.3509
2.6641
2.6641
2.6641
2.6641
2.6641
2.6641
42.0512
42.0512
42.0512
42.0512
42.0512
42.0512
4.5854
4.5854
4.5854
4.5854
4.5854
4.5854
8.7588
8.7588
8.7588
8.7588
8.7588
8.7588
102.9506
96.3625
87.1857
75.3928
71.6947
68.8933
The Athena TM Project:
Gypsum Board and Associated Finishing Products
5.0
5-1
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
Water
Calcium carbonate
Gypsum plaster
Mica
Talc
Clay
PVA resin
Other
Total
Setting (Dry) Compound
[MJ/kg of
compound]
[MJ/m2 of board]
[MJ/kg of
compound]
[MJ/m2 of board]
0.00000
0.01412
0.00095
0.00103
0.00046
0.00000
0.00003
0.00000
0.00952
0.00064
0.00069
0.00031
0.00000
0.00002
0.00986
0.01578
0.00194
0.00135
0.00076
0.00347
0.00555
0.00068
0.00048
0.00027
0.01658
0.01117
0.02968
0.01045
The Athena TM 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)
Water
Clay
Talc
Mica
Calcium carbonate
PVA resin
Other
Total
note:
West Region
Central Region
East Region
0.00000
0.02285
0.14896
0.07840
0.58576
0.00896
0.00280
0.00000
0.03808
0.03405
0.07840
0.58576
0.00896
0.00280
0.00000
0.03808
0.01277
0.07840
0.11715
0.00896
0.00280
0.84773
0.74805
0.25816
all energy in form of diesel (road)
TABLE 5.3 AVERAGE ENERGY USE FOR READY MIX JOINT COMPOUNDS RAW
MATERIALS TRANSPORTATION (MJ/M 2 OF BOARD)
Water
Clay
Talc
Mica
Calcium carbonate
PVA resin
Other
Total
note:
all energy in form of diesel (road)
West Region
Central Region
East Region
0.00000
0.01540
0.10040
0.05284
0.39480
0.00604
0.00189
0.00000
0.02567
0.02295
0.05284
0.39480
0.00604
0.00189
0.00000
0.02567
0.00861
0.05284
0.07896
0.00604
0.00189
0.57137
0.50418
0.17400
The Athena TM 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
Gypsum plaster
Calcium carbonate
Mica
Clay
Other
Total
Central
total
(diesel road)
total
1.95552
0.40880
0.16128
0.06720
0.07840
2.67120
East
total
diesel road
diesel rail
1.56170
0.40880
0.16128
0.11200
0.07840
1.08640
0.40880
0.16128
0.11200
0.07840
0.47530
0.00000
0.00000
0.00000
0.00000
2.32218
1.84688
0.47530
diesel road
diesel rail
1.56170
0.08176
0.16128
0.11200
0.07840
1.08640
0.08176
0.16128
0.11200
0.07840
0.47530
0.00000
0.00000
0.00000
0.00000
1.99514
1.51984
0.47530
TABLE 5.5 AVERAGE ENERGY USE FOR SETTING JOINT COMPOUNDS RAW
MATERIALS TRANSPORTATION (MJ/M 2 OF BOARD)
West
Gypsum plaster
Calcium carbonate
Mica
Clay
Other
Total
Central
total
(diesel road)
total
0.68834
0.14390
0.05677
0.02365
0.02760
0.94026
East
total
diesel road
diesel rail
0.54972
0.14390
0.05677
0.03942
0.02760
0.38241
0.14390
0.05677
0.03942
0.02760
0.16731
0.00000
0.00000
0.00000
0.00000
0.81741
0.65010
0.16731
diesel road
diesel rail
0.54972
0.02878
0.05677
0.03942
0.02760
0.38241
0.02878
0.05677
0.03942
0.02760
0.16731
0.00000
0.00000
0.00000
0.00000
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 Athena TM 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)
Finished Paper for Joint Tape
Waste Paper
West Avg.
Central Avg.
East Avg.
diesel-road
diesel-road
HFO-marine
total finished
paper
0.3894
0.3894
0.3894
0.9652
0.6735
0.8501
0.0000
0.0000
0.0087
0.9652
0.6735
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
West Avg.
Central Avg.
East Avg.
Finished Paper for Joint Tape
diesel-road
diesel-road
HFO-marine
total finished
paper
0.00477
0.00477
0.00477
0.01183
0.00826
0.01042
0.00000
0.00000
0.00011
0.01183
0.00826
0.01053
TABLE 5.8 AVERAGE ENERGY USE FOR JOINT PAPER TAPE RAW MATERIALS
TRANSPORTATION (MJ/M 2 OF BOARD)
Waste Paper
West Avg.
Central Avg.
East Avg.
Finished Paper for Joint Tape
diesel-road
diesel-road
HFO-marine
total finished
paper
0.00468
0.00468
0.00468
0.01160
0.00809
0.01022
0.00000
0.00000
0.00010
0.01160
0.00809
0.01032
The Athena TM Project:
Gypsum Board and Associated Finishing Products
5.2
5-5
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)
Water
Clay
Talc
Mica
Calcium carbonate
PVA resin
Other
Processing
TOTAL
secondary
crushing
drying
grinding
total
minerals
processing
resin
production
processing
total
0.00056
0.00126
0.00116
0.01732
0.00003
-
0.00600
0.01340
0.01235
0.18449
0.00035
-
0.00034
0.00076
0.00070
0.01043
0.00002
-
0.00690
0.01542
0.01420
0.21224
0.00041
-
0.01855
-
0.05400
0.00690
0.01542
0.01420
0.21224
0.01855
0.00041
0.05400
0.02033
0.21659
0.01225
0.24917
0.01855
0.05400
0.32172
The Athena TM 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/M 2 OF GYPSUM BOARD)
Water
Clay
Talc
Mica
Calcium carbonate
PVA resin
Other
Processing
TOTAL
secondary
crushing
drying
grinding
total
minerals
processing
resin
production
processing
total
0.00038
0.00085
0.00078
0.01167
0.00002
-
0.00404
0.00903
0.00832
0.12435
0.00024
-
0.00023
0.00051
0.00047
0.00703
0.00001
-
0.00465
0.01039
0.00957
0.14305
0.00027
-
0.01250
-
0.03640
0.00465
0.01039
0.00957
0.14305
0.01250
0.00027
0.03640
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)
Water
Clay
Talc
Mica
Calcium carbonate
PVA resin
Other
Total raw mat.
Processing
TOTAL
natural gas
oil
diesel road
electric
total
0.00340
0.00760
0.00700
0.10465
0.00371
0.00020
0.12657
-
0.00004
0.00008
0.00007
0.00108
0.00000
0.00127
-
0.00249
0.00557
0.00513
0.07663
0.00015
0.08996
-
0.00097
0.00217
0.00200
0.02988
0.01484
0.00006
0.04992
0.05400
0.00690
0.01542
0.01420
0.21224
0.01855
0.00041
0.26772
0.05400
0.12657
0.00127
0.08996
0.10392
0.32172
The Athena TM 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/M 2 OF GYPSUM BOARD)
Water
Clay
Talc
Mica
Calcium carbonate
PVA resin
Other
Total raw mat.
Processing
TOTAL
natural gas
oil
diesel road
electric
total
0.00229
0.00512
0.00472
0.07054
0.00250
0.00013
0.08531
-
0.00002
0.00005
0.00005
0.00073
0.00000
0.00086
-
0.00168
0.00375
0.00346
0.05165
0.00010
0.06063
-
0.00065
0.00146
0.00135
0.02014
0.01000
0.00004
0.03364
0.03640
0.00465
0.01039
0.00957
0.14305
0.01250
0.00027
0.18044
0.03640
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)
Gypsum plaster
Calcium carbonate
Mica
Clay
Other
Compounding
TOTAL
secondary
crushing
drying
grinding
calcination
stucco
grinding
processing
total
0.01935
0.01209
0.00238
0.00166
0.00093
-
0.20612
0.12876
0.02540
0.01764
0.00988
-
0.01166
0.00728
0.00144
0.00100
0.00056
-
0.50680
-
-
0.00297
-
0.04320
0.74690
0.14812
0.02922
0.02029
0.01136
0.04320
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/M 2 OF GYPSUM BOARD)
Gypsum plaster
Calcium carbonate
Mica
Clay
Other
Compounding
TOTAL
secondary
crushing
drying
grinding
calcination
stucco
grinding
processing
total
0.00681
0.00425
0.00084
0.00058
0.00033
0.07256
0.04532
0.00894
0.00621
0.00348
0.00410
0.00256
0.00051
0.00035
0.00020
0.17839
-
-
-
-
-
0.00105
-
0.01521
0.26291
0.05214
0.01028
0.00714
0.00400
0.01521
0.01281
0.13650
0.00772
0.17839
0.00105
0.01521
0.35168
The Athena TM 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)
Gypsum plaster
Calcium carbonate
Mica
Clay
Other
Compounding
TOTAL
natural gas
oil
diesel road
electric
total
0.45063
0.07304
0.01441
0.01000
0.00560
-
0.16370
0.00076
0.00015
0.00010
0.00006
-
0.08561
0.05348
0.01055
0.00733
0.00410
-
0.04694
0.02085
0.00411
0.00286
0.00160
0.04320
0.74690
0.14812
0.02922
0.02029
0.01136
0.04320
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/M 2 OF GYPSUM BOARD)
Gypsum plaster
Calcium carbonate
Mica
Clay
Other
Compounding
TOTAL
natural gas
oil
diesel road
electric
total
0.15863
0.02571
0.00507
0.00352
0.00197
-
0.05763
0.00027
0.00005
0.00004
0.00002
-
0.03014
0.01882
0.00371
0.00258
0.00144
-
0.01653
0.00734
0.00145
0.00101
0.00056
0.01521
0.26291
0.05214
0.01028
0.00714
0.00400
0.01521
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 Athena TM 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
GJ/tonne of paper
MJ/m of tape
MJ/m2 of gypsum board
5.3
natural gas
oil
electric
total paper
11.60470
0.14229
0.13945
0.61080
0.00749
0.00734
2.91480
0.03574
0.03503
15.13020
0.18552
0.18181
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 Athena TM 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
Calgary
Winnipeg
Toronto
Montreal
Halifax
490.5
234
90
372
90
126
0
300
1740
0
0
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)
Vancouver
Calgary
Winnipeg
Toronto
Montreal
Halifax
Truck
diesel-road
Rail
diesel-rail
Total
0.57879
0.27612
0.10620
0.43896
0.10620
0.14868
0.00000
0.14700
0.85260
0.00000
0.00000
0.55125
0.57879
0.42312
0.95880
0.43896
0.10620
0.69993
TABLE 5.21 WEIGHTED AVERAGE TRANSPORTATION ENERGY FOR FINISHED
READY MIX JOINT COMPOUNDS (MJ/M 2 OF BOARD)
Vancouver
Calgary
Winnipeg
Toronto
Montreal
Halifax
Truck
diesel-road
Rail
diesel-rail
Total
0.39010
0.18610
0.07158
0.29586
0.07158
0.10021
0.00000
0.09908
0.57465
0.00000
0.00000
0.37154
0.39010
0.28518
0.64623
0.29586
0.07158
0.47175
The Athena TM Project:
Gypsum Board and Associated Finishing Products
5-11
TABLE 5.22 WEIGHTED AVERAGE TRANSPORTATION ENERGY FOR FINISHED
SETTING JOINT COMPOUNDS (MJ/M 2 OF BOARD)
Vancouver
Calgary
Winnipeg
Toronto
Montreal
Halifax
Truck
diesel-road
Rail
diesel-rail
Total
0.20373
0.09719
0.03738
0.15451
0.03738
0.05234
0.00000
0.05174
0.30012
0.00000
0.00000
0.19404
0.20373
0.14894
0.33750
0.15451
0.03738
0.24638
TABLE 5.23 WEIGHTED AVERAGE TRANSPORTATION ENERGY FOR FINISHED
JOINT PAPER TAPE (MJ/M OF TAPE)
Vancouver
Calgary
Winnipeg
Toronto
Montreal
Halifax
Truck
diesel-road
Rail
diesel-rail
Total
0.00710
0.00339
0.00130
0.00538
0.00130
0.00182
0.00000
0.00180
0.01045
0.00000
0.00000
0.00676
0.00710
0.00519
0.01176
0.00538
0.00130
0.00858
TABLE 5.24 WEIGHTED AVERAGE TRANSPORTATION ENERGY FOR FINISHED
JOINT PAPER TAPE (MJ/M 2 OF BOARD)
Vancouver
Calgary
Winnipeg
Toronto
Montreal
Halifax
5.4
Truck
diesel-road
Rail
diesel-rail
Total
0.00695
0.00332
0.00128
0.00527
0.00128
0.00179
0.00000
0.00177
0.01025
0.00000
0.00000
0.00662
0.00695
0.00508
0.01152
0.00527
0.00128
0.00841
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 Athena TM 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
ready mix joint compounds
setting (dry) joint compounds
joint paper tape
1.25
0.77
-
Raw Materials Manufacturing
Transport
40.50
59.95
7.24
24.27
25.98
89.62
Finished
Goods
Transport
33.98
13.30
3.14
Extraction
100
RM Transport
Manufacturing
% of total energy use
Finished Transport
80
60
40
20
0
Ready Mix
Setting Compound
Joint Tape
Fig. 5.1: Breakdown of Energy Use in Joint Finishing Products Production by Process Stage
The Athena TM 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
Extraction
Manufacturing
Raw
Materials
Transport
Total
to
Gate
Finished
Products
Transport
Total
to
Market
minerals
processing
resin
production
processing
total
manufacturing
0.84773
0.84773
0.74805
0.74805
0.25816
0.25816
0.24917
0.24917
0.24917
0.24917
0.24917
0.24917
0.01855
0.01855
0.01855
0.01855
0.01855
0.01855
0.05400
0.05400
0.05400
0.05400
0.05400
0.05400
0.32172
0.32172
0.32172
0.32172
0.32172
0.32172
1.18603
1.18603
1.08635
1.08635
0.59646
0.59646
0.57879
0.42312
0.95880
0.43896
0.10620
0.69993
1.76482
1.60915
2.04515
1.52531
0.70266
1.29639
0.57137
0.57137
0.50418
0.50418
0.17400
0.17400
0.16794
0.16794
0.16794
0.16794
0.16794
0.16794
0.01250
0.01250
0.01250
0.01250
0.01250
0.01250
0.03640
0.03640
0.03640
0.03640
0.03640
0.03640
0.21684
0.21684
0.21684
0.21684
0.21684
0.21684
0.79938
0.79938
0.73220
0.73220
0.40201
0.40201
0.39010
0.28518
0.64623
0.29586
0.07158
0.47175
1.18949
1.08457
1.37843
1.02806
0.47359
0.87377
[MJ/kg of compound]
Vancouver
Calgary
Winnipeg
Toronto
Montreal
Halifax
0.01658
0.01658
0.01658
0.01658
0.01658
0.01658
[MJ/m 2 of board]
Vancouver
Calgary
Winnipeg
Toronto
Montreal
Halifax
0.01117
0.01117
0.01117
0.01117
0.01117
0.01117
The Athena TM 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
0.95427
0.95427
0.85459
0.85459
0.36470
0.36470
0.00000
0.00000
0.00000
0.00000
0.00000
0.00000
0.12657
0.12657
0.12657
0.12657
0.12657
0.12657
0.00127
0.00127
0.00127
0.00127
0.00127
0.00127
0.10392
0.10392
0.10392
0.10392
0.10392
0.10392
1.18603
1.18603
1.08635
1.08635
0.59646
0.59646
0.64318
0.64318
0.57599
0.57599
0.24581
0.24581
0.00000
0.00000
0.00000
0.00000
0.00000
0.00000
0.08531
0.08531
0.08531
0.08531
0.08531
0.08531
0.00086
0.00086
0.00086
0.00086
0.00086
0.00086
0.07004
0.07004
0.07004
0.07004
0.07004
0.07004
0.79938
0.79938
0.73220
0.73220
0.40201
0.40201
[MJ/kg of compound]
Vancouver
Calgary
Winnipeg
Toronto
Montreal
Halifax
[MJ/m 2 of board]
Vancouver
Calgary
Winnipeg
Toronto
Montreal
Halifax
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
1.53306
1.23039
0.96079
1.29355
0.47090
0.51338
0.00000
0.14700
0.85260
0.00000
0.00000
0.55125
0.12657
0.12657
0.12657
0.12657
0.12657
0.12657
0.00127
0.00127
0.00127
0.00127
0.00127
0.00127
0.10392
0.10392
0.10392
0.10392
0.10392
0.10392
1.76482
1.60915
2.04515
1.52531
0.70266
1.29639
1.03328
0.82928
0.64757
0.87185
0.31739
0.34602
0.00000
0.09908
0.57465
0.00000
0.00000
0.37154
0.08531
0.08531
0.08531
0.08531
0.08531
0.08531
0.00086
0.00086
0.00086
0.00086
0.00086
0.00086
0.07004
0.07004
0.07004
0.07004
0.07004
0.07004
1.18949
1.08457
1.37843
1.02806
0.47359
0.87377
[MJ/kg of compound]
Vancouver
Calgary
Winnipeg
Toronto
Montreal
Halifax
[MJ/m 2 of board]
Vancouver
Calgary
Winnipeg
Toronto
Montreal
Halifax
The Athena TM 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
Materials
Transport
Manufacturing
minerals
processing
processing
Total
to
Gate
Finished
Products
Transport
Total
to
Market
total
manufacturing
[MJ/kg of compound]
Vancouver
Calgary
Winnipeg
Toronto
Montreal
Halifax
0.02968
0.02968
0.02968
0.02968
0.02968
0.02968
2.67120
2.67120
2.32218
2.32218
1.99514
1.99514
0.95589
0.95589
0.95589
0.95589
0.95589
0.95589
0.04320
0.04320
0.04320
0.04320
0.04320
0.04320
0.99909
0.99909
0.99909
0.99909
0.99909
0.99909
3.69997
3.69997
3.35095
3.35095
3.02391
3.02391
0.57879
0.42312
0.95880
0.43896
0.10620
0.69993
4.27876
4.12309
4.30975
3.78991
3.13011
3.72384
0.01045
0.01045
0.01045
0.01045
0.01045
0.01045
0.94026
0.94026
0.81741
0.81741
0.70229
0.70229
0.33647
0.33647
0.33647
0.33647
0.33647
0.33647
0.01521
0.01521
0.01521
0.01521
0.01521
0.01521
0.35168
0.35168
0.35168
0.35168
0.35168
0.35168
1.30239
1.30239
1.17953
1.17953
1.06442
1.06442
0.20373
0.14894
0.33750
0.15451
0.03738
0.24638
1.50612
1.45133
1.51703
1.33405
1.10180
1.31079
[MJ/m 2 of board]
Vancouver
Calgary
Winnipeg
Toronto
Montreal
Halifax
The Athena TM Project:
Gypsum Board and Associated Finishing Products
TABLE 5.28A
5-16
CRADLE TO GATE ENERGY USE IN SETTING JOINT COMPOUNDS
PRODUCTION BY ENERGY FORM AND REGION
diesel-road
diesel-rail
natural gas
oil
electric
TOTAL
2.86195
2.86195
2.03763
2.03763
1.71059
1.71059
0.00000
0.00000
0.47530
0.47530
0.47530
0.47530
0.55368
0.55368
0.55368
0.55368
0.55368
0.55368
0.16477
0.16477
0.16477
0.16477
0.16477
0.16477
0.11956
0.11956
0.11956
0.11956
0.11956
0.11956
3.69997
3.69997
3.35095
3.35095
3.02391
3.02391
1.00741
1.00741
0.71725
0.71725
0.60213
0.60213
0.00000
0.00000
0.16731
0.16731
0.16731
0.16731
0.19490
0.19490
0.19490
0.19490
0.19490
0.19490
0.05800
0.05800
0.05800
0.05800
0.05800
0.05800
0.04209
0.04209
0.04209
0.04209
0.04209
0.04209
1.30239
1.30239
1.17953
1.17953
1.06442
1.06442
[MJ/kg of compound]
Vancouver
Calgary
Winnipeg
Toronto
Montreal
Halifax
[MJ/m 2 of board]
Vancouver
Calgary
Winnipeg
Toronto
Montreal
Halifax
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
3.44074
3.13807
2.14383
2.47659
1.81679
1.85927
0.00000
0.14700
1.32790
0.47530
0.47530
1.02655
0.55368
0.55368
0.55368
0.55368
0.55368
0.55368
0.16477
0.16477
0.16477
0.16477
0.16477
0.16477
0.11956
0.11956
0.11956
0.11956
0.11956
0.11956
4.27876
4.12309
4.30975
3.78991
3.13011
3.72384
1.21114
1.10460
0.75463
0.87176
0.63951
0.65446
0.00000
0.05174
0.46742
0.16731
0.16731
0.36135
0.19490
0.19490
0.19490
0.19490
0.19490
0.19490
0.05800
0.05800
0.05800
0.05800
0.05800
0.05800
0.04209
0.04209
0.04209
0.04209
0.04209
0.04209
1.50612
1.45133
1.51703
1.33405
1.10180
1.31079
[MJ/kg of compound]
Vancouver
Calgary
Winnipeg
Toronto
Montreal
Halifax
[MJ/m 2 of board]
Vancouver
Calgary
Winnipeg
Toronto
Montreal
Halifax
The Athena TM 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
Manufacturing
Total
to
Gate
Finished
Joint
Tape
Transport
Total
to
Market
waste
paper
finished
paper
total RMs
transport
0.38940
0.38940
0.38940
0.38940
0.38940
0.38940
0.96520
0.96520
0.67350
0.67350
0.85880
0.85880
1.35460
1.35460
1.06290
1.06290
1.24820
1.24820
15.13020
15.13020
15.13020
15.13020
15.13020
15.13020
16.48480
16.48480
16.19310
16.19310
16.37840
16.37840
0.57879
0.42312
0.95880
0.43896
0.10620
0.69993
17.06359
16.90792
17.15190
16.63206
16.48460
17.07833
0.00477
0.00477
0.00477
0.00477
0.00477
0.00477
0.01183
0.01183
0.00826
0.00826
0.01053
0.01053
0.01661
0.01661
0.01303
0.01303
0.01530
0.01530
0.18552
0.18552
0.18552
0.18552
0.18552
0.18552
0.20213
0.20213
0.19855
0.19855
0.20083
0.20083
0.00710
0.00519
0.01176
0.00538
0.00130
0.00858
0.20923
0.20732
0.21031
0.20394
0.20213
0.20941
0.00468
0.00468
0.00468
0.00468
0.00468
0.00468
0.01160
0.01160
0.00809
0.00809
0.01032
0.01032
0.01628
0.01628
0.01277
0.01277
0.01500
0.01500
0.18181
0.18181
0.18181
0.18181
0.18181
0.18181
0.19809
0.19809
0.19458
0.19458
0.19681
0.19681
0.00695
0.00508
0.01152
0.00527
0.00128
0.00841
0.20504
0.20317
0.20610
0.19986
0.19809
0.20522
[MJ/kg]
Vancouver
Calgary
Winnipeg
Toronto
Montreal
Halifax
[MJ/m of tape]
Vancouver
Calgary
Winnipeg
Toronto
Montreal
Halifax
[MJ/m 2 of board]
Vancouver
Calgary
Winnipeg
Toronto
Montreal
Halifax
The Athena TM 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
dieselroad
dieselrail
HFOmarine
natural
gas
oil
electric
TOTAL
1.35460
1.35460
1.06290
1.06290
1.23950
1.23950
0.00000
0.00000
0.00000
0.00000
0.00000
0.00000
0.00000
0.00000
0.00000
0.00000
0.00870
0.00870
11.60470
11.60470
11.60470
11.60470
11.60470
11.60470
0.61080
0.61080
0.61080
0.61080
0.61080
0.61080
2.91480
2.91480
2.91480
2.91480
2.91480
2.91480
16.48490
16.48490
16.19320
16.19320
16.37850
16.37850
0.01661
0.01661
0.01303
0.01303
0.01520
0.01520
0.00000
0.00000
0.00000
0.00000
0.00000
0.00000
0.00000
0.00000
0.00000
0.00000
0.00011
0.00011
0.14229
0.14229
0.14229
0.14229
0.14229
0.14229
0.00749
0.00749
0.00749
0.00749
0.00749
0.00749
0.03574
0.03574
0.03574
0.03574
0.03574
0.03574
0.20213
0.20213
0.19855
0.19855
0.20083
0.20083
0.00000
0.00000
0.00000
0.00000
0.00000
0.00000
0.00000
0.00000
0.00000
0.00000
0.00010
0.00010
0.13945
0.13945
0.13945
0.13945
0.13945
0.13945
0.00734
0.00734
0.00734
0.00734
0.00734
0.00734
0.03503
0.03503
0.03503
0.03503
0.03503
0.03503
0.19809
0.19809
0.19458
0.19458
0.19681
0.19681
[MJ/kg]
Vancouver
Calgary
Winnipeg
Toronto
Montreal
Halifax
[MJ/m of tape]
Vancouver
Calgary
Winnipeg
Toronto
Montreal
Halifax
[MJ/m2 of board]
Vancouver
Calgary
Winnipeg
Toronto
Montreal
Halifax
0.01628
0.01628
0.01277
0.01277
0.01489
0.01489
The Athena TM 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
dieselroad
dieselrail
HFOmarine
natural
gas
oil
electric
TOTAL
1.93339
1.63072
1.16910
1.50186
1.34570
1.38818
0.00000
0.14700
0.85260
0.00000
0.00000
0.55125
0.00000
0.00000
0.00000
0.00000
0.00870
0.00870
11.60470
11.60470
11.60470
11.60470
11.60470
11.60470
0.61080
0.61080
0.61080
0.61080
0.61080
0.61080
2.91480
2.91480
2.91480
2.91480
2.91480
2.91480
17.06369
16.90802
17.15200
16.63216
16.48470
17.07843
0.02371
0.02000
0.01434
0.01842
0.01650
0.01702
0.00000
0.00180
0.01045
0.00000
0.00000
0.00676
0.00000
0.00000
0.00000
0.00000
0.00011
0.00011
0.14229
0.14229
0.14229
0.14229
0.14229
0.14229
0.00749
0.00749
0.00749
0.00749
0.00749
0.00749
0.03574
0.03574
0.03574
0.03574
0.03574
0.03574
0.20923
0.20732
0.21031
0.20394
0.20213
0.20941
0.00000
0.00177
0.01025
0.00000
0.00000
0.00662
0.00000
0.00000
0.00000
0.00000
0.00010
0.00010
0.13945
0.13945
0.13945
0.13945
0.13945
0.13945
0.00734
0.00734
0.00734
0.00734
0.00734
0.00734
0.03503
0.03503
0.03503
0.03503
0.03503
0.03503
0.20504
0.20317
0.20610
0.19986
0.19809
0.20522
[MJ/kg]
Vancouver
Calgary
Winnipeg
Toronto
Montreal
Halifax
[MJ/m of tape]
Vancouver
Calgary
Winnipeg
Toronto
Montreal
Halifax
[MJ/m2 of board]
Vancouver
Calgary
Winnipeg
Toronto
Montreal
Halifax
0.02323
0.01960
0.01405
0.01805
0.01617
0.01668
REFERENCES
1.
2.
Canadian Industry Program for Energy Conservation (CIPEC), Ministry of Energy, Mines and
Resources Canada, 1989.
Confidential information from the leading PVA resin manufacturer, January 1996.
The Athena TM Project:
Gypsum Board and Associated Finishing Products
6.0
6-1
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 Athena TM 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)
Natural gas
Diesel road
Diesel rail
H.F. oil marine
H.F. oil industrial.
Coal - Central
CO2
SO2
NOx
VOC
CH 4
CO
49.700
70.700
70.700
74.000
74.000
87.600
0.0002
0.1020
0.1020
0.4500
0.8375
0.8360
0.0590
0.8070
1.4000
0.2000
0.1600
0.2500
0.00120
0.08690
0.07000
0.36000
0.00290
0.00150
0.00130
0.02170
0.00780
0.04000
0.00082
0.00054
0.01500
0.44300
0.05700
0.00740
0.01440
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 Athena TM Project:
Gypsum Board and Associated Finishing Products
6-3
TABLE 6.2 WEIGHTED AVERAGE TPM EXTRACTION FACTORS APPLICABLE TO
CANADIAN GYPSUM INDUSTRY
West
Central
East
Natural gypsum as
% of total supply
TPM emissions
(kg/tonne of rock)
TPM emissions
(kg/tonne of stucco)
86.50
85.33
81.26
0.5100
0.0970
0.3662
0.7297
0.1369
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/M 2 OF 1/2" REGULAR GYPSUM BOARD)
West Avg.
Central Avg.
East Avg.
CANADA
CO 2
SO 2
NO x
VOC
CH 4
CO
TPM
13.42
4.78
16.12
10.13
0.0194
0.0267
0.0502
0.0326
0.1531
0.0336
0.1588
0.0976
0.0165
0.0029
0.0166
0.0100
0.0041
0.0007
0.0041
0.0025
0.0841
0.0172
0.0845
0.0521
4.6419
0.8709
3.1312
2.3275
The Athena TM 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/M 2 OF 1/2" REGULAR GYPSUM BOARD)
West Avg.
Central Avg.
East Avg.
CANADA
CO 2
SO 2
NO x
VOC
CH 4
CO
753.17
153.92
453.40
371.37
2.0090
0.2221
1.0769
0.8615
7.6994
1.7569
4.3813
3.8322
1.6250
0.1892
0.8887
0.7059
0.2581
0.0472
0.1605
0.1256
2.9497
0.9644
2.2790
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 Athena TM 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
Inventory 2
uncontrolled
controlled
emissions
emissions*
raw material drying
primary grinding
calcining
conveying
board sawing
TOTAL
TOTAL g/m2 for 1/2"
board; gypsum use
7.6637 kg/m2 of board
notes:
U.S. EPA AP-42 1985 4
uncontrolled
emissions
controlled
emissions**
20.0
0.5
45.0
0.35
65.85
2.0
0.05
4.5
0.035
6.585
5 – 60
1.3
21
0.005
27.305 – 82.305
0.02
0.06
0.003
0.083
504.66
50.47
209.26 – 630.76
0.636
* assuming 90% control efficiencies, ** with baghouse / fabric filter
The Athena TM Project:
Gypsum Board and Associated Finishing Products
6-6
TABLE 6.6 ESTIMATES OF PARTICULATE EMISSION FACTORS FOR GYPSUM
PROCESSING BY REGION (G/M 2 OF 1/2" BOARD)
Weighted TPM Emissions
West Region
Central Region
East Region
1.7494
0.2109
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
West
Central
East
CANADA
ATMOSPHERIC EMISSIONS DUE TO STUCCO CALCINATION
(G/M 2 OF 1/2” REGULAR GYPSUM BOARD)
CO2
SO2
NOx
VOC
CH 4
CO
TPM
642.37
435.98
668.64
541.27
2.4903
1.1865
3.0635
1.9472
0.9770
1.4019
2.8025
1.6262
0.0188
0.1052
0.2280
0.1128
0.0135
0.0317
0.0622
0.0344
0.1703
0.5832
1.2052
0.6277
1.7494
0.2109
0.7546
0.7163
TABLE 6.8 ATMOSPHERIC EMISSIONS DUE TO GYPSUM PAPER PRODUCTION
(G/M 2 OF 1/2” REGULAR GYPSUM BOARD)
West
Central
East
CANADA
CO2
SO2
NOx
VOC
CH 4
CO
293.27
293.27
293.27
293.27
0.2423
0.2423
0.2423
0.2423
0.3689
0.3689
0.3689
0.3689
0.0074
0.0074
0.0074
0.0074
0.0073
0.0073
0.0073
0.0073
0.0862
0.0862
0.0862
0.0862
The Athena TM Project:
Gypsum Board and Associated Finishing Products
6-7
TABLE 6.9 ATMOSPHERIC EMISSIONS DUE TO BOARD MANUFACTURING
(G/M 2 OF 1/2” REGULAR GYPSUM BOARD)
West
Central
East
CANADA
CO2
SO2
NOx
VOC
CH 4
CO
1012.53
907.84
1090.85
976.50
3.2303
2.1708
6.2933
3.3985
1.4801
1.2645
1.8370
1.4518
0.0287
0.0248
0.0347
0.0281
0.0222
0.0209
0.0202
0.0210
0.2750
0.2535
0.2696
0.2625
TABLE 6.10 SUBTOTAL OF ATMOSPHERIC EMISSIONS FROM ALL THREE
MANUFACTURING STEPS (G/M 2 OF 1/2” REGULAR GYPSUM BOARD)
West
Central
East
CANADA
CO2
SO2
NOx
VOC
CH 4
CO
TPM
1948.18
1637.09
2052.76
1811.04
5.9629
3.5996
9.5991
5.5880
2.8260
3.0353
5.0084
3.4469
0.0550
0.1374
0.2701
0.1483
0.0430
0.0599
0.0897
0.0628
0.5315
0.9228
1.5611
0.9765
1.7494
0.2109
0.7546
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 Athena TM 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
Calgary
Winnipeg
Toronto
Montreal
Halifax
90
225
90
153
288
279
0
300
400
0
0
847.5
0
0
0
0
0
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/M 2 OF 1/2" REGULAR GYPSUM BOARD)
West
Central
East
Vancouver
Calgary
Winnipeg
Toronto
Montreal
Halifax
CO2
SO2
NOx
VOC
CH 4
CO
60.54
235.15
172.28
102.92
193.73
432.29
0.0873
0.3393
0.2485
0.1485
0.2795
0.6602
0.6910
3.3870
2.9036
1.1748
2.2113
6.8514
0.0744
0.2690
0.1850
0.1265
0.2381
0.5034
0.0186
0.0557
0.0309
0.0316
0.0595
0.0880
0.3793
1.0159
0.4694
0.6449
1.2139
1.3676
The Athena TM Project:
Gypsum Board and Associated Finishing Products
6.3
6-9
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/M 2 OF 1/2" REGULAR GYPSUM BOARD)
West
Central
East
Vancouver
Calgary
Winnipeg
Toronto
Montreal
Halifax
CO2
SO2
NOx
VOC
CH 4
CO
TPM
2775.30
2949.91
1968.06
1898.70
2716.01
2954.57
8.0786
8.3305
4.0969
3.9968
11.0056
11.3863
11.3696
14.0655
7.7294
6.0006
11.7598
16.3998
1.7708
1.9654
0.5146
0.4560
1.4135
1.6787
0.3238
0.3609
0.1388
0.1395
0.3138
0.3423
3.9446
4.5812
2.3739
2.5494
5.1384
5.2921
6.3913
6.3913
1.0818
1.0818
3.8858
3.8858
The Athena TM Project:
Gypsum Board and Associated Finishing Products
6-10
TABLE 6.13 ATMOSPHERIC EMISSIONS DUE TO PRODUCTION OF
1/2" REGULAR GYPSUM BOARD (G/M 2 )
CO 2
SO 2
NO x
VOC
CH 4
CO
TPM
0.1531
0.0336
0.1588
0.0976
0.0165
0.0029
0.0166
0.0100
0.0041
0.0007
0.0041
0.0025
0.0841
0.0172
0.0845
0.0521
4.6419
0.8709
3.1312
2.3275
Gypsum extraction & processing emissions
West
Central
East
CANADA
13.42
4.78
16.13
10.13
0.0194
0.0267
0.0502
0.0326
Total raw materials transportation emissions
West
Central
East
CANADA
753.17
153.92
453.40
371.37
2.0090
0.2221
1.0769
0.8615
7.6994
1.7569
4.3813
3.8322
1.6250
0.1892
0.8887
0.7059
0.2581
0.0472
0.1605
0.1256
2.9497
0.9644
2.2790
1.7605
5.9629
3.5996
9.5991
5.5880
2.8260
3.0353
5.0084
3.4469
0.0550
0.1374
0.2701
0.1483
0.0430
0.0599
0.0897
0.0628
0.5315
0.9228
1.5611
0.9765
1.7494
0.2109
0.7546
0.7163
7.9913
3.8483
10.7261
6.4821
10.6785
4.8258
9.5485
7.3767
1.6964
0.3295
1.1753
0.8643
0.3052
0.1079
0.2543
0.1909
3.5653
1.9045
3.9245
2.7891
6.3913
1.0818
3.8858
3.0438
0.0744
0.2690
0.1850
0.1265
0.2381
0.5034
0.0186
0.0557
0.0309
0.0316
0.0595
0.0880
0.3793
1.0159
0.4694
0.6449
1.2139
1.3676
1.7708
1.9654
0.5146
0.4560
1.4135
1.6787
0.3238
0.3609
0.1388
0.1395
0.3138
0.3423
3.9446
4.5812
2.3739
2.5494
5.1384
5.2921
Total manufacturing emissions
West
Central
East
CANADA
1948.18
1637.09
2052.76
1811.04
Cradle to gate emissions
West
Central
East
CANADA
2714.76
1795.78
2522.28
2192.53
Transportation emissions for the finished product
West
Central
East
Vancouver
Calgary
Winnipeg
Toronto
Montreal
Halifax
60.54
235.15
172.28
102.92
193.73
432.29
0.0873
0.3393
0.2485
0.1485
0.2795
0.6602
0.6910
3.3870
2.9036
1.1748
2.2113
6.8514
Total emissions associated with 1/2" regular board
West
Central
East
Vancouver
Calgary
Winnipeg
Toronto
Montreal
Halifax
2775.30
2949.91
1968.06
1898.70
2716.01
2954.57
8.0786
8.3305
4.0969
3.9968
11.0056
11.3863
11.3696
14.0655
7.7294
6.0006
11.7598
16.3998
6.3913
6.3913
1.0818
1.0818
3.8858
3.8858
The Athena TM 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/M 2 )
CO 2
SO 2
NO x
VOC
CH 4
CO
TPM
0.1564
0.0344
0.1622
0.0996
0.0168
0.0030
0.0169
0.0102
0.0042
0.0007
0.0042
0.0026
0.0858
0.0176
0.0863
0.0532
4.6214
0.8671
3.1173
2.3172
Gypsum extraction & processing emissions
West
Central
East
CANADA
13.70
4.88
16.46
10.34
0.0198
0.0272
0.0512
0.0333
Total raw materials transportation emissions
West
Central
East
CANADA
765.89
155.03
460.52
376.74
2.0469
0.2237
1.0960
0.8762
7.8256
1.7696
4.4458
3.8849
1.6554
0.1906
0.9044
0.7178
0.2625
0.0476
0.1631
0.1275
2.9918
0.9714
2.3118
1.7822
6.0050
3.6141
9.6534
5.6186
2.8304
3.0488
5.0515
3.4651
0.0550
0.1394
0.2746
0.1504
0.0430
0.0603
0.0907
0.0632
0.5314
0.9314
1.5828
0.9860
1.7417
0.2100
0.7513
0.7132
8.0717
3.8650
10.8006
6.5280
10.8124
4.8527
9.6596
7.4497
1.7273
0.3329
1.1959
0.8784
0.3097
0.1086
0.2580
0.1932
3.6090
1.9204
3.9809
2.8214
6.3631
1.0771
3.8686
3.0303
0.0755
0.2731
0.1878
0.1284
0.2417
0.5110
0.0189
0.0565
0.0314
0.0321
0.0604
0.0893
0.3851
1.0313
0.4765
0.6547
1.2323
1.3883
1.8028
2.0004
0.5207
0.4613
1.4376
1.7069
0.3286
0.3663
0.1400
0.1407
0.3184
0.3474
3.9941
4.6404
2.3970
2.5751
5.2132
5.3692
Total manufacturing emissions
West
Central
East
CANADA
1948.86
1633.40
2054.01
1809.58
Cradle to gate emissions
West
Central
East
CANADA
2728.45
1793.31
2530.99
2196.66
Transportation emissions for the finished product
West
Central
East
Vancouver
Calgary
Winnipeg
Toronto
Montreal
Halifax
61.46
238.72
174.89
104.48
196.67
438.84
0.0887
0.3444
0.2523
0.1507
0.2837
0.6702
0.7015
3.4383
2.9476
1.1926
2.2449
6.9552
Total emissions associated with 1/2" type X board
West
Central
East
Vancouver
Calgary
Winnipeg
Toronto
Montreal
Halifax
2789.91
2967.17
1968.20
1897.79
2727.65
2969.83
8.1604
8.4161
4.1173
4.0157
11.0844
11.4708
11.5139
14.2507
7.8003
6.0453
11.9044
16.6147
6.3631
6.3631
1.0771
1.0771
3.8686
3.8686
The Athena TM 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/M 2 )
CO 2
SO 2
NO x
VOC
CH 4
CO
TPM
0.1737
0.0382
0.1802
0.1107
0.0187
0.0033
0.0188
0.0113
0.0047
0.0008
0.0047
0.0028
0.0954
0.0196
0.0959
0.0591
5.0903
0.9551
3.4336
2.5523
Gypsum extraction & processing emissions
West
Central
East
CANADA
15.22
5.42
18.29
11.49
0.0220
0.0302
0.0569
0.0370
Total raw materials transportation emissions
West
Central
East
CANADA
849.24
171.13
510.36
417.28
2.2718
0.2469
1.2158
0.9716
8.6753
1.9534
4.9248
4.3015
1.8372
0.2103
1.0032
0.7959
0.2912
0.0525
0.1808
0.1412
3.3135
1.0723
2.5604
1.9719
6.3049
3.7661
10.0183
5.8569
2.9678
3.2343
5.3960
3.6762
0.0577
0.1518
0.3010
0.1637
0.0450
0.0644
0.0983
0.0676
0.5569
1.0038
1.7257
1.0634
1.9184
0.2313
0.8275
0.7855
8.5986
4.0433
11.2910
6.8655
11.8168
5.2259
10.5010
8.0884
1.9136
0.3655
1.3230
0.9710
0.3409
0.1178
0.2838
0.2117
3.9657
2.0956
4.3820
3.0945
7.0087
1.1863
4.2611
3.3378
0.0834
0.3016
0.2075
0.1418
0.2670
0.5644
0.0208
0.0625
0.0347
0.0354
0.0667
0.0986
0.4253
1.1391
0.5263
0.7231
1.3611
1.5334
1.9970
2.2152
0.5729
0.5073
1.5899
1.8874
0.3617
0.4033
0.1524
0.1532
0.3505
0.3825
4.3911
5.1048
2.6220
2.8187
5.7430
5.9154
Total manufacturing emissions
West
Central
East
CANADA
2042.87
1704.00
2150.99
1892.12
Cradle to gate emissions
West
Central
East
CANADA
2907.33
1880.55
2679.64
2320.89
Transportation emissions for the finished product
West
Central
East
Vancouver
Calgary
Winnipeg
Toronto
Montreal
Halifax
67.88
263.66
193.16
115.40
217.22
484.69
0.0979
0.3804
0.2787
0.1665
0.3134
0.7402
0.7748
3.7976
3.2555
1.3172
2.4794
7.6818
Total emissions associated with 1/2" MR board
West
Central
East
Vancouver
Calgary
Winnipeg
Toronto
Montreal
Halifax
2975.21
3170.99
2073.71
1995.95
2896.85
3164.32
8.6966
8.9790
4.3220
4.2098
11.6044
12.0312
12.5916
15.6144
8.4814
6.5431
12.9803
18.1828
7.0088
7.0088
1.1863
1.1863
4.2611
4.2611
The Athena TM Project:
Gypsum Board and Associated Finishing Products
6-13
TABLE 6.16 ATMOSPHERIC EMISSIONS DUE TO PRODUCTION OF
5/8" REGULAR GYPSUM BOARD (G/M 2 )
CO 2
SO 2
NO x
VOC
CH 4
CO
TPM
0.2001
0.0440
0.2075
0.1275
0.0215
0.0038
0.0217
0.0131
0.0054
0.0010
0.0054
0.0033
0.1098
0.0225
0.1104
0.0681
6.0610
1.1372
4.0884
3.0390
Gypsum extraction & processing emissions
West
Central
East
CANADA
17.53
6.24
21.06
13.23
0.0253
0.0348
0.0655
0.0426
Total raw materials transportation emissions
West
Central
East
CANADA
969.33
191.42
581.10
473.96
2.6035
0.2762
1.3903
1.1092
9.8918
2.1850
5.5963
4.8782
2.1049
0.2353
1.1468
0.9084
0.3326
0.0588
0.2062
0.1606
3.7618
1.1994
2.9075
2.2296
7.5366
4.5089
12.1142
7.0373
3.4999
3.7856
6.3310
4.3128
0.0680
0.1760
0.3487
0.1900
0.0528
0.0749
0.1139
0.0787
0.6536
1.1660
1.9989
1.2356
2.2842
0.2754
0.9853
0.9353
10.1655
4.8199
13.5700
8.1891
13.5918
6.0145
12.1348
9.3185
2.1945
0.4151
1.5172
1.1114
0.3908
0.1347
0.3255
0.2425
4.5252
2.3879
5.0167
3.5332
8.3453
1.4126
5.0737
3.9743
0.0949
0.3432
0.2361
0.1614
0.3038
0.6422
0.0237
0.0711
0.0394
0.0403
0.0759
0.1122
0.4840
1.2961
0.5989
0.8227
1.5487
1.7448
2.2894
2.5377
0.6512
0.5765
1.8210
2.1594
0.4145
0.4619
0.1741
0.1750
0.4014
0.4377
5.0092
5.8213
2.9868
3.2107
6.5653
6.7614
Total manufacturing emissions
West
Central
East
CANADA
2401.78
2001.27
2534.00
2224.65
Cradle to gate emissions
West
Central
East
CANADA
3388.64
2198.94
3136.16
2711.80
Transportation emissions for the finished product
West
Central
East
Vancouver
Calgary
Winnipeg
Toronto
Montreal
Halifax
77.24
300.00
219.78
131.30
247.16
551.50
0.1114
0.4328
0.3171
0.1894
0.3566
0.8423
0.8816
4.3210
3.7043
1.4987
2.8211
8.7407
Total emissions associated with 5/8" regular board
West
Central
East
Vancouver
Calgary
Winnipeg
Toronto
Montreal
Halifax
3465.88
3688.64
2418.72
2330.24
3383.31
3687.65
10.2769
10.5983
5.1370
5.0094
13.9266
14.4123
14.4734
17.9128
9.7188
7.5132
14.9560
20.8755
8.3453
8.3453
1.4126
1.4126
5.0737
5.0737
The Athena TM 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/M 2 )
CO 2
SO 2
NO x
VOC
CH 4
CO
TPM
0.2029
0.0446
0.2105
0.1293
0.0219
0.0039
0.0220
0.0133
0.0055
0.0010
0.0055
0.0033
0.1114
0.0228
0.1119
0.0691
6.1473
1.1534
4.1466
3.0823
Gypsum extraction & processing emissions
West
Central
East
CANADA
17.78
6.33
21.36
13.42
0.0256
0.0353
0.0665
0.0432
Total raw materials transportation emissions
West
Central
East
CANADA
981.18
192.82
587.86
479.14
2.6379
0.2782
1.4079
1.1228
10.0103
2.2009
5.6587
4.9303
2.1326
0.2370
1.1613
0.9194
0.3368
0.0592
0.2086
0.1624
3.8030
1.2082
2.9394
2.2517
7.5768
4.5247
12.1652
7.0674
3.5085
3.8021
6.3737
4.3335
0.0682
0.1778
0.3528
0.1919
0.0529
0.0753
0.1149
0.0791
0.6545
1.1746
2.0191
1.2451
2.3167
0.2793
0.9993
0.9486
10.2404
4.8383
13.6395
8.2334
13.7216
6.0476
12.2429
9.3930
2.2226
0.4186
1.5361
1.1246
0.3951
0.1355
0.3290
0.2448
4.5688
2.4057
5.0705
3.5658
8.4640
1.4327
5.1459
4.0309
0.0970
0.3505
0.2411
0.1648
0.3103
0.6559
0.0242
0.0726
0.0403
0.0412
0.0775
0.1146
0.4943
1.3238
0.6117
0.8403
1.5818
1.7821
2.3196
2.5731
0.6597
0.5835
1.8464
2.1920
0.4193
0.4677
0.1758
0.1767
0.4065
0.4437
5.0631
5.8926
3.0173
3.2460
6.6522
6.8525
Total manufacturing emissions
West
Central
East
CANADA
2406.06
2001.69
2538.77
2227.04
Cradle to gate emissions
West
Central
East
CANADA
3405.02
2200.84
3147.99
2719.60
Transportation emissions for the finished product
West
Central
East
Vancouver
Calgary
Winnipeg
Toronto
Montreal
Halifax
78.89
306.41
224.48
134.11
252.44
563.29
0.1138
0.4421
0.3239
0.1935
0.3642
0.8603
0.9005
4.4134
3.7835
1.5308
2.8814
8.9275
Total emissions associated with 5/8" type X board
West
Central
East
Vancouver
Calgary
Winnipeg
Toronto
Montreal
Halifax
3483.91
3711.43
2425.32
2334.95
3400.43
3711.27
10.3542
10.6824
5.1621
5.0317
14.0037
14.4998
14.6221
18.1350
9.8311
7.5784
15.1243
21.1704
8.4640
8.4640
1.4327
1.4327
5.1459
5.1459
The Athena TM 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/M 2 )
CO 2
SO 2
NO x
VOC
CH 4
CO
TPM
0.2228
0.0489
0.2310
0.1419
0.0240
0.0042
0.0241
0.0145
0.0060
0.0011
0.0060
0.0036
0.1223
0.0251
0.1229
0.0758
6.5267
1.2246
4.4025
3.2725
Gypsum extraction & processing emissions
West
Central
East
CANADA
19.52
6.95
23.45
14.73
0.0282
0.0388
0.0730
0.0474
Total raw materials transportation emissions
West
Central
East
CANADA
1076.80
211.45
645.08
525.73
2.8954
0.3051
1.5452
1.2322
10.9853
2.4135
6.2091
5.4094
2.3407
0.2599
1.2745
1.0090
0.3696
0.0649
0.2289
0.1782
4.1727
1.3249
3.2252
2.4702
7.9213
4.7002
12.5839
7.3414
3.6680
4.0167
6.7699
4.5772
0.0713
0.1921
0.3830
0.2072
0.0553
0.0801
0.1236
0.0842
0.6842
1.2579
2.1831
1.3341
2.4597
0.2965
1.0610
1.0072
10.8448
5.0440
14.2020
8.6211
14.8761
6.4792
13.2101
10.1286
2.4360
0.4562
1.6817
1.2308
0.4309
0.1461
0.3586
0.2661
4.9792
2.6079
5.5311
3.8802
8.9864
1.5211
5.4635
4.2797
0.1060
0.3831
0.2635
0.1802
0.3391
0.7170
0.0265
0.0793
0.0440
0.0450
0.0847
0.1253
0.5403
1.4469
0.6686
0.9185
1.7289
1.9478
2.5420
2.8191
0.7198
0.6364
2.0208
2.3986
0.4573
0.5102
0.1901
0.1911
0.4433
0.4839
5.5195
6.4262
3.2765
3.5264
7.2600
7.4790
Total manufacturing emissions
West
Central
East
CANADA
2515.52
2084.40
2651.63
2323.40
Cradle to gate emissions
West
Central
East
CANADA
3611.83
2302.79
3320.17
2863.85
Transportation emissions for the finished product
West
Central
East
Vancouver
Calgary
Winnipeg
Toronto
Montreal
Halifax
86.23
334.92
245.36
146.58
275.92
615.69
0.1244
0.4832
0.3540
0.2115
0.3981
0.9403
0.9842
4.8239
4.1354
1.6732
3.1495
9.7580
Total emissions associated with 5/8" MR board
West
Central
East
Vancouver
Calgary
Winnipeg
Toronto
Montreal
Halifax
3698.06
3946.75
2548.16
2449.38
3596.09
3935.85
10.9692
11.3280
5.3980
5.2555
14.6001
15.1423
15.8603
19.7001
10.6146
8.1524
16.3596
22.9681
8.9864
8.9864
1.5211
1.5211
5.4635
5.4635
The Athena TM 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/M 2 )
CO 2
SO 2
NO x
VOC
CH 4
CO
TPM
0.1082
0.0238
0.1122
0.0689
0.0116
0.0021
0.0117
0.0071
0.0029
0.0005
0.0029
0.0018
0.0594
0.0122
0.0597
0.0368
3.2594
0.6115
2.1986
1.6343
Gypsum extraction & processing emissions
West
Central
East
CANADA
9.48
3.37
11.39
7.15
0.0137
0.0188
0.0354
0.0230
Total raw materials transportation emissions
West
Central
East
CANADA
548.45
119.56
332.89
274.96
1.4428
0.1725
0.7794
0.6269
5.6262
1.3647
3.2380
2.8509
1.1680
0.1470
0.6436
0.5143
0.1873
0.0367
0.1172
0.0926
2.1865
0.7492
1.6883
1.3225
4.0291
2.4460
6.3484
3.7506
1.9975
2.1629
3.5101
2.4384
0.0389
0.0975
0.1904
0.1049
0.0310
0.0431
0.0642
0.0451
0.3815
0.6597
1.1092
0.6969
1.2284
0.1481
0.5299
0.5030
5.4856
2.6373
7.1632
4.4005
7.7319
3.5514
6.8603
5.3583
1.2186
0.2465
0.8457
0.6263
0.2212
0.0803
0.1843
0.1394
2.6274
1.4210
2.8572
2.0562
4.4878
0.7596
2.7285
2.1373
0.0541
0.1956
0.1346
0.0920
0.1732
0.3661
0.0135
0.0405
0.0225
0.0230
0.0432
0.0640
0.2759
0.7389
0.3414
0.4690
0.8828
0.9946
0.2348
0.2618
0.1027
0.1032
0.2276
0.2483
2.9033
3.3663
1.7624
1.8901
3.7400
3.8518
Total manufacturing emissions
West
Central
East
CANADA
1390.53
1179.30
1458.03
1296.59
Cradle to gate emissions
West
Central
East
CANADA
1948.45
1302.24
1802.31
1578.69
Transportation emissions for the finished product
West
Central
East
Vancouver
Calgary
Winnipeg
Toronto
Montreal
Halifax
44.03
171.02
125.29
74.85
140.90
314.39
0.0635
0.2467
0.1808
0.1080
0.2033
0.4801
0.5026
2.4633
2.1117
0.8544
1.6083
4.9828
Total emissions associated with 5/16" mobile home board
West
Central
East
Vancouver
Calgary
Winnipeg
Toronto
Montreal
Halifax
1992.48
2119.47
1427.53
1377.09
1943.21
2116.70
5.5491
5.7324
2.8181
2.7453
7.3665
7.6433
8.2345
10.1952
5.6631
4.4058
8.4685
11.8431
1.2727
1.4142
0.3811
0.3385
1.0189
1.2118
4.4878
4.4878
0.7596
0.7596
2.7285
2.7285
The Athena TM Project:
Gypsum Board and Associated Finishing Products
6-17
TABLE 6.20 ATMOSPHERIC EMISSIONS DUE TO PRODUCTION OF
1" SHAFTLINER GYPSUM BOARD (G/M 2 )
CO 2
SO 2
NO x
VOC
CH 4
CO
TPM
0.3757
0.0826
0.3897
0.2394
0.0405
0.0072
0.0407
0.0245
0.0101
0.0018
0.0102
0.0061
0.2063
0.0423
0.2073
0.1279
11.4330
2.1451
7.7120
5.7325
Gypsum extraction & processing emissions
West
Central
East
CANADA
32.92
11.72
39.56
24.84
0.0475
0.0654
0.1231
0.0800
Total raw materials transportation emissions
West
Central
East
CANADA
1777.39
331.09
1058.25
856.93
4.8274
0.4777
2.5620
2.0351
18.0857
3.7792
10.1349
8.7842
3.9002
0.4070
2.1122
1.6650
0.6115
0.1016
0.3769
0.2915
6.7951
2.0746
5.2547
3.9802
12.8218
7.5040
20.3542
11.8257
5.7395
6.3509
10.9323
7.2760
0.1113
0.3155
0.6365
0.3407
0.0851
0.1271
0.2006
0.1341
1.0572
2.0271
3.5857
2.1547
4.3088
0.5194
1.8586
1.7643
17.6967
8.0470
23.0393
13.9407
24.2009
10.2127
21.4569
16.2996
4.0520
0.7296
2.7893
2.0303
0.7067
0.2306
0.5877
0.4316
8.0586
4.1440
9.0476
6.2627
15.7417
2.6645
9.5706
7.4968
0.1759
0.6358
0.4374
0.2990
0.5628
1.1898
0.0439
0.1317
0.0731
0.0747
0.1405
0.2080
0.8966
2.4013
1.1096
1.5243
2.8692
3.2326
4.2279
4.6878
1.1670
1.0286
3.3522
3.9792
0.7506
0.8383
0.3036
0.3052
0.7283
0.7957
8.9552
10.4598
5.2535
5.6682
11.9169
12.2802
Total manufacturing emissions
West
Central
East
CANADA
3905.11
3189.32
4126.19
3584.98
Cradle to gate emissions
West
Central
East
CANADA
5715.41
3532.13
5223.99
4466.75
Transportation emissions for the finished product
West
Central
East
Vancouver
Calgary
Winnipeg
Toronto
Montreal
Halifax
143.10
555.82
407.20
243.27
457.91
1021.78
0.2064
0.8019
0.5875
0.3510
0.6606
1.5605
1.6334
8.0057
6.8630
2.7767
5.2268
16.1941
Total emissions associated with 1" shaftliner board
West
Central
East
Vancouver
Calgary
Winnipeg
Toronto
Montreal
Halifax
5858.51
6271.23
3939.33
3775.40
5681.91
6245.77
17.9032
18.4986
8.6345
8.3980
23.6999
24.5998
25.8343
32.2066
17.0757
12.9894
26.6837
37.6510
15.7418
15.7418
2.6645
2.6645
9.5706
9.5706
The Athena TM Project:
Gypsum Board and Associated Finishing Products
6-18
TABLE 6.21 ATMOSPHERIC EMISSIONS DUE TO PRODUCTION OF
1/2" GYPSUM FIBERBOARD (GFB) (G/M 2 )
CO 2
SO 2
NO x
VOC
CH 4
CO
TPM
0.2045
0.0220
0.0055
0.1122
6.1276
Gypsum extraction & processing emissions
17.91
0.0258
Total raw materials transportation emissions
229.97
1.069
1.409
0.856
0.104
0.352
3.376
4.752
0.285
0.105
1.750
0.9697
4.4705
6.3650
1.1623
0.2145
2.2146
7.0973
44.833
37.448
27.161
13.941
9.796
3.836
2.242
1.872
1.358
0.697
0.490
0.413
0.250
0.209
0.151
0.078
0.055
0.103
1.825
1.525
1.106
0.568
0.399
2.106
51.1979
43.8128
33.5258
20.3062
16.1607
10.2013
3.4040
3.0347
2.5204
1.8594
1.6521
1.5754
0.4643
0.4231
0.3658
0.2922
0.2691
0.3177
4.0399
3.7393
3.3204
2.7822
2.6134
4.3205
Total manufacturing emissions
2141.39
Cradle to gate emissions
2389.28
Transportation emissions for the finished product
Vancouver
Calgary
Winnipeg
Toronto
Montreal
Halifax
2264.06
1891.11
1371.62
704.03
494.68
336.10
3.266
2.728
1.979
1.016
0.714
0.485
Total emissions associated with 1/2" GFB
West
Central
East
Vancouver
Calgary
Winnipeg
Toronto
Montreal
Halifax
4653.34
4280.39
3760.90
3093.31
2883.96
2725.37
7.7369
7.1988
6.4493
5.4862
5.1842
4.9554
7.0973
7.0973
7.0973
7.0973
7.0973
7.0973
The Athena TM Project:
Gypsum Board and Associated Finishing Products
6-19
TABLE 6.22 ATMOSPHERIC EMISSIONS DUE TO PRODUCTION OF
5/8" GYPSUM FIBERBOARD (GFB) (G/M 2 )
CO 2
SO 2
NO x
VOC
CH 4
CO
TPM
0.2537
0.0273
0.0068
0.1393
7.6031
Gypsum extraction & processing emissions
22.23
0.0321
Total raw materials transportation emissions
285.35
1.326
1.748
1.062
0.129
0.437
4.189
5.906
0.354
0.131
2.174
1.2031
5.5470
7.9072
1.4424
0.2664
2.7503
8.8062
55.992
46.769
33.921
17.411
12.234
4.791
2.800
2.338
1.696
0.871
0.612
0.516
0.312
0.261
0.189
0.097
0.068
0.129
2.280
1.904
1.381
0.709
0.498
2.630
63.8994
54.6760
41.8285
25.3184
20.1411
12.6984
4.2420
3.7809
3.1385
2.3130
2.0541
1.9583
0.5783
0.5269
0.4554
0.3634
0.3345
0.3952
5.0300
4.6544
4.1314
3.4592
3.2484
5.3804
Total manufacturing emissions
2665.02
Cradle to gate emissions
2972.60
Transportation emissions for the finished product
West
Central
East
Vancouver
Calgary
Winnipeg
Toronto
Montreal
Halifax
2827.61
2361.83
1713.03
879.27
617.81
419.75
4.079
3.407
2.471
1.269
0.891
0.606
Total emissions associated with 5/8" GFB
West
Central
East
Vancouver
Calgary
Winnipeg
Toronto
Montreal
Halifax
5800.21
5334.43
4685.63
3851.87
3590.41
3392.35
9.6264
8.9545
8.0184
6.8155
6.4383
6.1526
8.8062
8.8062
8.8062
8.8062
8.8062
8.8062
The Athena TM Project:
Gypsum Board and Associated Finishing Products
6-20
REFERENCES
1.
2.
3.
4.
5.
“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.
“A Nationwide Inventory of Emissions of Air Contaminants”, Environment Canada, Report
EPS 3-EP-83-10, December 1983.
“Metals Mining and Milling Process Profiles with Environmental Aspects, U.S.
Environmental Protection Agency, EPA-600/2-76-167, Washington, USA, 1976.
“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.
“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 Athena TM Project:
Gypsum Board and Associated Finishing Products
7.0
7-1
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 Athena TM 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
1.17206
1.17206
1.17206
1.17206
1.17206
1.17206
0.00169
0.00169
0.00169
0.00169
0.00169
0.00169
0.01338
0.01338
0.01338
0.01338
0.01338
0.01338
0.00144
0.00144
0.00144
0.00144
0.00144
0.00144
0.00036
0.00036
0.00036
0.00036
0.00036
0.00036
0.00734
0.00734
0.00734
0.00734
0.00734
0.00734
0.31314
0.31314
0.31314
0.31314
0.31314
0.31314
0.78997
0.78997
0.78997
0.78997
0.78997
0.78997
0.00114
0.00114
0.00114
0.00114
0.00114
0.00114
0.00902
0.00902
0.00902
0.00902
0.00902
0.00902
0.00097
0.00097
0.00097
0.00097
0.00097
0.00097
0.00024
0.00024
0.00024
0.00024
0.00024
0.00024
0.00495
0.00495
0.00495
0.00495
0.00495
0.00495
0.21106
0.21106
0.21106
0.21106
0.21106
0.21106
g/kg of compound
Vancouver
Calgary
Winnipeg
Toronto
Montreal
Halifax
g/m2 of board
Vancouver
Calgary
Winnipeg
Toronto
Montreal
Halifax
The Athena TM 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
2.09851
2.09851
2.09851
2.09851
2.09851
2.09851
0.00303
0.00303
0.00303
0.00303
0.00303
0.00303
0.02395
0.02395
0.02395
0.02395
0.02395
0.02395
0.00258
0.00258
0.00258
0.00258
0.00258
0.00258
0.00064
0.00064
0.00064
0.00064
0.00064
0.00064
0.01315
0.01315
0.01315
0.01315
0.01315
0.01315
0.56066
0.56066
0.56066
0.56066
0.56066
0.56066
0.73867
0.73867
0.73867
0.73867
0.73867
0.73867
0.00107
0.00107
0.00107
0.00107
0.00107
0.00107
0.00843
0.00843
0.00843
0.00843
0.00843
0.00843
0.00091
0.00091
0.00091
0.00091
0.00091
0.00091
0.00023
0.00023
0.00023
0.00023
0.00023
0.00023
0.00463
0.00463
0.00463
0.00463
0.00463
0.00463
0.19735
0.19735
0.19735
0.19735
0.19735
0.19735
g/kg of compound
Vancouver
Calgary
Winnipeg
Toronto
Montreal
Halifax
g/m2 of board
Vancouver
Calgary
Winnipeg
Toronto
Montreal
Halifax
TABLE 7.3
ATMOSPHERIC EMISSIONS DUE TO READY MIX JOINT COMPOUND RAW
MATERIALS TRANSPORTATION
CO2
SO2
NOx
VOC
CH4
CO
59.93437
59.93437
52.88699
52.88699
18.25191
18.25191
0.08647
0.08647
0.07630
0.07630
0.02633
0.02633
0.68412
0.68412
0.60367
0.60367
0.20834
0.20834
0.07367
0.07367
0.06501
0.06501
0.02243
0.02243
0.01840
0.01840
0.01623
0.01623
0.00560
0.00560
0.37554
0.37554
0.33139
0.33139
0.11436
0.11436
40.39577
40.39577
35.64583
35.64583
12.30179
12.30179
0.05828
0.05828
0.05143
0.05143
0.01775
0.01775
0.46109
0.46109
0.40688
0.40688
0.14042
0.14042
0.04965
0.04965
0.04381
0.04381
0.01512
0.01512
0.01240
0.01240
0.01094
0.01094
0.00378
0.00378
0.25312
0.25312
0.22335
0.22335
0.07708
0.07708
g/kg of compound
Vancouver
Calgary
Winnipeg
Toronto
Montreal
Halifax
g/m2 of board
Vancouver
Calgary
Winnipeg
Toronto
Montreal
Halifax
The Athena TM 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
188.85384
188.85384
164.17813
164.17813
141.05640
141.05640
0.27246
0.27246
0.23686
0.23686
0.20350
0.20350
2.15566
2.15566
2.15585
2.15585
1.89193
1.89193
0.23213
0.23213
0.19376
0.19376
0.16535
0.16535
0.05797
0.05797
0.04378
0.04378
0.03669
0.03669
1.18334
1.18334
0.84526
0.84526
0.70038
0.70038
66.47655
66.47655
57.79070
57.79070
49.65185
49.65185
0.09591
0.09591
0.08338
0.08338
0.07163
0.07163
0.75879
0.75879
0.75886
0.75886
0.66596
0.66596
0.08171
0.08171
0.06821
0.06821
0.05820
0.05820
0.02040
0.02040
0.01541
0.01541
0.01291
0.01291
0.41654
0.41654
0.29753
0.29753
0.24653
0.24653
g/kg of compound
Vancouver
Calgary
Winnipeg
Toronto
Montreal
Halifax
g/m2 of board
Vancouver
Calgary
Winnipeg
Toronto
Montreal
Halifax
TABLE 7.5 ATMOSPHERIC EMISSIONS DUE TO JOINT PAPER TAPE RAW
MATERIALS TRANSPORTATION
CO2
SO2
NOx
VOC
CH4
CO
95.77022
95.77022
75.14703
75.14703
88.27645
88.27645
0.13817
0.13817
0.10842
0.10842
0.13034
0.13034
1.09316
1.09316
0.85776
0.85776
1.00202
1.00202
0.11771
0.11771
0.09237
0.09237
0.11084
0.11084
0.02939
0.02939
0.02306
0.02306
0.02725
0.02725
0.60009
0.60009
0.47086
0.47086
0.54916
0.54916
1.17430
1.17430
0.92142
0.92142
1.08241
1.08241
0.00169
0.00169
0.00133
0.00133
0.00160
0.00160
0.01340
0.01340
0.01052
0.01052
0.01229
0.01229
0.00144
0.00144
0.00113
0.00113
0.00136
0.00136
0.00036
0.00036
0.00028
0.00028
0.00033
0.00033
0.00736
0.00736
0.00577
0.00577
0.00673
0.00673
1.15081
1.15081
0.90299
0.90299
1.06076
1.06076
0.00166
0.00166
0.00130
0.00130
0.00157
0.00157
0.01314
0.01314
0.01031
0.01031
0.01204
0.01204
0.00141
0.00141
0.00111
0.00111
0.00133
0.00133
0.00035
0.00035
0.00028
0.00028
0.00033
0.00033
0.00721
0.00721
0.00566
0.00566
0.00660
0.00660
kg/tonne of paper
Vancouver
Calgary
Winnipeg
Toronto
Montreal
Halifax
g/meter of tape
Vancouver
Calgary
Winnipeg
Toronto
Montreal
Halifax
g/m2 of board
Vancouver
Calgary
Winnipeg
Toronto
Montreal
Halifax
The Athena TM 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
gypsum plaster
2.085 kg/tonne
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 Athena TM 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
12.74505
12.74505
12.74505
12.74505
12.74505
12.74505
0.01027
0.01027
0.01027
0.01027
0.01027
0.01027
0.08027
0.08027
0.08027
0.08027
0.08027
0.08027
0.00797
0.00797
0.00797
0.00797
0.00797
0.00797
0.00212
0.00212
0.00212
0.00212
0.00212
0.00212
0.04177
0.04177
0.04177
0.04177
0.04177
0.04177
1.28019
1.28019
1.28019
1.28019
1.28019
1.28019
8.59016
8.59016
8.59016
8.59016
8.59016
8.59016
0.00692
0.00692
0.00692
0.00692
0.00692
0.00692
0.05410
0.05410
0.05410
0.05410
0.05410
0.05410
0.00537
0.00537
0.00537
0.00537
0.00537
0.00537
0.00143
0.00143
0.00143
0.00143
0.00143
0.00143
0.02815
0.02815
0.02815
0.02815
0.02815
0.02815
0.86285
0.86285
0.86285
0.86285
0.86285
0.86285
g/kg of compound
Vancouver
Calgary
Winnipeg
Toronto
Montreal
Halifax
g/m2 of board
Vancouver
Calgary
Winnipeg
Toronto
Montreal
Halifax
TABLE 7.7 ATMOSPHERIC EMISSIONS DUE TO MANUFACTURING OF SETTING
JOINT COMPOUND AND ITS CONSTITUENTS
CO2
SO2
NOx
VOC
CH4
CO
TPM
51.09884
51.09884
51.09884
51.09884
51.09884
51.09884
0.15454
0.15454
0.15454
0.15454
0.15454
0.15454
0.18902
0.18902
0.18902
0.18902
0.18902
0.18902
0.01514
0.01514
0.01514
0.01514
0.01514
0.01514
0.00435
0.00435
0.00435
0.00435
0.00435
0.00435
0.08203
0.08203
0.08203
0.08203
0.08203
0.08203
4.92157
4.92157
4.92157
4.92157
4.92157
4.92157
17.98679
17.98679
17.98679
17.98679
17.98679
17.98679
0.05440
0.05440
0.05440
0.05440
0.05440
0.05440
0.06653
0.06653
0.06653
0.06653
0.06653
0.06653
0.00533
0.00533
0.00533
0.00533
0.00533
0.00533
0.00153
0.00153
0.00153
0.00153
0.00153
0.00153
0.02888
0.02888
0.02888
0.02888
0.02888
0.02888
1.73239
1.73239
1.73239
1.73239
1.73239
1.73239
g/kg of compound
Vancouver
Calgary
Winnipeg
Toronto
Montreal
Halifax
g/m2 of board
Vancouver
Calgary
Winnipeg
Toronto
Montreal
Halifax
The Athena TM 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
621.95279
621.95279
621.95279
621.95279
621.95279
621.95279
0.51387
0.51387
0.51387
0.51387
0.51387
0.51387
0.78241
0.78241
0.78241
0.78241
0.78241
0.78241
0.01570
0.01570
0.01570
0.01570
0.01570
0.01570
0.01559
0.01559
0.01559
0.01559
0.01559
0.01559
0.18287
0.18287
0.18287
0.18287
0.18287
0.18287
0.30000
0.30000
0.30000
0.30000
0.30000
0.30000
7.62614
7.62614
7.62614
7.62614
7.62614
7.62614
0.00630
0.00630
0.00630
0.00630
0.00630
0.00630
0.00959
0.00959
0.00959
0.00959
0.00959
0.00959
0.00019
0.00019
0.00019
0.00019
0.00019
0.00019
0.00019
0.00019
0.00019
0.00019
0.00019
0.00019
0.00224
0.00224
0.00224
0.00224
0.00224
0.00224
0.00368
0.00368
0.00368
0.00368
0.00368
0.00368
7.47361
7.47361
7.47361
7.47361
7.47361
7.47361
0.00617
0.00617
0.00617
0.00617
0.00617
0.00617
0.00940
0.00940
0.00940
0.00940
0.00940
0.00940
0.00019
0.00019
0.00019
0.00019
0.00019
0.00019
0.00019
0.00019
0.00019
0.00019
0.00019
0.00019
0.00220
0.00220
0.00220
0.00220
0.00220
0.00220
0.00360
0.00360
0.00360
0.00360
0.00360
0.00360
[kg/tonne of paper]
Vancouver
Calgary
Winnipeg
Toronto
Montreal
Halifax
[g/meter of tape]
Vancouver
Calgary
Winnipeg
Toronto
Montreal
Halifax
[g/m2 of board]
Vancouver
Calgary
Winnipeg
Toronto
Montreal
Halifax
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 Athena TM 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
40.92045
29.91458
67.78716
31.03447
7.50834
49.48505
0.05904
0.04316
0.09780
0.04477
0.01083
0.07139
0.46708
0.42863
1.27934
0.35424
0.08570
0.89173
0.05030
0.03428
0.06891
0.03815
0.00923
0.05151
0.01256
0.00714
0.00895
0.00953
0.00230
0.00753
0.25640
0.13070
0.09564
0.19446
0.04705
0.09729
27.58039
20.16243
45.68855
20.91723
5.06062
33.35292
0.03979
0.02909
0.06592
0.03018
0.00730
0.04812
0.31481
0.28890
0.86228
0.23876
0.05776
0.60103
0.03390
0.02311
0.04645
0.02571
0.00622
0.03472
0.00847
0.00481
0.00604
0.00642
0.00155
0.00507
0.17282
0.08809
0.06446
0.13107
0.03171
0.06557
g/kg of compound
Vancouver
Calgary
Winnipeg
Toronto
Montreal
Halifax
g/m2 of board
Vancouver
Calgary
Winnipeg
Toronto
Montreal
Halifax
TABLE 7.10 ATMOSPHERIC EMISSIONS DUE TO TRANSPORTATION OF FINISHED
SETTING JOINT COMPOUND
CO2
SO2
NOx
VOC
CH4
CO
40.92045
29.91458
67.78716
31.03447
7.50834
49.48505
0.05904
0.04316
0.09780
0.04477
0.01083
0.07139
0.46708
0.42863
1.27934
0.35424
0.08570
0.89173
0.05030
0.03428
0.06891
0.03815
0.00923
0.05151
0.01256
0.00714
0.00895
0.00953
0.00230
0.00753
0.25640
0.13070
0.09564
0.19446
0.04705
0.09729
14.40400
10.52993
23.86108
10.92413
2.64294
17.41874
0.02078
0.01519
0.03442
0.01576
0.00381
0.02513
0.16441
0.15088
0.45033
0.12469
0.03017
0.31389
0.01770
0.01207
0.02426
0.01343
0.00325
0.01813
0.00442
0.00251
0.00315
0.00335
0.00081
0.00265
0.09025
0.04601
0.03367
0.06845
0.01656
0.03424
g/kg of compound
Vancouver
Calgary
Winnipeg
Toronto
Montreal
Halifax
g/m2 of board
Vancouver
Calgary
Winnipeg
Toronto
Montreal
Halifax
The Athena TM 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
40.92045
29.91458
67.78716
31.03447
7.50834
49.48505
0.00000
0.02999
0.17393
0.00000
0.00000
0.11246
0.46708
0.54726
1.96739
0.35424
0.08570
1.33659
1.48283
1.47959
1.55018
1.44533
1.43251
1.52269
0.04195
0.03653
0.03202
0.03259
0.02920
0.03442
0.00000
0.07350
0.42630
0.00000
0.00000
0.27563
0.50175
0.36680
0.83118
0.38053
0.09206
0.60677
0.00072
0.00053
0.00120
0.00055
0.00013
0.00088
0.00573
0.00526
0.01569
0.00434
0.00105
0.01093
0.00062
0.00042
0.00084
0.00047
0.00011
0.00063
0.00015
0.00009
0.00011
0.00012
0.00003
0.00009
0.00314
0.00160
0.00117
0.00238
0.00058
0.00119
0.49172
0.35946
0.81456
0.37292
0.09022
0.59463
0.00071
0.00052
0.00118
0.00054
0.00013
0.00086
0.00561
0.00515
0.01537
0.00426
0.00103
0.01072
0.00060
0.00041
0.00083
0.00046
0.00011
0.00062
0.00015
0.00009
0.00011
0.00011
0.00003
0.00009
0.00308
0.00157
0.00115
0.00234
0.00057
0.00117
[kg/tonne of paper]
Vancouver
Calgary
Winnipeg
Toronto
Montreal
Halifax
[g/meter of tape]
Vancouver
Calgary
Winnipeg
Toronto
Montreal
Halifax
[g/m2 of board]
Vancouver
Calgary
Winnipeg
Toronto
Montreal
Halifax
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 Athena TM 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
114.77194
103.76607
134.59127
97.83858
39.67737
81.65408
0.15746
0.14158
0.18606
0.13303
0.04912
0.10968
1.24485
1.20639
1.97667
1.05156
0.38769
1.19372
0.13338
0.11737
0.14333
0.11256
0.04108
0.08336
0.03343
0.02801
0.02766
0.02824
0.01038
0.01561
0.68106
0.55536
0.47614
0.57496
0.21053
0.26077
1.59333
1.59333
1.59333
1.59333
1.59333
1.59333
77.35629
69.93833
90.71452
65.94320
26.74255
55.03485
0.10613
0.09543
0.12540
0.08966
0.03311
0.07393
0.83903
0.81311
1.33227
0.70875
0.26130
0.80457
0.08990
0.07910
0.09660
0.07587
0.02769
0.05618
0.02253
0.01888
0.01865
0.01903
0.00700
0.01052
0.45904
0.37431
0.32092
0.38752
0.14189
0.17576
1.07390
1.07390
1.07390
1.07390
1.07390
1.07390
g/kg of compound
Vancouver
Calgary
Winnipeg
Toronto
Montreal
Halifax
g/m2 of board
Vancouver
Calgary
Winnipeg
Toronto
Montreal
Halifax
TABLE 7.13 TOTAL ATMOSPHERIC EMISSIONS DUE TO PRODUCTION OF
SETTING JOINT COMPOUND
CO2
SO2
NOx
VOC
CH4
CO
TPM
282.97164
271.96577
285.16264
248.40995
201.76209
243.73880
0.48906
0.47318
0.49222
0.43920
0.37190
0.43246
2.83571
2.79726
3.64816
2.72306
2.19060
2.99663
0.30014
0.28413
0.28039
0.24963
0.19229
0.23457
0.07552
0.07010
0.05773
0.05830
0.04399
0.04921
1.53493
1.40922
1.03609
1.13490
0.84261
0.89285
5.48223
5.48223
5.48223
5.48223
5.48223
5.48223
99.60602
95.73195
100.37725
87.44030
71.02025
85.79606
0.17215
0.16656
0.17326
0.15460
0.13091
0.15223
0.99817
0.98463
1.28415
0.95852
0.77109
1.05482
0.10565
0.10001
0.09870
0.08787
0.06769
0.08257
0.02658
0.02467
0.02032
0.02052
0.01548
0.01732
0.54029
0.49605
0.36470
0.39949
0.29660
0.31428
1.92975
1.92975
1.92975
1.92975
1.92975
1.92975
g/kg of compound
Vancouver
Calgary
Winnipeg
Toronto
Montreal
Halifax
g/m2 of board
Vancouver
Calgary
Winnipeg
Toronto
Montreal
Halifax
The Athena TM 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
758.64346
747.63759
764.88698
728.13429
717.73758
759.71429
0.71107
0.69519
0.72008
0.66706
0.65504
0.71560
2.34265
2.30420
2.91951
1.99441
1.87013
2.67616
0.18371
0.16770
0.17697
0.14621
0.13577
0.17805
0.05754
0.05212
0.04761
0.04818
0.04514
0.05036
1.03936
0.91365
0.74938
0.84819
0.77908
0.82932
0.30000
0.30000
0.30000
0.30000
0.30000
0.30000
9.30218
9.16723
9.37874
8.92809
8.80061
9.31531
0.00872
0.00852
0.00883
0.00818
0.00803
0.00877
0.02872
0.02825
0.03580
0.02445
0.02293
0.03281
0.00225
0.00206
0.00217
0.00179
0.00166
0.00218
0.00071
0.00064
0.00058
0.00059
0.00055
0.00062
0.01274
0.01120
0.00919
0.01040
0.00955
0.01017
0.00368
0.00368
0.00368
0.00368
0.00368
0.00368
9.11614
8.98389
9.19116
8.74953
8.62460
9.12901
0.00854
0.00835
0.00865
0.00802
0.00787
0.00860
0.02815
0.02769
0.03508
0.02397
0.02247
0.03216
0.00221
0.00202
0.00213
0.00176
0.00163
0.00214
0.00069
0.00063
0.00057
0.00058
0.00054
0.00061
0.01249
0.01098
0.00900
0.01019
0.00936
0.00997
0.00360
0.00360
0.00360
0.00360
0.00360
0.00360
[kg/tonne of paper]
Vancouver
Calgary
Winnipeg
Toronto
Montreal
Halifax
[g/meter of tape]
Vancouver
Calgary
Winnipeg
Toronto
Montreal
Halifax
[MJ/m2 of board]
Vancouver
Calgary
Winnipeg
Toronto
Montreal
Halifax
The Athena TM 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
1.17206
1.17206
1.17206
1.17206
1.17206
1.17206
0.00169
0.00169
0.00169
0.00169
0.00169
0.00169
0.01338
0.01338
0.01338
0.01338
0.01338
0.01338
0.00144
0.00144
0.00144
0.00144
0.00144
0.00144
0.00036
0.00036
0.00036
0.00036
0.00036
0.00036
0.00734
0.00734
0.00734
0.00734
0.00734
0.00734
0.31314
0.31314
0.31314
0.31314
0.31314
0.31314
59.93437
59.93437
52.88699
52.88699
18.25191
18.25191
0.08647
0.08647
0.07630
0.07630
0.02633
0.02633
0.68412
0.68412
0.60367
0.60367
0.20834
0.20834
0.07367
0.07367
0.06501
0.06501
0.02243
0.02243
0.01840
0.01840
0.01623
0.01623
0.00560
0.00560
0.37554
0.37554
0.33139
0.33139
0.11436
0.11436
12.74505
12.74505
12.74505
12.74505
12.74505
12.74505
0.01027
0.01027
0.01027
0.01027
0.01027
0.01027
0.08027
0.08027
0.08027
0.08027
0.08027
0.08027
0.00797
0.00797
0.00797
0.00797
0.00797
0.00797
0.00212
0.00212
0.00212
0.00212
0.00212
0.00212
0.04177
0.04177
0.04177
0.04177
0.04177
0.04177
1.28019
1.28019
1.28019
1.28019
1.28019
1.28019
0.09843
0.09843
0.08826
0.08826
0.03829
0.03829
0.77777
0.77777
0.69732
0.69732
0.30198
0.30198
0.08308
0.08308
0.07442
0.07442
0.03185
0.03185
0.02087
0.02087
0.01871
0.01871
0.00808
0.00808
0.42466
0.42466
0.38050
0.38050
0.16348
0.16348
1.59333
1.59333
1.59333
1.59333
1.59333
1.59333
40.92045
29.91458
67.78716
31.03447
7.50834
49.48505
0.05904
0.04316
0.09780
0.04477
0.01083
0.07139
0.46708
0.42863
1.27934
0.35424
0.08570
0.89173
0.05030
0.03428
0.06891
0.03815
0.00923
0.05151
0.01256
0.00714
0.00895
0.00953
0.00230
0.00753
0.25640
0.13070
0.09564
0.19446
0.04705
0.09729
114.77194
103.76607
134.59127
97.83858
39.67737
81.65408
0.15746
0.14158
0.18606
0.13303
0.04912
0.10968
1.24485
1.20639
1.97667
1.05156
0.38769
1.19372
0.13338
0.11737
0.14333
0.11256
0.04108
0.08336
0.03343
0.02801
0.02766
0.02824
0.01038
0.01561
0.68106
0.55536
0.47614
0.57496
0.21053
0.26077
Extraction
Vancouver
Calgary
Winnipeg
Toronto
Montreal
Halifax
Raw Materials Transport
Vancouver
Calgary
Winnipeg
Toronto
Montreal
Halifax
Manufacturing
Vancouver
Calgary
Winnipeg
Toronto
Montreal
Halifax
Cradle to Gate Emissions
Vancouver
Calgary
Winnipeg
Toronto
Montreal
Halifax
73.85148
73.85148
66.80411
66.80411
32.16903
32.16903
Finished Products Transport
Vancouver
Calgary
Winnipeg
Toronto
Montreal
Halifax
TOTAL
Vancouver
Calgary
Winnipeg
Toronto
Montreal
Halifax
1.59333
1.59333
1.59333
1.59333
1.59333
1.59333
The Athena TM 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/M 2 OF BOARD)
CO2
SO2
NOx
VOC
CH4
CO
TPM
0.78997
0.78997
0.78997
0.78997
0.78997
0.78997
0.00114
0.00114
0.00114
0.00114
0.00114
0.00114
0.00902
0.00902
0.00902
0.00902
0.00902
0.00902
0.00097
0.00097
0.00097
0.00097
0.00097
0.00097
0.00024
0.00024
0.00024
0.00024
0.00024
0.00024
0.00495
0.00495
0.00495
0.00495
0.00495
0.00495
0.21106
0.21106
0.21106
0.21106
0.21106
0.21106
40.39577
40.39577
35.64583
35.64583
12.30179
12.30179
0.05828
0.05828
0.05143
0.05143
0.01775
0.01775
0.46109
0.46109
0.40688
0.40688
0.14042
0.14042
0.04965
0.04965
0.04381
0.04381
0.01512
0.01512
0.01240
0.01240
0.01094
0.01094
0.00378
0.00378
0.25312
0.25312
0.22335
0.22335
0.07708
0.07708
8.59016
8.59016
8.59016
8.59016
8.59016
8.59016
0.00692
0.00692
0.00692
0.00692
0.00692
0.00692
0.05410
0.05410
0.05410
0.05410
0.05410
0.05410
0.00537
0.00537
0.00537
0.00537
0.00537
0.00537
0.00143
0.00143
0.00143
0.00143
0.00143
0.00143
0.02815
0.02815
0.02815
0.02815
0.02815
0.02815
0.86285
0.86285
0.86285
0.86285
0.86285
0.86285
0.06634
0.06634
0.05949
0.05949
0.02581
0.02581
0.52421
0.52421
0.47000
0.47000
0.20354
0.20354
0.05600
0.05600
0.05016
0.05016
0.02147
0.02147
0.01407
0.01407
0.01261
0.01261
0.00545
0.00545
0.28622
0.28622
0.25646
0.25646
0.11018
0.11018
1.07390
1.07390
1.07390
1.07390
1.07390
1.07390
27.58039
20.16243
45.68855
20.91723
5.06062
33.35292
0.03979
0.02909
0.06592
0.03018
0.00730
0.04812
0.31481
0.28890
0.86228
0.23876
0.05776
0.60103
0.03390
0.02311
0.04645
0.02571
0.00622
0.03472
0.00847
0.00481
0.00604
0.00642
0.00155
0.00507
0.17282
0.08809
0.06446
0.13107
0.03171
0.06557
77.35629
69.93833
90.71452
65.94320
26.74255
55.03485
0.10613
0.09543
0.12540
0.08966
0.03311
0.07393
0.83903
0.81311
1.33227
0.70875
0.26130
0.80457
0.08990
0.07910
0.09660
0.07587
0.02769
0.05618
0.02253
0.01888
0.01865
0.01903
0.00700
0.01052
0.45904
0.37431
0.32092
0.38752
0.14189
0.17576
Extraction
Vancouver
Calgary
Winnipeg
Toronto
Montreal
Halifax
Raw Materials Transport
Vancouver
Calgary
Winnipeg
Toronto
Montreal
Halifax
Manufacturing
Vancouver
Calgary
Winnipeg
Toronto
Montreal
Halifax
Cradle to Gate Emissions
Vancouver
Calgary
Winnipeg
Toronto
Montreal
Halifax
49.77590
49.77590
45.02597
45.02597
21.68192
21.68192
Finished Products Transport
Vancouver
Calgary
Winnipeg
Toronto
Montreal
Halifax
TOTAL
Vancouver
Calgary
Winnipeg
Toronto
Montreal
Halifax
1.07390
1.07390
1.07390
1.07390
1.07390
1.07390
The Athena TM 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
2.09851
2.09851
2.09851
2.09851
2.09851
2.09851
0.00303
0.00303
0.00303
0.00303
0.00303
0.00303
0.02395
0.02395
0.02395
0.02395
0.02395
0.02395
0.00258
0.00258
0.00258
0.00258
0.00258
0.00258
0.00064
0.00064
0.00064
0.00064
0.00064
0.00064
0.01315
0.01315
0.01315
0.01315
0.01315
0.01315
0.56066
0.56066
0.56066
0.56066
0.56066
0.56066
188.85384
188.85384
164.17813
164.17813
141.05640
141.05640
0.27246
0.27246
0.23686
0.23686
0.20350
0.20350
2.15566
2.15566
2.15585
2.15585
1.89193
1.89193
0.23213
0.23213
0.19376
0.19376
0.16535
0.16535
0.05797
0.05797
0.04378
0.04378
0.03669
0.03669
1.18334
1.18334
0.84526
0.84526
0.70038
0.70038
51.09884
51.09884
51.09884
51.09884
51.09884
51.09884
0.15454
0.15454
0.15454
0.15454
0.15454
0.15454
0.18902
0.18902
0.18902
0.18902
0.18902
0.18902
0.01514
0.01514
0.01514
0.01514
0.01514
0.01514
0.00435
0.00435
0.00435
0.00435
0.00435
0.00435
0.08203
0.08203
0.08203
0.08203
0.08203
0.08203
4.92157
4.92157
4.92157
4.92157
4.92157
4.92157
0.43003
0.43003
0.39443
0.39443
0.36107
0.36107
2.36863
2.36863
2.36882
2.36882
2.10490
2.10490
0.24985
0.24985
0.21148
0.21148
0.18306
0.18306
0.06296
0.06296
0.04878
0.04878
0.04168
0.04168
1.27852
1.27852
0.94044
0.94044
0.79556
0.79556
5.48223
5.48223
5.48223
5.48223
5.48223
5.48223
40.92045
29.91458
67.78716
31.03447
7.50834
49.48505
0.05904
0.04316
0.09780
0.04477
0.01083
0.07139
0.46708
0.42863
1.27934
0.35424
0.08570
0.89173
0.05030
0.03428
0.06891
0.03815
0.00923
0.05151
0.01256
0.00714
0.00895
0.00953
0.00230
0.00753
0.25640
0.13070
0.09564
0.19446
0.04705
0.09729
282.97164
271.96577
285.16264
248.40995
201.76209
243.73880
0.48906
0.47318
0.49222
0.43920
0.37190
0.43246
2.83571
2.79726
3.64816
2.72306
2.19060
2.99663
0.30014
0.28413
0.28039
0.24963
0.19229
0.23457
0.07552
0.07010
0.05773
0.05830
0.04399
0.04921
1.53493
1.40922
1.03609
1.13490
0.84261
0.89285
Extraction
Vancouver
Calgary
Winnipeg
Toronto
Montreal
Halifax
Raw Materials Transport
Vancouver
Calgary
Winnipeg
Toronto
Montreal
Halifax
Manufacturing
Vancouver
Calgary
Winnipeg
Toronto
Montreal
Halifax
Cradle to Gate Emissions
Vancouver
Calgary
Winnipeg
Toronto
Montreal
Halifax
242.05119
242.05119
217.37548
217.37548
194.25375
194.25375
Finished Products Transport
Vancouver
Calgary
Winnipeg
Toronto
Montreal
Halifax
TOTAL
Vancouver
Calgary
Winnipeg
Toronto
Montreal
Halifax
5.48223
5.48223
5.48223
5.48223
5.48223
5.48223
The Athena TM 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/M 2 OF BOARD)
CO2
SO2
NOx
VOC
CH4
CO
TPM
0.73867
0.73867
0.73867
0.73867
0.73867
0.73867
0.00107
0.00107
0.00107
0.00107
0.00107
0.00107
0.00843
0.00843
0.00843
0.00843
0.00843
0.00843
0.00091
0.00091
0.00091
0.00091
0.00091
0.00091
0.00023
0.00023
0.00023
0.00023
0.00023
0.00023
0.00463
0.00463
0.00463
0.00463
0.00463
0.00463
0.19735
0.19735
0.19735
0.19735
0.19735
0.19735
66.47655
66.47655
57.79070
57.79070
49.65185
49.65185
0.09591
0.09591
0.08338
0.08338
0.07163
0.07163
0.75879
0.75879
0.75886
0.75886
0.66596
0.66596
0.08171
0.08171
0.06821
0.06821
0.05820
0.05820
0.02040
0.02040
0.01541
0.01541
0.01291
0.01291
0.41654
0.41654
0.29753
0.29753
0.24653
0.24653
17.98679
17.98679
17.98679
17.98679
17.98679
17.98679
0.05440
0.05440
0.05440
0.05440
0.05440
0.05440
0.06653
0.06653
0.06653
0.06653
0.06653
0.06653
0.00533
0.00533
0.00533
0.00533
0.00533
0.00533
0.00153
0.00153
0.00153
0.00153
0.00153
0.00153
0.02888
0.02888
0.02888
0.02888
0.02888
0.02888
1.73239
1.73239
1.73239
1.73239
1.73239
1.73239
0.15137
0.15137
0.13884
0.13884
0.12710
0.12710
0.83376
0.83376
0.83382
0.83382
0.74092
0.74092
0.08795
0.08795
0.07444
0.07444
0.06444
0.06444
0.02216
0.02216
0.01717
0.01717
0.01467
0.01467
0.45004
0.45004
0.33104
0.33104
0.28004
0.28004
1.92975
1.92975
1.92975
1.92975
1.92975
1.92975
14.40400
10.52993
23.86108
10.92413
2.64294
17.41874
0.02078
0.01519
0.03442
0.01576
0.00381
0.02513
0.16441
0.15088
0.45033
0.12469
0.03017
0.31389
0.01770
0.01207
0.02426
0.01343
0.00325
0.01813
0.00442
0.00251
0.00315
0.00335
0.00081
0.00265
0.09025
0.04601
0.03367
0.06845
0.01656
0.03424
99.60602
95.73195
100.37725
87.44030
71.02025
85.79606
0.17215
0.16656
0.17326
0.15460
0.13091
0.15223
0.99817
0.98463
1.28415
0.95852
0.77109
1.05482
0.10565
0.10001
0.09870
0.08787
0.06769
0.08257
0.02658
0.02467
0.02032
0.02052
0.01548
0.01732
0.54029
0.49605
0.36470
0.39949
0.29660
0.31428
Extraction
Vancouver
Calgary
Winnipeg
Toronto
Montreal
Halifax
Raw Materials Transport
Vancouver
Calgary
Winnipeg
Toronto
Montreal
Halifax
Manufacturing
Vancouver
Calgary
Winnipeg
Toronto
Montreal
Halifax
Cradle to Gate Emissions
Vancouver
Calgary
Winnipeg
Toronto
Montreal
Halifax
85.20202
85.20202
76.51617
76.51617
68.37732
68.37732
Finished Products Transport
Vancouver
Calgary
Winnipeg
Toronto
Montreal
Halifax
TOTAL
Vancouver
Calgary
Winnipeg
Toronto
Montreal
Halifax
1.92975
1.92975
1.92975
1.92975
1.92975
1.92975
The Athena TM 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
95.77022
95.77022
75.14703
75.14703
88.27645
88.27645
0.13817
0.13817
0.10842
0.10842
0.13034
0.13034
1.09316
1.09316
0.85776
0.85776
1.00202
1.00202
0.11771
0.11771
0.09237
0.09237
0.11084
0.11084
0.02939
0.02939
0.02306
0.02306
0.02725
0.02725
0.60009
0.60009
0.47086
0.47086
0.54916
0.54916
621.95279
621.95279
621.95279
621.95279
621.95279
621.95279
0.51387
0.51387
0.51387
0.51387
0.51387
0.51387
0.78241
0.78241
0.78241
0.78241
0.78241
0.78241
0.01570
0.01570
0.01570
0.01570
0.01570
0.01570
0.01559
0.01559
0.01559
0.01559
0.01559
0.01559
0.18287
0.18287
0.18287
0.18287
0.18287
0.18287
0.30000
0.30000
0.30000
0.30000
0.30000
0.30000
0.65204
0.65204
0.62228
0.62228
0.64421
0.64421
1.87557
1.87557
1.64017
1.64017
1.78442
1.78442
0.13341
0.13341
0.10806
0.10806
0.12654
0.12654
0.04498
0.04498
0.03865
0.03865
0.04283
0.04283
0.78295
0.78295
0.65373
0.65373
0.73203
0.73203
0.30000
0.30000
0.30000
0.30000
0.30000
0.30000
40.92045
29.91458
67.78716
31.03447
7.50834
49.48505
0.05904
0.04316
0.09780
0.04477
0.01083
0.07139
0.46708
0.42863
1.27934
0.35424
0.08570
0.89173
0.05030
0.03428
0.06891
0.03815
0.00923
0.05151
0.01256
0.00714
0.00895
0.00953
0.00230
0.00753
0.25640
0.13070
0.09564
0.19446
0.04705
0.09729
758.64346
747.63759
764.88698
728.13429
717.73758
759.71429
0.71107
0.69519
0.72008
0.66706
0.65504
0.71560
2.34265
2.30420
2.91951
1.99441
1.87013
2.67616
0.18371
0.16770
0.17697
0.14621
0.13577
0.17805
0.05754
0.05212
0.04761
0.04818
0.04514
0.05036
1.03936
0.91365
0.74938
0.84819
0.77908
0.82932
Raw Materials Transport
Vancouver
Calgary
Winnipeg
Toronto
Montreal
Halifax
Manufacturing
Vancouver
Calgary
Winnipeg
Toronto
Montreal
Halifax
Cradle to Gate Emissions
Vancouver
Calgary
Winnipeg
Toronto
Montreal
Halifax
717.72301
717.72301
697.09982
697.09982
710.22924
710.22924
Finished Materials Transport
Vancouver
Calgary
Winnipeg
Toronto
Montreal
Halifax
TOTAL
Vancouver
Calgary
Winnipeg
Toronto
Montreal
Halifax
0.30000
0.30000
0.30000
0.30000
0.30000
0.30000
The Athena TM 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
1.17430
1.17430
0.92142
0.92142
1.08241
1.08241
0.00169
0.00169
0.00133
0.00133
0.00160
0.00160
0.01340
0.01340
0.01052
0.01052
0.01229
0.01229
0.00144
0.00144
0.00113
0.00113
0.00136
0.00136
0.00036
0.00036
0.00028
0.00028
0.00033
0.00033
0.00736
0.00736
0.00577
0.00577
0.00673
0.00673
7.62614
7.62614
7.62614
7.62614
7.62614
7.62614
0.00630
0.00630
0.00630
0.00630
0.00630
0.00630
0.00959
0.00959
0.00959
0.00959
0.00959
0.00959
0.00019
0.00019
0.00019
0.00019
0.00019
0.00019
0.00019
0.00019
0.00019
0.00019
0.00019
0.00019
0.00224
0.00224
0.00224
0.00224
0.00224
0.00224
0.00368
0.00368
0.00368
0.00368
0.00368
0.00368
0.00799
0.00799
0.00763
0.00763
0.00790
0.00790
0.02300
0.02300
0.02011
0.02011
0.02188
0.02188
0.00164
0.00164
0.00133
0.00133
0.00155
0.00155
0.00055
0.00055
0.00047
0.00047
0.00053
0.00053
0.00960
0.00960
0.00802
0.00802
0.00898
0.00898
0.00368
0.00368
0.00368
0.00368
0.00368
0.00368
0.50175
0.36680
0.83118
0.38053
0.09206
0.60677
0.00072
0.00053
0.00120
0.00055
0.00013
0.00088
0.00573
0.00526
0.01569
0.00434
0.00105
0.01093
0.00062
0.00042
0.00084
0.00047
0.00011
0.00063
0.00015
0.00009
0.00011
0.00012
0.00003
0.00009
0.00314
0.00160
0.00117
0.00238
0.00058
0.00119
9.30218
9.16723
9.37874
8.92809
8.80061
9.31531
0.00872
0.00852
0.00883
0.00818
0.00803
0.00877
0.02872
0.02825
0.03580
0.02445
0.02293
0.03281
0.00225
0.00206
0.00217
0.00179
0.00166
0.00218
0.00071
0.00064
0.00058
0.00059
0.00055
0.00062
0.01274
0.01120
0.00919
0.01040
0.00955
0.01017
Raw Materials Transport
Vancouver
Calgary
Winnipeg
Toronto
Montreal
Halifax
Manufacturing
Vancouver
Calgary
Winnipeg
Toronto
Montreal
Halifax
Cradle to Gate Emissions
Vancouver
Calgary
Winnipeg
Toronto
Montreal
Halifax
8.80043
8.80043
8.54756
8.54756
8.70855
8.70855
Finished Materials Transport
Vancouver
Calgary
Winnipeg
Toronto
Montreal
Halifax
TOTAL
Vancouver
Calgary
Winnipeg
Toronto
Montreal
Halifax
0.00368
0.00368
0.00368
0.00368
0.00368
0.00368
The Athena TM 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/M 2 OF BOARD)
CO2
SO2
NOx
VOC
CH4
CO
TPM
1.15081
1.15081
0.90299
0.90299
1.06076
1.06076
0.00166
0.00166
0.00130
0.00130
0.00157
0.00157
0.01314
0.01314
0.01031
0.01031
0.01204
0.01204
0.00141
0.00141
0.00111
0.00111
0.00133
0.00133
0.00035
0.00035
0.00028
0.00028
0.00033
0.00033
0.00721
0.00721
0.00566
0.00566
0.00660
0.00660
7.47361
7.47361
7.47361
7.47361
7.47361
7.47361
0.00617
0.00617
0.00617
0.00617
0.00617
0.00617
0.00940
0.00940
0.00940
0.00940
0.00940
0.00940
0.00019
0.00019
0.00019
0.00019
0.00019
0.00019
0.00019
0.00019
0.00019
0.00019
0.00019
0.00019
0.00220
0.00220
0.00220
0.00220
0.00220
0.00220
0.00360
0.00360
0.00360
0.00360
0.00360
0.00360
0.00784
0.00784
0.00748
0.00748
0.00774
0.00774
0.02254
0.02254
0.01971
0.01971
0.02144
0.02144
0.00160
0.00160
0.00130
0.00130
0.00152
0.00152
0.00054
0.00054
0.00046
0.00046
0.00051
0.00051
0.00941
0.00941
0.00786
0.00786
0.00880
0.00880
0.00360
0.00360
0.00360
0.00360
0.00360
0.00360
0.49172
0.35946
0.81456
0.37292
0.09022
0.59463
0.00071
0.00052
0.00118
0.00054
0.00013
0.00086
0.00561
0.00515
0.01537
0.00426
0.00103
0.01072
0.00060
0.00041
0.00083
0.00046
0.00011
0.00062
0.00015
0.00009
0.00011
0.00011
0.00003
0.00009
0.00308
0.00157
0.00115
0.00234
0.00057
0.00117
9.11614
8.98389
9.19116
8.74953
8.62460
9.12901
0.00854
0.00835
0.00865
0.00802
0.00787
0.00860
0.02815
0.02769
0.03508
0.02397
0.02247
0.03216
0.00221
0.00202
0.00213
0.00176
0.00163
0.00214
0.00069
0.00063
0.00057
0.00058
0.00054
0.00061
0.01249
0.01098
0.00900
0.01019
0.00936
0.00997
Raw Materials Transport
Vancouver
Calgary
Winnipeg
Toronto
Montreal
Halifax
Manufacturing
Vancouver
Calgary
Winnipeg
Toronto
Montreal
Halifax
Cradle to Gate Emissions
Vancouver
Calgary
Winnipeg
Toronto
Montreal
Halifax
8.62442
8.62442
8.37661
8.37661
8.53438
8.53438
Finished Materials Transport
Vancouver
Calgary
Winnipeg
Toronto
Montreal
Halifax
TOTAL
Vancouver
Calgary
Winnipeg
Toronto
Montreal
Halifax
0.00360
0.00360
0.00360
0.00360
0.00360
0.00360
The Athena TM Project:
Gypsum Board and Associated Finishing Products
7-19
REFERENCES
1.
2.
3.
4.
5.
“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.
Canadian Industry Program for Energy Conservation (CIPEC), Ministry of Energy, Mines and
Resources Canada, 1989.
“A Nationwide Inventory of Emissions of Air Contaminants”, Environment Canada, Report
EPS 3-EP-83-10, December 1983.
“Metals Mining and Milling Process Profiles with Environmental Aspects, U.S.
Environmental Protection Agency, EPA-600/2-76-167, Washington, USA, 1976.
“Compilation of Air Pollutant Emission Factors”, U.S. Environmental Protection Agency,
EPA AP-42, 4th edition, Research Triangle Park, NC, September 1985.
The Athena TM Project:
Gypsum Board and Associated Finishing Products
8.0
8-1
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 Athena TM Project:
Gypsum Board and Associated Finishing Products
TABLE 8.1
8-2
GYPSUM EXTRACTION LIQUID EFFLUENT CHARACTERISTICS 1,2,4
Natural gypsum
FGD gypsum
minewater
weighted
average
Flow [m3/day]
Hydrogen ion [pH]
Specific conductance [microS/cm]
Total suspended solids
Aluminum
Zinc
Phenolics
Sulfide
Oil & grease
Ammonia & ammonium
Nitrate & nitrite
Dissolved Organic Compounds (DOC)
Chlorides
Sulfates
weighted avg.
annual loading
treated effluent from sand filters
before discharge to equalization
pond
average
average
annual loading
199 - 4010
7.78 - 7.94
1600 - 3100
300
[mg/L]
[kg/yr]
28.378
0.672
0.008
0.002
0.017
1.034
0.358
2.686
3.615
42.282
1044.831
31207.94
891.33
10.70
0.41
6.29
1085.62
315.16
2622.88
2781.66
34497.04
1157168.98
[mg/L]
[kg/yr]
0.050
0.015
0.001
0.002
5.48
1.64
0.11
0.22
4.280
468.66
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/M 2 OF 1/2" REGULAR GYPSUM BOARD)
Total suspended solids
Aluminum
Zinc
Phenolics
Sulfide
Oil & grease
Ammonia & ammonium
Nitrate & nitrite
Dissolved Organic Compounds (DOC)
Chlorides
Sulfates
West Region
Central Region
East Region
(Vancouver, Calgary)
Winnipeg, Toronto)
(Montreal, Halifax)
0.25371
0.00725
0.00009
0.00000
0.00005
0.00883
0.00256
0.02132
0.02261
0.28045
9.40744
0.25028
0.00749
0.00019
0.00001
0.00006
0.00871
0.03182
0.02103
0.02231
0.27666
9.28019
0.23834
0.00726
0.00022
0.00001
0.00007
0.00829
0.04120
0.02003
0.02124
0.26346
8.83755
The Athena TM 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]
Hydrogen ion [pH]
Specific conductance [microS/cm]
Total suspended solids
Biochemical Oxygen Demand (BOD)
Aluminum
Zinc
Iron
Copper
Boron
Cyanides
Oil & grease
Manganese
Lead
Molybdenum
Nickel
Silver
Cobalt
Cadmium
Chromium
203.00
4.9 - 8.4
362.60
[mg/L]
[kg/day]
[g/tonne of paper]
243.40
270.70
1.38
0.36
2.14
1.07
1.72
0.10
13.50
0.12
0.02
0.01
0.01
0.01
0.00
0.00
0.01
46.30
55.00
0.27
0.07
0.45
0.24
0.34
0.00
2.80
0.02
0.00
0.00
0.00
0.00
0.00
0.00
0.00
270.44089
321.25807
1.57709
0.40887
2.62848
1.40185
1.98596
0.00000
16.35496
0.11682
0.00000
0.00000
0.00000
0.00000
0.00000
0.00000
0.00000
The Athena TM Project:
Gypsum Board and Associated Finishing Products
TABLE 8.4
8-4
GYPSUM BOARD PLANT LIQUID EFFLUENT CHARACTERISTICS 1
Gypsum Board Plant
(weighted averages)
annual loading
Flow [m3/day]
Hydrogen ion [pH]
Specific conductance [microS/cm]
Total suspended solids
Aluminum
Zinc
Phenolics
Sulfide
Oil & grease
Ammonia & ammonium
Nitrate & nitrite
Dissolved Organic Compounds (DOC)
Chlorides
Sulfates
4330 - 5500
7.89 - 7.96
2050 - 2500
[mg/L]
[kg/yr]
35.85
0.32
0.00
0.00
0.05
0.76
0.40
1.70
2.62
41.39
1219.60
75063.91
923.51
0.00
0.00
134.92
1376.26
397.22
1780.66
6976.95
84293.61
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 Athena TM Project:
Gypsum Board and Associated Finishing Products
8-5
TABLE 8.5 WEIGHTED AVERAGE EFFLUENT LOADING DUE TO GYPSUM BOARD
MANUFACTURING (G/M 2 OF 1/2" REGULAR GYPSUM BOARD)
Total suspended solids
Biochemical Oxygen Demand (BOD)
Aluminum
Zinc
Iron
Copper
Boron
Phenolics
Sulfide
Cyanides
Oil & grease
Ammonia & ammonium
Nitrate & nitrite
Dissolved Organic Compounds (DOC)
Chlorides
Sulfates
Paper
manufacturing
Gypsum board
manufacturing
Total
manufacturing
0.12752
0.15148
0.00074
0.00019
0.00124
0.00066
0.00094
0.70549
0.83301
0.15148
0.00942
0.00019
0.00124
0.00066
0.00094
0.00000
0.00127
0.00000
0.02065
0.00373
0.01674
0.06557
0.79223
10.86528
0.00868
0.00000
0.00000
0.00127
0.00000
0.00771
0.01293
0.00373
0.01674
0.06557
0.79223
10.86528
TABLE 8.6 TOTAL WEIGHTED AVERAGE EFFLUENT LOADING DUE TO GYPSUM
BOARD PRODUCTION (G/M 2 OF 1/2" REGULAR GYPSUM BOARD)
Total suspended solids
Biochemical Oxygen Demand (BOD)
Aluminum
Zinc
Iron
Copper
Boron
Phenolics
Sulfide
Oil & grease
Ammonia & ammonium
Nitrate & nitrite
Dissolved Organic Compounds (DOC)
Chlorides
Sulfates
West Region
Central Region
East Region
(Vancouver, Calgary)
Winnipeg, Toronto)
(Montreal, Halifax)
1.08672
0.15148
0.01667
0.00028
0.00124
0.00066
0.00094
0.00000
0.00132
0.02947
0.00630
0.03806
0.08819
1.07268
20.27272
1.08329
0.15148
0.01691
0.00038
0.00124
0.00066
0.00094
0.00001
0.00133
0.02935
0.03555
0.03777
0.08788
1.06889
20.14547
1.07135
0.15148
0.01668
0.00041
0.00124
0.00066
0.00094
0.00001
0.00133
0.02894
0.04493
0.03677
0.08682
1.05569
19.70283
The Athena TM Project:
Gypsum Board and Associated Finishing Products
8.2
8-6
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 Athena TM 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/M 2 ) - 1/2" REGULAR & TYPE X
1/2" Regular Gypsum Board
1/2" Type X Gypsum Board
West
Central
East
West
Central
East
0.25371
0.00725
0.00009
0.00000
0.00005
0.00883
0.00256
0.02132
0.02261
0.28045
9.40744
0.25028
0.00749
0.00019
0.00001
0.00006
0.00871
0.03182
0.02103
0.02231
0.27666
9.28019
0.23834
0.00726
0.00022
0.00001
0.00007
0.00829
0.04120
0.02003
0.02124
0.26346
8.83755
0.25259
0.00721
0.00009
0.00000
0.00005
0.00879
0.00255
0.02123
0.02251
0.27921
9.36588
0.24917
0.00746
0.00019
0.00001
0.00006
0.00867
0.03168
0.02094
0.02221
0.27544
9.23920
0.23729
0.00723
0.00022
0.00001
0.00007
0.00825
0.04102
0.01994
0.02115
0.26230
8.79851
Gypsum Extraction
Total suspended solids
Aluminum
Zinc
Phenolics
Sulfide
Oil & grease
Ammonia & ammonium
Nitrate & nitrite
DOC
Chlorides
Sulfates
Paper and Gypsum Board Production
Total suspended solids
BOD
Aluminum
Zinc
Iron
Copper
Boron
Phenolics
Sulfide
Oil & grease
Ammonia & ammonium
Nitrate & nitrite
DOC
Chlorides
Sulfates
0.83301
0.15148
0.00942
0.00019
0.00124
0.00066
0.00094
0.00000
0.00127
0.02065
0.00373
0.01674
0.06557
0.79223
10.86528
0.82427
0.14480
0.00935
0.00018
0.00118
0.00063
0.00090
0.00000
0.00126
0.02025
0.00372
0.01666
0.06528
0.78873
10.81728
TOTAL EFFLUENT
Total suspended solids
BOD
Aluminum
Zinc
Iron
Copper
Boron
Phenolics
Sulfide
Oil & grease
Ammonia & ammonium
Nitrate & nitrite
DOC
Chlorides
Sulfates
1.08672
0.15148
0.01667
0.00028
0.00124
0.00066
0.00094
0.00000
0.00132
0.02947
0.00630
0.03806
0.08819
1.07268
20.27272
1.08329
0.15148
0.01691
0.00038
0.00124
0.00066
0.00094
0.00001
0.00133
0.02935
0.03555
0.03777
0.08788
1.06889
20.14547
1.07135
0.15148
0.01668
0.00041
0.00124
0.00066
0.00094
0.00001
0.00133
0.02894
0.04493
0.03677
0.08682
1.05569
19.70283
1.07686
0.14480
0.01657
0.00027
0.00118
0.00063
0.00090
0.00000
0.00131
0.02904
0.00627
0.03789
0.08780
1.06795
20.18316
1.07344
0.14480
0.01681
0.00037
0.00118
0.00063
0.00090
0.00001
0.00133
0.02892
0.03539
0.03760
0.08749
1.06417
20.05648
1.06156
0.14480
0.01658
0.00040
0.00118
0.00063
0.00090
0.00001
0.00133
0.02850
0.04474
0.03660
0.08643
1.05103
19.61579
The Athena TM 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/M 2 ) - 1/2" MR & 5/8" REGULAR
1/2" Moisture Resistant Board
5/8" Regular Gypsum Board
West
Central
East
West
Central
East
0.27822
0.00795
0.00010
0.00000
0.00006
0.00968
0.00281
0.02338
0.02480
0.30754
10.31623
0.27446
0.00821
0.00021
0.00001
0.00007
0.00955
0.03489
0.02307
0.02446
0.30338
10.17670
0.26137
0.00796
0.00024
0.00001
0.00007
0.00909
0.04518
0.02197
0.02330
0.28891
9.69130
0.33128
0.00946
0.00011
0.00000
0.00007
0.01152
0.00335
0.02784
0.02953
0.36619
12.28350
0.32680
0.00978
0.00025
0.00001
0.00008
0.01137
0.04155
0.02747
0.02913
0.36124
12.11735
0.31121
0.00948
0.00028
0.00002
0.00009
0.01083
0.05380
0.02616
0.02774
0.34401
11.53939
Gypsum Extraction
Total suspended solids
Aluminum
Zinc
Phenolics
Sulfide
Oil & grease
Ammonia & ammonium
Nitrate & nitrite
DOC
Chlorides
Sulfates
Paper and Gypsum Board Production
Total suspended solids
BOD
Aluminum
Zinc
Iron
Copper
Boron
Phenolics
Sulfide
Oil & grease
Ammonia & ammonium
Nitrate & nitrite
DOC
Chlorides
Sulfates
0.90474
0.15573
0.01028
0.00020
0.00127
0.00068
0.00096
0.00000
0.00139
0.02211
0.00409
0.01835
0.07191
0.86877
11.91491
1.05026
0.15335
0.01209
0.00020
0.00125
0.00067
0.00095
0.00000
0.00166
0.02470
0.00487
0.02185
0.08562
1.03444
14.18704
TOTAL EFFLUENT
Total suspended solids
BOD
Aluminum
Zinc
Iron
Copper
Boron
Phenolics
Sulfide
Oil & grease
Ammonia & ammonium
Nitrate & nitrite
DOC
Chlorides
Sulfates
1.18296
0.15573
0.01823
0.00029
0.00127
0.00068
0.00096
0.00000
0.00145
0.03179
0.00690
0.04174
0.09671
1.17631
22.23115
1.17919
0.15573
0.01850
0.00040
0.00127
0.00068
0.00096
0.00001
0.00146
0.03166
0.03899
0.04142
0.09637
1.17215
22.09161
1.16610
0.15573
0.01824
0.00044
0.00127
0.00068
0.00096
0.00001
0.00146
0.03120
0.04928
0.04032
0.09520
1.15768
21.60621
1.38154
0.15335
0.02155
0.00031
0.00125
0.00067
0.00095
0.00000
0.00172
0.03622
0.00822
0.04969
0.11515
1.40063
26.47054
1.37706
0.15335
0.02187
0.00044
0.00125
0.00067
0.00095
0.00001
0.00174
0.03606
0.04642
0.04932
0.11475
1.39567
26.30439
1.36147
0.15335
0.02157
0.00048
0.00125
0.00067
0.00095
0.00002
0.00174
0.03552
0.05867
0.04801
0.11336
1.37844
25.72643
The Athena TM 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/M 2 ) - 5/8" TYPE X AND MR
5/8" Type X Gypsum Board
5/8" Moisture Resistant Board
West
Central
East
West
Central
East
0.33599
0.00960
0.00012
0.00000
0.00007
0.01169
0.00339
0.02824
0.02995
0.37140
12.45831
0.33145
0.00992
0.00025
0.00001
0.00008
0.01153
0.04214
0.02786
0.02954
0.36638
12.28980
0.31564
0.00962
0.00029
0.00002
0.00009
0.01098
0.05456
0.02653
0.02813
0.34890
11.70361
0.35673
0.01019
0.00012
0.00000
0.00007
0.01241
0.00360
0.02998
0.03180
0.39432
13.22720
0.35190
0.01053
0.00026
0.00001
0.00009
0.01224
0.04474
0.02958
0.03137
0.38899
13.04829
0.33512
0.01021
0.00031
0.00002
0.00009
0.01166
0.05793
0.02817
0.02987
0.37044
12.42592
Gypsum Extraction
Total suspended solids
Aluminum
Zinc
Phenolics
Sulfide
Oil & grease
Ammonia & ammonium
Nitrate & nitrite
DOC
Chlorides
Sulfates
Paper and Gypsum Board Production
Total suspended solids
BOD
Aluminum
Zinc
Iron
Copper
Boron
Phenolics
Sulfide
Oil & grease
Ammonia & ammonium
Nitrate & nitrite
DOC
Chlorides
Sulfates
1.06001
0.14935
0.01223
0.00019
0.00122
0.00065
0.00092
0.00000
0.00168
0.02473
0.00494
0.02216
0.08684
1.04916
14.38894
1.12906
0.16288
0.01300
0.00021
0.00133
0.00071
0.00101
0.00000
0.00178
0.02648
0.00525
0.02353
0.09220
1.11391
15.27698
TOTAL EFFLUENT
Total suspended solids
BOD
Aluminum
Zinc
Iron
Copper
Boron
Phenolics
Sulfide
Oil & grease
Ammonia & ammonium
Nitrate & nitrite
DOC
Chlorides
Sulfates
1.39600
0.14935
0.02182
0.00031
0.00122
0.00065
0.00092
0.00000
0.00175
0.03642
0.00834
0.05040
0.11679
1.42056
26.84725
1.39145
0.14935
0.02215
0.00044
0.00122
0.00065
0.00092
0.00001
0.00176
0.03626
0.04708
0.05002
0.11638
1.41554
26.67873
1.37564
0.14935
0.02184
0.00048
0.00122
0.00065
0.00092
0.00002
0.00177
0.03571
0.05951
0.04869
0.11497
1.39806
26.09255
1.48579
0.16288
0.02319
0.00033
0.00133
0.00071
0.00101
0.00000
0.00185
0.03889
0.00885
0.05351
0.12399
1.50823
28.50418
1.48096
0.16288
0.02354
0.00047
0.00133
0.00071
0.00101
0.00001
0.00187
0.03872
0.04999
0.05311
0.12356
1.50290
28.32527
1.46418
0.16288
0.02321
0.00051
0.00133
0.00071
0.00101
0.00002
0.00188
0.03814
0.06318
0.05170
0.12207
1.48435
27.70291
The Athena TM 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/M 2 ) - 5/16" MH AND 1" SL
5/16" Mobile Home Board
1" Shaftliner
West
Central
East
West
Central
East
0.17815
0.00509
0.00006
0.00000
0.00004
0.00620
0.00180
0.01497
0.01588
0.19692
6.60561
0.17574
0.00526
0.00013
0.00001
0.00005
0.00611
0.02234
0.01477
0.01566
0.19426
6.51627
0.16736
0.00510
0.00015
0.00001
0.00005
0.00582
0.02893
0.01407
0.01492
0.18499
6.20546
0.62489
0.01785
0.00021
0.00001
0.00013
0.02174
0.00631
0.05252
0.05570
0.69075
23.17045
0.61644
0.01845
0.00046
0.00002
0.00016
0.02144
0.07837
0.05181
0.05494
0.68140
22.85705
0.58703
0.01788
0.00054
0.00003
0.00016
0.02042
0.10148
0.04934
0.05232
0.64890
21.76683
Gypsum Extraction
Total suspended solids
Aluminum
Zinc
Phenolics
Sulfide
Oil & grease
Ammonia & ammonium
Nitrate & nitrite
DOC
Chlorides
Sulfates
Paper and Gypsum Board Production
Total suspended solids
BOD
Aluminum
Zinc
Iron
Copper
Boron
Phenolics
Sulfide
Oil & grease
Ammonia & ammonium
Nitrate & nitrite
DOC
Chlorides
Sulfates
0.62753
0.15699
0.00687
0.00020
0.00128
0.00069
0.00097
0.00000
0.00089
0.01707
0.00262
0.01175
0.04604
0.55628
7.62927
1.86977
0.15699
0.02215
0.00020
0.00128
0.00069
0.00097
0.00000
0.00312
0.03985
0.00920
0.04122
0.16151
1.95126
26.76111
TOTAL EFFLUENT
Total suspended solids
BOD
Aluminum
Zinc
Iron
Copper
Boron
Phenolics
Sulfide
Oil & grease
Ammonia & ammonium
Nitrate & nitrite
DOC
Chlorides
Sulfates
0.80568
0.15699
0.01195
0.00026
0.00128
0.00069
0.00097
0.00000
0.00093
0.02327
0.00442
0.02672
0.06192
0.75321
14.23488
0.80327
0.15699
0.01212
0.00033
0.00128
0.00069
0.00097
0.00001
0.00094
0.02319
0.02496
0.02652
0.06171
0.75054
14.14553
0.79489
0.15699
0.01196
0.00035
0.00128
0.00069
0.00097
0.00001
0.00094
0.02290
0.03155
0.02582
0.06096
0.74128
13.83473
2.49466
0.15699
0.04000
0.00041
0.00128
0.00069
0.00097
0.00001
0.00325
0.06159
0.01551
0.09374
0.21720
2.64201
49.93156
2.48621
0.15699
0.04060
0.00066
0.00128
0.00069
0.00097
0.00002
0.00328
0.06129
0.08756
0.09303
0.21645
2.63267
49.61816
2.45681
0.15699
0.04003
0.00074
0.00128
0.00069
0.00097
0.00003
0.00329
0.06027
0.11067
0.09056
0.21383
2.60017
48.52794
The Athena TM 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/M 2 ) - 1/2" AND 5/8" GFB
1/2" Gypsum Fiberboard
5/8" Gypsum Fiberboard
East
East
0.32602
0.00931
0.00011
0.00000
0.00007
0.01134
0.00329
0.02740
0.02906
0.36038
12.08843
0.40452
0.01155
0.00014
0.00001
0.00008
0.01407
0.00409
0.03400
0.03606
0.44716
14.99940
0.90654
0.00000
0.01115
0.00000
0.00000
0.00000
0.00000
0.00000
0.00163
0.01662
0.00480
0.02150
0.08426
1.01801
13.96174
1.12484
0.00000
0.01384
0.00000
0.00000
0.00000
0.00000
0.00000
0.00202
0.02062
0.00595
0.02668
0.10455
1.26315
17.32381
1.23256
0.00000
0.02046
0.00011
0.00000
0.00000
0.00000
0.00000
0.00170
0.02796
0.00809
0.04890
0.11332
1.37838
26.05017
1.52937
0.00000
0.02539
0.00014
0.00000
0.00000
0.00000
0.00001
0.00210
0.03470
0.01004
0.06068
0.14061
1.71031
32.32321
Gypsum Extraction
Total suspended solids
Aluminum
Zinc
Phenolics
Sulfide
Oil & grease
Ammonia & ammonium
Nitrate & nitrite
DOC
Chlorides
Sulfates
GFB Production
Total suspended solids
BOD
Aluminum
Zinc
Iron
Copper
Boron
Phenolics
Sulfide
Oil & grease
Ammonia & ammonium
Nitrate & nitrite
DOC
Chlorides
Sulfates
TOTAL EFFLUENT
Total suspended solids
BOD
Aluminum
Zinc
Iron
Copper
Boron
Phenolics
Sulfide
Oil & grease
Ammonia & ammonium
Nitrate & nitrite
DOC
Chlorides
Sulfates
The Athena TM 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
[mg/L of
effluent]
Total suspended solids [TSS]
Aluminum
Zinc
Phenolics
Sulfide
Oil & grease
Ammonia & ammonium
Nitrate & nitrite
Dissolved organic compounds [DOC]
Chlorides
Sulfates
24.22
0.57
0.01
0.00
0.01
0.88
0.31
2.29
3.08
36.08
891.55
Limestone quarry water
g/tonne of
gypsum
[mg/L of
effluent]
g/tonne of
CaCO3
29.04387
0.82952
0.00996
0.00038
0.00585
1.01034
0.29330
2.44100
2.58877
32.10489
1076.92658
103.70
0.76
0.00
0.01
0.04
1.77
1.41
2.90
2.49
1290.03
217.71
80.17464
0.26055
0.02077
0.00713
0.04669
2.19849
0.73995
3.38014
3.73075
449.11891
261.46478
TABLE 8.13 AVERAGE EFFLUENT LOADING DUE TO JOINT COMPOUNDS
PRODUCTION
Ready Mix Compounds
Total suspended solids [TSS]
Aluminum
Zinc
Phenolics
Sulfide
Oil & grease
Ammonia & ammonium
Nitrate & nitrite
Dissolved organic compounds [DOC]
Chlorides
Sulfates
Setting Compounds
[g/kg of
compound]
[g/m 2 of
board]
[g/kg of
compound]
[g/m 2 of
board]
0.049227
0.000160
0.000013
0.000004
0.000029
0.001350
0.000454
0.002075
0.002291
0.275759
0.160539
0.033179
0.000108
0.000009
0.000003
0.000019
0.000910
0.000306
0.001399
0.001544
0.185862
0.108204
0.058261
0.000619
0.000017
0.000004
0.000027
0.001723
0.000552
0.003167
0.003434
0.250056
0.763933
0.020508
0.000218
0.000006
0.000001
0.000010
0.000606
0.000194
0.001115
0.001209
0.088020
0.268904
The Athena TM Project:
Gypsum Board and Associated Finishing Products
8-13
TABLE 8.14 AVERAGE EFFLUENT LOADING DUE TO PAPER JOINT TAPE
PRODUCTION
Flow [m3/day]
Hydrogen ion [pH]
Conductance [microS/cm]
Biochemical Oxygen Demand (BOD)
Total suspended solids [TSS]
Oil&grease
Aluminum
Boron
Copper
Iron
Manganese
Zinc
203.00
4.9 - 8.4
362.60
[mg/L]
[kg/day]
[g/tonne
of paper]
[g/meter of
tape]
[g/m2 of
board]
270.70
243.40
13.50
1.38
1.72
1.07
2.14
0.12
0.36
55.00
46.30
2.80
0.27
0.34
0.24
0.45
0.02
0.07
321.25807
270.44089
16.35496
1.57709
1.98596
1.40185
2.62848
0.11682
0.40887
0.003939
0.003316
0.000201
0.000019
0.000024
0.000017
0.000032
0.000001
0.000005
0.003860
0.003250
0.000197
0.000019
0.000024
0.000017
0.000032
0.000001
0.000005
REFERENCES
1.
2.
3.
4.
5.
6.
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.
Communication from B. Matlock, Nova Scotia Department of the Environment, February 22,
1996.
Communication from M. de Spot, Greater Vancouver Regional District (GVRD), March 4,
1996.
Communication from R.S. Daly, Ontario Hydro, February 27, 1996.
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.
“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 Athena TM Project:
Gypsum Board and Associated Finishing Products
9.0
9-1
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 Athena TM Project:
Gypsum Board and Associated Finishing Products
TABLE 9.1
9-2
GYPSUM EXTRACTION SOLID WASTE BY REGION
natural gypsum
as percentage of total gypsum
supply [%]
solid waste
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]
Central region (Winnipeg, Toronto) [kg/tonne of stucco]
East region (Montreal, Halifax)
[kg/tonne of stucco]
Note:
86.50
85.33
81.26
350.68
345.94
329.44
* 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 Athena TM Project:
Gypsum Board and Associated Finishing Products
9-3
TABLE 9.2 TOTAL SOLID WASTE ASSOCIATED WITH GYPSUM BOARD
PRODUCTION BY REGION [KG/M 2 OF BOARD]
[kg of solid waste/m 2 ]
[kg of
stucco/m 2 ]
1/2" regular gypsum board
1/2" Type X gypsum board
1/2" MR gypsum board
5/8" regular gypsum board
5/8" type X gypsum board
5/8" MR gypsum board
5/16" mobile home board
1" shaftliner
1/2" gypsum fiberboard (GFB)*
5/8" gypsum fiberboard (GFB)*
notes:
9.2
6.3610
6.3329
6.9755
8.3057
8.4239
8.9438
4.4665
15.6671
8.1738**
10.1421**
West
Central
East
2.2307
2.2208
2.4462
2.9126
2.9541
3.1364
1.5663
5.4941
-
2.2005
2.1908
2.4131
2.8733
2.9141
3.0940
1.5451
5.4198
-
2.0955
2.0863
2.2980
2.7362
2.7751
2.9464
1.4714
5.1613
2.6928
3.3412
* includes perlite
** GFB is produced only in the East region
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 postconsumers waste paper as a part of its raw materials stream. This recycling and reuse of byproducts 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 byproduct 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 Athena TM 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
West Avg.
Central Avg.
East Avg.
CANADA
DISTRIBUTION OF GYPSUM SOURCES BY GEOGRAPHICAL REGION (%)
Natural
Gypsum
Synthetic
Gypsum
Recycled /
external
Recycled /
internal
86
85
81
85
0
7
10
6
8
4
2
4
6
4
7
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 Athena TM 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-productsderived 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.
2.
3.
4.
5.
6.
“The State of Canada’s Environment”, Environment Canada, Ottawa 1991, p. 11-20.
U.S. Environmental Protection Agency (EPA), Industrial Process Profiles for Environmental
Use: Chapter 17, The Gypsum and Board Industry, 1977.
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.
“Gypsum Board Systems: Technical Report”, Topic I-9250, AIA Environmental Resource
Guide, July 1993.
H.N. Soud, M. Takeshita, “FGD Handbook”, Chapter 4 - FGD Installations on Coal-Fired
Plants, IEACR/65 Report, IEA Coal Research, London, January 1994.
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 Athena TM Project:
Gypsum Board and Associated Finishing Products
7.
8.
9.
9-6
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.
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.
“Certificate of Recycling”, Westroc Industries Limited, June 1993.