FOSTERING INDUSTRIAL SYMBIOSIS FOR A SUSTAINABLE RESOURCE INTENSIVE INDUSTRY ACROSS THE EXTENDED CONSTRUCTION VALUE CHAIN This project has received funding from the European Union’s Horizon 2020 research and innovation programme under grant agreement N° 642154. Eco-Ceramic Tiles Pre-industrial and Industrial scale Demonstrations 3 rd Webinar -15th October 2019 Luis Guaita – KERABEN GRUPO
Eco-Ceramic Tiles
Apr 07, 2023
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PowerPoint PresentationFOSTERING INDUSTRIAL SYMBIOSIS FOR A SUSTAINABLE RESOURCE INTENSIVE INDUSTRY ACROSS THE EXTENDED CONSTRUCTION VALUE CHAIN
This project has received funding from the European Union’s Horizon 2020 research and innovation programme under grant agreement N° 642154.
Eco-Ceramic Tiles Pre-industrial and Industrial scale Demonstrations 3rd Webinar -15th October 2019
Luis Guaita – KERABEN GRUPO
Eco-Ceramic Tiles
Case Study 4 has been possible thanks to the industrial symbiosis among different industries, in the field of Natural Stones, Metallurgic and Ceramic sectors.
Case Study 4: Eco Wall and Eco Porcelain Tiles
3
Eco-Ceramic Tiles
ECO-PORCELAIN TILES: Tough ceramic tile of porcelain stoneware based material for outdoor use in high traffic sites, sidewalks and other urban destinations with partial replacement of VRM by SRM from Salt Slag Oxides based materials.
Target: Eco-Wall and Eco-Porcelain tiles
ECO-POROUS WALL TILES: Light ceramic tile of porous based material for indoor use in walls or ceilings with partial replacement in the composition of Virgin Raw Materials by Secondary Raw Materials from Natural Stone residue.
It has been developed a new type of tiles including a relevant amount of Secondary Raw Materials as a component of the ceramic body of tiles, which have been conceived and manufactured according to ECO-design criteria.
4
Group III W.A. > 10%
ECO-PORCELAIN TILES ECO-WALL TILES
NO
1
Prototyping and pre-industrial validation3
Pilot production for demonstration4
Characterization studies and lab prototyping on ceramic tile products (ECO-WALL TILE and an ECO-PORCELAIN TILE) have been conducted by ICV & KERABEN.
The Virgin Raw Materials substitution achieved was:
ECO-PORCELAIN TILES ECO-WALL TILES
+ Recycling in own process: 32,5% 39,4%
MATERIAL SUBSTITUTION in:
Eco-Ceramic Tiles
Difficulties:
ECO-WALL TILES High humidity content of SRM (>22%) → New Drying Stage Presence of coarse particles (>40μm) → New Sieving Stage Modification of the paste colour → Control
ECO-PORCELAIN TILES Modification of the paste colour → Control Presence of metallic particles. → New Sieving Stage The amount of fluxing agents is too high → Different firing cycle
Eco-Ceramic Tiles
PREPARATION OF THE SRM Experiment for drying natural stone slurries using Microwave technology
It has been experienced several technical difficulties when developing the new ECO-TILES caused by issues like an excess of humidity in the natural stone slurries (>22%). An experiment for drying the marble slurries was conducted using Microwave technology.
3
Eco-Ceramic Tiles
Eco-Ceramic Tiles
Curves of Humidity evaporation and energy used for drying the marble slurries
The results obtained can be summarized as follows:
Humidity wet basis: 20.32 ± 0.07 % Humidity dry basis: 25.51 ± 0.11 %
Measured Microwave energy consumption (10% humidity): 38 kWh/ton Electrical energy consumption (10% humidity): 46 kWh/ton Estimated microwave energy with filled bed: ~26 kWh/ton
Total estimated energy: ~ 35 kWh/ton
Figure shows the temperature cycle recorded by the optical pyrometer, humidity and evaporation of water in the material and the energy consumption during a drying cycle in which the equipment is working continuously irradiating with 4 magnetrons of 750 W.
3
Eco-Ceramic Tiles
Raw Materials
ECO-WALL TILES and the ECO PORCELAIN TILES should have an acceptable behaviour during the production process at industrial scale. Several adjustments have being done because of this.
Prototyping and pre-industrial validation3
Eco-Ceramic Tiles
Semi-industrial trial for the pilot production of the new compositions3
Eco-Ceramic Tiles
Production of 100 pieces of Eco-Wall Tiles with a size of 25x50 cm
Production of 60 pieces of Eco-Porcelain Tiles with a size of 50x50 cm
Semi-industrial trial for the pilot production of the new compositions3
Eco-Ceramic Tiles
Semi-industrial trial for the pilot production of the new compositions3
Eco-Ceramic Tiles
Semi-industrial trial for the pilot production of the new compositions3
Eco-Ceramic Tiles
Raw Materials
ECO-WALL TILES and the ECO PORCELAIN TILES should have an acceptable behaviour during the production process at industrial scale. Several adjustments have being done because of this.
Pilot production for real scale demonstration4
Eco-Ceramic Tiles
Eco-Ceramic Tiles
FISSAC platform
Eco-Ceramic Tiles
• Case Study 4 Eco-porcelain tiles Madrid – Spain KERABEN & ACC
Eco-Ceramic Tiles
• Case Study 4 Eco-porcelain tiles Madrid – Spain KERABEN & ACC
Eco-Ceramic Tiles
• Case Study 4 Eco-porcelain tiles Madrid – Spain KERABEN & ACC
Eco-Ceramic Tiles
Laying possibilities …
Eco-Ceramic Tiles
Conclusions
• The semi-industrial pilot productions carried out so far have proved a limited feasibility for the replacement of a significant amount of VRM by SRM coming from the Natural Stone and Metallurgic sectors. It has been reached TRL 7.
• It has been produced 123.12 m2 (456 pieces) of ECO WALL TILES achieving a substitution of 51.9 wt % of VRM by recycled materials.
• It has been produced 240.00 m2 (960 pieces) of ECO PORCELAIN TILES achieving a substitution of 42.5 wt % of VRM by recycled materials.
• The new ECO-CERAMIC TILES have been installed in a Demo Park in Madrid, and will be under observation for at least 1 year.
• Unfortunately, so far no technical benefits have been observed in the production using the SRM, and there is also no clear improvement in the performance of the product. The production of the new ECO TILES is feasible, but it’s difficult to justify new investments required.
Thank you !!!
Eco-Ceramic Tiles
This project has received funding from the European Union’s Horizon 2020 research and innovation programme under grant agreement N° 642154.
Eco-Ceramic Tiles Pre-industrial and Industrial scale Demonstrations 3rd Webinar -15th October 2019
Luis Guaita – KERABEN GRUPO
Eco-Ceramic Tiles
Case Study 4 has been possible thanks to the industrial symbiosis among different industries, in the field of Natural Stones, Metallurgic and Ceramic sectors.
Case Study 4: Eco Wall and Eco Porcelain Tiles
3
Eco-Ceramic Tiles
ECO-PORCELAIN TILES: Tough ceramic tile of porcelain stoneware based material for outdoor use in high traffic sites, sidewalks and other urban destinations with partial replacement of VRM by SRM from Salt Slag Oxides based materials.
Target: Eco-Wall and Eco-Porcelain tiles
ECO-POROUS WALL TILES: Light ceramic tile of porous based material for indoor use in walls or ceilings with partial replacement in the composition of Virgin Raw Materials by Secondary Raw Materials from Natural Stone residue.
It has been developed a new type of tiles including a relevant amount of Secondary Raw Materials as a component of the ceramic body of tiles, which have been conceived and manufactured according to ECO-design criteria.
4
Group III W.A. > 10%
ECO-PORCELAIN TILES ECO-WALL TILES
NO
1
Prototyping and pre-industrial validation3
Pilot production for demonstration4
Characterization studies and lab prototyping on ceramic tile products (ECO-WALL TILE and an ECO-PORCELAIN TILE) have been conducted by ICV & KERABEN.
The Virgin Raw Materials substitution achieved was:
ECO-PORCELAIN TILES ECO-WALL TILES
+ Recycling in own process: 32,5% 39,4%
MATERIAL SUBSTITUTION in:
Eco-Ceramic Tiles
Difficulties:
ECO-WALL TILES High humidity content of SRM (>22%) → New Drying Stage Presence of coarse particles (>40μm) → New Sieving Stage Modification of the paste colour → Control
ECO-PORCELAIN TILES Modification of the paste colour → Control Presence of metallic particles. → New Sieving Stage The amount of fluxing agents is too high → Different firing cycle
Eco-Ceramic Tiles
PREPARATION OF THE SRM Experiment for drying natural stone slurries using Microwave technology
It has been experienced several technical difficulties when developing the new ECO-TILES caused by issues like an excess of humidity in the natural stone slurries (>22%). An experiment for drying the marble slurries was conducted using Microwave technology.
3
Eco-Ceramic Tiles
Eco-Ceramic Tiles
Curves of Humidity evaporation and energy used for drying the marble slurries
The results obtained can be summarized as follows:
Humidity wet basis: 20.32 ± 0.07 % Humidity dry basis: 25.51 ± 0.11 %
Measured Microwave energy consumption (10% humidity): 38 kWh/ton Electrical energy consumption (10% humidity): 46 kWh/ton Estimated microwave energy with filled bed: ~26 kWh/ton
Total estimated energy: ~ 35 kWh/ton
Figure shows the temperature cycle recorded by the optical pyrometer, humidity and evaporation of water in the material and the energy consumption during a drying cycle in which the equipment is working continuously irradiating with 4 magnetrons of 750 W.
3
Eco-Ceramic Tiles
Raw Materials
ECO-WALL TILES and the ECO PORCELAIN TILES should have an acceptable behaviour during the production process at industrial scale. Several adjustments have being done because of this.
Prototyping and pre-industrial validation3
Eco-Ceramic Tiles
Semi-industrial trial for the pilot production of the new compositions3
Eco-Ceramic Tiles
Production of 100 pieces of Eco-Wall Tiles with a size of 25x50 cm
Production of 60 pieces of Eco-Porcelain Tiles with a size of 50x50 cm
Semi-industrial trial for the pilot production of the new compositions3
Eco-Ceramic Tiles
Semi-industrial trial for the pilot production of the new compositions3
Eco-Ceramic Tiles
Semi-industrial trial for the pilot production of the new compositions3
Eco-Ceramic Tiles
Raw Materials
ECO-WALL TILES and the ECO PORCELAIN TILES should have an acceptable behaviour during the production process at industrial scale. Several adjustments have being done because of this.
Pilot production for real scale demonstration4
Eco-Ceramic Tiles
Eco-Ceramic Tiles
FISSAC platform
Eco-Ceramic Tiles
• Case Study 4 Eco-porcelain tiles Madrid – Spain KERABEN & ACC
Eco-Ceramic Tiles
• Case Study 4 Eco-porcelain tiles Madrid – Spain KERABEN & ACC
Eco-Ceramic Tiles
• Case Study 4 Eco-porcelain tiles Madrid – Spain KERABEN & ACC
Eco-Ceramic Tiles
Laying possibilities …
Eco-Ceramic Tiles
Conclusions
• The semi-industrial pilot productions carried out so far have proved a limited feasibility for the replacement of a significant amount of VRM by SRM coming from the Natural Stone and Metallurgic sectors. It has been reached TRL 7.
• It has been produced 123.12 m2 (456 pieces) of ECO WALL TILES achieving a substitution of 51.9 wt % of VRM by recycled materials.
• It has been produced 240.00 m2 (960 pieces) of ECO PORCELAIN TILES achieving a substitution of 42.5 wt % of VRM by recycled materials.
• The new ECO-CERAMIC TILES have been installed in a Demo Park in Madrid, and will be under observation for at least 1 year.
• Unfortunately, so far no technical benefits have been observed in the production using the SRM, and there is also no clear improvement in the performance of the product. The production of the new ECO TILES is feasible, but it’s difficult to justify new investments required.
Thank you !!!
Eco-Ceramic Tiles
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