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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 TilesPre-industrial and Industrial scale Demonstrations3rd Webinar -15th October 2019
Luis Guaita – KERABEN GRUPO
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Eco-Ceramic Tiles
Case Study 4 has been possible thanks to the industrial symbiosis among different industries, in the field of NaturalStones, Metallurgic and Ceramic sectors.
Case Study 4: Eco Wall and Eco Porcelain Tiles
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Eco-Ceramic Tiles
ECO-PORCELAIN TILES:Tough ceramic tile of porcelain stonewarebased material for outdoor use in high trafficsites, sidewalks and other urban destinationswith partial replacement of VRM by SRM fromSalt Slag Oxides based materials.
Target: Eco-Wall and Eco-Porcelain tiles
ECO-POROUS WALL TILES:Light ceramic tile of porous based material forindoor use in walls or ceilings with partialreplacement in the composition of Virgin RawMaterials by Secondary Raw Materials fromNatural Stone residue.
It has been developed a new type of tiles including a relevant amount of Secondary Raw Materials as a component ofthe ceramic body of tiles, which have been conceived and manufactured according to ECO-design criteria.
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Eco-Ceramic Tiles
MANUFACTURING PROCESS
WATER ABSORPTION CAPACITY
Group I W.A. ≤ 3%
Group IIa 3% < W.A. ≤ 6%
Group IIb 6% < W.A. ≤ 10%
Group III W.A. > 10%
A Extruded
Tiles
AI Lower water
absorption
AIIa Medium-Low
water absorption
AIIb Medium-High
water absorption
AIII High
water absorption
B Pressed
Tiles
BIa W.A. ≤ 0.5%
Very Low water absorption
BIIa Medium-Low
water absorption
BIIb Medium-High
water absorption
BIII High
water absorption
BIb 0.5% < W.A. ≤ 3%
Low water absorption
Ceramic Tile Classification under standard EN 14411
ECO-PORCELAIN TILES ECO-WALL TILES
Eco-Ceramic Tiles
Product features required
Manufacturing Process
Characteristics
Ceramic paste requirements
Raw materials characteristics
Raw materials selection
Formulation of each
composition
Laboratory experiments
& prototyping
Pre-industrialtrial 0,5-1 Ton
(20-50 m2)
Production20-40 Ton(200 m2)OK
NO
Analysis of results
METHODOLOGY applied for the development of the ECO-TILES
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2 3 4
Definition of technical requirements1
Eco-design of new products formulation2
Prototyping and pre-industrial validation3
Pilot production for demonstration4
Eco-Ceramic Tiles
ECO-DESIGN of new products2
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
10,0% 12,5%Subsitution of VRM by SRM:
+ Recycling in own process: 32,5% 39,4%
MATERIAL SUBSTITUTION in:
Total substitution of VRM: 42,5% 51,9%
Eco-Ceramic Tiles
ECO-DESIGN of new products2
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 SRMExperiment 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.
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Eco-Ceramic Tiles
Video①3
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/tonElectrical energy consumption (10% humidity): 46 kWh/tonEstimated 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.
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PressingMilling andSpray Drying
Drying Glazing &decoration
ECO Porcelain & Wall Tiles
RawMaterials
GlazePreparation
SecondaryRaw
Materials
Firing
Eco-Ceramic Tiles
RawMaterials
ECO-WALL TILES and the ECO PORCELAIN TILES should have an acceptable behaviourduring 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 ②
Eco-Ceramic Tiles
Production of 100 pieces of Eco-Wall Tileswith a size of 25x50 cm
Production of 60 pieces of Eco-Porcelain Tileswith a size of 50x50 cm
Semi-industrial trial for the pilot production of the new compositions3 ②
Eco-Ceramic Tiles
Semi-industrial trial for the pilot production of the new compositions3 ③
Eco-Ceramic Tiles
Semi-industrial trial for the pilot production of the new compositions3 ③
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PressingMilling andSpray Drying
Drying Glazing &decoration
ECO Porcelain & Wall Tiles
RawMaterials
GlazePreparation
SecondaryRaw
Materials
Firing
Eco-Ceramic Tiles
RawMaterials
ECO-WALL TILES and the ECO PORCELAIN TILES should have an acceptable behaviourduring the production process at industrial scale. Several adjustments have being done because of this.
Pilot production for real scale demonstration4
Eco-Ceramic Tiles
Pilot production for real scale demonstration4
Eco-Ceramic Tiles
FISSAC platform
Case Study 4: Installation of eco-innovative tiles in Spain
Eco-Ceramic Tiles
Demo ParkECO-PORCELAIN TILES
ECO-WALL TILES
3 m
1 mock-up: ~25 m2
FISSAC Case StudiesREAL SCALE DEMONSTRATION
• Case Study 4 Eco-porcelain tiles Madrid – Spain KERABEN & ACC
Eco-Ceramic Tiles
FISSAC Case StudiesREAL SCALE DEMONSTRATION
• Case Study 4 Eco-porcelain tiles Madrid – Spain KERABEN & ACC
Eco-Ceramic Tiles
FISSAC Case StudiesREAL SCALE DEMONSTRATION
• Case Study 4 Eco-porcelain tiles Madrid – Spain KERABEN & ACC
Eco-Ceramic Tiles
Laying possibilities …
Eco-Ceramic Tiles
On site installation
Eco-Ceramic Tiles
On site installation
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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