increased “green value” of glazed porcelain
TRANSCRIPT
Qualicer ‘20, 10-11/02/2020
Lucrezia Volpi
Department of Sciences and Methods for Engineering, University of Modena and Reggio, Emilia,
Reggio Emilia 42122, Italy
Increased “green value” of glazed porcelain stoneware tiles through the eco-design of raw materials
Introduction
LIFE PROJECT “FORCE OF THE FUTURE”:Evaluation and dynamic monitoring
of the sustainability
LCA+LCC+S-LCA
CERAMIC INDUSTRY: materials and energy-intensive sector environmental impacts
Need to implement strategies
Introduction
LIFE PROJECT “FORCE OF THE FUTURE”:Evaluation and dynamic monitoring
of the sustainability
LCA+LCC+S-LCA
CERAMIC INDUSTRY: materials and energy-intensive sector environmental impacts
Need to implement strategies
Eco-design approach for anaccurate selection of rawmaterials, considering theirsupply system.
3 formulations
SOURCES OF RAW MATERIAL SUPPLY
COMPOSITION 1 [%]
COMPOSITION 2 [%]
COMPOSITION 3 [%]
Extra-EU Clay 25 20 -
Extra-EU Na-feldspar 38 22 20
EU Clay 25 25 30
National clay - - 30
National K-feldspar 5 23 20
National K-sand 7 10 -
TOTAL EXTRA-EU RAW MATERIALS
63 42 20
Analyzed formulations
0
20
40
60
80
100
Comp. 1 Comp. 2 Comp. 3
% Extra-EU
EU
Preparation and testing
Wet grinding
Drying of the slip
Humidification (6 wt.%)
Dry-pressing 470kg/cm2
Firing 1210 °C (45 min)
Planetary ball mill-34% H2O, 66 wt.% dry raw materials, 0.15 wt.% tripolyphosphate as dispersant
105 °C for 24h followed by disagglomeration of the powder cake
Industrial roller kiln
Laboratory hydraulic press using a cylinder mold (50 cm diameter)
Sample preparation by standard laboratory procedures
Preparation and testing
• Water absorption (ISO 10545-3:2018)
• Linear firing shrinkage (LFS%)
• Colour (L*, a*, b*)
• Apparent density, a (weight and geometry)
• Real density, r (He picnometry)
• *Total porosity,
• Chemical composition (XRF)
• Phase composition (XRPD-Rietveld-RIR)
∗𝑃𝑇 = 100 × 1 −
a
r
• Phase composition (XRPD-Rietveld)
• Chemical composition (XRF)
• Grainsize distribution
• Apparent density of the pressedcompact, a (weight and geometry)
• Sintering curves (Optical dilatometry)
Raw materials mixtures and green compacts
Fired ceramic bodies
Characterizations
Preparation and testing
1 2 3
Quartz 27.4 (2) 32.2 (2) 33.4 (2)
Kaolinite 19.1 (4) 13.1 (5) 12.8 (3)
Illite/mica 11.0 (5) 16.0 (6) 16.5 (3)
Plagioclase 38.8 (3) 30.8 (3) 28.4 (2)
K-feldspar 3.2 (4) 6.9 (4) 8.4 (2)
Calcite 0.4 (1) 0.8 (1) 0.5 (1)
+
• More quartz
• Less kaolinite
• More illlite/mica
• Less plagioclase
• More K-feldspar
+
+--
Mineralogical composition Chemical composition
• More quartz SiO2
• More illlite/mica K2O
• Less plagioclase Na2O
• More K-feldspar K2O
1 2 3
SiO2 68.3 69.2 70.2
Al2O3 20.1 18.1 17.6
Fe2O3 0.44 1.13 1.05
TiO2 0.47 0.59 0.51
MgO 0.23 0.42 0.34
CaO 0.70 0.96 0.58
Na2O 4.06 2.64 2.49
K2O 1.74 2.89 3.36
*LOI 3.79 3.91 3.59
Preparation and testing
1 2 3
Dry
den
sity
(g/
cm3
)
1.80
1.85
1.90
1.95
2.00
2.05
Grainsize distribution of raw materials mixtures Dry density of compacts
Composition d(0.1) d(0.5) d(0.9) 1 1.4 7.5 34.7 2 1.3 6.5 33.0 3 1.3 7.4 37.9
1
2
3
Physical properties of mixes and compacts
Preparation and testing
Temperature (°C)
200 400 600 800 1000 1200
Exp
ansi
on
(%
)
-6
-4
-2
0
Sintering behaviour
Preparation and testing
Technological properties of fired bodies
1 2 3
WA
(%
)
0.00
0.25
0.50
0.75
Water absorption (WA)
Porcelain stoneware <0.5 wt.% (BIa according to ISO 13006)
200 mm mm
Tile surface
Preparation and testing
Colorimetric parameters
1
1 2 3
L*
0
20
40
60
80
100
78.6
62.1 63.0
2 3
11.6 12.1 12.2
0.46% 1.18% 1.09%Fe2O3
1 2 3
a*
0.0
0.5
1.0
1.5
2.0
2.5
3.0
1.1
2.4 2.6
Preparation and testing
Highlights
• A water absorption <0.5 % were obtained using an industrial firing cycle (1210°C, 45min).
• The successive replacement of extra-EU raw materials led to a higher concentration ofFe2O3 and thus lower whiteness (L*) and increased reddish tone (a*).
• All three compositions showed similar behaviour during the grinding, pressing and sintering processes and also similar technologic characteristics.
Life Cycle Assessment
DEFINITION: the LCA is a methodology that assesses in a quantitative manner all
the environmental burdens connected with a product or service, from to the extraction of raw materials to the end of life.
Goal and scope definition
Inventory analysis
Impact assessment
Interpretation
PHASES
ISO 14040-14046
FINAL STORAGE
DISTRIBUTION
INSTALLATION
USE
END OF LIFE
Wastewater with solids + Raw waste
Fired scrap
Slip waste
Evap. water
Sifted mat. Clean. waste
Clean. waste
MILLING
Raw mat. body SpheresPebblesThinnerWater ATOMIZATION
Atm. emiss.Filter emiss.
Atm. emiss. Filter emiss.
Atm. emiss. Filter emiss.SORTING – PACKAGING
Evap. water
FIRING
INTERM. STORAGE
CUTTING
SQUARING
LAPPING
Atm. emiss.Filter emiss.
Sludges (filtr./non filtr.)
Atomized massAtomized mass
Natural gas
ElectricityElectricity (self-produced)To the grid
Sludges, aqeoussusp.
PRESSING
DRYING
GLAZING – DECORATION
Pigment (135.03 t)
GritInk
MILLING (GLAZE)
Raw mat. glazeSpheresWater
Atm. emiss.Filter emiss.
Atm. emiss. Filter emiss.
Atm. emiss. Filter emiss.
Evap. water
Evap. water
Raw waste
INVENTORY ANALYSIS
Life Cycle Assessment
0
2000
4000
6000
8000
10000
12000
Pt
Life Cycle Assessment
0
2000
4000
6000
8000
10000
12000
Pt
0
2000
4000
6000
8000
10000
12000
Pt
111043 Pt
36969 Pt
29753 Pt
Total: 45244 Pt
Total: 43954 Pt
Total: 41169 Pt
-2.8
5%
-6.3
4%
0
2000
4000
6000
8000
10000
12000
Pt
Dynamic sustainability tool
An LCA study requires expertise and time!
DYNAMIC SUSTAINABILITY
TOOL
Dynamic sustainability tool
Data from ERP Data from Excel
Business Intelligence Software
Dynamic sustainability tool
Amount of raw materials
Amount of water
Electricity consumption
Natural gas consumption
Waste
…
VARIABLES
Time reference unit: one month
Dynamic sustainability tool
Integration of the three dimensions of sustainability
ENVIRONMENTAL ECONOMIC
SOCIAL
SUSTAINABILITY ASSESSMENT
Dynamic sustainability tool
• Three of the several raw materials mixtures designed for the production of porcelainstoneware tiles were analyzed both from the technological and environmental pointof view.
• Extra-EU raw materials were successively replaced by European raw materials inorder to evaluate possible changes.
• Laboratory tests highlight that the compositions show similar characteristics and arein line with typical stoneware porcelain tiles.
• From the environmental point of view, composition 3 shows the best results; thisconfirms that an accurate eco-design for the supply of raw materials can really affectthe environmental performance of the ceramic tiles.
CONCLUSIONS
Project Overview
LIFE: Force of the Future (Forture)New circular business concepts for the predictive and dynamic
environmental and social design of the economic activities
Associated Beneficiaries:
With the contribution of the LIFE financial instrument of the European Community. Project Duration: October 2017 – September 2020
Coordinating Beneficiary:
Thank you for your attention
L. Volpi(1), A. M. Ferrari(1), D. Settembre-Blundo(2), F.E. García-Muiña(3), M. Lassinantti-Gualtieri(4), C.
Siligardi(4)
(1) Department of Sciences and Methods for Engineering, University of Modena and Reggio, Emilia, Reggio Emilia 42122, Italy(2) Gruppo Ceramiche Gresmalt, Sassuolo 41049, Italy
(3) Department of Business Administration (ADO), Applied Economics II and Fundaments of Economic Analysis, Rey-Juan-Carlos
University, Madrid 28032, Spain(4) Department of Engineering “Enzo Ferrari”, University of Modena and Reggio Emilia, Modena 41125, Italy