trip - a new cycle of life in the stone industry

A new cycle of life in the stone industry


TRIP – TECHNIQUES RECOVERY INNOVATIVE PRINTABLE

ABSTRACT

TRIP – TechniquesRecovery Innovative Printable

Sustainable solution for the recycling of sludge processing of natural

stone to use as raw material for a new 3D printing technique.

The project has several objectives “eco”, as it is aimed at achieving a

closed production cycle, in which every industrial area minimize the

materials of result and the production of waste from landfill.

The global land suffered a great environmental impact, caused by the

quarry operations and the industrial processing of marble; so this project

completely recycled the marble dust, avoiding the complex disposal

process with high cost.



The project highlights not only the quality of the materials, the beauty

of the stones, but also the relationship between landscape and quarries,

including quarry operations and environment, a sustainable path that

increases the value of culture and technical skills.

The idea is based on previous experience from research project at

lab scale, through editing a prusa i3 3D printer, available in kit to be

assembled.

The “sludge waste” back in the solid state with superior characteristics,

and this “mixture” can cost up to 1/3 of the starting raw material.

The goal is planning large-scale 3D printer and define a new building

material to share with the community the way for a new cycle of life in

the stone industry.

BACKGROUND: ENVIRONMENTAL PROBLEM / SLUDGE



The vast quantity of natural stone products used in the construction

industry generates significant amounts of sludge deposits - estimated

at five million tons per year in Europe. These deposits are typically

disposed of in poorly controlled or un-controlled dumps. This can lead to

persistent and gradual contamination of soil, groundwater and surface

water.

Today there are no common European policies for a sustainable

management of the resources and residues in concordance with other

European initiatives.

OBJECTIVE



- Create a new life cycle of the stone industry, a sustainable path that values culture and technical skills through materials and companies

- Fighting the waste of raw material and disposal costs

- Reduce environmental impact designing a 3D printer that works with dense-fluid materials in the construction field

-Identify a new eco label

-Identify a new technology district

Main objective is the development of a new productive process for the recycling of sludges produced during the industrial processing of Natural Stone products.



Nowadays, sludges deposits are mostly deposited in poorly controlled

or uncontrolled dumps causing a significant environmental impact in

producer regions.

Valorization of the sludges will be achieved by means of a new process

of the products based on a new technology.

In this project, a pilot plan for 3D printing has been performed and the

resulting sludge has been used as raw materials in SME.

Today the result of the pilot project certifies by a national accreditation

body the level of quality of the “eco” material.

PRINTER

PRINTER



TRIP3DPRINTER employs linear guides in the X, Y, and Z directions,

similar to 3D printers standard and CNC milling machines.

The entire system is numerically controlled and thus fully automated.

The hardware is designed to be scalable, simple, and modifiable.



SCALABILITY

The printer is designed as a scalable machine.

That machine has dimensions: 8x10 x 3.30 meters but it may be larger.

HARDWARE

Hardware is very similar to 3D printer and CNC milling machine hardware:

there are two fixed tracks in the x direction, the tracks lean on a bearing

structure and are connected by a girder where is connected a cross-slide

which moves in the y direction and on it is mounted the arm containing

the extruder that moves in the z direction.

Cross-slide is connected to the arm that contains the extruder for the

cement.



EXTRUDER

The extruder is placed inside the robotic arm that moves on the z axis,

and is connected by means to a tank containing the sludge that is pushed

with a system of pressure pumps.

The extruder have a screw system or direct injection.

ELECTRONICS

The onboard electronic sused are similar to thosefound in CNC milling

machines and 3D printers. Motors, servos, solenoids, valves, sensors, and

other hardware are controlled with a microcontroller and supplementary

power supply. The microcontroller need software that can interpret

numerical control code and subsequently drive the motors and other

equipment to compete operations.



SOFTWARE

The entire system is automated and numerically controlled, and need a powerful

software to create the numerical code in a smart, easy, and efficient manner.

The software istaken on a open source cloud accessible to all. The software slicer

converte the 3D model in instructions that interact with the 3D printer and sets all

printing parameters. All these instructions are received from the printer thanks

to a specific code, the G-code. While to create 3D models to be printed just use

the traditional software CAD / CAM.

PLANT FOR THE SLUDGE

All rejects from marble are stocked in an appropriate recipient, where the mixing

process takes place. In this process the sludge is added a binder and the relative

fibers. When the mixtureis ready, the fluid is pushed toward the extruder by

means a pressure system controlled. This facility is equipped with a washing

system which allows a correctmaintenance.







MISSION



STRENGHT

Today the research in this area focus on the reuse of sludgeusing a drying

process.

It’s developing a fabrication of new products based on the recycled

sludges, includes bricks, self-mounting construction products,

pre-cast products including concrete beams, joists, concrete bricks,

panels, agglomerated stone and cementindustry.

The final characteristics of those products respect to the conventional

products in addition to being “eco” have all the advantages of 3D printing.



GREATER INNOVATION

- ability to print prototypes in hours, obtain feedback, refine designs

and repeat the cycle until you get a perfect result

BETTER COMMUNICATION

- a realistic 3d model and color is able to convey far more information

than a picture on your computer

- creation of three-dimensional physical models for numerous

applications in a fast, simple and convenient

SHORTER TIME TO MARKET

- 3d printing more prototypes on demand streamlines design cycles


Lower development costs

- lower costs for traditional processes of prototyping and manufacturing

- early identification of design errors

- reducetravel to production facilities

Customer acquisition

- ability to show potential clients, sponsors and interest groups of realistic

3d models

it is a growing market to get the best for the customer



FALLOUT

- Recovery of waste of marble processing

- Recycling of waste materials

- Reduceddisposalcosts

- Gain from the marketing of final products

- New horizons for industrial production

- New approaches of 3D printing

www.triptechnology.com

trip - a new cycle of life in the stone industry

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