LIFECERAM. Zero waste in ceramic tile manufacture.Paqui Quereda VázquezHead of the Laboratory for Ceramic CompositionsArea of Materials and Ceramic Tecnologies

LIFE12 ENV/ES/230-LIFE CERAM is co-funded by the European Commission LIFE+ Environment Policy and Governance programme.

e1

Diapositiva 1

e1 Aquí, abajo de izquierda a derecha el logo de otras empresas si fuera necesarioeblasco; 12/01/2011

LIFECERAM

Title of the project: LIFE CERAM. Zero Waste in Ceramic Tile Manufacture

Funding programme: LIFE +

Call: 2012

Budget: 799,502 € 50 % UE Co-funding

Length: Start 01/09/2013 End 30/06/2016

Website of the project: http://www.lifeceram.eu

LIFECERAM

Consortium:

Co-ordinator:

AICE-ITC. R&D centre.

Partners and roles:

Asociación Española de fabricantes de azulejos y Pavimentos Cerámicos (ASCER). Manufacturers association.

Chumillas & Tarongi. Machinery manufacturer.

Keros Cerámica. Tile manufacturer.

Vernis. Frit and glaze manufacturer.

LIFECERAM

DESCRIPTION OF THE PROJECT

Background:The manufacturing of ceramic tiles generates wastes at different stages of the production process (1.4 million ton/year).

Raw materia ls

M illingspray drying

Pressing Drying Glazing Fir ing Tile

Gl aze p reparat ion

Raw materia ls

M illingspray drying

Pressing Drying Glazing Fir ing Tile

Gl aze p reparat ion

Green scraps Glaze sludgeGreen scraps

Fired scrapsDust from theKiln filters

Raw materia ls

M illingspray drying

Pressing Drying Glazing Fir ing Tile

Gl aze p reparat ion

Raw materia ls

M illingspray drying

Pressing Drying Glazing Fir ing Tile

Gl aze p reparat ion

Green scraps Glaze sludgeGreen scraps

Fired scrapsDust from theKiln filters

Frit residues

Polishing sludge

LIFECERAM

DESCRIPTION OF THE PROJECT

Background:

Green scrap45%

Fired scrap41%

Frit residues2%

Dust fromkiln filters0.2%Polishing sludge

8%

Glaze sludge4%

0%

20%

40%

60%

80%

100%

Greenscrap

Firedscrap

Polishingsludge

Glazesludge

Frit residuesDust fromkiln filters

LIFECERAM

DESCRIPTION OF THE PROJECT

Objectives:

� To achieve zero-waste in the manufacture of ceramic tiles.

The strategy consists of:

� Developing a new ceramic tile, consisting mainly of

waste, for outdoor applications.

� Designing a sustainable process based on dry milling and

granulation technologies.

LIFECERAM

58,012,32,6

0,409,7

1,661,982,690,162,474,091,090,020,05

-2,72

Glazesludge

63,316,90,13,83,01,21,82,80,70,20,20,1---

6,0

Greenscrap

67,217,90,14,13,31,21,93,00,70,20,30,1---

0,2

Firedscrap

1,000,310,22

<0,1562

0,440,250,460,010,010,120,022,531,4132,07,63

Dust fromkiln filters

60,64,78,00,1

12,02,92,03,40,12,96,62,4----

60,915,20,930,843,813,573,332,480,460,462,510,650,030,79

-3,90

SiO2Al 2O3B2O3Fe2O3CaOMgONa2OK2OTiO2ZrO2ZnOBaO

SClF

ppc

Fritresidues

Polishingsludge

ACTION B1. CHARACTERIZATION OF WASTES

LIFECERAM

ACTION B2. BODY COMPOSITION PREPARATION PROCESS

HAMMER MILL DISC MILL PENDULUM MILL

GRANULATION

LOW INTENSITY HIGH INTENSITY

DRY MILLING

LIFECERAM

ACTION B2. BODY COMPOSITION PREPARATION PROCESS

DRY MILLING

HAMMER MILL DISC MILL PENDULUM MILL

GRANULATION

LOW INTENSITY HIGH INTENSITY

LIFECERAM

ACTION B3. BODY AND GLAZE COMPOSITIONS

2

3

4

5

6

7

8

1120 1130 1140 1150 1160 1170 1180 1190 1200 1210

Temperature (ºC)

Line

ar s

hrin

kage

(%

)

0

2

4

6

8

10

Wat

er a

bsor

ptio

n (%

)

Lifeceram body

Stoneware tile

Porcelain tile

L.S. W.A.

LIFECERAM

ACTION B4. INDUSTRIAL TRIALS

LIFECERAM

ACTION B5. TECHNICAL AND ENVIRONMENTAL ASSESSMENT

38Modulus of rupture. EN ISO 10545-4 (N/mm2)

6060 (15 mm)Breaking load. EN ISO 10545-4 (N)

54Slip resistance. ENV 12633. USRV

2,32Bulk density (g/cm3)

2,7Water absorption (%)

The urban tile can be classified as non-hazardous based on the results of the environmental characterisation tests:

� Leaching tests

� Determination of gas emissions

Technical assessment

Environmental assessment

LIFECERAM

CONCLUSIONS

� In the LIFE CERAM project, the different wastes generated in the ceramic tile manufacturing process have been characterised.

� An urban floor tile has been developed, whose body is entirely made up of these wastes.

� A highly sustainable body preparation process has been designed, that allows all ceramic wastes to be recycled.

� The body composition displays appropriate behaviour in the different production process stages and exhibits the required properties for use as urban flooring.

� The product is respectful with the environment, despite being made up of wastes, as the acid compound emissions are similar to those of current body compositions and the ion concentrations in the leaching tests are lower than those required to classify a waste as inert.

� Industrial trials have been conducted to validate the results obtained in the laboratory and their results have been satisfactory.