Overview di progetto Project overview Dr Elisa Rambaldi Centro Ceramico Dr. Elisa Rambaldi, Centro Ceramico
Project details Project details 2
Project partners oject pa t e s From month 1(January 2015) From month 1(January 2015) From month 19 (July 2016) From month 19 (July 2016) Till month 18 (June 2016) Till month 18 (June 2016) Till month 36 (December 2017) Till month 36 (December 2017) 3
Project Background oject ac g ou d NEW CONCEPT OF CERAMIC MIX: Natural raw materials PLASTICIZER, FLUXING AND TEMPERIG are substituted by: Natural raw materials PLASTICIZER, FLUXING AND TEMPERIG are substituted by: 4
Scientific research Scientific research Geographical provenience of scientific papers on waste recycling in porcelain stoneware mixes (from 2000 till 2017). Source: SCOPUS database. 5
Statistical analysis 2017 – EU market Market analysis Market analysis Percentages of sellers and shops in which Percentages of sellers and shops in which “sustainable” ceramic tiles are recognizable recognizable (LEED, EPD, Ecolabel, ...) or not recognizable not recognizable Recognizable Not recogniable g 6
7 30% 30%
Project AIM oject 1. Saving of natural resources 2. Reduction of thermal Industrial production of porcelain Industrial production of porcelain energy energy consumption stoneware tiles containing 70% of of pre pre and and post post consumer consumer wastes. 70% 70% 70% 70% 3. Valorisation and recovery of wastes 8
Post ‐ consumer wastes: glass ost co su e astes: g ass Glass from urban separate collection 1 673 000 ton/year 1,673,000 ton/year ~60,000 ton 4% yearly collection TILES 4.16 Mm 2 /year 30% available (about 500,000 ton/year) 1% Italian production 70% reused by glass industry 70% reused by glass industry Glass SAVEL C Glass SAVEL C Glass coming from urban separate collection NOT suitable for the glass i d industry. It is produced in the MINERALI t It i d d i th MINERALI INDUSTRIALI’s plant. 9
Pre ‐ consumer wastes: by ‐ products of Pre consumer wastes: by products of the ceramic industry ation es destina y c industry of waste ceramic Data 2015 Integrated Report 2017 g p % o by Unfired scrap tiles Unfired scrap tiles It represents about 4% of the total production and usually it is reused in the same production in a close cycle. 10
Pre consumer wastes: by products of Pre ‐ consumer wastes: by ‐ products of the ceramic industry % or, WRF% use Facto RR , % Data 2015 Integrated Report 2017 g p FR Waste Reu 85 W Industries with complete cycle with partial cycle p y 11
Project activities Project activities 12
Results at month 18 esu ts at o t 8 FINCIBEC’s Industrial Production : sustainabel FINCIBEC’s Industrial Production ceramic tiles (25x25 cm) containing 96% of recycled ( ) g 96% of recycled % % y y TILES materials . This product, in accordance with materials EN 14411, belongs to class BIIb (water absorption 6 < E ≤ 10%) (water absorption 6 < E ≤ 10%) 13
Project final results oject a esu ts MARAZZI’s Industrial production: Porcelain stoneware tiles (class BIa) containing 85% of recycled materials ( ) g y Format 30x60 cm glazed and not glazed 14
Project final results oject a esu ts MARAZZI’s Industrial production: Porcelain stoneware tiles (class BIa) containing 85% of recycled materials ( ) g y Format 15x15 cm glazed 15
Raw materials Raw materials To produce 100 m 2 of tiles, it is necessary: Saving of natural resources: feldspars and sands: 100% clays: 62% clays: 62% 16
The process WINCER tiles are obtained with traditional process in which the maximum i hi h th i firing temperature if 1025°C is sufficient to reach a water absorption belo absorption below to 0.5%. to 0 5% WINCER tiles belong to group BIa and have belong to group BIa and have to fulfill with the requirements of annex G of EN 14411. 17
Model of production and offer Model of production and offer Due to technical reasons, these tiles are produced in a dedicated production line produced in a dedicated production line dedicated production line not dedicated production line , not shared with other type of production. The most versatile format is the 30x60 cm. It can be included in the “large format” group, suitable both for outdoor and indoor destinations. b h f d d i d d i i 18
Series “STONEWORK GL SR, tipo WINCER, codice K1EH” 19
Lower environmental impact p LCA STUDY (ISO 14040 e ISO 14044) Tile Environmental indicators (EN 15804) Environmental indicators (EN 15804) Traditional tile Traditional tile 85% recycled Global Warming Potential , GWP 1.09% 24-25% [kg CO 2 -eq.] [kg CO 2 eq.] Ozone Depletion Potential, ODP 0.43% 69-75% [kg CFC11-eq.] Acidification Potential AP Acidification Potential, AP 2.80% 54-56% [kg SO 2 -eq.] Eutrophication Potential, EP 3.35% 3.35% 26-27% 26 27% [kg (PO 4 ) 3 -eq.] Pothochem. Ozone Creation Pot., POCP 2.08% 37-39% [kg Ethen eq.] [ g q ] 20
ENVIRONMENTAL sustainability sustainability WINCER tiles obtained the certification LEED Certiquality for the amount Certiquality for the amount of recycled materials: 85% (30% pre-consumer and 55% post-consumer wastes). p ) 21
Lower amount of quartz in the WINCER spray dried powder respect to a traditional spray dried powder: -55% traditional spray dried powder: 55% 55% 55% SOCIAL sustainability Lower Respirable fraction of p Crystalline Silica (RSC): RCS values in WINCER production are lower of about 63%, respect to those of a traditional porcelain stoneware. 22
ECONOMIC ECONOMIC Traditional mix for per 1m 2 tile Cost/m 2 Compos. kg sustainability Clay y 36% 7.92 0.55 € Feldspar sand 64% 14.08 0.55 € Chemical agents 0.002 € Lower industrial costs for mix Milling 0.66 € TOTAL 100% 22 1.76 € preparation: •Lower expenses for raw WINCER mix for 1m 2 tile materials Cost/m 2 Compos. p kg g •Recovery of pre and post Clay 15% 3.3 0.26€ consumer wastes Unfired scrap tiles 30% 6.6 0.0066 € •Lower methane and energy Scrap glass p g 55% 12.1 0.363 € consumption ti Chemical agents 0.002 € Milling 0.55 € TOTALE 100% 22 1.18 € Decreasing of cost production : -33% 33% 23
ENVIRONMENTAL ENVIRONMENTAL sustainability SOCIAL sustainability ECONOMIC ECONOMIC sustainability TILES 24
EUROPEAN EUROPEAN 3. Widening of the ceramic products added value market by including y g more sustainable ones in substitution of other materials. 2. Acquisition of the 2 Acquisition of the 4. Reduction of energy world leadership in consumption and CO 2 the production of e emissions. ss o s high recycled content high recycled content ceramic tiles. 5. Higher health in the workplace workplace. 1 1. Promotion of the Circular Economy 25
EUROPEAN EUROPEAN added value TILES WINCER tiles developed at national level represent: a model of sustainable sustainable tiles tiles able to boost other ceramic company in Italy or in Europe; or in Europe; a virtuous virtuous example example among marketable sustainable products, in line with the EU policies that will become more and more restrictive. p 26
C Contact t t rambaldi@centroceramico.it www.wincer-project.eu 27
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