After LIFE Communication plan - FOUNDRYTILE · 2018. 10. 26. · foundry sands) into a resource for...

LIFE14 ENV/ES/000252

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After LIFE Communication plan LIFE14 ENV/ES/000252

July 2018

Valorization of iron foundry sands and dust in ceramic tile production process


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Project description

THE PROBLEM

The environmental problem addressed in this project is the management of sands and dusts discarded in the iron foundry industry, which currently represent around 300,000 tons per year in Spain.

Although there are several valorization alternatives which have been demonstrated and can be applied to different foundry by-products fractions, the real situation is that less than 50% of these by-products are actually valorised.

On the other hand, the sector of ceramic tile production consumes large quantities of raw materials, especially sands and clays, which could be partially replaced by these by-products.

OBJECTIVE

The project has demonstrated the technical, economic and environmental feasibility of the valorization of the fine fraction and the iron foundry sands in the production of ceramic tiles as substitutes for raw materials: red clays, in red-firing ceramic products and white clays, in ceramic white cooking products. Consequently, the solution promotes the concept of circular economy, key to sustainable development, since it reinforces the industrial symbiosis between companies in the foundry sector and the ceramic sector. Additionally, the project contributes to the implementation of the European Waste Directive (Directive 2008/98/EC) and the objectives and goals of the Roadmap towards an efficient use of resources in Europe.

The new application entails the following main benefits: preservation of natural resources, increase of foundry waste valorization, reduction of the environmental footprint and increase in the competitiveness of the companies from the foundry and ceramic sectors.


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Methodology and results

Opportunity

Requirements

Adequacy Test

Validation

¿Sustainable? Implementation

Regulatory framework

Selection and characterization of foundry by-products

Definition of pre-treatments Laboratory scale tests Pilot and industrial scale tests Analysis of the life cycle and the cost

cycle. Socioeconomic impact.

Selection and characterization of by-products Definition of pretreatments

Obtaining products at pilot scale

August 2018

Final project

September 2015

Start project

December 2017

June 2017 June 2016 May 2018

Obtaining products at an industrial scale. Analysis

of the chemical risk in human health

Socioeconomic impact. LCA and

LCC.


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RESULTS

Database with the characteristics of foundry by-products and acceptability criteria for ceramic products.

Characterization of 23 representative samples of 20 types of foundry sands and dusts from 10 foundries.

Evaluation of different technologies to adequate by-products by reducing their iron and organic carbon content. It is demonstrated that the magnetic separation and the thermal treatment allow increasing the substitution ratio of by-products from 2.2 to 5%.

Formulation and characterization of ceramic tile compositions of different types with percentages of by-products comprised between 1 and 5%.

Validation on a pilot scale of the 4 main types of ceramic compositions with percentages of by-products of 2.2% (for three of the types) and 1% (for the type of tile with the highest purity requirements in raw materials).

Production of 20 tons of spray-dried powder for both white wall tiles and porcelain tiles with by-products and manufacture of approximately 800 m2 of tiles for each product in a ceramic tile manufacturing company located in the province of Castellón, the core of the Spanish ceramic cluster.

Verification of the absence of impact on gaseous emissions associated with the firing of ceramic tiles due to the introduction of by-products.

Through the Life Cycle Analysis (LCA) methodology, it has been demonstrated that the proposed by-product valorization involves environmental benefits for all the evaluated products, confirming its viability as a circular economy strategy.

In the Cost Cycle Analysis (LCC), it has been validated that the valorization of foundry by-products allows a cost reduction in both sectors involved, mainly due to the reduction of raw materials consumption in the ceramic sector and to the reduction of waste management costs in foundry industry.

The Chemical Risk Analysis for human health has shown that the use and manufacture of tiles incorporating foundry by-products does not result in an unacceptable additional risk to human health.

Participation of more than 300 agents of the ceramic sector and foundry companies in the project.

Dissemination of the importance of the use of foundry by-products and promotion of their acceptance by society.

Dissemination of project experiences to companies and / or entities at European level.


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Figure 1. Prototypes obtained at pilot scale.

Figure 2. Pilot scale processing in ITC


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Figure 3. Processing at pilot scale in EUTOMI.

Figure 4. Industrial scale tests of the production of ceramic tiles with foundry by-products. Production of spray-dried powder.

Figure 5. Industrial scale tests of the production of ceramic tiles with foundry by-products. Pressing of the supports.


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Figure 6. Industrial scale tests of the production of ceramic tiles with foundry by-products. Glazing of the supports.

Figure 7. Industrial-scale tests of the production of ceramic tiles with foundry by-products. Firing.

Figure 8. Industrial-scale tests of the production of ceramic tiles with foundry by-products. Finished product.


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IMPACT

Contribution to the establishment of industrial symbiosis strategies focused on promoting the circular economy, transforming a waste (sand and fine fraction of foundry sands) into a resource for another sector.

Valorization of about 260,000 tons per year of foundry by-products in the ceramic sector at national level with the consequent decrease of by-products deposited in landfills.

Reduction of the environmental impact in the production process of ceramic tiles. FOUNDRYTILE provides environmental advantages over conventional production for a maximum transport distance of by-products between 875 and 1,025 km (depending on the type of evaluated products), taking into account CO2 emissions. This fact guarantees the environmental viability of the FOUNDRYTILE solution at a European level.

Reduction of the carbon footprint throughout the life cycle of ceramic tiles, saving up to 8,500 tons of CO2 per year at national sectorial level.

Reduction of the extraction of natural raw materials from quarries with the consequent preservation of natural resources.

Reduction of the cost derived from the management of foundry by-products. Reduction of the manufacturing costs of ceramic tiles by replacing conventional raw

materials by foundry by-products. Improvement of the competitiveness of ceramic companies by reducing the costs

associated with raw materials. Increase the knowledge and training of workers in the ceramic and foundry sector in

the field of circular economy. The results of the FOUNDRYTILE will be a reference at European level through the

documents of best available techniques (BREF documents), both from the ceramic sector and from the foundry sector.


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Communication strategy

COMMUNICATION TOOLS

Project website: www.foundrytile.eu. Public information available about the project description and results obtained, as well as access to graphic material in digital format (> 1,700 visits).

Graphic material of distribution: Layman's Report (300 units), leaflet (750 units) and posters (2 units). This material is also available in digital format on the project website.

Promotional video: also available on the project website. https://www.youtube.com/watch?v=ELqRL2OoFuE

Information boards: 5 information boards located in the facilities of the coordinator and all the partners.

Demonstrator’s points: 3 demonstrator’s points with samples of ceramic products obtained at the coordinator's headquarters and at the headquarters of two of the partners.

Electronic newsletter: 7 electronic newsletters showing with project progress.

Media: news, articles and press releases.

Guide for the diffusion of the requirements of the by-products and ceramic applications.


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COMMUNICATION ACTIONS

Press releases:

o El Diario Digital de Castellón, El periódico del Azulejo, RETEMA, FUNDIPRESS, Technical newsletter of FEAF…

Dissemination of the project on the partners’ websites

Launching meeting in Barcelona (November 2015), Bilbao (November 2015) and Castellón (May 2016).

Assistance to several conferences and sessions:

o Innovative initiatives aimed at promoting the circular economy of the foundry sands in IK4-AZTERLAN in Durango (November 2017).

o CAEF Environmental Committee II (November 2016 in Düsseldorf, April 2017 in Vienna and May 2018 in Düsseldorf).

o Environmental Committee of CerameUnie in Brussels (March 2016 and October 2017)

o Congress on Waste Engineering and Circular Economy (VII Ibero-American Symposium on Waste Engineering) in Santander (June 2017).

o Regional Infodays of the LIFE Program in Valencia (July 2016, May 2017 and May 2018)

o Innova Ceramics Forum in Valencia (February 2016 and 2018)

Fairs and general exhibitions::

o CEVISAMA 2016, 2017 and 2018 (Valencia)

o Qualicer Congress 2018 and 2016 (Castellón)

o Feria de Subcontratación 2017 (Bilbao)


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COMMUNICATION ACTIONS

Networking with several LIFE projects:

o Foundry sector: LIFE ECO-SANDFILL, LIFE FOUNDRYSAND, LIFE GREENZO

o Ceramic sector: LIFE CERAM, LIFE ECOTILES, LIFE CLAYGLASS, LIFE SLUDGE4AGGREGATES

Technical Workshop for LIFE projects presentation organized by CTM (November 2016)

Leaflets distributed in various events:

o 16th International Waste Management and Landfill Symposium (Sta. Margherita de Pula, Italy, October 2017)

o IFAT 2018 (International Trade Fair for Water, Sewage, Waste and Raw Materials) (Munich, Germany, May 2018)

o Intergune + 2018 (Bilbao, February 2018)


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Future dissemination activities

The objective of the dissemination of the FoundryTile project is to publicize the results obtained in order to promote the implementation of the validated alternative, both nationally and internationally.

The future actions detailed below will be carried out in accordance with the usual activity of each beneficiary, with the active participation of a professional team of the different participating entities.

The time period in which these actions will be carried out depends on each one, but it can be estimated in a period of 1-5 years.

1 – Project website maintenance

DESCRIPTION

The website will remain active for a minimum period of five years after the project end. Through the website, it will be possible to continue having access to all the information related to the project. Likewise, the content will be updated with new information related to environmental problems and future implementations of the evaluated solution. www.foundrytile.eu

RESPONSIBLE

Asociación Española de Fabricantes de Azulejos y Pavimentos Cerámicos (ASCER)

PERIOD / FREQUENCY

2018-2023/periodically BUDGET

2.000€

2 – Distribution of dissemination material

DESCRIPTION

The dissemination material of the project, mainly leaflets and the Layman's Report, will be distributed in the different diffusion events, to different project stakeholders contacted by project partners. More copies will be printed if necessary. All the material is also digitally downloadable through the project website. Dissemination of the project video in dissemination events.

RESPONSIBLE

Fundació CTM Centre Tecnològic, Asociación de Fundidores del País Vasco y Navarra (AFV), Asociación de Investigación de las Industrias Cerámicas (AICE-ITC), Asociación Española de Fabricantes de Azulejos y Pavimentos Cerámicos (ASCER) and EUROATOMIZADO, S.A.

PERIOD / FREQUENCY

2018-2020

BUDGET

2.000€


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3 – Information board

DESCRIPTION

The information boards of the project will be kept in a visible place in the facilities of the Fundació CTM Centre Tecnològic, la Asociación de Fundidores del País Vasco y Navarra (AFV), la Asociación de Investigación de las Industrias Cerámicas (AICE-ITC), la Asociación Española de Fabricantes de Azulejos y Pavimentos Cerámicos (ASCER) and EUROATOMIZADO, S.A. until 2021.

RESPONSIBLE


PERIOD / FREQUENCY

2018-2021

BUDGET

0 €

4 – Demonstrators’ points

DESCRIPTION

Demonstrators’ points with the ceramic tiles produced in the industrial tests will be kept in a visible place in the facilities of Fundació CTM Centre Tecnològic, Asociación de Investigación de las Industrias Cerámicas (AICE-ITC) and Asociación Española de Fabricantes de Azulejos y Pavimentos Cerámicos (ASCER) until 2021.

RESPONSIBLE

Fundació CTM Centre Tecnològic, Asociación de Investigación de las Industrias Cerámicas (AICE-ITC) and Asociación Española de Fabricantes de Azulejos y Pavimentos Cerámicos (ASCER).

PERIOD / FREQUENCY

2018-2021

BUDGET

0 €

5 – Incorporation of the results of the project in the revision of the documents of “Best Available Techniques Reference Document (BREFs)” prepared by the European Commission for the foundry and ceramic sector

DESCRIPTION

The active participation of ASCER and AFV beneficiaries in the review processes of the documents of "Best Available Techniques Reference Document (BREFs)" prepared by the European Commission for the foundry and ceramic sector, guarantees that the results of the project will be taken into account in these reviews, planned for the next few years.

RESPONSIBLE


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Asociación de Fundidores del País Vasco y Navarra (AFV) and Asociación Española de Fabricantes de Azulejos y Pavimentos Cerámicos (ASCER).

PERIOD / FREQUENCY

2018-2021

BUDGET

1.000 €

6– Promotion of the project in seminars, congresses and fairs

DESCRIPTION

The partners will participate in events of interest to promote and present the results obtained in the project both nationally and internationally. In these events, project dissemination material will be distributed. The main identified events for project dissemination are:

CEVISAMA 2019, 2020 QUALICER 2020 CONAMA 2020 Feria de Subcontratación 2019 Cersaie 2019, 2020 GIFA 2019 Feria de Subcontratación 2019 6th International Slag Valorization Symposium 2019, (April) Congress of the Spanish Society of Ceramics and Glass Coverings 2019, 2020…

RESPONSIBLE


PERIOD / FREQUENCY

2018-2020

BUDGET

8.000€

7 – Publications and dissemination of the project in the media

DESCRIPTION

Press releases that are considered appropriate to disseminate the results of the project will be made. Two publications will also be carried out at a national or international level in sector journals or SCI journals of the scientific-technical results of the project. Possible magazines:

FUNDIPRESS Técnica cerámica Ceramic Forum International.


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RESPONSIBLE

Fundació CTM Centre Tecnològic, Asociación de Investigación de las Industrias Cerámicas (AICE-ITC) and EUROATOMIZADO, S.A.

PERIOD / FREQUENCY

2018-2019

BUDGET

5.000€

Exploitation / industrial implementation plan

In order to accelerate the industrial implementation of the Foundrytile project, it is recommended to establish bilateral agreements with the foundry company - manufacturer of spray-dried powder. To do this, the foundry companies must provide information about the characteristics of their foundry by-products, especially for the parameters established as critical (organic carbon and iron). Based on the results, an agreement will be established between both parties, which will specify the conditions of supply, cost, homogenization and adequate limit parameters to guarantee the constancy of the properties of the by-products. This option is the most direct and quick for the recovery of foundry by-products, although it has the disadvantages that the foundry company has to be responsible for having a constant by-product collection, both in quantities and properties.

As an alternative, the option of collaborating with an intermediate company, waste manager, already established in the Basque Country and Catalonia (the main communities where foundry companies are concentrated) or newly created, whose mission is to collect the foundry by-products, homogenize and control them considering the defined critical parameters (organic carbon and iron). If necessary, this company will be responsible for pre-treating them to adapt them to the requirements of the ceramic process. Finally, this company will be in charge of establishing agreements with the ceramic sector and managing the transport of by-products, with the expenses of this activity being passed on to the cost of the by-product.

In addition to the agreements between companies, there will be a collaboration with working groups responsible of the review of the BREFs documents of both sectors involved, in order to include the results of the project as recommendations and thus facilitate their industrial implementation.


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Project identification

Project coordinator

Project beneficiaries

Project reference: LIFE14 ENV/ES/000252 Location: Spain Duration: 03/09/2015- 31/08/2018 Total budget: 1.205.363€ LIFE Program contribution: 722.884€

www.foundrytile.eu [email protected], [email protected]

Fundació CTM Centre Tecnològic Plaça de la Ciència, 2 08243 Manresa (Barcelona). Spain Tel. +34 93 877 73 73 E-mail: [email protected]

The FoundryTile Project (2015-2018) was funded by the LIFE program of the European Commission

With the collaboration of the Generalitat Valenciana- IVACE

After LIFE Communication plan - FOUNDRYTILE · 2018. 10. 26. · foundry sands) into a resource for...

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