LEEMA%project%–Success%Storyamanac.eu/site/wp-content/uploads/2015/04/AMANAC... · 2 s...

Dr. Ch. DedeloudisS&B Industrial Minerals S.A (IMERYS Group)

Project Coordinator

LEEMA project – Success Story

This project has received funding from the European Union’s Seventh Framework Programme for research, technological development and demonstration under grant agreement no 285059

Workshop on Impact of the Energy-‐efficient Buildings PPP, Brussels, 27-‐28 April 2015

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Large Indu

strie

s

S&B INDUSTRIAL MINERALS GR

Etex Group (Redco) BE

SCHLAGMANN BAUSTOFFWERKE DETHERMAL CHERAMICS deFRANCE FR

Morando S.r.I. IT

FIBRAN GR

SME FENIX TNT S.r.o. CZ

AMS Solutions GR

Universities–

Research Institu

tes NATIONAL TECHNICAL

UNIVERSITY OF ATHENS GR

MPA University of Stuttgart DECentre Scientifique et Technique de la Construction (BBRI) BE

MFPA University of Weimar DE

D'APPOLONIA SPA ITArchitects Council of Europe (ACE) BE


Overview

ü Project Coordinator: S&B INDUSTRIAL MINERALS (Greece)ü Work Programme: EeB-‐NMP.2011-‐1: Materials for new energy efficient building components with reduced embodied energyü Starting Date: 01/01/2012ü Duration: 48 monthsü Grant Agreement No: 285059ü Cost: 8,118,299.84 €ü EU Funding: 4,670,000.00 €ü Website: www.leema.eu

Low Embodied Energy Advanced (Novel) Insulation Materials and Insulating Masonry Components for Energy Efficient Buildings

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Challenge for the construction industry

• Reduce manufacturing EnergyEmbodied energy may account for 20% of the building’s energy use

• Building components with improved thermal properties

Greener, Energy Efficient and Resource Efficient Europe

“20-‐20-‐20 objective” ü -‐20 % greenhouse gas emissionsü -‐20% energy consumptionü +20% share for renewable energy


Challenge

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ü Development of a new generation of inorganic insulation materials and building insulation masonry components (“3I”) with lower embodied energy (>50%) and lower cost (15%) and upgraded properties compared to the commercial ones

ü Improvement of durability and energy performance at building level

ü Safer and cleaner indoor building environment due to incombustibility and absence of organic/fibrous compounds

ü Use of wastes of industrial minerals exploitation, recycled rejects from the glass industry and industrial by-‐products

ßInsulating Inorganic Incombustible Materials and Masonry Components


Objectives

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Inorganic Polymers ü Inorganic=incombustibleü Good mechanical properties-‐ quick compressive

strength development ü Low thermal conductivity coefficientü Exploitation of aluminosilicate/ silicate wastes ,

recycled materials, by-‐productsü Energy efficient synthesis processü Low carbon footprintü Compatibility with current manufacturing

processes


The Idea: Inorganic Polymers

Mixing

Curing

Expansion

Crushing/ sieving

Foaming

Curing

Shaping

Shaping

Curing

ü Use of mineral tailings-‐wastes, recycled glass and other industrial by-‐products

ü Mixing at ambient conditionsü Curing at low temperatures

(50-‐100 oC) for 24-‐72h to obtain mechanical properties

ü Expansion using energy efficient Infrared Heating

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Activation solution

Rawmaterials


Low energy production processes

GranularFoamed

Compact

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The LEEMA Products


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3I Loose Fill Materials (3I LFM)

Applicationsü Loose Fill Insulation (cavity walls, floors etc.)ü Lightweight aggregate for concrete or clay based productsü Fillers for plasters, mortars, paints and joint compoundsMain advantagesü Lightweight,multifunctional, inorganic, inert and incombustibleü Excellent thermal performance: λ 0.033 – 0.045 W/(mK)ü Synthetic: Properties and particle size can be fine-‐tuned according

to application; (density 15-‐>120 kg/m3

ü Sustainable: based on wastes and recycled raw materials, expanded at moderate temperatures (500 -‐ 600ºC) compared to expanded perlite (~~ 1200ºC) using Infrared heating

• Free flowing and easy to install without special training or equipment, using standard procedures applied for loose-‐filling insulation materials


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3I Loose Fill Materials (3I LFM)

Material ApplicationLoose Bulk Density (Kg/m3)

λ10(W/mK)

1/R for 20cm insulation

(… is approx. U –value)(W/(m2K))

EE (MJ eq./FU)

LEEMA3I LFM

For Brick cavities/EPBs

38.9 0.034 0.17

For Fibre boards 76.7 0.039 0.20For Cavity walls

insulation61.8 0.038 0.19 20

Expanded perlite Commercial Loose

Fill insulation90 0.050 0.25 45

EPS beads 28 0.033 0.17 82

54% to 76% lower embodied energy per FU

Simulations based on preliminary results indicate that 3I LFM can reduce space heating energy demands by 70%


Functional Unit ( FU) is defined as 1 m2 of insulation with a thermal resistance R = 1 m2K/W

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3I Binders

Main advantages:ü Based on mineral tailings (wastes)ü Mechanical properties obtained after curing at low temperatures (~70 oC)

after a few daysü Compatible with traditional aggregates and conventional shaping methods

(moulding or extrusion)ü Suitable for the production of pre-‐fabricated non-‐structural construction

elementsü Embodied energy (for a typical perlite-‐based geopolymer) ~ 1.37 MJ/kg

(cement 5.2 MJ/kg, fired ceramic bricks 3 MJ/Kg)

Material Type Comp. Strength (MPa)

Flex. Strength (MPa)

λ(W/(mK))

Density(Kg/m3)

LEEMA3I Binders

21 6 0.19 148028 8 0.26 1600

Cement 0.72 1860

Clay Bricks 0.8-‐1.3 1890-‐2000


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3I Fibre Boards, 3I EPBs3I Fibre boards 3I Loose Fill Materials replacing expanded perlite or exfoliated vermiculiteü Successful Pilot scale production – No significant changes

in production processü λ 0.11-‐0.14 W/(mK) ü At the same recipe, 3I LFM leads to similar density (up to

+5%) but higher flexural strength (up to +44%), ü A new product with higher loose fill loading than the

current recipe will be produced, which will lead to a product with better insulation properties and much lower embodied energy

ü 3I binders could be used to replace cement, using moulding or extrusion as shaping methods

3I EPB3I Loose Fill Materials replacing expanded perlite in Fesco boardsü λ< 0.05 W/(mK)ü Density ~150 Kg/m3

ü Flexural Strength ~0.35 MPa


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3I Insulating Bricks

The “simple approach”: 3I Loose Fill Materials replacing expanded perliteü λ value of infill 0.035 W/(mK) (-‐12.5-‐

20% compared to perlite)ü Same production process ü Overall brick λ value ≤ 0.090 W/(mK)ü Embodied energy under evaluation,

estimated only 10-‐15% less The “futuristic” approach:3I binders replacing the ceramic brick bodyü ≈ Mechanical properties, similar density

and λ without using porosity modifiersü Similar production process, without

firing (>60% lower embodied energy)ü Optimized Extrusion under soft-‐clay

conditions


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3I Foam Blocks

Main advantagesü Sustainable: Based on perlite wastes ü Foamed using inorganic or organic foaming agentsü Mechanical properties obtained after curing at low

temperatures (~70 oC) after a few daysü Easy to cut – retain shape and strengthü Embodied energy calculation in progress, estimation

at least 50% less since cement is replaced completely

Material Type

λ(W/(mK))

Density(Kg/m3)

Comp. Strength (MPa)

1/R for 20 cm insulation

(… is approx. U –value) (W/(m2K))

3I Foamed Blocks 0.06-‐0.12 344-‐680 0.7-‐2.7 0.31-‐0.60

Aerated Concrete 0.6-‐1.4 200-‐

1600 1-‐10 3.0-‐7.0

Autoclaved Aerated Concrete

0.07-‐0.21 300-‐800 1.3-‐8.5 0.35-‐1.05


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LEEMA Successes

ü Success 1: A new insulation product has been developed as Loose Filling materials for cavity walls insulation that exhibit similar performance to commercial organic counterparts (EPB) and up to 76% reduced embodied energy

ü This loose fill material could be used as lightweight aggregate in replacement of expanded perlite or expanded polystyrene in the manufacturing of different construction materials like fiber cement boards and bricks

ü Success 2: A new fiber cement board has been developed of lower density, higher thermal insulation and lower embodied energy

ü Success 3: A thermal insulating brick with an overall λ value ≤ 0.090 W/(mK) and of at least 10-‐15% lower embodied energy vs current solutions. A more futuristic approach where the whole brick will be from geopolymer has been proven in concept. Thus, the new brick will have at least 60% less embodied energy

ü Success 4: The inorganic polymers (binders or lightweight aggregates) are compatible with current manufacturing processes used by the construction material industries, eliminating energy consuming steps such as clay firing.

ü Success 5: A new foam block to replace aerated concrete blocks with at least 50% less embodied energy.


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Further information

Thank you for your attention!

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This project has received funding from the European Union’s Seventh Framework Programme for research, technological development and demonstration under grant agreement no 285059


For more information visit the project’s website www.leema.eu

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