01_CI4_LIFECERAM_Javier García

4th Technology-Business Networking Event
HABITAT, CONSTRUCTION, ARCHITECTURE & CERAMICS

Organizers:

Supporters:

Fco Javier García Ten
Manager of the Ceramic Materials and Technologies Area, Project Manager

Cerámica Innova 4: From research to market


Title of the project and acronym: LIFE CERAM
Zero Waste in Ceramic Tile Manufacture
Organizers:
Funding programme: LIFE +
Call: 2012
Budget: 799,502 €
Supporters:

50 % UE Co-funding

Length: START 01/09/2013

End 30/06/2016

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



Consortium:
– Co-ordinator:
• AICE-ITC. R&D centre.
Organizers:

– Partners and roles:
• Asociación Española de fabricantes de azulejos y
Pavimentos Cerámicos (ASCER). Manufacturers
Supporters:
asociation.
• Chumillas & Tarongi. Machinery manufacturer.
• Keros Cerámica. Tile manufacturer.
• Vernis. Frit and glaze manufacturer.



DESCRIPTION OF THE PROJECT
Background:
The manufacturing of ceramic tiles generate waste at different
stages of the production process (1.5 million ton/year).
Organizers:

Raw
Supporters: mat erials

M illing
spray drying

Frit residues

Glaze preparat ion

Polishing sludge
Pressing

Drying

Glazing

Green scraps
Glaze sludge

Firing

Fired scraps

Tile


Background:
Organizers:
70 % of the waste are recycled in the current products.
Some waste are difficult to recycle in the current products and
Supporters:
process (changes in the product properties and manufacturing
problems):
 Hard residues (fired scraps)
 Waste with soluble compounds (dust from the kiln filters and
polishing sludge)




Objectives:
Organizers:
 To achieve zero-waste in the manufacture of ceramic tiles.
The strategy consists of:
 Developing a new ceramic tile, consisting mainly of
Supporters:
waste, for outdoor applications.
 Designing a sustainable process based on dry milling and
granulation technologies.



Action
2013
2014
Action
Name of the action
I
II III IV I
II III IV I
number
A. Preparatory actions
A1. State of the art in ceramic waste management at national &
A.1
European level
A2. Determination of technical and environmental key parameters
A.2
of existing products for urban paving
B. Implementation actions
B1. Characterization of ceramic and non ceramic residues
B.1
B2. Body composition preparation process
B.2
B3. Body and glaze compositions
B.3
B4. Industrial trials
B.4
B5. Technical and environmental assessment of the new product
B.5
C. Monitoring of the impact of the project actions
C1. Effectiveness of the Project actions
C.1
C2. Assessment of the socio-economic impact of the project
C.2
D. Communication and dissemination actions
D1. Project website
D.1
D2. Notice boards and layman´s report
D.2
D3. Beyond the consortium
D.3
E. Project management and monitoring of the project progress
E1. Day-to-day project Ten
E.1 Fco Javier Garcíamanagement
E2. Networking with other projects
E.2 Manager of the Ceramic Materials and Technologies Area, Project Manager
E3. After-LIFE Communication Plan
E.3

Organizers:

Supporters:


2015
II

III

2016
IV

I

II

III

IV


PREPARATORY ACTIONS
Actions A1 and A2

B1
Characterization of ceramic and non
ceramic residues

B2
Body composition
preparation process

B3

Body and glaze
compositions

Supporters:

B4
Industrial trials

B5
Technical and environmental
assessment of the new product

MONITORING OF THE IMPACT OF THE PROJECT ACTIONS
Actions C1 and C2

PROJECT MANAGEMENT
Actions E1 to E3

Organizers:

IMPLEMENTATION ACTIONS

DISSEMINATION ACTIONS
Actions D1 to D3




Expected results:
Organizers:
 To demonstrate the feasibility of achieving zero-waste in
ceramic tile manufacture.
 Manufacturing the new tile will provide:
Supporters:
 65% saving in water consumption
 30% saving in energy input
 30% reduction in CO2 emissions
 During the life span of the project:

Manager  5%Ceramic Materials and Technologies Area, Project Manager
of the reduction of annually generated waste

 20% reduction in waste disposal at landfills



Problems detected and obtained experience
Organizers:
 No problems have been detected (until now ..)
 Time goes very fast
Supporters:





Other highlights:
Organizers:
 The first results about the project will be publish in
QUALICER 2014. Comparative study of the bulk and surface
properties of products used in urban paving (concrete,
natural stone and porcelain tiles)
Supporters:



01_CI4_LIFECERAM_Javier García

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