PROJECT DESCRIPTION
BACKGROUND
Around 1300 million square metres of ceramic tiles were produced in Europe in 2008, a figure that has only slightly decreased over the last few years. New regulations have led to a progressive decrease in harmful gas emissions from ceramic manufacturing, while technological advances have helped reduce water and energy consumption. However, the manufacture of porcelain stoneware tiles is still highly inefficient, mainly due to the high temperature firing step and the finishing operations, which are energy intensive and generate large amounts of solid waste. In order to be recycled, this waste must first be transported to post-processing sites to undergo high energy milling. It can then be reintroduced into the ceramic tile manufacturing process or used as an inert material. The only way to really mitigate the climate change impacts associated with the manufacture of fireproof, hard and chemical resistant floorings is to develop a new material that no longer requires high-temperature processing, can be manufactured industrially, is aesthetically appealing and does not produce waste.
OBJECTIVES
The objective of the LIFE SUSTAINABLE MISSION project was to demonstrate an innovative, zero-waste and zero-emissions approach to tile manufacturing, using recycled raw materials to create large surface tiles for walls and floors. Such products would be manufactured with minimal energy consumption and CO2 emissions, thanks to lower firing temperatures and milder finishing operations.
The superior thermal properties of the new tiles would be based on the introduction of up to 70% recycled waste (glass and ceramic-based materials). Such materials would allow all the finishing operations to be conducted on unfired tiles, thus generating waste that can be easily reintroduced into the manufacturing process, avoiding the use of water and minimising energy consumption. These benefits would extend to the firing stage and include a lower sintering temperature, a lower energy consumption (mainly due to a reduction of the temperature in the operations from 1250 to 950°C), the minimisation of defects (typical of high-temperature processes), a reduction in the amount of defective parts, and the complete recyclability of the final product. The aim was to produce tiles that are recyclable at the end of their life, given that their high content of glass former makes them suitable to add (up to 40%) to the new ceramic body composition.
RESULTS
The LIFE SUSTAINABLE MISSION project demonstrated a new production that reduces waste and emissions. The new generation of ‘no waste’ NW-tiles are composed of 70% recycled waste with a high percentage (70%) of glass scraps. The project thus showed how the principles of the circular economy could be incorporated into the tile production sector.
The production process uses fewer virgin raw materials, less energy and less water. Overall energy consumption is reduced by up to 20% during manufacturing and 50% during the cutting and polishing phases. The production of NW-tiles thus allows for an average 57% reduction in energy consumption when compared to the production of traditional tiles. Furthermore, water use is reduced by up to 60%, with no use of water during the finishing operations, and natural gas consumption is reduced by up to 20%. The production process thus leads to a 38% reduction in CO2 emissions and up to a 90% reduction in the transportation of raw materials. The NW-tiles are 100% recyclable at their end of life, and can be transformed either into new NW-tiles or into building applications.
The total waste amount produced is moreover also reduced during the finishing operations of the NW-tiles. Around 1.95 kg of scraps per m2 of finished product will no longer be disposed of as ‘special waste’ but rather recycled as inert materials into asphalts. This outcome is possible thanks to the new chemical composition of silica, alumina and magnesia, which accounts for more than 90% by weight of the new tiles.
The project demonstrated the feasibility of the process on an industrial scale; three NW ceramic compositions, glazed and unglazed, were produced in three different colours. The project was moreover shown to be economically feasible. Cost savings are significant, resulting mainly from lower energy costs (-30%), manufacturing costs (-40%), and raw materials costs (- 50%).
The project also showed that the production of the new tiles can generate employment: four new job positions (three permanent and one temporary) were created to develop the demonstration line. The overall economic impact of the NW-tiles is also positive. The new process is expected to improve returns by 5-30% by the end of the first year after the project.
The project achievements show how EU policies in several areas can be implemented, including the Roadmap to a Resource-efficient Europe, the Circular Economy Action Plan, the Waste Framework Directive the Low-carbon economy roadmap 2050, and the Energy Efficiency Directive.
The beneficiary intends to continue communicating the project outcomes to stakeholders over the coming years, especially through its large market network, along with the Facebook page ‘Think Eco Live Green’, which shares the experiences and outcomes of several LIFE projects focused on sustainability in the tile sector. The beneficiary is also developing marketing strategies for selling the new NW-tiles, but it says that more product development is required before they can be commercially launched.
Further information on the project can be found in the project's layman report and After-LIFE Communication Plan (see "Read more" section).
