PROJECT DESCRIPTION
BACKGROUND
In Europe, inkjet technology has prevailed over other traditional tile decorating techniques, such as screen-printing and rotogravure, due to its higher productivity rates and lower manufacturing costs. However, the ink products used generate high volumes of hazardous wastes, which are increasing due to the growing demand for large decorative ceramic slabs.
Ceramic inkjet inks are commonly made up of complex mixtures consisting of a heavy metal-based solid component along with inorganic pigments, refractory materials, ceramic frits, organic solvents and different additives. The presence of heavy metals, along with the organic nature of the solvents used, in the formulation pose a significant health risk and threat to the environment.
Currently, all inject ink waste in the EU is sent to landfill following the chemical and a physical separation of the solid fraction. Although this waste management generates harmful wastewater in the cleaning stages, alternatives are not readily pursued due to the complexity of the separation process, the sub-micron particle sizes required, and the non-aqueous nature of the solvents present in the ceramic inkjet ink wastes.
The use of ceramic inkjet inks generated 2,399 tonnes of hazardous waste in 2019, costing €14.4 million in disposal. Spain is responsible for 641 tonnes/year and Italy around 503 tonnes/year, representing a total annual cost more than €6 million.
OBJECTIVES
The LIFE REPLAY project aims to demonstrate the technical and economic feasibility of using ceramic inkjet ink wastes as a new raw material for the ceramic industry. For this purpose, wastes will first be processed by a prototype and separated into a heavy metal inorganic pigment, and an organic solvent. These components will then be reintroduced into the production process of pigments, ceramic inkjet inks, cleaners and ceramic tiles.
The project will contribute to the implementation of the Waste Framework Directive, the Roadmap to a resource-efficient Europe and the Circular Economy Action Plan through the promotion of resource efficiency and new business models aligned with the waste management hierarchy. It is also in line with the Raw Materials Initiative, aiming to boost resource efficiency and the supply of secondary raw materials through recycling.
RESULTS
Expected results:
- Prototype with separation capacity of 0.5 t/h and separation performance of 90-98%;
- Management of 100 tonnes of ceramic inkjet ink wastes, with the processing of these wastes to obtain 58.8 tonnes of organic effluent and 39.2 tonnes of solid component;
- Production of 10 000 m2 of ceramic tiles replacing 30-40% organic solvent and 100% inorganic pigment with the secondary products from the processing of ceramic inkjet ink wastes;
- 80 tonnes of ceramic inkjet inks, 30 tonnes of pigment and 9 tonnes of cleaner from the new solid and liquid components;
- Elimination of the generation of industrial wastewater during the separation process of ceramic inkjet ink wastes; and
- 46% and 56% reduction in energy consumption during the ceramic inkjet ink manufacturing process and the inorganic pigment production process respectively.
- New technology proposed as emergent technology to be included in the Best Available Techniques Reference Document for the Ceramics Industry (CER BREF).
