LIFE Hypobrick European Project
The main differences of the new process (Alkaline Activation Process-AAP), with respect to the traditional ceramic one are the substitution o the firing stage (conducted at temperatures above 1,000 ºC) by a curing stage carried out at low temperature (<150 ºC), and the possibility of recycling a wide variety of industrial wastes. AAP is based in the dissolution of amorphous silicates and aluminosilicates by an alkaline solution, followed by the polymerisation of the resulting monomers to provide hardness and strength to the material.
The project will focus on the manufacturing of the new bricks in Southern and Northern European countries (Spain and Germany) in which the wastes available and the constructive requirements are quite different and cover the trends existing in a significant number of European countries.
– To produce new materials for building that accomplish with all the environmental and administrative legislation.
– To formulate waste-based mixtures for manufacturing the new bricks with the AAP that accomplish the technical and environmental requirements of the international standards and of the market.
– To define the operating variables of the process stages involved in the AAP.
– To modify the industrial facilities to allow the manufacturing of the new building material.
– To solve the potential production problems that may arise during the pilot and industrial trials in order to obtain building products free of defects and with the require properties to be commercialised.
– To obtain a cost-effective and economically viable building material with an innovative process that favour their commercialisation.
– To make an agreement with another manufacturing companies (out of the Consortium) to replicate and transfer the project results.
– Asociación de Investigación de las Industrias Cerámicas (ITC-AICE)
– Ladrillos Mora, S.L. (MORA)
– Recycling, Consulting & Services, S.L. (RCS)
– Schlagmann Poroton GmbH & Co. KG (SCHLAGMANN)
– Technische Hochschule Nuernberg Georg Simon Ohm (THN)
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Objetives & Scope
Implementation of a new manufacturing process (AAP) with an extremely low energy consumption for the reduction of GHG emissions
Current Brick Manufacturing Process
Alkaline Activation Process (AAP)
Contributes to achieve the objectives of EU policies:
- Reducing waste generated
- Maximising recycling
- Reducing CO2 emissions
- Reducing E consumptions
- Reducing emission of volatile compounds
1000 ton bricks produced
- Reduction of GHG emissions: 184 ton CO2 (92% reduction).
- Reduction of acid gases emissions: 4.1 kg HF, 39.6 kg SOx, 12.7 kg HCl (100% reduction).
- Reduction of Total Organic Compounds (TOC): 34.5 kg (100% reduction).
- Reduction of Particulate Matter (PM): 17.6 kg (100% reduction).
- Reduction of primary raw materials input (clay, flux, quartz): 1,000 ton.
- Waste recycling (1,000 ton): 200 ton CRTWG, 280 ton FA, 20 ton WEEE, 40 ton scraps, 60 ton CDW.
- Thermal energy reduction (that accounts for 90% of the energy input): 2,070 GJ (90% reduction).
- Climate change Mitigation policy area
– To move brick manufacturing industries (EII industries) towards a low carbon transition
– Transfer and replication of the solution proposed to other building products will represent a reduction of more than 80% in GHG emissions
– To help the whole building industry to achieve the objectives established in the 2050 low carbon economy roadmaps
- The guidelines of the EC on circular economy as the new bricks will use secondary raw materials from other industrial sectors
- Actions which enhance the functioning of the emissions trading system and which have an impact on energy and greenhouse gas intensive industrial production (EU policy areas according to the LIFE Programme Multiannual Work Programme 2018-2020)
– Ceramic sector is considered as EII, since fossil fuels are used to provide the thermal energy required in the driers and kilns
(REPLICATION, TRANSFER, MARKET UPTAKE)
- Transfer and replication of the solution proposed to other building products: Ceramic (tiles, roof-tiles, pipes, big slabs, etc.)
- Non-ceramic (concrete and concrete derivates) – Replicate project results in 1 company at the end of the project
- To develop a business plans for the companies (MORA and SCHLAGMANN) that will exploit the solution in the target markets
- Research centers and consultancy company: new advisory services
- Replicability/transferability plan for the HYPOBRICK solution to other companies in the same or different sectors and taking into account different geographic markets
- Communication Plan: commercial visits to potential partners, fairs and congress, own workshops, sectorial meetings…
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This project is financed by the LIFE Programme 2014-2020 of the European Union for the Environment and Climate Action under the project number LIFE18/CCM/ES/001114)
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