The main innovative concept is a new technology providing nearly full recovery of the flue gases of the kiln, using it to preheat the combustion air in preheating zone of the kiln. The system is optimized by a fully computerized management of air and gas flow, and advanced materials for thermal insulation of walls and vaults.
This leads, according to first studies since 2008 and extensive lab-tests and simulations since 2011, to about 45% improvement of energy performance, respecting Ceramic BREF (Reference Document on Best Available Techniques in the Ceramic Manufacturing Industry-August 2007) and increasing the knowledge of significant data with respect to the materials used for it. The test results confirm a TRL4, amply sufficient to proceed to the realization of the prototype.
PROJECT STEPS
The project will be implemented throughout the following steps:
MATERIALS SELECTION AND KILN DESIGN
PROTOTYPE BUILDING
VALIDATION IN INDUSTRIAL TESTS IN SANITARY WARE FIRING
TRANSFERABILITY TO OTHER INDUSTRIAL APPLICATIONS (re-firing of sanitary ware in Romania and tableware in Italy)
ANALYSIS OF OUTCOMES
BUSINESS PLAN FOR FUTURE EXPLOITATION
Alongside the above mentioned pilot and demonstration actions, other actions will run in parallel:
TECHNICAL VERIFICATIONS AND TESTS
built on a gradually increasing scale alongside all project activities as to counter potential difficulties in the earliest possible moment
MONITORING OF IMPACT
through a Life Cycle Impact Assessment methodology, focusing on environmental as well as socio-economic impacts
COMMUNICATION & DISSEMINATION
towards the general public, stakeholders, and potential customers. From the very beginning, communication will primarily focus on the environmental issues the project seeks to tackle. Later on, results will be disseminated with a strong focus on potential end-users, organizing project events, publishing articles and showcasing the project at sector fairs
PROJECT MANAGEMENT
providing for a sound coordination and management of resources, personnel, and activities, as well as for quality control on outputs and deliverables, monitoring of progress and communication with the European Commission