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2016-11-07 Russian Federation: A New Paradigm for Eco-Design: PoROus Ceramics from Natural Clay Shale and Slate Proess

A New Paradigm for Eco-Design: PoROus Ceramics from Natural Clay Shale and Slate Proess

Description of the project offered: 

State of the art construction materials design, central to environmental impacts of buildings, have hardly benefited from recent eco-design advances. The sector is rather energy-intensive and polluting, and 
has not experienced major breakthroughs for many decades. The EU roadmap for a competitive low carbon economy calls for reducing greenhouse gas (GHG) emissions by 80-95% until 2050.
Through a radical departure from conventional engineering practice, this proposal brings forward a new paradigm for materials eco-design: Maximizing the potentials for ecologically adapted technology development through material selections and process choices in manufacturing.
The European IPPC Bureau (2007) is reviewing around 50 techniques for pollution prevention and control in the ceramic manufacturing industry. 
The proposed project changes all of this. The technical parameters of the projects are much better than the best available technologies (BAT) of the ceramic manufacturing industry. With a very diverse raw material base, the project offers a whole new paradigm for eco-design, opens new horizons for researching new concepts of the future technology that addresses today’s challenges and describes an efficient control system. Besides, it helps achieve the following:
 Stop using fossil fuels (gas, oil);
 Lower the environmental impact by reducing the emission of greenhouse gases, nitrogen oxides, dust and noise;
 Save resources (mostly energy, water is not required);
 Considerably reduce the area of open mines and free more land for agriculture.
PROCESS is an innovative technology which uses natural properties of certain geologic materials and well-known volcanic rocks formed without water and oxygen (such as pumice or volcanic tuff) and capable of increasing their volume as affected by volcanic scoria. Proposed technology changes a person’s view on industrial landscape – due to the lack of dust, noise and bulky productions; this technology is easily transformable, transportable and can be located close to the major construction objects, significantly reducing the transporting of products.
New material itself is a porous ceramic material which can be considered as an intermediary between glass and ceramics. It is formed by means of heating of clay slate and 0.5-20 mm mudstones and usually contains 5% of quartz, 8% of spinel, 3 % of mullite and 84% of X-ray amorphous material. 
KVARIT can be obtained in closed molds put into a muffle furnace under a temperature of 1150–1250 0С (2102–2282 0F) and with the use of autoadhesion and filling in of the entire mould.
If we obtain a grant, we will be able to perform the following research:
Phase I (R&D):
 In-depth study of creation of synthetic pumice and volcanic tuff as well as usage of the autoadhesion processes and additive agents, such as carbon fibre, for adjusting material’s attributes
 Tribological studies during selection of materials for concrete forms
 Studies and certifications of the resulting material
 Development of the methodology and technological processes for laboratory production of the material.
Phase II (Pilot):
 Launching of a pilot production with average daily output of 1.5-2 m3 and testing of the 
production equipment with the total throughout of 30,000 thermal cycles a year; the same number of thermal cycles is performed by engine pistons of modern cars in 10 minutes at 3,000 rpm, or at a speed of 80–100 km/h.
Based on results of the conducted studies, technological readiness of the R&D can be levelled up from TRL-3-4 to TRL-7.
Project proposer:   Eduard Kokaia (Russian Federation)
Partner role:  Project participant 
Partner organisation:  Small or medium-sized enterprise (SME)
Call for proposal title:  CALL: FET-Open – Novel ideas for radically new technologies 
Call for proposal identifier:  H2020-FETOPEN-2016-2017

Description of the collaboration sought: 

Expertise sought: Intellectual property rights, Scientific research, Coordination. Cooperation, Innovation. Technology transfer, Sustainable development, Environmental protection, Other technology, Robotics, Automation, Materials technology, Construction technology, Industrial manufacture, 
Roles sought: Project participant, Project coordinator, 
Organisation types sought: Research, Industry, Technology transfer, Consultancy, Small or medium-sized enterprise (SME), 
Countries sought: Finland, France, Germany, Hungary, Italy, Spain, Sweden, United Kingdom, Norway, Albania, Bosnia and Herzegovina, Croatia, Iceland, Israel, Liechtenstein, Macedonia, the former Yugoslav Republic of, Montenegro, Serbia, Switzerland, Turkey, Canada, Georgia, Russian Federation, United States, Austria, Belgium, Denmark, 

Call for proposal specific information
The referenced call for proposals has no specific fields defined.