Project LIFE07 ENV/IT/ NOVEDI - NO VEtro in DIscarica LAYMAN S REPORT LIFE+ 07 ENV/IT/ NOVEDI. NO VEtro in DIscarica LAYMAN S REPORT

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1 LIFE+ 07 ENV/IT/ NOVEDI NO VEtro in DIscarica NOVEDI Project Layman s report page 1

2 Summary of the project The NOVEDI project, through an original special glass processing technology, focused on glass rejects not included in cities separate waste collection but usually landfilled, has enabled the reuse of these glass rejects into foam glass, a porous gravel of apparent density of 0,2 kg/liter, with remarkable characteristics of thermal insulation usable in the building sector. Use of such foam glass as inert in the composition of lightweight structural concrete (density 1800 kg/m 3 ) and super-lightweight insulating concretes (density 1000 kg/m 3 ) has been demonstrated in the realisation of a demonstration building with a foreseen energy consumption of 15 kwh/m 2 /year. For the construction of this building kilo of recycled glass has been used, composed of 85 % soda lime glass rejects; 5 % front monitor glass rejects; 5% fiber glass rejects and 5 % of a mixture of lamp and artistic glass rejects. This building can be considered the symbol of the project where it evinces recovery of glass otherwise destined for landfill and replacing raw materials extracted from quarries. In addition, the LCA (life cycle assessment - evaluation at the end of life) performed on this building led to the result of complete recyclability of the foam glass materials used. The project has as well performed an effective sensibilisation action of citizens and principle actors of the building sector on eco-compatible building a sto enhance use of these kind of products with the double objective of consumption of recycled waste and energy efficiency. Websites: Actions and operational practices The project was developed through the implementation of 11 actions, among which the most significant were: 1 - Characterization of materials used; 2 - Preparation of starting glasses; 3 - Preparation of glass foam on a laboratory scale; 4 - Realization and experimentation of the pilot plant for the production of granular foam; 5 - Construction of demonstrative building; 6 - Awareness and dissemination of the results. NOVEDI Project Layman s report page 2

3 Action 1 - Characterization of materials used Action 1 featured, with scientific support of the University of Padova, the characterisation of five different types of special glass waste (TV monitor and PC display glass, glass of lamps, mosaics glass, stained glass, fiber glass) that, due to their chemical composition, are not suitable for use in the glass industry, and therefore are generally vested in landfill. These analyses offered the technical guidance for the pre-treatment of the special glass rejects, aimed at their use in the mixtures to be foamed. The characterization permitted to identify some basic parameters for the correct behaviour of the most suitable mixtures for foaming (particle size, reactivity, fusibility, stability during heating, ionic desorption,...). Definition of the optimal type of treatment and particle size characteristics for foaming as a function in particular of the microstructure of the foam and the reactivity during the foaming process of different blends of special glasses. Picture 1 Special Glass characterization Action 2 - Preparation of the starting glass This action is developed in a semi-industrial using in part process technologies already present in Sasil, and in part implementing new treatment machinery necessary to achieve the objectives studied and developed in Action 1. In particular, we have made some treatment units, within the Sasil plant, where they were treated in a differentiated manner and special glazing, with both technologies to wet and dry. The installations comprised a new wet process technology which allows the reduction of starting vitreous material to be used for foaming into the necessary average particle size between 20 and NOVEDI Project Layman s report page 3

4 25 micron. A very difficult task, given the extreme flexibility and elasticity of fiber glass, which make grinding into micrometer size complex. The purpose of Action 2 was to obtain a quantity of processed special glass, necessary and sufficient to be used in the following stage 3 (laboratory tests) and subsequently in stage 4 for the production of foam with the pilot plant. At the end more than 150 tons of special glass have been treated, ready for use in the pilot plant, allowing a production of 750 m 3 of foam glass. Action 3 - Preparation of glass foam on a laboratory scale This action was carried out in collaboration between the University of Padua, who carried out the testing in mitten, and Sasil, which transferred the tests on a small continuous laboratory furnace. This has served to define the necessary foaming additives both qualitatively and quantitatively. Furthermore, for the same foaming agents, different cooking behavior of the various mixtures as a function of the internal structure of the foam glass has been tested. In line with the objectives a series of samplings of foam glass with different behavior compared to the basic parameters have been realised, concerning: - mechanical strength; - thermal insulation; - absorption of water; - density; These samples served as a reference for the performance of the tests in the pilot plant for the production of foam glass. Glass Powder at the enter of the small laboratory furnace Small furnace for laboratory tests Foaming Glass at the output of the laboratory furnace Picture 2 Preparation of foam glass on laboratory scale NOVEDI Project Layman s report page 4

5 Action 4 - Realization and experimentation of the pilot plant for the production of granular foam The pilot plant consists of 4 sections: - Fine grinding to obtain the average grain size suitable for the various glasses used in mixture (20-25 microns); - Dosing, mixing and homogenization of the various glasses with additives micronized with reagents foaming; - Electric oven cooking, foaming and granulation to obtain the granular foam glass; - Particle size reduction of the granular foam so as to obtain the different dimensions suitable for each use-option. This pilot plant was constructed on an area of about 500 m 2, including the storage area of the foam glass for a capacity of about 500 m 3, divided into two boxes for the two types of foam glass: the most performant from the point of view of structural strength and the most suitable for use as insulation and thermal insulation. All set objectives were achieved: - Obtainment of foam glass with different characteristics as a function of mechanical strength, fire resistance, density and thermal insulation; - Obtainment of foam glass with microstructure variable in function uses more structural and less insulating and vice versa; - Obtainment of foam glass qualitatively compatible with generic uses, as a compromise between the various characteristics. Picture 3 Foam Glass at the exit of the furnace NOVEDI Project Layman s report page 5

6 Action 5 - Construction of demonstrative building The construction of the demonstrative building appeared the most complex action: firstly, it was the first example in Italy of use of foam glass as aggregate in structural and insulating concrete; and secondly it is the first case in the world where such a foam glass is produced starting from these particular types of waste glass. These two reasons complicated notably certification of the materials to be used in structural concrete mixture, due to the low modulus of elasticity of the concrete itself, related to the size of the bubbles present inside the foam glass. It resulted in a long series of tests, using foams of glass with different microstructure to search for a compromise between modulus of elasticity, mechanical strength, bulk density and insulation capacity. The complexity of this operation to find the right compromise has implied a delay of almost a year compared to the original program. It is for this reason that the construction of the demonstration started very late and at the end date of the project the building was completed only with the walls of the 1st and 2nd floor and the 1st floor slab. At the end of September 2012 all parts concerning use of foam glass have been completed, for a total use of about 400 m 3 of foam glass, equal to a consumption of kg of micronized glass, of which kg special glass. In May 2013 the building will be ready for inauguration. Compared to the initial project, during fine-tuning of the architectural design, it was decided to change layout and size of the solar panels. A technologically highly innovative choice has been made, for a system of photovoltaic solar tracking with a dual purpose: - pursue the optimal exposure to the sun for maximum energy efficiency; - search for the optimum shading of the window of the building, facing south, to minimize radiation in summer and maximize it in winter, in order to take full advantage of energy. This was accomplished by means of an original system of automatic handling of photovoltaic panels on a large arc tube made of steel. The translational movement of the panel on the arc develops in east-west direction and the rotational movement is developed around the axis of the arc tube. NOVEDI Project Layman s report page 6

7 Picture 4 Demonstrative Building Project NOVEDI Project Layman s report page 7

8 Action 6 - Awareness and dissemination Awareness raising and dissemination of the NOVEDI project was performed commitment by the Province of Biella, Sasil s partner in the project. with great Starting from networking all local building sector stakeholders from constructors to architects, producers and local administrations and on the basis of a study carried out to understand the real needs of the territory as to achieve an increase of investments in eco-compatible and energy efficient building, the Province has carried out a huge information campaign. Cornerstone was the institution of a physical and online energy desk, in which the stakeholders network collaborated and the NOVEDI project functioned as the emblem for sensitizing and informing target groups on the issues of building insulation and consequent energy savings, as well as the environmental value of recycling waste otherwise destined for landfill. The portal offers a vade mecum for citizens, permits questions to experts, and features films and documents on the activities carried out. In order to achieve a wider territorial impact, the Province of Biella has organized several local meetings with citizens spread over its territory, and has been present at numerous local manifestations with a dedicated stand, always supported by Sasil illustrating in detail the objectives and results of the NOVEDI project. Sasil and the Province of Biella have also participated with an own stand at several exhibitions at national level (eg. SAIE and Ecomondo Rimini); published an article in Glass World Wide review, and organised a final conference which can be viewed on video on Picture 5 - Brochure realized for Novedi Project NOVEDI Project Layman s report page 8

9 Conclusion The demonstrative building can be considered the emblem of the NOVEDI project: 80% recycled materials have been used, namely: kg of glass otherwise destined for landfill; m 2 of tiles with base dough containing recycled glass treated by Sasil; m 2 of artificial mineral wool made with dough produced with various waste materials processed at the Sasil plant (roof insulation); - 50 m 2 of photovoltaic panels, whose ultra-clear glass was produced from recovered quartz, with high purity silica provided by Sasil to a flat glass factory specializes in the production of glass for solar panels. Introduction of the foam glass on the market has not yet been successful, due to the crisis in the construction sector. We believe however that with the monitoring data of the new demonstrative building based on foam glass soon positive feedback may be achieved, justifying subsequently the construction of an industrial production line. Picture 6 Foam Glass NOVEDI Project Layman s report page 9