Technological Evolution for Local and Low-impact Utilization of Strategic raw materials for CERamics
Technological Evolution for Local and Low-impact Utilization of Strategic raw materials for CERamics
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The TELLUS 4CER project was created to address one of the main challenges facing the ceramics industry: dependence on critical and strategic raw materials (CRM/SRM). The aim is to develop advanced technologies for the recovery, recycling, and valorization of Recycled Raw Materials (RRM), integrating them into production processes in a controlled and traceable manner.
The project no longer uses the term "Secondary Raw Materials (SRM)," which is considered ambiguous, but adopts the term RRM to indicate materials that are actually recycled and reintroduced into the production cycle, in line with the directives of the Ministry and the digital traceability practices envisaged.
Through new separation and purification methods, eco-design tools based on predictive models, and the creation of a digital passport for materials, TELLUS 4CER aims to:
reduce the consumption of virgin raw materials,
optimize production cycles,
guarantee the quality and certification of recycled materials,
contribute to the transition towards a more efficient and circular industrial model.
The project is funded by the Ministry of the Environment and Energy Security (MASE) and represents a concrete step towards the adoption of scientific and technological solutions capable of reducing the environmental footprint and improving the competitiveness of the ceramic sector.
The context and the challenge ahead
The context and the challenge ahead
Although recognized internationally as an industrial leader, the Italian ceramics sector is currently facing complex challenges that can no longer be postponed:
Dependence on critical and strategic raw materials (CRM/SRM): tile production requires clay, feldspar, and other mineral resources whose availability is subject to geopolitical constraints and market fluctuations. This dependence represents a risk to the stability of the supply chain;
High energy consumption: ceramic firing cycles require large amounts of energy. Currently, the sector consumes an average of about 6 GJ/ton of product as a baseline, with a direct economic and environmental impact;
Significant environmental footprint: the Global Warming Potential (GWP) associated with tile production is currently around 10 kg CO₂eq per m². A reduction is necessary to align with European policies on decarbonization and circular transition;
Poor integration of Recycled Raw Materials (RRM): although available, recycled materials from ceramic waste still have limitations in terms of quality, variability, and lack of standards, which make their industrial adoption complex.
These critical issues highlight the urgent need for new, more efficient, resilient, and sustainable production models capable of reducing the use of virgin resources and cutting costs and emissions.
Our solution
Our solution
TELLUS 4CER develops and validates a set of integrated technologies to make the ceramics sector less dependent on critical raw materials and more aligned with the principles of the circular economy.
The approach is based on three main pillars:
Recovery and purification of Recycled Raw Materials (RRM)
Recovery and purification of Recycled Raw Materials (RRM)
Development of innovative chemical-physical processes (alkaline or acid treatments, membrane filtration, selective precipitation, centrifugation) to remove contaminants such as glues, cements, and impurities.
Targeted extraction of metal oxides from enameled surfaces.
Objective: to obtain high-quality RRM, reducing the need for virgin raw materials.
Eco-design of sustainable ceramic formulations
Eco-design of sustainable ceramic formulations
Integration of RRMs into new ceramic mixtures without compromising strength, aesthetics, and regulatory compliance (ISO 10545 and ISO 59020).
Use of predictive models and simulations based on artificial intelligence to optimize mixtures.
Target: replace at least 30% of critical raw materials with RRMs.
Traceability and digitization of the supply chain
Traceability and digitization of the supply chain
Creation of a digital passport to certify the origin and characteristics of RRMs throughout the value chain.
Integration of data-sharing and blockchain technologies to ensure transparency, reliability, and industrial adoption.
A systemic project
A systemic project
In addition to technological aspects, TELLUS 4CER includes activities such as:
Optimization of production processes through numerical simulations and economic models.
Industrial symbiosis, promoting integration between the ceramics sector and other material-intensive industries.
Training and technology transfer to consolidate skills and accelerate the adoption of the solutions developed.
Impact and expected value
Impact and expected value
30%
of critical raw materials replaced
of critical raw materials replaced
- 17%
of energy consumption
of energy consumption
- 20%
of CO₂ emissions
of CO₂ emissions
50k m³/anno
of water saving
of water saving
Partnership
Partnership
The TELLUS 4CER project is based on collaboration between industry and academia, combining manufacturing and research expertise.
Ceramic company that develops and manufactures floor and wall tiles.
The project provides direct experience in industrial processes and ceramic formulations, testing Recycled Raw Materials (RRM) on actual production lines to assess their compatibility and performance.
[INSERIRE LOGO UNICAL]
University with established expertise in materials chemistry and industrial processes.
It contributes to the project by studying advanced techniques for the treatment, purification, and recovery of RRMs, with a particular focus on the removal of contaminants and improving the quality of recycled materials.
[INSERIRE LOGO UNIPA]
University with experience in the field of modeling and materials engineering.
Within the project, it develops predictive models and simulation tools based on artificial intelligence to optimize ceramic formulations and support eco-design.
Project roadmap
Project roadmap
The TELLUS 4CER project is divided into four main phases, linking scientific research to industrial validation and the dissemination of results.
Research
Research
Analysis of critical issues in the ceramics sector related to critical raw materials, energy, and emissions.
Collection and characterization of ceramic waste to define its composition, variability, and recovery potential.
Study of treatment methods (chemical-physical and mechanical) to separate contaminants and obtain Recycled Raw Materials (RRM) of controlled quality.
Development
Development
Fine-tuning of purification processes (alkaline/acid washing, membrane filtration, centrifugation, selective precipitation).
Definition of ceramic formulations with different percentages of RRM, evaluating their resistance, aesthetics, and regulatory compatibility.
Development of predictive models and simulation tools based on artificial intelligence to optimize mixtures and reduce experimentation times and costs.
Validation
Validation
Production of ceramic samples in the laboratory with RRM-enriched mixtures.
Pilot tests on semi-industrial lines to verify the behavior and performance of the materials.
Industrial-scale validation at Gresmalt, with measurements of energy efficiency, aesthetic quality, and compliance with international standards (ISO 10545, ISO 59020).
Distribution
Distribution
Creation of a digital passport to track the origin, quality, and performance of RRMs throughout the supply chain.
Scientific dissemination activities (publications, conferences, workshops) and industrial dissemination activities (presentations to stakeholders and industry associations).
Technology transfer and training activities to promote the adoption of solutions in ceramic companies and other manufacturing sectors.
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