NKUA
“SUSTAINABLE STONE & MARBLE INDUSTRY: CLEAN PRODUCTION, WASTE MANAGEMENT AND ECO-INNOVATION”
TRAINNING COURSE
Sustainability of the Natural Stone Industry Management of Waste & By-products, Water and Energy
(Nuno Bonito)
Ramallah 10-11 March 2014 SUSTAINABLE STONE & MARBLE INDUSTRY NKUA Contents
Part I - Introduction Part II - Characterization of the Natural Stone Sector Part III - Waste & By-products • Definitions • Wastes in Natural Stone Sector • Wastes in Stone Quarrying and Processing • Waste Management • Waste Management Hierarchy • Case Studies Part IV - Energy and Water Management • Energy in the Natural Stone Processes • Best Practices • Water in the Natural Stone Processes • Best Practices Part V - Life Cycle Analysis and Eco-Management Part VII - References
Ramallah: 10-11 March 2014 SUSTAINABLE STONE & MARBLE INDUSTRY NKUA
““SustainableSustainable Development is the one that meets the ppresentresent needs without compromising the ability of future generations to meet their own needs.needs.””
World Commission on Environment and Development ((BBruntlandruntland Commission), 1987.
Ramallah: 10-11 March 2014 SUSTAINABLE STONE & MARBLE INDUSTRY NKUA
Part I --IntroductionIntroduction
Main Objectives ofof thethe Training Course:: Course
• Focus on the reduction and reuse of generated waste (in particular slurry waste) • Promotion of innovative policies:
• Cleaner extraction and production of stones and marbles • Economic, Social and Environmental Sustainability of the sector.
Increase the participants understanding of opportunities and challenges related to the development and implementation of cleaner production processes and eco-innovative policies for the stone and marble sector.
Ramallah: 10-11 March 2014 SUSTAINABLE STONE & MARBLE INDUSTRY NKUA
After thetheactivity thetheparticipants will bebeable toto::
- Have a better understanding of best practices and successful case studies at national and international level.
- Identify challenges and opportunities to promote a greener stone and marble sector.
- Develop professional networking and cross-sectorial collaborations.
Ramallah: 10-11 March 2014 SUSTAINABLE STONE & MARBLE INDUSTRY NKUA
Part II --CharacterizationCharacterization of the Natural Stone Sector
Objectives:
• Contextualize the Natural Stone Sector in Portugal
• Brief Explanation of the Production Chain • Quarries • Processing Plants.
Ramallah: 10-11 March 2014 SUSTAINABLE STONE & MARBLE INDUSTRY NKUA Natural Stone Sector
Marble Quarry (Portugal – séc. I to III) Marble Quarry (Portugal – beginning of XX century)
The use of Natural Stone has followed the history of men Megalitic monument transformed in Chapel almost from its origins, creating a relationship of coexistence (Séc XVII) - (Portugal) that can be considered somewhat timeless .
The stones used for construction purposes are usually called dimensional or ornamental stones .
Granite and Calcareous Stone (Marble and Limestone) constitute the main raw materials amounting to almost 70% of World production of dimensional stones.
Ramallah: 10-11 March 2014 SUSTAINABLE STONE & MARBLE INDUSTRY NKUA The Ornamental Stone industry isis::
• A Traditional Activity.
•Usually related with a bad image in what concerns to the environmental questions.
•An important activity that provides significant employment and strongly develops the regions where it is located.
The management trough a sustainable perspective with the integration of economic, environmental and social aspects is a key factor towards a better efficiency of the current process and for continuing this industry for future generations.
Ramallah: 10-11 March 2014 SUSTAINABLE STONE & MARBLE INDUSTRY NKUA Portuguese Ornamental Stone
Portugal has a significant diversity of rocks with aptitude for ornamental use – More than 200 comercial types between Marbles, Granites, Limestones and Shale.
Portugal in the recent decades has been always among the 10 largest exporters of ornamental rocks.
Ramallah: 10-11 March 2014 SUSTAINABLE STONE & MARBLE INDUSTRY NKUA
The large growth of the sector took place between 1990 and 2000 , with special emphasis on the level of extraction, where the value has quadrupled. This period was the best industry cycle , which resulted in the development of structural and technological terms in industry.
In Portugal operate, about 605 quarries , which have been reported in the competent entities, which produced approximately 2.9 million tons of raw materials and about 2.500 processing units and other activities within the sector of ornamental rocks . This industrial structure created direct employment and 25,000 jobs.
The ornamental rock sector is constituted essentially by small and medium-sized enterprises (SMEs) and micro-enterprises, from family members, many of them with only one worker. There are a few large companies, however with very little significance to the national context.
Ramallah: 10-11 March 2014 SUSTAINABLE STONE & MARBLE INDUSTRY NKUA Caracterization of thetheProduction Chain
The ornamental rock production chain consists of three main phases, including the extraction (quarrying), transformation (Processing) and Application/Maintaining:
Quarrying : is the first phase in the production of stone. We intend to at this stage, in the quarries, extract blocks of regular shape and size of the mineral mass.
Processing : corresponds to the rendering of the rock, in the factory, being the stage where the blocks are transformed into finished product .
Aplication/Maintaining : the construction sector is the main consumer of stone products, these are widely used for the construction of floors and other interior applications, facades, patios, sidewalks, squares, sculptures and many other items for configuration and equipment from the most diverse spaces.
Ramallah: 10-11 March 2014 SUSTAINABLE STONE & MARBLE INDUSTRY NKUA Stone Production Chain and Related Efficiency (I(I--Stone)Stone)
Ramallah: 10-11 March 2014 SUSTAINABLE STONE & MARBLE INDUSTRY NKUA
Quarrying
The purpose of the extraction activities in a quarry is the extraction of blocks.
In brief the process of block extraction can be outlined in general, in four stages:
•Primary cut, •Bank overturning,
•Cutting bank in marketable blocks, Production of Production of •Material handling. marketable size bank blocks blocks
Bank overturning Wastes In several cases though, where the deposit characteristics are adequate, Cut into marketable blocks of marketable dimensions are size blocks produced directly, thus compacting the first three stages in just one.
Handling
Ramallah: 10-11 March 2014 SUSTAINABLE STONE & MARBLE INDUSTRY NKUA Various cutting techniques can be used depending on the type and the characteristics of the stone (marble, granite). The blocks as well as the wastes are handled by loaders and trucks to the processing plants or the disposal area respectively.
Ramallah: 10-11 March 2014 SUSTAINABLE STONE & MARBLE INDUSTRY NKUA
Ramallah: 10-11 March 2014 SUSTAINABLE STONE & MARBLE INDUSTRY NKUA
Processing
Dimensional stone blocks extracted from the quarries have to be processed in order to be transformed into the final products that will be fed in the market.
Today the market demands for final products of high accuracy and quality in Dimensions and Finishing.
The processing phase is the most important section of the modern stones industry . The specific kind of natural stone to be processed must always be taken under consideration, because it determines the processing cycle , the choice of machinery , the technology employed, the processing cost and the commercial value of the products.
Ramallah: 10-11 March 2014 SUSTAINABLE STONE & MARBLE INDUSTRY NKUA General Processing flow chart for stone products.
Block Squaring
Block Sawing
Marble/Granite Slate
Slab strengthening Slab splitting
Slab polishing Cutting to size
Cutting to strips The processing sequence in general involves the stages of block
Finishing squaring , block sawing in slabs, slab polishing , slab cutting into strips , strip cutting into tiles and finishing .
Ramallah: 10-11 March 2014 SUSTAINABLE STONE & MARBLE INDUSTRY NKUA
Part III --WasteWaste & ByBy--productsproducts
Objectives:
• Define Waste
• Understand the Wastes in the Natural Stone Sector
• Quarrying
• Processing • Understand the Waste Management Options
• Present Case Studies /Best Practices
Ramallah: 10-11 March 2014 SUSTAINABLE STONE & MARBLE INDUSTRY NKUA Definition of Waste
In a general way Waste is any material or substance whose owner or producer wants or intends to dispose .
First, something becomes Waste when it loses its primary function for the user. A Waste is therefore relative to this primary function . However what is considered Waste with regard to this primary function may be useful for a secondary function .
This relative nature explains why certain Wastes keep a significant economic value
The concept of Waste is also relative to the technological state of the art and to where it is generated.
Ramallah: 10-11 March 2014 SUSTAINABLE STONE & MARBLE INDUSTRY NKUA
According to the existing EU legislation the responsibility for the final destination and the costs of the Waste management is of who produces them.
When the producer is unknown or indeterminate , the responsibility for the final waste destination and for the respective costs belongs to the respective detainee .
In Europe the detainees of industrial wastes must obligatorily make it’s control, through the fulfilling of registers in accordance with the constant codes in the European Waste Catalogue (EWC) and the Waste Framework Directive.
The EWC aims to assure the identification and classification of wastes and defines the operations of valuatio n and elimination of wastes and corresponds to codes that are the same in all the European Union
Ramallah: 10-11 March 2014 SUSTAINABLE STONE & MARBLE INDUSTRY NKUA
Regarding the waste produced by the Natural Stone Sector, the EWC distinguishes between the various waste categories including it in the general code 01
01 – Wastes resulting from exploration, mining, quarrying, physical and chemical treatment of minerals 01.01 Wastes from mineral excavation 01.01.02 Wastes from mineral non - metalliferous excavation 01.04 Wastes from physical and chemical processing of non - metalliferous minerals 01 .04 .07 Wastes containing dangerous substances from physical and chemical processing of non - metalliferous minerals 01.04.08 Waste gravel and crushed rocks other than those mentioned in 010407 01.04.09 Waste sand and clays 01.04.10 Dusty and powdery wastes other than those mentioned in 010407 01.04.12 Tailings and other wastes from washing and cleaning of minerals 01.04.13 Wastes from stone cutting and sawing other than those mentioned in 010407 01.04.99 Wastes not otherwise specified 01.05 Drilling mud and other drilling wastes 01.05.04 Freshwater drilling mud and wastes
Ramallah: 10-1101.05.99 March 2014 Wastes not otherwise specified SUSTAINABLE STONE & MARBLE INDUSTRY NKUA Wastes in Natural Stone Sector
Quarrying activities which include the extraction of stone resources can deliver from 50 to 95 % waste material (mainly rock without ornamental value ) while in the subsequent phases of processing up to 41 % of the original input material is turned into waste.
1. Quarrying (total waste: 50-95%)
1.1 Defective blocks 1.2. 1.3. Shapeless small 1.4. Small size rocks, with poor Shapeless/irregular blocks < 0.5 m (from dust and slurry aesthetical-technical blocks (cannot be cut in squaring or fractured (drilling and cutting) properties (third slabs) deposit) choice blocks)
2. Processing (total waste: 20-40%)
2.1. Large-medium 2.2. Medium-small 2.3. Fine waste size waste (broken size waste (broken (sludge) slabs) strips, chips from trimming)
Types of stone waste from the quarrying and processing of natural stones.
Ramallah: 10-11 March 2014 SUSTAINABLE STONE & MARBLE INDUSTRY NKUA
Wastes in Stone Quarrying and Processing
In the extraction and processing activities the main operations are carried out with water as a cooling agent for the equipment. Thus, amounts of slurry are produced which is a mixture of water and fine particles of the stone material.
In most of the cases the slurry is collected and recycled in order to retrieve the water in the process.
Ramallah: 10-11 March 2014 SUSTAINABLE STONE & MARBLE INDUSTRY NKUA
The most common wastes produced in the natural stone sector are:
Rock without ornamental value
Corresponds to a great volume of stone that is extracted from the quarries and that does not fulfill the necessary parameters to go trough the rest of the process as ornamental stone .
• Very High volumes involved (normally above 70% of the extracted rocks) • Is the main waste produced in the quarries, • Nowadays represents the most difficult management problems. • In the processing plants the quantities of this waste are not so evident although its management is the same.
These wastes are the result of the normal extraction process and are usually stored in huge landfills near the quarries.
Ramallah: 10-11 March 2014 SUSTAINABLE STONE & MARBLE INDUSTRY NKUA
In a Processing Plant the most significant waste is the Stone Mud - Sludge
The mud occurs in the sawing and cutting of the stone – processed whit the use of water – and is constituted by water and very small stone sediments (at a microscopic scale).
Nowadays the natural stone processing plants carry out pre-treatment actions before dumping this waste : • The industrial effluent is treated in decantation plants to recover the clean water that will be circulated back to the cutting/sawing devices . • After decanting then pumping the remaining phase, which is rich in sediment, through filter presses , obtaining wet lumps with an approximate content of 20% of water.
About 80% of the Water is Recirculated and the dried mud is then easier to transport to the dump site.
Ramallah: 10-11 March 2014 SUSTAINABLE STONE & MARBLE INDUSTRY NKUA
Sample of a typical Marble/Calcareous Sludge
Marble %
Humidity 21.9
Loss at 950 °C 41.5
SiO2 + insoluble residue 0.43
Insoluble residue 0.403
SiO 2 0.027
CaO 52.4
Fe 2O3 0.06
Al 2O3 0,8
MgO 1.64
Na 2O 0.02
K2O 0,02
CaCO 3 93.4
Ramallah: 10-11 March 2014 SUSTAINABLE STONE & MARBLE INDUSTRY NKUA
Integrated mud treatment Dry mud disposal (Decantation Plant, Filter Press and Tanks).
Ramallah: 10-11 March 2014 SUSTAINABLE STONE & MARBLE INDUSTRY NKUA
Wastes common to several operations (called non specific since they are result from “subsidiary” proceedings); metal wastes, used tires, used oils, etc.
Used oils and lubricants • originated from the regular inspection to the machines, equipment and vehicles. • liquid waste. • Wastes with very important environmental impacts.
Must be stored temporarily and under special conditions (in stanching cans over decanting basins) for deliver to a specialized enterprise that collect them and take it to the appropriate treatment.
Ramallah: 10-11 March 2014 SUSTAINABLE STONE & MARBLE INDUSTRY NKUA
Vehicle Batteries and Used Tires • Originated in the regular inspection of the vehicles. • Should be stored temporarily under special conditions.
Metallic Wastes • All the metallic items resulting from the exploitation and processing of the natural stone • Old cutting disks, wire, machines and pieces of machines out of use, old vehicles, etc . • Solid waste that has to be temporarily stored in a non permeable place.
Ramallah: 10-11 March 2014 SUSTAINABLE STONE & MARBLE INDUSTRY NKUA Waste Management
The Waste Management should aim the prevention/reduction of the waste production or the reduction of the wastes dangerousness , especially through the reuse and the adjustment of the productive processes , through the adoption of cleaner technologies , as well as best environmental practices .
Ramallah: 10-11 March 2014 SUSTAINABLE STONE & MARBLE INDUSTRY NKUA
Considering the most significant quantities of wastes produced in the ornamental stone industry we are dealing with the same natural constituents of the bed rock. Calcium Carbonate for calcareous rocks or Silica and Feldspars for siliceous rocks.
So if by one and its possible to work in situ the reduction of the waste production .
By other and it’s possible to find other industrial application were these wastes can be used has raw material conducing to an important valuation.
Ramallah: 10-11 March 2014 SUSTAINABLE STONE & MARBLE INDUSTRY NKUA
Waste Management Hierarchy
The waste management hierarchy is a concept that promotes waste avoidance ahead of recycling and disposal.
At the same time is a tool that policymakers have used to rank waste management options according to their environmental benefits.
(European Council, 1991).
Ramallah: 10-11 March 2014 SUSTAINABLE STONE & MARBLE INDUSTRY NKUA
Waste Reuse
Reuse implies the use of stone waste as a resource - through the extraction of industrial minerals using various processes (e.g. separation, concentration, micronization).
Granite Waste: it is possible to obtain selected feldspar concentrations (sodic and potassic) for the ceramic industry, and quartz for the glass industry.
Calcareous Waste: due to their high contents of CaCO3, various possibilities of Reuse have already been proposed in different industrial sectors, making their reuse decidedly more “attractive” in comparison to granite waste.
The potential uses of the carbonates obtained by treating calcareous wastes can be : cement production, paper production, glass production, in the productive cycle of water paints, in the chemical industry, in the production of fertilizers and amendments for the agriculture, in the desulphurization of electric plants fumes.
Ramallah: 10-11 March 2014 SUSTAINABLE STONE & MARBLE INDUSTRY NKUA
Options for Reuse/Recover (Quarriying)
1. Quarrying wastes
1.1 Defective blocks with poor aesthetical-technical properties (third choice blocks)
Low price products: external elements
1.3. Shapeless small 1.2. Shapeless/irregular blocks < 0.5 m (from blocks (cannot be cut in squaring or fractured slabs) deposit)
Aggregate production for Crushing and Armour stones Tiles for coverings, Roads, sidewalks, curb Restoration of urban construction works, classification (for granite) floorings stones historical centres concrete, mortar
1.4. Debris and dust (drilling and cutting)
Ceramics (sodic and Granite potassic feldspars), Quarry works Artificial stones, Industrial minerals Glass (quartz), (fillings, ramps, terrazzo tiles Concrete, Disposal access roads) (small chips) Marble sites waterproofing
Cement, Agriculture (fertilizers, soils neutralization), Paper, Paints, Plastics, desulphurization of fumes, animal foods, resin products, lead recovery from batteries, iron and steel production, Solvay soda, bituminous mixes, fine art copies
Ramallah: 10-11 March 2014 SUSTAINABLE STONE & MARBLE INDUSTRY NKUA
Options for Reuse /Recover(Processing)
2. Processing wastes
2.1. Medium-large sized scraps (broken, rejected slabs) 2.2. Small-medium sized scraps (broken strips, chips Aggregates Selection and storage of good from trimming) quality scraps for low cost rustic floorings and coverings for external applications Crushing and classification for aggregates or stones for gardens and earth fillings
2.3. Fine waste (sludge)
Marble Ceramics (sodic and potassic Granite feldspars), Glass (quartz), Concrete, Disposal sites Cement, Agriculture (fertilizers, soils neutralization), Paper, waterproofing Paints, Plastics, desulphurization of fumes, animal foods, resin products, lead recovery from batteries, iron and steel production, Solvay soda, bituminous mixes
Ramallah: 10-11 March 2014 SUSTAINABLE STONE & MARBLE INDUSTRY NKUA
Waste Disposal
The waste disposal is the last option in the Waste Management Hierarchy. Disadvantages:
The facilities should be located as close as possible to the quarry in order to avoid unnecessary transport and control the cost of handling. Sometimes the waste is disposed on exploitable stone reserves . Environmental impacts on soil, water and landscape. The waste disposal has socio-economic problems essential due to visual impacts.
Advantages:
In the most of the situations is the only possible option.
Ramallah: 10-11 March 2014 SUSTAINABLE STONE & MARBLE INDUSTRY NKUA Case Studies ––ExampleExample ofofGood Practices
•• Aggregate Stone Production
•• Compact MarbleMarble/Stone/Stone
•• Recycling thetheMarble Sludge in OtherIndustries
•• REWASTONE PROJECT
•• RECYSLURRY PROJECT
•• Cleaner Technologies
Ramallah: 10-11 March 2014 SUSTAINABLE STONE & MARBLE INDUSTRY NKUA
Aggregate Stone Production (reuse/(reuse/recyclingrecycling))
• Assumption of the stone without ornamental value as a secondary raw material (by-product) that can be used in other industries like construction.
• The quarry owners are using this solution for themselves or making commercial connections with other industrials related to the aggregate production in order for them to “explore” the dumps located near their
quarries. Aggregate production in a dump near a marble quarry (Vila Viçosa – Portugal). • This waste management scheme coexists in time and space with the old schemes (surface landfills) bringing visible benefits for all the region were the quarries are located.
Ramallah: 10-11 March 2014 SUSTAINABLE STONE & MARBLE INDUSTRY NKUA
Compact MarbleMarble/Stone/Stone (reuse/recycling(reuse/ recycling))
Another option for recycling quarry waste is the production of “artificial” stone elements.
Aggregates + Consolidation Agent (e.g. resin) + Colorant
Ramallah: 10-11 March 2014 SUSTAINABLE STONE & MARBLE INDUSTRY NKUA
Recycling thethe Marble Sludge in Other Industries
• Calcareous sludge contains a lot of CaCO 3 • It could well replace industrial limestone in many applications.
Advantages • Remarkable benefits since this would eliminate the need to dispose wastes in dumps and operate limestone quarries.
Disadvantages/Constraints • It must solve the problem of humidity and transportation of sludge. • Complications could also derive from its degree of whiteness. • The presence of other components and • its particle size, especially if the applications require high quality products.
Ramallah: 10-11 March 2014 SUSTAINABLE STONE & MARBLE INDUSTRY NKUA
Some options for reuse of calcareous sludge:
• Cement Manufacture : Concrete is made by fusing mixtures of limestone and clay, or clay and marl (marl is limestone with clay-like features) in special furnaces. (Control the Water Content ).
• Fillers for the Paper Industry : Depending on the type of paper, the percentage of calcium carbonate added as filler ranges between 8 % and 20 %. (Control the Whitness, the granulometry and the Water Content)
• Fillers and pigments for the manufacture of water paints: Calcium carbonate is used in the formulation of paints both as filler and as pigment. Limestone is usually used in powder form: solvent inks may not contain more than 1-2 humidity, while water inks contain about 40. In this sense the use of muds with a humidity of 25 to 30 would not be problematic.
Ramallah: 10-11 March 2014 SUSTAINABLE STONE & MARBLE INDUSTRY NKUA
• Plastic Fillers: CaCO3 is largely used as a filler to produce PVC, not to provide the filled material with any special property, but just to save on the cost of the raw materials and because it has a better tolerance to impurities. (Control de granulometry and the water content )
• Neutralization of acidic farmlands : Calcium by-products (calcium carbonate CaCO3, quick lime CaO, slaked lime or calcium hydroxide Ca(OH)2 ) are largely used to correct the acidity of excessively acidic farmlands . In particular, acidic soils have a pH of 3-3.5, while alkaline ones have a pH of 9-10.
• Production of Fertilizers: Calcium nitrate Ca(NO 3)2 is commonly used as a fertiliser. Is usually made by direct reaction between a solution of nitric acid and solid calcium carbonate, as follows:
CaCO 3 + 2HNO 3 = Ca(NO 3)2 + CO 2 + H 2O
Ramallah: 10-11 March 2014 SUSTAINABLE STONE & MARBLE INDUSTRY NKUA
• Production of Animal Food: Calcium carbonate is one of the most essential components of animal food, of which it makes up 7 to 10 %. Of course, it must contain no heavy metals, have a suitable particle size and an adequate humidity content. In particular, it can be used as a “ventilated product” when the grain size is smaller than 0.35 mm or as “pellets” when the grain size is smaller than 1-2 mm.
• Bituminous Mixes: Bituminous mixes are used to make road surfaces. The formulation of such mixes is approximately 6 % bitumen (an oil refining by -product) and 94 % inert materials (basically sand and chippings of various sizes), selected and mixed to produce particle sizes offering a good permeation of the inert materials.
• Ceramics Industry: There are some very successful experiments using the sludge in the ceramics in order to produce bricks and other structural pieces
Ramallah: 10-11 March 2014 SUSTAINABLE STONE & MARBLE INDUSTRY NKUA
REWASTONE PROJECT
• Marble and Granite Sludge
• OBJECTIVES:
• Characterize the Marble and Granite Sludge produced in Portugal and Spain.
• Application of the wastes in: • Ceramic Industry (bricks) • Construction Materials (concrete)
• Waste Pre-treatment • Water content aprox: 25% • The transport cost influences directly the use of the sludge
Ramallah: 10-11 March 2014 SUSTAINABLE STONE & MARBLE INDUSTRY NKUA
Construction Materials (concretes)
Standard Mixture 5% Marble Sludge 10% Marble Sludge 20% MarbleSludge
Ramallah: 10-11 March 2014 SUSTAINABLE STONE & MARBLE INDUSTRY NKUA
Ceramic Industry (bricks)
2,7 m
Ramallah: 10-11 March 2014 SUSTAINABLE STONE & MARBLE INDUSTRY NKUA
RECYSLURRY PROJECT
Project Life+ ENV/ES/000480 - Valorization and Recycling of Slurries Produced During Manufacturing Stone Sector to Use as Raw Materials for Industrial Applications
Novelda – Alicante
• Identification of the most suitable applications for using the valorised and characterised slurries as raw materials • Development of a pilot plan for the characterization and valorisation processes • Performance of real scale tests at factories replacing conventional raw materials for slurries • Testing of new developed products using in force standards • Re-design of the slurry dumps for converting in storage places for raw materials • Identification and transferring of worldwide best practices • Establishment of a normative framework to promote the recycling process by means of regulation of the dumps and promotion of ecolabel products
Ramallah: 10-11 March 2014 SUSTAINABLE STONE & MARBLE INDUSTRY NKUA
Cleaner Technologies
• Specific equipment such are de cutting equipment with water use or the dust collectors. • Waste reduction. • Water reuse. • Dust and Noise control.
Cutting equipment whit water use and a dust control equipment (finish phase of a processing plant and quarry (perfuration))
Ramallah: 10-11 March 2014 NTUA.HMCS – ACTION 4 NKUA 3 3 Rehabilitation of environment through ofenvironment Rehabilitation etc. plants interventions, architectural Installation of mobile crusher –crusher ofmobile Installation - grinder pulveriser and technologiesof contemporary Use fordepositmethods geological ultrasonice.g. geo-radars, evaluation methods e.g. land rehabilitatedusesof New sports recreational, discs cutting ofthinnerUse inspection/selectionof cameraUse classification forquality methods ofdryer rotary fora Installation CaCO intosolid sludge converting applications for various sell and mixture • • • • • • • selected areas selected - Efficiency Efficiency -Wastes Reduce Good Practices to Improve the Material Material the Improve to Practices Good Sell wastes directly as low quality quality low as directly wastes Sell aggregates or as stone logistics” “waste Implement to prior block Reinforce/repair resine.g. via cutting, impregnation ofdisc cutting Optimization speed raw as sell and sludge Collect (wet e.g. or dry) in material or gypsum ceramics cement, industry (collection in pre in (collection to size) according • • • • • • blocks) sludge) operation (damaged, Waste water water Waste Block removal Block Cutting (Scraps) Cutting treatment (Liquid (Liquid treatment Overall quarrying quarrying Overall irregular small size size small irregular
Quarry Processing Plant Ramallah: 10-11 March 2014 10-11 March Ramallah: SUSTAINABLE STONE & MARBLE MARBLE & STONE INDUSTRY SUSTAINABLE SUSTAINABLE STONE & MARBLE INDUSTRY NKUA
Part IV ––EnergyEnergy and Water Management
Objectives:
• Understand the Use of the Energy and Water in the Process
• Present Best Practices toward a better Efficiency
Ramallah: 10-11 March 2014 SUSTAINABLE STONE & MARBLE INDUSTRY NKUA Energy
The energy appears in the extraction process and manufacturing in several forms, electricity, diesel and other "secondary" which will be dependent on the first two, compressed air, which can be produced by a diesel or electric compressor.
Note: Quarry A includes a crushing plant.
Ramallah: 10-11 March 2014 SUSTAINABLE STONE & MARBLE INDUSTRY NKUA
Energy – Good Practices
• How can a manufacturer of natural stone
• improve energy efficiency?
• reduce energy costs ?
Ramallah: 10-11 March 2014 NTUA.HMCS – ACTION 4 n
NKUA and Proper dimensioning ofdieseldimensioning generators Proper generators ofstate-of-the-art Acquisition productio power for sources energy Use ofrenewable co-generation. for or production oflocal energy biomass for Exploitation in measures anti-pollution ofrecent Implementation vehicles low novel with machinery ofexisting Replacement equipment consumption co-generation • • • • • • ions s s ion ution grid) ution Energy Efficiency Efficiency Energy • Regular engine and vehicle maintenance vehicle andengine Regular specification product to equipment match Selectand Optimization of generators operation (local (local distrib operation ofgenerators Optimization logistics oftransportation Optimization vehicles for fuels Use ofrenewable consumpt power to monitor electrical meters Install Regular energy audits energy Regular equipment production ofenergy maintenance Regular specificat to according operation machinery Optimum stops andmultiplehalts Avoid maintenance inspectionand Regular • • • • • • • • • • •
Quarry Transport Processing plant Ramallah: 10-11 March 2014 10-11 March Ramallah: SUSTAINABLE STONE & MARBLE MARBLE & STONE INDUSTRY SUSTAINABLE SUSTAINABLE STONE & MARBLE INDUSTRY NKUA Water Water is an essential element both in the quarrying or in the processing of dimensional rock. Its function is to cool the drilling and cutting diamond tools and clean the cuts. Simultaneously this use complies with environmental functions also allowing the reduction of dust emissions into the atmosphere.
Origins: • Surface water (rivers, lagoons, etc.) • Groundwater (aquífer). • Public Supply.
Ramallah: 10-11 March 2014 SUSTAINABLE STONE & MARBLE INDUSTRY NKUA Waste Water
In the ornamental stone the production of liquid effluents has particular importance since the general processes take place in wet conditions, either in quarries or in the processing plants.
On the other hand most of the wastewater, water and suspended solids (stone dust), require a strict management and have relatively high costs.
Optimal values for reuse are located close to 80% of water necessary to the production process, both for quarrying and processing. To suppress the normal loss of water in the recirculation system, usually through the sludge process or evaporation / infiltration, it will be necessary to supply external connection with the origins mentioned above.
Ramallah: 10-11 March 2014 SUSTAINABLE STONE & MARBLE INDUSTRY NKUA Water Polution
Main Environmental Impacts, that may have influences in the Public Health:
• Intersection, Destruction or Occupation of waterlines • Changing the quality of surface water (by the increase of suspended solids, oils or lubricants). • Intersection and lowering of groundwater levels. • Change in groundwater quality (essentially in permeable stones like the calcareous).
Ramallah: 10-11 March 2014 SUSTAINABLE STONE & MARBLE INDUSTRY NKUA
Water Management – Good Practices
• Maintenance of pipes and tanks to prevent/leaks;
• Control of equipment flow rates ;
• Implementation and maintenance of a system of wastewater treatment;
• Monitoring the dosage of flocculants for waste-water treatment;
• Collection and Recycling of water used in the production process.
Ramallah: 10-11 March 2014 SUSTAINABLE STONE & MARBLE INDUSTRY NKUA
Water is a Scarce resource and indispensable for the Human Life The Correct Management is Extremely Important
Quarry Management
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Processing Plant Management
Ramallah: 10-11 March 2014 SUSTAINABLE STONE & MARBLE INDUSTRY NKUA
Part VV––LifeLife Cycle Analysis and EcoEco--ManagementManagement
Objectives:
• Brief approach to the life cycle analysis and ecomanagement has na important tool toward the Sustainability
Ramallah: 10-11 March 2014 SUSTAINABLE STONE & MARBLE INDUSTRY NKUA
Life Cycle Analysis has gained recognition as the most powerful tool for achieving cleaner production for both processes and products
PLAN DO CHECK ACT
LCA METHODOLOGY
a) Recording of the inputs (raw materials, agents, water and energy resources) and the outputs (products, atmospheric emissions, solid wastes, etc.) of most processes that occur during the life cycle of the studied product;
b) Evaluation of the potential environmental impacts, which are related to the inputs and outputs of the system;
c) Interpretation of the results of the inventory analysis and the impact evaluation stage, according to the objectives/targets of the LCA.
Ramallah: 10-11 March 2014 SUSTAINABLE STONE & MARBLE INDUSTRY NKUA
LCA STRUCTURE
3. LIFE CYCLE IMPACT 4. LIFE CYCLE ASSESSMENT INTERPRETATION 1. GOAL AND SCOPE DEFINITION
2. LIFE CYCLE INVENTORY ANALYSIS
The target of LCA is the measurement of the environmental burden of an economical system during its life from a quantitative approach, as much as this is possible.
Ramallah: 10-11 March 2014 SUSTAINABLE STONE & MARBLE INDUSTRY NKUA
VIDEO PRESENTATION Sustainability
Ramallah: 10-11 March 2014 SUSTAINABLE STONE & MARBLE INDUSTRY NKUA Main References
I-Stone (2005): Re-engineering of natural stone production chain through knowledge based processes, eco-innovation and new organisational paradigms; I-Stone Integrated project, PRIORITY 3, Assessment of currently applied stone waste management schemes (D5.10); December 2005.
I-Stone (2006): Re-engineering of natural stone production chain through knowledge based processes, eco-innovation and new organisational paradigms; I-Stone Integrated project, PRIORITY 3, First Review of Best Available Waste Management Techniques (D5.11); April 2006.
I-Stone (2006): Re-engineering of natural stone production chain through knowledge based processes, eco-innovation and new organisational paradigms; I-Stone Integrated project, PRIORITY 3, Preliminary LCA study of the stone production chain and waste management (D5.14); June 2006.
I-Stone (2006): Re -engineering of natural stone production chain through knowledge based processes, eco -innovation and new organisational paradigms; I-Stone Integrated project, PRIORITY 3, Feasibility Study of Alternative Stone Waste Uses (D5.15); June 2006.
I-Stone (2007): Re-engineering of natural stone production chain through knowledge based processes, eco-innovation and new organisational paradigms; I-Stone Integrated project, PRIORITY 3, Development of Sustainable (D5.16); August 2007.
OSNET Editions vol. 1, “ Machines and tools for stone quarrying and processing” , edited by S. Carosio, I. Paspaliaris, Athens 2003.
OSNET Editions vol. 2, “ Dimension stone quarrying in Europe and stability of quarrying operations” , edited by N. Terezopoulos, I. Paspaliaris, Athens 2003.
OSNET Editions vol. 7, “ Optimizing quarrying techniques and practices” , edited by N. Terezopoulos, I. Paspaliaris, Athens 2004.
OSNET Editions vol. 9, “ Complementary technologies for stone processing” , edited by S. Midha, I. Paspaliaris, Athens 2004.
OSNET Editions vol. 12, “ Environmental friendly practices for natural stone exploitation” , edited by A. Dieb, N. Bonito, I. Paspaliaris, Athens 2004.
Ramallah: 10-11 March 2014 SUSTAINABLE STONE & MARBLE INDUSTRY NKUA
Thank You!
Ramallah: 10-11 March 2014