The general aim of the project is the valorisation of industrial production of the micronized fluorided lime (MFL) as a by-product of frit smelting and its application in new products. The specific objective is the formulation and market implementation of various value added products made from MFL. The innovative technology of smelting gases recycling will be used to enhance traditionally acknowledged technologies used merely for the purification of gases and thereby ensuring the compliance with environmental legislation and policy. So far, the reuse of by-products was impossible or unfulfilled mainly due to the inhomogeneous composition of produced lime.

Our proposed innovative technology is built on the innovative concept of regulating and monitoring a system which will enhance a stable and constant quality of the by-product (MFL). The by-product will be used as a substitute for the raw material in frit and enamel production (closed manufacturing) or as a new raw material for specialized ceramic compounds. Technical innovations are proposed in all main parts of unit: the inflow of gases, filtration unit and the reactor for neutralization and separation unit.

Technical description

The baseline of proposed technology is the recycling of solid waste achieved by the innovative process of flue gas dry-neutralization. The flue gases from smelting furnaces contain fluoride, which interact with lime particles through the process of dry-neutralization through chemical reaction between lime and HF(hidroflouric acid). Due to innovative design of separation unit and advanced methodology for automatized regulation, it is possible to ensure a formation of homogenized micronized fluorided lime (MFL) for reuse in production of high quality ceramic products.

In a simple way, the technology for production of MFL is based on the reaction between fluoride gases (arising in technological process of melting of frits) and lime through chemical reaction of neutralization. The micronized lime is injected in reactor with adjustable feed rate regarding content of HF concentration in flue gases. This assures an optimal reaction rate and material consumption. The product of neutralization is so-called MFL, which acts now as a raw material for new frits and special ceramic products.

Overview of the market

The potential markets for products with recycled MFL are divided into three main segments:

  • market for specialized ceramic components
  • market for electrostatic black powder and ground coat enamel for system 2C/1F wet/dry
  • market for other products (MFL is substitution for other raw materials)

Furthermore, we can divide the market considering geographical positions of our consumers respecting various products. Ceramic frits and enamels are based mostly in EU and Mediterranean market, while the market for boilers frits and specialized ceramic frits has practically no geographical boundaries on globally.

Exploitation of results

The whole quantity of produced micronized fluorided lime (MFL) is planned to be reused in our production of frits, enamels and specialized ceramic compounds.

Ceramic components on the basis of MFL will be put on the market in cooperation with the partner company Emaylum from Italy, which will distribute the products through their market network across the EU. Additional opportunities for market uptake are envisaged in the countries of the former Soviet Union and in the Arab countries.

For replication of the technology, replicating entity could be any SME or industry with ecological problems due to acid furnace gases. The proposed innovative solutions of regulation and reactor separation devices could be replicated also for other systems of dry neutralization of flue gases.

Concept & Objectives

New production line for micronized fluorided lime will allow us to wholly move to smelting with the use of oxygen burners, which will considerably reduce the flow of gases and the fuel consumption as well as completely abolish the blind heating of furnace needed to maintain temperature conditions. The removal of old technology will also significantly reduce the consumption of electricity as well as waste generated from neutralization of flue gases which will be reused and incorporated in new products.

With the usage of oxy-fuel burners the overall cost of production will also be decreased. All these results will push our company toward economic and environmental sustainability.

Work packages

The main work packages (WPs) are:

  • Management
  • Design, installation and improvement of new technological unit
  • Formulation and quality optimization of frits and enamels
  • Exploitation and Business plan
  • Dissemination and reporting activities

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