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FP7

DAPHNE Result In Brief

Project ID: 314636
Funded under: FP7-NMP
Country: Spain

New process for eco-friendly ceramics, glass and cement

Although microwave heating is an established technique used by industry for low-temperature processes such as a drying, it has not been applied at high temperatures to full-scale industrial processes. An EU-funded consortium therefore set out to improve the efficiency of the most energy-intensive part of the production chain: the firing process.
New process for eco-friendly ceramics, glass and cement
The project DAPHNE (Development of adaptive production systems for eco-efficient firing processes) was set up to explore energy-saving solutions for the ceramics, glass and cement industries by substituting high-temperature heating with microwave technology.

Project partners developed smart monitoring and control solutions to provide real-time information on energy consumption and product quality on the basis of key performance indicators. They designed, tested and demonstrated solutions based on the self-adaptive control of a high-temperature microwave system and the active control of production lines, which incorporated the proposed microwave solutions.

Researchers first produced a lab-scale prototype and then a semi-industrial prototype with two different modules for processing five target materials: ceramic frits, clinker, slag cement, metakaolin and glass. The challenge was to reduce energy consumption by 40 % whilst achieving high productivity with less environmental impacts by reducing process emissions to below prescribed limits.

Work conducted by DAPHNE is particularly relevant to energy research, smart energy networks, and energy efficiency and saving. As well as reducing the need for energy it also encourages recycling, reducing demands for raw materials and their transport, and lower carbon dioxide emissions.

The project's outcomes will therefore help to bring about a radical reduction in total energy demand, thereby supporting the European Strategic Energy Technology Plan and the Energy Efficiency Plan 2011.

Related information

Keywords

Ceramics, glass, cement, microwave heating, firing process, DAPHNE, energy consumption
Record Number: 188726 / Last updated on: 2016-10-26
Domain: Industrial Technologies
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