Action B.3 – Demonstration Action

Proposed starting and end date of action: 01/07/13-01/05/14
Actual starting and expected end date of action: 01/07/13-14/11/14
Status: Completed

Description:

In this Action implementation of the proposed scenarios demonstrated in Action B.2 were actualized.

Demonstration of a new waste management procedure for the waste quarry slurry was carried out, involving the utilization of the waste demonstrating (a) the appropriate chemical analysis needed to be made to the waste (b) the sound way of storing and transferring the quarry slurry to the industries as raw material and (c) the revenue gains of the utilization of the waste to the quarry industries by reducing fines or reducing the fees required to dispose the waste in landfills or at the quarry area.

The objectives of the demonstration, considering the real conditions were:

  • the ideal amount of samples needed for the chemical analysis of the slurry;
  • the appropriate management of the samples (prescriptions for collection, storage, transfer);
  • the type of chemical analysis needed;
  • the appropriate prescription for storing the quarry slurry before being delivered to industry (area needed and type of storage);
  • the appropriate transfer method from quarries to industries (prescriptions, type of tanker truck);
  • the level of cost saving per tonne of slurry by not paying fines and usage rights to dispose the waste in landfills or at the quarry area; and
  • the total environmental benefit from the alternative management of the quarry slurry

Furthermore, the cooperating clay brick/tile and cement industries participated in the implementation of the scenarios by applying the predefined quantities of quarry slurry in their production procedure for a load of products for each proposed scenario. The demonstration activities were be overseen and coordinated by MANRE and N&A.

Methods Employed:

Clay brick/tile Factory Demonstration:

During the demonstration action for the bricks production, a total of sixteen basic scenarios for two types of bricks were implemented (eight for each type of brick) in order to identify the best percentage participation rate of the intrusive quarry slurry replacement in the mixture. Based on the results of the empirical assessment and taking into account the results of the laboratory analyses on the chemical characteristics of the produced bricks it was decided that that since both types of bricks were fulfilling the minimum requirements of the Quality Standard CYS EN 771-1:2011, not to proceed with the implementation of the “corrective” scenarios. All scenarios fulfilled the requirements of the Quality Standard CYS EN 771-1 as set by the National Technical Committee TE04, for both brick types UB 2809 and UB 3309 and therefore it has been decided that the scenario with the maximum intrusive quarry slurry participation in the mixture to be selected as the “best”. This scenario utilizes 36% intrusive quarry slurry – 4% red clay (90% replacement of red clay) and 60% gray clay in the total material mixture. In this respect, more quantities of quarry slurry can be utilized and therefore, savings on priority resources such as soil, air, nature and biodiversity, energy and manpower can be achieved.

This demonstration action involved the use of loads of waste quarry slurry in the production of batches of red bricks. A total of 16 repetitions of the demonstration took place where every repetition involves the production of one batch of bricks. A budget for the carrying out of 5 additional safety or verification repetitions is declared in the project proposal. Each batch comprises of 3000 bricks and it is preliminary estimated that 60tns of quarry slurry will be used for each repetition. Each demonstration will involve the use of different quantities of waste quarry slurry and different combination with the other raw material in the brick mix.

Each demonstration repetition involved the following general activities:

  • Delivery of approximately 50tns of quarry slurry in the clay brick/tile factory
  • laboratory work on each load to record its characteristics
  • preparation of the brick mix based on each of the predefined scenarios
  • production of bricks and placement in the brick moulds
  • drying of the bricks in special ovens
  • baking of the bricks in the ovens

A significant number of monitoring activities was implemented in order to receive the necessary data to make corrections in the following demonstrations:

  • Chemical and physical analysis i.e. humidity content for every brick mixture
  • Monitoring of fuel consumption
  • Monitoring of oven temperatures
  • Estimation of CO2 emissions
  • vehicle movements
  • energy consumption
  • production time
  • Physical tests on the produced batch of bricks and comparison against the factory's standards

Cement Factory Demonstration:

During the demonstration action at the VCW, further to the results of the chemical analysis of the intrusive and calcareous quarry slurry, it was decided to investigate the following applications:

  • 30% substitution of clay from intrusive slurry for the producing of clinker
  • Production of cement with limestone substitution by calcareous slurries and intrusive slurry in the percentages of 5%, 10%, 15% and 20%.

Each demonstration repetition for both industries involved the following general activities: laboratory work on the load to record its characteristics; preparation of cement mixtures based on the pre-defined scenarios; production of clinker/cement. A significant number of monitoring activities was implemented in order to receive necessary data such as: physical/chemical characteristics of mixtures; fuel consumption; energy consumption; physical/chemical tests on produced batches for comparison reasons against the quality standards. A total of 22000 tons of clinker and 1980 tons of cement were produced with the use of 2500 tons of waste quarry slurry.

Each demonstration repetition involvesd the following general activities:

  • Delivery of approximately of quarry slurry in the cement factory
  • laboratory work on each load to record its characteristics
  • preparation of the cement mix based on each of the predefined scenarios
  • production of cement
  • A significant number of monitoring activities will be implemented in order to receive the necessary data to make corrections in the following demonstrations:
  • Chemical and physical analysis i.e. humidity content for every cement mixture
  • Monitoring of fuel consumption
  • Monitoring of oven temperatures
  • Estimation of CO2 emissions
  • vehicle movements
  • energy consumption
  • production time
  • Physical/chemical tests on the produced batch of cement and comparison against the factory's standards

During the implementation of the demonstration activities other parameters will also be recorded for every demonstration both for the brick and cement industry such as:

  • environmental parameters (liquid waste production, solid waste production etc.)
  • financial parameters such as fuel costs, energy costs, manpower costs, transport costs etc.

Results:

  • Records with core data regarding the appropriate procedure for managing the quarry slurry from production until utilization in industry;
  • Records with environmental and financial parameters involved in managing process;
  • Production of cement and clay brick/tile products with the use of quarry slurry for each implementation scenario regarding the percentage of the quarry slurry participation;
  • Records with core data regarding the appropriate procedure for quarry slurry installment in the production chain of each industry;
  • Records with indicative figures of factors connected with the CO2 emissions and other environmental parameters from each industry involved;
  • Records with costs for each scenario implemented.
  • Reports that includes:
  • The appropriate procedure for managing the quarry slurry from production until utilization in industry. This will include recommendations related to the collection, storage, transfer and methods of using the slurry;
  • Identification of technical/environmental/financial benefits and drawbacks of the proposed procedure;
  • Estimation of the financial burden for the transferring and utilizing quarry slurry to cement and brick/tile industries including real expenses for tracking and the implementation of modifications in the production activities and control in each industry;
  • The environmental cost/benefits of the implementation of the demonstration action including indicative figures of factors connected with the CO2 emissions and other environmental parameters from each industry involved;
  • Technical specification guidelines for the production of cement and clay brick/tile products with the use of quarry slurry for each implementation scenario regarding the percentage of the quarry slurry usage in the raw materials and the appropriate procedure for quarry slurry installment in the production procedure of each industry;
  • Quality control measures to be implemented in each industry to ensure the quality of products.
  • Environment LIFE Programme
  • Department of Environment
  • Nicolaides and Associates Ltd
  • Latomia Pharmakas PLC
  • Vasiliko Cement Works
  • United Brickworks