“KVARIT” sustainable industrial production innovation project (thermal insulation building material made of ceramic foam).
The production capacity of the production plant is 50,000 m3 per year (an alternative to expanded clay concrete blocks) allows:
Elimination of 8,000 - 10,000 tons of CO2 emissions per year.
Liquidation of water consumption 10,000 - 12,000 tons per year (concrete preparation).
Exclusion of cement consumption from 12,000 to 15,000 tons per year.
The involvement of fertile lands, which were otherwise used for clay quarries, is excluded (extraction of raw materials for expanded clay / expanded clay / production).
In a long list of methods for the production of ceramic foam, the minimum number of components is 3-4 names, including industrial waste suitable for the production of expanded clay, in our technology there can be only one component - shale with a fraction of 0.5-20 mm.
The carbon-free production method eliminates: emissions of noise, water vapour, dust, nitrogen and nitrogen oxides.
Waste can be used in construction, in the production of geopolymer concrete, in land reclamation and as materials for protecting winter roads from icing.
Research from the Istanbul University School of Medicine shows that volcanic tuff-modified montmorillonite clay, in its original or chemically modified form, can act as lightweight synthetic building walls, allowing VOCs to be filtered out and thereby limiting human exposure https://journals.sagepub. com/doi/abs/10.1177/0748233711422727
Raw materials - crushed stone from carbon-free clay slates (roofing slate / shale), mudstones and other intumescent materials with a fraction of 0.5 to 20 mm, including: overburden and mining waste, roofing shale waste up to 85%. in the manufacture of roofing slabs or any raw material for the production of expanded clay.
Theoretically required power consumption is 270 kW/m3 for products with a density of 500 kg/m3.
Product cost is competitive; this conclusion should be drawn from the following:
1. The technology under consideration does not require cement.
2. The technology used does not provide for water consumption.
3. The technology used does not require additional production facilities.
4. The total power consumption is theoretically comparable to that of expanded clay / expanded clay / production.
The new material was in the early stages of research in America, Europe and Russia and was not considered in the context of the Kyoto agreement to reduce greenhouse gas emissions, so the production methods of that period were not introduced or improved.
The Research and Design Institute of Concrete and Reinforced Concrete: http://www.niizhb-fgup.ru/ determined the main technical characteristics of ceramic foam products: