Valorization of Forest and Agricultural Biomass for the

Spanish Ceramic Tile Industry

Daniel Gabaldón-Estevan | Kaunas 20/11/2015Department of Sociology and Social Anthropology, Faculty of Social Sciences, University of Valencia- Valencia (ES) - daniel.gabaldon@uv.es

ESTIBMEIC Project - GV/2014/049

D. Alfonso , A. Mezquita, E. Monfort, D. Gabaldón-Estevan

Introduction and motivation 1.

Methodology for biomass resources evaluation 2.

Evolution and actual energy demand of the ceramic tile industry 3.

Environmental impact reduction through biomass introduction 4.

Conclusions 5.

ESTIBMEIC Project - GV/2014/049Socio-Technical Study on the Incorporation of Biofuels in the Energy Mix Ceramic Industry

Project financed by:

0. Index

Introduction and motivation 1.

Methodology for biomass resources evaluation 2.

Evolution and actual energy demand of the ceramic tile industry 3.

Environmental impact reduction through biomass introduction 4.

Conclusions 5.

0.

Towards 2050 1.1

Reduction of greenhouse emissions by at least 20%

Obtaining 20% of the energy from renewable sources

Increase by 20% the energy efficiency

What about this challenge?

5

A return to biomass? [ESTIBMEIC GV/2014/049 Socio-Technical Study on the Incorporation of Biofuels in the Energy Mix Ceramic Industry]

1.2

The global transition from fossil fuel-based energy sources to renewable energy sources will be most effective, for at least the near future, by utilizing local resources and existing infrastructure. [Parent et al. 2014]

6

Onda

L’Alcora

Vila-real

Castellón Almazora

Sant Joan de Moró

Locating the industry [Gabaldón-Estevan, D. (2010). Industry & territory [fotography]. Presented at XX Concurso de Fotografía Científica, Técnica y Artística de Cerámica y Vidrio, 27-29 October 2010. L Congreso Anual de la Sociedad Española de Cerámica y Vidrio]

1.3

7

Onda

L’Alcora

Castellón

Sant Joan de Moró

Locating the industry 1.4

Introduction and motivation 1.

Methodology for biomass resources evaluation 2.

Evolution and actual energy demand of the ceramic tile industry 3.

Environmental impact reduction through biomass introduction 4.

Conclusions 5.

0.

Methodology for biomass resources evaluation 2.1

Areas of influence

Biomass sources&

- Forestry- Agricultural crops:

- Woody crops [olives, grapes, oranges, almonds, apples, etc.] and

- Herbaceous crops [rice, wheat, barley, maize]

- Agro-industries:- Olive oil industries; - Wine production industries; - Dry fruits peeling plants; - Rice mills;…

Biomass resources quantification. Generation ratios for agricultural residues[Di Blasi et al, 1997; Dias & Azevedo, 2002; Voivontas et al, 2001; EUBIONET, 2002 & 2003; ECN, 2014) and from direct analysis performed during both BIOVAL and ESTIBMEIC projects]

2.2

Code 

Biomass resource

(type of crop)

Description Waste biomass generation ratio(referred to wet

biomass)

Higher heating value(MJ·kg-1 dry)

Moisture(% wet

basis, fresh)

Ash(% dry basis)

AGAi Agricultural residues from woody crops

Annual tree prunings

1.8-4.1 (t·year-1· hm-2 of cropland) 17.2-18.4 30 – 40 % 1.8-3.4 %

AGBi Agricultural residues from herbaceous crops

Cereal straw, maize cobs and stalks

1.5-7.8 (t·year-1· hm-2 of cropland ) 16.8-18.1 20 – 30 %a 4.2-7.5%b

FRi Forestry residues

Silviculture waste

1.0 – 1.9 (t·year-1· hm-2 of woodland) 18 – 20% 29 – 45% 1.2 – 3.4%

AIi

Agro-industrial residues

Fruit peels and pulp, cereal husk, dry fruit shells

0.16 - 3.6 (t·t-1 of product) 16 – 22.0% 50 – 65%c 2 – 6%d

a fresh Maize cobs and stalks have a moisture content of 55-65%b rice straw has an ash content (in % dry basis) of around 18%c dry fruits shells and rice husk have low moisture content in the range 8-12% (in % wet basis)d rice husk has an ash content (in % dry basis) of around 17%

Biomass resources availability for energy use [Voivontas et al, 2001; EUBIONET, 2003; and additional surveys performed by the authors ]

2.3

Biomass resource

Availability for energy use Additional considerations

Tree prunings(AGAi)

60 – 80% It was considered that biomass from plots smaller than a minimum value (0.6 – 0.8 hm2) would not be collected due to difficult accessibility and logistics (for the same total area, many small plots instead of few big ones provide higher management complexity)

Cereal straw & similar (AGBi)

15 – 30% (rice straw & corn stalks 50 – 60%)

Forestry(FRi)

20 – 40%

This percentage represents the waste biomass produced due to silviculture treatments really performed in Spain compared with the theoretical potential value computed according to woodland surface.

Introduction and motivation 1.

Methodology for biomass resources evaluation 2.

Evolution and actual energy demand of the ceramic tile industry 3.

Environmental impact reduction through biomass introduction 4.

Conclusions 5.

0.

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2000

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1985

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Year

Ene

rgy

cons

umpt

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(GW

h/ye

ar)

Natural Gas Other fuels Electricity

Energy mix and consumption (GWh/year) (Spain, 1985 to 2011) [Monfort, E.; Mezquita, A.; Vaquer, E.; Gabaldón-Estevan, D. (2014) Path-dependency and path-making in the energy system in the Spanish ceramic tile cluster. Bol. Soc. Esp. Ceram. V. 53 (3) 111-120]

3.1

Results: Identification of the target processes [Schematic illustration of the single-fired ceramic tile manufacturing process and Thermal specific consumption (kWh/m2) by sub process (2007) Source: Monfort, E.; Mezquita, A.; Vaquer, E.; Gabaldón-Estevan, D. (2014) La evolución energética del sector español de baldosas cerámicas Bol. Soc. Esp. Ceram. V. 53 (3) 111-120]

3.2

Raw materials

MillingSpray drying

Glazepreparation

Pressing Drying Glazing Firing

Floor tile

Wall tile

Raw materials

MillingSpray drying

Glazepreparation

Pressing Drying Glazing Firing

Floor tile

Wall tile

Most common ceramic tile manufacturing process in Europe (single-firing)

Thermal energy

Milling Spray drying; 9,8 [36%]

Drying; 2,4 [9%]

Firing; 15,23; [55%]

Greenhouse emissions [Monfort, E.; Mezquita, A.; Vaquer, E.; Gabaldón-Estevan, D. (2014) La evolución energética del sector español de baldosas cerámicas Bol. Soc. Esp. Ceram. V. 53 (3) 111-120]

3.3

CO2 emissions (kg CO2/t fired product) (2008)

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4

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1985 1990 1995 2000 2005 2010 2012

Spec

ific

CO

2 em

issi

on (k

g C

O2/m

2 )

Evolution of the specific CO2 emissions (Spain, 1985 to 2012) [Gabaldón-Estevan, D.; Mezquita, A.; Ferrer, S.: Monfort, E. (2014) Is European Union Environmental Policy Efficient at Promoting a Post-carbon Industry? The Case of Energy in the European Ceramic Tile Sector. Proceedings of the 11th ICIM 2014, Vaasa (Finland) 104-113]

3.4

- combustion air pre-heating, - energy recovery from kilns to dryers or spray dryers, - improvements in burners design, etc.,

With the technologies available optimal efficiency, has nearly been achieved as the ceramic sector is using Best Available Techniques.

Still, some activities are being implemented to further reduce energy consumption, such as:

However important further CO2 emissions reduction should only be achieved by incorporating new technologies.

Introduction and motivation 1.

Methodology for biomass resources evaluation 2.

Evolution and actual energy demand of the ceramic tile industry 3.

Environmental impact reduction through biomass introduction 4.

Conclusions 5.

0.

Environmental impact reduction through the introduction of biomass in the manufacturing process of ceramic tile products 4.1

Being firing and drying the environmental hot spots the manufacturing process, biomass could be used on drying process (with indirect heat exchanger) with oil boiler.The major factors influencing design of equipment are:

(1) the fuel properties (e.g. bulk density, moisture, proximate and ultimate analysis, calorific value, ash properties, and size characteristics);

(2) the thermal requirement (e.g. heat load, processing temperature, furnace and heat exchanger design, etc.);

(3) the economics (e.g. cost of available fuels, labour rates, equipment costs);

(4) the local factors (e.g. operational and construction/maintenance skills, spares availability, roads and local infrastructure, environmental legislation); and

(5) the fuel handling.

Environmental impact reduction through the introduction of biomass in the manufacturing process of ceramic tile products 4.2

Biomass at Castellon provincial level [BIOVAL Ref. MAC/3/C216]:(1)biomass transport cost (including first transformation), is about 60 €/t. (2)biomass available in the province is mainly of forest origin (60% of the area of the province is forest land) and there is great potential for biomass from woody crops (mainly citrus, olive and almond trees). (3)forest residual biomass is estimated at 40,000 tons (4)agricultural waste is estimated at 150,000 tons.

The properties of this biomass as fuel are suitable for use in energy: -calorific value (dry) of 17.5 - 19.9 MJ/kg and -ash percentages of 1-3% (dry basis).The representative price of forest-based chips (the most commercially available) is in the range 45-55 €/t (25% moisture approx.).

Environmental impact reduction through the introduction of biomass in the manufacturing process of ceramic tile products 4.3

Summing up:(1)The drying process fuel consumption is of about 3 to 3.9 kWh/m2 depending on type of tile (Monfort et al. 2010), (2)1 tone of fresh biomass has about 2,980 kWh, (3)thus each tone could cover drying fuel need equivalent to 764 up to 993.3 m2 of tiles.

Therefore net CO2 savings, taking into account biomass transport and conditioning, could be about 0.5 to 0.6 kg CO2 per m2.

Introduction and motivation 1.

Methodology for biomass resources evaluation 2.

Evolution and actual energy demand of the ceramic tile industry 3.

Environmental impact reduction through biomass introduction 4.

Conclusions 5.

0.

Conclusions I 5.1

In the present paper we have presented a study on the viability of the incorporation of biofuels in the energy mix of the Spanish ceramic tile industry with three objectives:

(1)To identify the potential use of biomass resources, with a special focus of forest and agricultural biomass, in the manufacturing process of ceramic tile products. And for that we have shown a methodology for biomass resources evaluation and present relevant data on forest and agricultural biomass for the ceramic tile industry in the Castellon province.

(2)To identify the part of the manufacture of ceramic tile products where it can be more easily introduced. And we have identify the drying phase of the production process, as the driers of the green bodies of the tiles represents 9% of actual thermal energy consumption.

(3)To asses the reduced environmental impact from the manufacture of ceramic materials through a reduction in carbon dioxide emissions. And we have estimated a reduction of about 0.5 to 0.6 kg CO2 per m2.

Conclusions II 5.2

Still, technical, economic and social analysis of each identified opportunity has to be further studied for obtaining a better picture of the challenges to boost the sustainable use of biomass for energy in the production processes of the ceramic industry.

Also, other positive consequences for sustainable development of rural areas, such as the development of ecosystem services, the generation of employment and the better management of forestry and agricultural areas should be included to better asses the benefits of the incorporation of biofuels in the energy mix ceramic industry.

Our references 5.3 Gabaldón-Estevan, D.; Mezquita, A.; Ferrer, S.: Monfort, E. (2014) Is European Union Environmental Policy Efficient at Promoting a Post-carbon Industry? The Case of Energy in the European Ceramic Tile Sector. Proceedings of the 11th ICIM 2014, Vaasa (Finland) 104-113 http://icim.vamk.fi/2014/uploads/UploadPaperDir/11thICIM2014.pdf Mezquita, A.; Monfort, E.;Vaquer, E.; Ferrer, S.; Pitarch, J.M.; Arnal, M.A.; Cobo, F. (2014) Reduction of CO2-emissions in ceramic tiles manufacture by combining energy-saving measures. Cfi Ber. DKG 85, 91 (5) pp. E37-E42.Monfort, E.; Mezquita, A.; Vaquer, E.; Gabaldón-Estevan, D. (2014) La evolución energética del sector español de baldosas cerámicas Bol. Soc. Esp. Ceram. V. 53 (3) 111-120http://boletines.secv.es/upload/2014070792201.201453111.pdf Gabaldón-Estevan, D.; Criado, E.; Monfort, E. (2014) The Green Factor in European Manufacturing: A case study of the Spanish ceramic tile industry. Journal of Cleaner Production 70, 242-250 http://www.sciencedirect.com/science/article/pii/S0959652614001620 Gabaldón-Estevan, D.; Hekkert M.P. (2013) How Does the Innovation System in the Spanish Tile Sector Function? Bol. Soc. Esp. Ceram. V. 52 (3) 151-158 http://boletines.secv.es/upload/20130704104006.201352151.pdf Gabaldón-Estevan, D.; Fernández de Lucio, I. and Molina Morales, FX. (2012) Distritual Innovation Systems. ARBOR-Ciencia pensamiento y cultura, 188 (753), pp. 63-73 http://arbor.revistas.csic.es/index.php/arbor/article/download/1448/1457Gabaldón-Estevan, D. (2011) El sistema distritual de innovación cerámico de Castellón. Universitat de València. Servei de Publicacions. http://rodrigo.uv.es/bitstream/handle/10550/23431/gabaldon.pdf?sequence=1Monfort, E.; Mezquita, A.; Granel, R.; Vaquer, E.; Escrig, A.; Miralles, A.; Zaera, V. (2010) Analysis of energy consumption and carbon dioxide emissions in ceramic tile manufacture Bol. Soc. Esp. Ceram. V. 49 (4) pp. 303-310 http://boletines.secv.es/upload/20100901173134.201049303.pdf Mezquita, A.; Monfort, E.; Zaera, V. (2009) Sector azulejero y comercio de emisiones: reducción de emisiones de CO2, benchmarking europeo. Bol. Soc. Esp. Ceram. V. 48(4) pp. 211-222 http://boletines.secv.es/upload/20090904100231.200948211.pdf Tortajada Esparza, E.; Gabaldón-Estevan, D. and Fernández de Lucio I. (2008) La evolución tecnológica del distrito cerámico de Castellón: la contribución de la industria de fritas, colores y esmaltes. Bol. Soc. Esp. Ceram. V. 47 (2) pp. 57-80 http://boletines.secv.es/upload/20080512114901.47[2]57-80.pdf

Daniel Gabaldón-Estevan | Kaunas 20/11/2015Department of Sociology and Social Anthropology, Faculty of Social Sciences, University of Valencia- Valencia (ES) - Daniel.Gabaldon@uv.es

https://uv.academia.edu/DanielGabald%C3%B3nEstevan

https://www.researchgate.net/profile/Daniel_Gabaldon-Estevan

https://www.linkedin.com/pub/daniel-gabad%C3%B3n-estevan/23/722/aaa

http://www.slideshare.net/DanielGabaldnEstevan

http://orcid.org/0000-0003-2086-5012

http://www.researcherid.com/rid/B-5195-2011

Thank you for your attention 5.4 ESTIBMEIC Project - GV/2014/049Socio-Technical Study on the Incorporation of Biofuels in the Energy Mix Ceramic Industry

Project financed by: