1. business and industrial
2. chemicals industry
3. plastics and polymers

LEEMA project – Success Story
Dr. Ch. Dedeloudis
S&B Industrial Minerals S.A (IMERYS Group)
Project Coordinator
Workshop on Impact of the Energy-­‐efficient Buildings PPP, Brussels, 27-­‐28 April 2015
This project has received funding from the European Union’s Seventh Framework Programme for research, technological development and demonstration under grant agreement no 285059
Overview
Universities –
SME
Research Institutes
ü Project Coordinator: S&B INDUSTRIAL MINERALS (Greece)
ü Work Programme: EeB-­‐NMP.2011-­‐1: Materials for new energy efficient building components with reduced embodied energy
ü Starting Date: 01/01/2012
ü Duration: 48 months
ü Grant Agreement No: 285059
ü Cost: 8,118,299.84 €
ü EU Funding: 4,670,000.00 €
ü Website: www.leema.eu
Large Industries
Low Embodied Energy Advanced (Novel) Insulation Materials and Insulating Masonry Components for Energy Efficient Buildings
S&B INDUSTRIAL MINERALS
GR
Etex Group (Redco)
BE
SCHLAGMANN BAUSTOFFWERKE
THERMAL CHERAMICS de
FRANCE
Morando S.r.I.
DE
FIBRAN
GR
FENIX TNT S.r.o.
CZ
AMS Solutions
NATIONAL TECHNICAL UNIVERSITY OF ATHENS MPA University of Stuttgart
Centre Scientifique et Technique de la Construction (BBRI)
MFPA University of Weimar
GR
D'APPOLONIA SPA Architects Council of Europe (ACE)
IT
Workshop on Impact of the Energy-­‐efficient Buildings PPP, Brussels, 27-­‐28 April 2015
FR
IT
GR
DE
BE
DE
BE
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Challenge
Greener, Energy Efficient and Resource Efficient Europe “20-­‐20-­‐20 objective” ü -­‐20 % greenhouse gas emissions
ü -­‐20% energy consumption
ü +20% share for renewable energy
Challenge for the construction industry
• Reduce manufacturing Energy
Embodied energy may account for 20% of the building’s energy use
• Building components with improved thermal properties
Workshop on Impact of the Energy-­‐efficient Buildings PPP, Brussels, 27-­‐28 April 2015
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Objectives
ü Development of a new generation of inorganic insulation materials and building insulation masonry components (“3I”) with lower embodied energy (>50%) and lower cost (15%) and upgraded properties compared to the commercial ones
ü Improvement of durability and energy performance at building level ü Safer and cleaner indoor building environment due to incombustibility and absence of organic/fibrous compounds ü Use of wastes of industrial minerals exploitation, recycled rejects from the glass industry and industrial by-­‐products
ß
Insulating Inorganic Incombustible Materials and Masonry Components
Workshop on Impact of the Energy-­‐efficient Buildings PPP, Brussels, 27-­‐28 April 2015
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The Idea: Inorganic Polymers
Inorganic Polymers
ü Inorganic=incombustible
ü Good mechanical properties-­‐ quick compressive strength development ü Low thermal conductivity coefficient
ü Exploitation of aluminosilicate/ silicate wastes , recycled materials, by-­‐products
ü Energy efficient synthesis process
ü Low carbon footprint
ü Compatibility with current manufacturing processes Workshop on Impact of the Energy-­‐efficient Buildings PPP, Brussels, 27-­‐28 April 2015
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Low energy production processes
Raw
materials
Mixing
Activation solution
Curing
Foaming
Shaping
Crushing/ sieving
Shaping
Curing
Expansion
Curing
ü Use of mineral tailings-­‐
wastes, recycled glass and other industrial by-­‐products ü Mixing at ambient conditions
ü Curing at low temperatures (50-­‐100 oC) for 24-­‐72h to obtain mechanical properties
ü Expansion using energy efficient Infrared Heating
Compact
Granular
Foamed
Workshop on Impact of the Energy-­‐efficient Buildings PPP, Brussels, 27-­‐28 April 2015
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The LEEMA Products
Workshop on Impact of the Energy-­‐efficient Buildings PPP, Brussels, 27-­‐28 April 2015
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3I Loose Fill Materials (3I LFM)
Applications
ü Loose Fill Insulation (cavity walls, floors etc.)
ü Lightweight aggregate for concrete or clay based products
ü Fillers for plasters, mortars, paints and joint compounds
Main advantages
ü Lightweight, multifunctional, inorganic, inert and incombustible
ü Excellent thermal performance: λ 0.033 – 0.045 W/(mK)
ü Synthetic: Properties and particle size can be fine-­‐tuned according to application; (density 15-­‐>120 kg/m3
ü Sustainable: based on wastes and recycled raw materials, expanded at moderate temperatures (500 -­‐ 600ºC) compared to expanded perlite (~~ 1200ºC) using Infrared heating
• Free flowing and easy to install without special training or equipment, using standard procedures applied for loose-­‐filling insulation materials
Workshop on Impact of the Energy-­‐efficient Buildings PPP, Brussels, 27-­‐28 April 2015
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3I Loose Fill Materials (3I LFM)
Material
Application
LEEMA
3I LFM
For Brick cavities/EPBs
For Fibre boards
For Cavity walls insulation
Expanded Commercial Loose perlite
Fill insulation
EPS beads
Loose Bulk Density (Kg/m3)
1/R for 20cm insulation
λ10
EE (W/mK) (… is approx. U –value) (MJ eq./FU)
(W/(m2K))
38.9
0.034
0.17
76.7
0.039
0.20
61.8
0.038
0.19
20
90
0.050
0.25
45
28
0.033
0.17
82
Functional Unit ( FU) is defined as 1 m2 of insulation with a thermal resistance R = 1 m2K/W
54% to 76% lower embodied energy per FU
Simulations based on preliminary results indicate that 3I LFM can reduce space heating energy demands by 70% Workshop on Impact of the Energy-­‐efficient Buildings PPP, Brussels, 27-­‐28 April 2015
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3I Binders
Material Type
LEEMA
3I Binders
Comp. Strength Flex. Strength λ
(MPa)
(MPa)
(W/(mK))
21
6
0.19
28
8
0.26
Density
(Kg/m3)
1480
1600
Cement
0.72
1860
Clay Bricks
0.8-­‐1.3
1890-­‐
2000
Main advantages:
ü Based on mineral tailings (wastes)
ü Mechanical properties obtained after curing at low temperatures (~70 oC) after a few days
ü Compatible with traditional aggregates and conventional shaping methods (moulding or extrusion)
ü Suitable for the production of pre-­‐fabricated non-­‐structural construction elements
ü Embodied energy (for a typical perlite-­‐based geopolymer) ~ 1.37 MJ/kg (cement 5.2 MJ/kg, fired ceramic bricks 3 MJ/Kg)
Workshop on Impact of the Energy-­‐efficient Buildings PPP, Brussels, 27-­‐28 April 2015
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3I Fibre Boards, 3I EPBs
3I Fibre boards 3I Loose Fill Materials replacing expanded perlite or exfoliated vermiculite
ü Successful Pilot scale production – No significant changes in production process
ü λ 0.11-­‐0.14 W/(mK) ü At the same recipe, 3I LFM leads to similar density (up to +5%) but higher flexural strength (up to +44%), ü A new product with higher loose fill loading than the current recipe will be produced, which will lead to a product with better insulation properties and much lower embodied energy ü 3I binders could be used to replace cement, using moulding or extrusion as shaping methods
3I EPB
3I Loose Fill Materials replacing expanded perlite in Fesco boards
ü λ< 0.05 W/(mK)
ü Density ~150 Kg/m3
ü Flexural Strength ~0.35 MPa
Workshop on Impact of the Energy-­‐efficient Buildings PPP, Brussels, 27-­‐28 April 2015
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3I Insulating Bricks
The “simple approach”: 3I Loose Fill Materials replacing expanded perlite
ü λ value of infill 0.035 W/(mK) (-­‐12.5-­‐
20% compared to perlite)
ü Same production process ü Overall brick λ value ≤ 0.090 W/(mK)
ü Embodied energy under evaluation, The “futuristic” approach:
estimated only 10-­‐15% less
3I binders replacing the ceramic brick body
ü ≈ Mechanical properties, similar density and λ without using porosity modifiers
ü Similar production process, without firing (>60% lower embodied energy)
ü Optimized Extrusion under soft-­‐clay conditions
Workshop on Impact of the Energy-­‐efficient Buildings PPP, Brussels, 27-­‐28 April 2015
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3I Foam Blocks
Material Type
1/R for 20 cm Comp. insulation
λ
Density
Strength 3
(W/(mK)) (Kg/m )
(… is approx. U –
(MPa)
value) (W/(m2K))
3I Foamed 0.06-­‐0.12 344-­‐680
Blocks
Aerated 200-­‐
0.6-­‐1.4
Concrete
1600
Autoclaved Aerated 0.07-­‐0.21 300-­‐800
Concrete
0.7-­‐2.7
0.31-­‐0.60
1-­‐10
3.0-­‐7.0
1.3-­‐8.5
0.35-­‐1.05
Main advantages
ü Sustainable: Based on perlite wastes ü Foamed using inorganic or organic foaming agents
ü Mechanical properties obtained after curing at low temperatures (~70 oC) after a few days
ü Easy to cut – retain shape and strength
ü Embodied energy calculation in progress, estimation at least 50% less since cement is replaced completely Workshop on Impact of the Energy-­‐efficient Buildings PPP, Brussels, 27-­‐28 April 2015
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LEEMA Successes
ü Success 1: A new insulation product has been developed as Loose Filling materials for cavity walls insulation that exhibit similar performance to commercial organic counterparts (EPB) and up to 76% reduced embodied energy
ü This loose fill material could be used as lightweight aggregate in replacement of expanded perlite or expanded polystyrene in the manufacturing of different construction materials like fiber cement boards and bricks ü Success 2: A new fiber cement board has been developed of lower density, higher thermal insulation and lower embodied energy
ü Success 3: A thermal insulating brick with an overall λ value ≤ 0.090 W/(mK) and of at least 10-­‐15% lower embodied energy vs current solutions. A more futuristic approach where the whole brick will be from geopolymer has been proven in concept. Thus, the new brick will have at least 60% less embodied energy
ü Success 4: The inorganic polymers (binders or lightweight aggregates) are compatible with current manufacturing processes used by the construction material industries, eliminating energy consuming steps such as clay firing.
ü Success 5: A new foam block to replace aerated concrete blocks with at least 50% less embodied energy.
Workshop on Impact of the Energy-­‐efficient Buildings PPP, Brussels, 27-­‐28 April 2015
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Further information
Thank you for your attention!
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@LEEMA FP7
For more information visit the project’s website www.leema.eu
LEEMA Project FP7
LEEMA Project FP7
LEEMA Project FP7
This project has received funding from the European Union’s Seventh Framework Programme for research, technological development and demonstration under grant agreement no 285059
Workshop on Impact of the Energy-­‐efficient Buildings PPP, Brussels, 27-­‐28 April 2015
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