General information
The OSSIGREEN project has successfully achieved the objective of valorising sludge from aluminium oxidation processes (AAW), transforming a special non-hazardous waste, typically destined for landfill, into a strategic resource for the automotive sector, specifically for the production of friction materials in braking systems.
The central innovative element lies in the application of industrial symbiosis and 'end-of-waste' principles, introducing the powder obtained from dried sludge as a light abrasive or filler into brake formulations.
This technological advancement was made possible by implementing a sludge treatment plant through an extrusion process and low-temperature drying (around 70°C), resulting in a stable end product with residual moisture reduced from 75-80% to around 10%.
The benefits generated by the project are manifold and involve technical, environmental and economic aspects: tribological and dynamometric tests have shown that the integration of powder, in percentages between 6% and 12%, maintains stable braking performance and can induce a slight decrease in particulate emissions (PM10), favouring compliance with the future stringent Euro 7 standard limits.
In terms of sustainability, the replacement of virgin alumina with this secondary raw material allows a 30% reduction in environmental impact (GWP) and offers a cost-effective solution, with a production cost of around €1.2/kg compared to €2/kg for virgin material, while eliminating landfill disposal costs.
These results can be enhanced through the integration of the powder, suitably ground and sieved, into industrial brake pad mixing cycles, offering the market a circular, competitive and non-hazardous component.
Start date
05/09/2022
End date
05/09/2024