This document summarizes a project to develop and implement coatings for respirable crystalline silica (RCS) in ceramic manufacturing processes to reduce RCS toxicity. The project has verified that coating treatments can be applied at the laboratory scale without negatively impacting process parameters or product properties. Toxicity tests also confirm that selected coatings inhibit RCS toxicity. The developed coating process is undergoing industrial trials and shows promise for inclusion in best practices guidance to render RCS safer.

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Organizers:
Supporters:
Dr. Eliseo Monfort Gimeno – Chemical Engineering Professor (Universidad Jaume I)
Head of Sustainability Area of ITC
Cerámica Innova 4: From research to market

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Industrial implementation of processes to render RCS
safer in manufacturing processes - SILICOAT
Organizers:
Funding programme: FP7 – Research for SME associations
Call: 31025060
Budget:
Supporters: 1 537 331,40 Total
Length: Start 01/11/2011
- 1 043 500,11 UE Funding
End 31/10/2014
Website of the project: www. silicoat.eu
Dr. Eliseo Monfort Gimeno – Chemical Engineering Professor (Universidad Jaume I)
Head of Sustainability Area of ITC
Cerámica Innova 4: From research to market

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Consortium:
– Co-ordinator:
Organizers:
– Partners and roles:
Supporters:
SMEs
SME-AGs
RTDs
Dr. Eliseo Monfort Gimeno – Chemical Engineering Professor (Universidad Jaume I)
Head of Sustainability Area of ITC
Cerámica Innova 4: From research to market

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Background:
RCS inhalation
No direct relationship
Organizers:
demonstrated. Non-conclusive
researches. Controversy among
different authors.
Conclusion: There are important
“external factors” in the
pathogenesis.
Supporters:
Demonstrated fact: high RCS dosis inhalation
produces silicosis.
Silicosis
IARC suggests that silicosis enhances lung
cancer risk
Lung cancer
Abstract:
The present project is the industrial implementation of coating
treatments in the ceramic manufacturing processes, transforming
Dr. Eliseo Monfort Gimeno – Chemical Engineering Professor (Universidad Jaume I)
the quartz-containing of Sustainability Area of intrinsically safe products.
Head raw materials into ITC
Cerámica Innova 4: From research to market

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• Certain substances can nullify RCS toxicity:
Polivinilpiridine-N-oxide (PVPNO) (Schlipköter & Brockhaus, 1961)
Organizers:
Aluminium lactate (Bégin et al., 1986)
Phospholipids (Wallace et al., 1986)
Organosilanes (Castranova et al., 1996)
Supporters:
• These substances:
Form a molecular coating on the RCS surface saturating silanol groups (SiOH).
Dr. Eliseo Monfort been industrially implemented yet.
They have not Gimeno – Chemical Engineering Professor (Universidad Jaume I)
Head of Sustainability Area of ITC
Cerámica Innova 4: From research to market

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Organosilanes: Example: PTMO
CH3
CH3
CH2
CH2
CH
Organizers: 2 + H O
2
CH2
Hydrolysis
Si
Si
OCH3
CH3O
+ CH3OH
OCH3
CH3O
OCH3
OH
CH3
Supporters:
CH2
CH3
CH2
CH2
H
+
H
O
O
O
CH2
H
Silanization CH3O
Si
H
OCH3 + H2O
H
Si
Dr. Eliseo Monfort Gimeno – Chemical Engineering Professor (Universidad Jaume I)
Si
Si
Si
Head of Sustainability Area of ITC
OCH3
CH3O
O
O
O
OH
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Si
Si
Si

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Objectives:
 Develop and implement respirable crystalline silica (RCS) coating
technologies in the ceramic process,
Organizers:
 To render RCS-containing materials use intrinsically safe from the
toxicological point of view.
Supporters:
Results:
The technical viability of the implementation of the coating
treatment in the ceramic process has been verified at laboratory
scale, without negative effects on either the process parameters or
the final product properties. The first toxicological tests confirm an
inhibitory effect Chemical Engineering Professor (Universidad Jaume I)
Dr. Eliseo Monfort Gimeno –of the selected coatings on the RCS toxicity.
Head of Sustainability Area of ITC
Cerámica Innova 4: From research to market

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Results
PTMO coating detection by thermogravimetry
Organizers:
0
Pérdida de masa · 10 3 (%/ºC)
-0,2
-0,4
0% PTMO
-0,6
Supporters:
0.5% PTMO
-0,8
-1
0.1% PTMO
-1,2
1% PTMO
-1,4
10% PTMO
-1,6
Dr. Eliseo Monfort Gimeno – Chemical Engineering Professor (Universidad Jaume I)
-1,8
Head of Sustainability Area of ITC
200
300
400
500
600
700
800
Temperatura (ºC)
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Results:
Nano-alumina coating micrographs
Organizers:
Supporters:
Dr. Eliseo Monfort Gimeno – Chemical Engineering Professor (Universidad Jaume I)
Head of Sustainability Area of ITC
Original surface
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Coated surface

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Results:
Toxicity tests results (including DQ12)
Organizers:
60,0
25,0
20,0
Tail intensity (%)
40,0
30,0
20,0
Supporters:
15,0
10,0
SI
VO
F1
Co
nt
ro
l
DQ
12
0,0
SI
VO
0,0
F1
Co
nt
ro
l
DQ
12
5,0
0,
4
SI
VO
PT 0,2
M
O
PT 1,4
M
O
PT 0,5
M
O
Na
0,
no
1
-a
lu
m
in
a
10,0
0,
4
SI
VO
PT 0,2
M
O
PT 1,4
M
O
PT 0,5
M
O
Na
0,
no
1
-a
lu
m
in
a
Citotoxicity (%)
50,0
Dr. Eliseo Monfort Gimeno – Chemical Engineering Professor (Universidad Jaume I)
Head of Sustainability Area of ITC
Cerámica Innova 4: From research to market

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Results:
Toxicity tests results
Organizers:
10,0
Tail intensity (%)
12,0
12,0
10,0
8,0
6,0
Supporters:
4,0
8,0
6,0
4,0
Dr. Eliseo Monfort Gimeno – Chemical Engineering Professor (Universidad Jaume I)
Head of Sustainability Area of ITC
Cerámica Innova 4: From research to market
Co
nt
ro
l
SI
VO
SI
VO
F1
0,0
Co
nt
ro
l
0,0
F1
2,0
0,
4
SI
VO
0,
2
PT
M
O
1,
4
PT
M
O
0,
5
PT
M
O
Na
0,
no
1
-a
lu
m
in
a
2,0
0,
4
SI
VO
0,
2
PT
M
O
1,
4
PT
M
O
0,
5
PT
M
O
Na
0,
1
no
-a
lu
m
in
a
Citotoxicity (%)
14,0

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Obtained experience
 A coating process has been developed to render RCS
Organizers:
safer.
 Several coating agents have demonstrated their
efficiency from a toxicological viewpoint.
Supporters:
 Some industrial trials are in progress to implement this
process at industrial scale in different ceramic
manufacturing companies.
 The developed process is a promising candidate to be
Dr. Eliseo Monfort Gimeno – Chemical Engineering Professor (Universidad Jaume I)
included in the “NEPSI Good practices Guide”
Head of Sustainability Area of ITC
Cerámica Innova 4: From research to market

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Organizers:
Supporters:
Dr. Eliseo Monfort Gimeno – Chemical Engineering Professor (Universidad Jaume I)
Head of Sustainability Area of ITC
Cerámica Innova 4: From research to market