ZENEX, a pioneering project applying sol-gel coatings reinforced with silica extracted from industrial waste, supported by ERDF funding

At Topciment® we are committed to sustainability. A core principle that is embedded in our corporate policy and, above all, in our social awareness and responsibility as a company in the construction sector. That is why our investment in R&D&I follows this path and, as a result of that work, the “ZENEX” project—which we will discuss throughout this article—was born.

Driven by our commitment to reducing the ecological footprint, “ZENEX” emerges as a pioneering project in the construction sector. It is based on a unique methodology involving the application of sol-gel coatings reinforced with crystalline silica extracted from industrial waste. This process significantly improves the mechanical and aesthetic properties of microcements, enables the reuse of heavy metals such as pigments, and consequently reduces dependence on critical raw materials.

This initiative, involving an investment of €333,273.21—largely funded by the Comunitat Valenciana Programme of the European Regional Development Fund (ERDF) 2021–2027— stands as a solution to the environmental challenge posed by the production of grinding and polishing waste in the ceramics industry, which reaches an alarming volume of 1,000 tonnes per day. This type of waste, composed of crystalline silica and heavy metals, has been classified by the European Union as "critical materials hazardous to health and the environment.

Processes carried out in the “ZENEX” project

The procedure that supports our pioneering “ZENEX” project, file number INNCAD/2024/48 , is structured as follows:

1. Selective separation of heavy materials using electrochemical cells.
2. Pre-treatment and neutralisation of crystalline silica waste.
3. Development of advanced formulations in our sol-gel coating laboratory.
4. Design of microcements with high mechanical performance.

Objectives behind the “ZENEX” project

There are also four main objectives that have driven the creation of this project and have been crucial in securing ERDF funding, valued at €233,291.52.

First, the recovery and valorisation of ceramic waste. To achieve this, an electrochemical separation process has been developed for heavy metals and crystalline silica derived from the aforementioned grinding and polishing residues. Second, the encapsulation of crystalline silica. How? By implementing the previously mentioned sol-gel coatings, which both eliminate breathable crystalline silica and result in improved properties of microcements. Third, the reduction of environmental impact. In this regard, efforts have been made to minimise industrial waste and discharges, moving toward a zero-waste model. And lastly—but no less important—, the optimisation of industrial processes. To this end, green and efficient technologies have been developed, enhancing the competitiveness of companies—ours included—in the construction and ceramics sectors.

Measurable results of the “ZENEX” project

The results delivered by our “ZENEX” project—tangible and a source of pride—motivate us to continue working along the sustainable path deeply embedded in our corporate policy. These are:

1. Innovative and sustainable microcement, with enhanced mechanical and aesthetic properties.
2. 100% reduction of grinding and polishing waste through valorization.
3. Efficient encapsulation of respirable crystalline silica, significantly minimising occupational hazards.
4. Positive impact on the circular economy and on the sustainability of the sector.
5. Increased industrial competitiveness and, above all, the creation of new business opportunities.

Investment made for the implementation of the “ZENEX” project

Below, and in order to highlight the investment allocated to our “ZENEX” project, we break down the different budget lines from 2024 to 2027—the time frame covered by this ERDF support programme.