Welcome to ZaaK Technologies
The clock is ticking.
We have reached the limits of the planet’s natural resources.
Our Greentech company processes waste from power plants into a substitute for quickly depleted natural sand.
Unsustainable use of natural resources is having a severe impact on our environment. With the megatrend of urbanization and the increasing number of people living in cities, it is expected that natural resources such as sand and aggregates, and even clean drinking water will continue to be depleted without replenishment.
A case in point is sand mining or dredging, which has a major impact on rivers, deltas and coastal and marine ecosystems, results in loss of land through river or coastal erosion, lowering of the water table and decrease in the amount of sediment supply.
We have ‘reached the limits’ of the planet’s natural resources
ZaaK has been researching and developing innovative technologies to upcycle mineral wastes and by-products into value-added products for sustainable management of our natural resources
With its proprietary technologies, ZaaK offers a single step solution to the environmental impacts from mineral wastes and by-products and fast depleting natural sand by upcycling the former into eco-friendly lightweight fine aggregates, called Lypors™. These lightweight fine aggregates are a substitute for natural sand and serve as a basis for secondary raw materials, which will conserve natural resources by constructing buildings with high resource and energy efficiency, lighter weight, and extended service life.
As a Greentech company and a pioneer in up-cycling, ZaaK envisions the establishment of a new standard for secondary raw materials on the global market.
Lypors™ Technology.
Recycling instead of dump. Upcycling instead of disposal.
A progressive solution to the age-old problem of wastes and by-products.
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The challenges faced by producers of mineral wastes and by-products require viable and forward-looking solutions. To safeguard our socio-economic future, technologies that promote the achievement of sustainable development goals and veer towards circular economy are greatly needed.
ZaaK is providing a progressive solution to the age-old problem of wastes and by-products, drastically reducing disposal problems, and pushing the above industries towards a zero-waste scenario through upcycling these wastes and by-products into high performance building materials.
ZaaK offers technological solutions to the thermal power, alumina, waste-to-energy and construction industries for their mineral wastes and by-products. ZaaK’s processes ensure these wastes and by-products can be effectively utilized instead disposed or deposited.
Input streams
From the sources to Lypors™ and Smart Spheres™
As a Greentech company and a pioneer in upcycling, ZaaK envisions the establishment of a new standard for secondary raw materials on the global market.
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Coal combustion ash
Our Lypors® technology is extremely versatile and can handle any types of coal combustion products whether they are freshly produced or deposited, hard coal ash, brown coal ash or a mixture of both ashes.
Biomass-coal co-combustion ashes
Our Lypors® technology is extremely versatile and handles biomass-coal co- combustion products whether they are freshly produced or deposited.
Incineration ash (work in progress)
ZaaK is one of the first companies which started to develop a solution for incineration ash, also known as waste-to-energy ash, which to a large part until now has been deposited underground.
Bauxite residue
Our Smart Spheres® technology is extremely versatile and can handle any type of bauxite residue streams whether they are freshly produced or deposited.
Sustainability.
Lypors™ is one of the best example of sustainability.
…whether it is production, transportation, construction, building, living or reuse.
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Lypors™ is one of the best example of sustainability whether it is production, transportation, construction, building, living or reuse. It is an eco-friendly material with positive social and environmental impacts. Lypors™ is a premium quality but a cost-effective construction sand material with diverse applications.
The Lypors™ technology offers a very meaningful step to achieve the twin objectives:
A) converting waste coal combustion products into a value-added construction sand and
B) also minimizing the consumption of sand, an ecologically sensitive natural resource, and savings of endangered rivers and coastal areas.
This has been recognized independently through innovation awards.
Lypors™ Life Cycle.
Lypors™ Life Cycle.
Lypors™ is made from upcycling industrial waste by-products such as fly ash, pond ash or stabilized ash and can be used in many applications and can be recycled several times.
Production.
Lypors™ are produced mainly from wastes. It can be used in producing lightweight, high strength and thermal insulating building material derivatives. It can be produced in different size, shape, strength and porosity meeting different market segments.
> 93%
of the raw material constituents is waste materials from the industry.
Construction.
Lypors™ based lightweight concrete and mortars achieves high speed of construction minimising labour costs and raw materials wastages.
20%
more plaster coverage for the given time and volume of mortars compared to natural sand based mortars.
Transportation.
Transportation cost is directly related to weight. Being ~50% lighter than sand and crushed stones, transportation is easier and leaves a smaller carbon foot print than alternate fine aggregates. Increased loading capacity for trucks means fewer trucks on the road and in the cities and country sides.
Up to 7%
fuel savings in transporting for the same volume of material compared to natural sand.
Living.
When used in the house construction, Lypors™ offer high levels of thermal and acoustic comfort and contributes to improved energy performance. This helps to reduce the carbon footprint, reduces energy bills and provides comfort to the home.
> 350%
better thermal insulation factor.
Re-use.
Lypors™ have circular life cycle instead of traditional linear. It creates highly efficient value chains from upcycling industrial wastes through to extract the maximum value from whilst in use, then recover and regenerate materials at the end of each service life
100%
Recyclable.
About our project
Additional information
Objective – Expected impacts – Partners
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Objective
The expected impacts of the project are as follows:
• Creating the engineering and scientific basis for the future industrial Lypors production plant.
• Integration of three sub-processes, which so far performed at different locations, into a single black box which will have significant technological improvement and impacts on various stakeholders.
• Addressing the challenge faced by thermal power plants from fly ash disposal around the world and assisting them in meeting disposal compliances as well as improving the economics of the plant operation.
• Addressing the challenge faced by many countries to access good quality of sand by providing Lypors as an alternative to natural sand.
• Increasing the utilization of fly ash, not just in Europe, but all over the world, by upcycling fly ash into value-added sand.
• Helping decision makers in Europe to frame strategic choices concerning conservation of natural resources and to integrate them in the future management of natural resources through research road mapping activity combined with economic feasibility modelling that will help the identification of critical pathways.
• Improving innovation capacity and the integration of new knowledge.
Expected impacts
To key objective is to design, build and demonstrate the production of Smart Sand / Lypors at integrated pilot scale:
The strategic objective of the project is to design, build and demonstrate the production of Smart Sand / Lypors at integrated pilot scale which becomes a technology showcase to stake holders such as thermal power plants, construction industry and end customers.
The other objective of the project is to certify the product produce from the plant to meet harmonized DIN EN 12620 (fine aggregates for concrete), DIN 13139 (sand for mortars) and DIN EN 13055:2016 (lightweight aggregates).
Additionally, the process and product will be optimized according to the market demand.
Partners
These partners are crucial for our project:
This project has received funding from the European Union’s Horizon 2020 research and innovation programme under grant agreement nº 738759
The British-Australian mining group, founded in 1873 – is one of the key partner of ZaaK Technologies supporting the project.
Contact us.
ZaaK Technologies GmbH
Am Wall 8a
14979 Großbeeren
info@zaaktechnologies.de