FACSA and reclaimed water for the ceramics industry

In a bold move towards sustainability and innovation in the industrial sector, the project LIFE Rewaincer – led by FACSA, a Spanish company belonging to the Gimeno Group, and supported by Zabala Innovation – has laid the foundations for a revolutionary model in water management in the ceramics sector and its replication in other industries.

The central objective of the project LIFE Rewaincer, which runs from June 2023 to December 2026, is the implementation of a new model for the application and use of reclaimed water in industrial environments, specifically in the ceramics sector. This is achieved through the regeneration of urban wastewater using membrane technologies, thus providing a sustainable alternative to the use of freshwater and reducing water stress in the Spanish region of Castellón.

To secure the support of the LIFE programme for this project, the Gimeno Group has relied on the collaboration of Zabala Innovation. “At the Gimeno Group, innovation is a key lever for our development and growth,” emphasises Gracia Maria Silvestre, the technical manager of LIFE Rewaincer. “Therefore, we have been working with Zabala Innovation for over 10 years in the development of innovation proposals, both at the regional and European levels. We have prepared several successful LIFE projects with this consultancy, and for this reason, we decided to seek their help in preparing the project LIFE Rewaincer as well.”

Alongside FACSA, the other partners in the project are the Spanish Association for Research in Ceramic Industries (ITC-AICE) and the ceramic industry SAMCA. The combination of expertise in the water sector, the ceramics industry, and technological research has allowed the challenge to be addressed from multiple perspectives and to ensure the technical, economic, and environmental feasibility of the proposed solution.

One of the pillars of the project has been the creation of a demonstration plant on an industrial scale, which is responsible for regenerating water from treated urban wastewater from the Cabanes treatment plant in the La Plana Alta area (Castellón). This plant not only demonstrates the technical feasibility of the proposal but also validates an alternative source of water for use in the production of ceramic pastes, thus contributing to the sustainability of the production process.

The project LIFE Rewaincer has also carried out a comprehensive evaluation of the environmental impact on the La Plana aquifer, as well as a technical and economic analysis of the proposed solution. The expected results are promising: a significant reduction in the extraction of freshwater from aquifers is anticipated, thereby contributing to the reuse of resources and the reduction of water stress in the area, as well as considerable savings in terms of water, energy consumption, and costs for the ceramics industry.

The aspect of dissemination and knowledge transfer has also been fundamental in the project LIFE Rewaincer. Close collaboration has been established with public bodies and industrial sectors to share the results and lessons learned during the execution of the project. This dissemination work not only ensures the replicability of the solution in other regions and sectors but also contributes to the creation of a new model for the management of treated urban wastewater.

Achieving these high-level results is not guaranteed. “It must be borne in mind that LIFE projects are highly competitive, with much competition,” emphasises Silvestre. This is why “it is necessary to prepare projects whose quality meets the demands of this programme, and Zabala Innovation has a great deal of experience in this regard,” she adds.

“We are pleased with the work done by Zabala Innovation in preparing the LIFE Rewaincer project, which has undoubtedly been key to its approval. The consultants from this firm are proactive and help and collaborate from the very first moment, bringing all their knowledge on the key aspects needed to achieve a high-quality LIFE proposal,” concludes Silvestre.