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Research paper : A strategy to reduce energy usage in ceramic fabrication (K. Watari et al.)−140−Synthesiology - English edition Vol.2 No.2 (2009) [14]organic additives, J. Ceram. Soc. Japan, 115, 191-94 (2007).M. Polat, K.Sato, T.Nagaoka and K.Watari: Effect of pH and hydration on the normal and lateral interaction forces between alumina surfaces, J. Colloid Interface Sci., 304, 378-387 (2006).AuthorsKoji WatariCompleted doctorate course at the Graduate School of Engineering, Nagaoka University of Technology in March 1990 (Doctor of Engineering). Joined the Government Industrial Research Institute, Nagoya, Agency of Industrial Science and Technology, Ministry of International Trade and Industry in April 1990. After working at the National Industrial Research Institute of Nagoya, became leader of the Low Environmental Load Sintering Technology Research Group, Advanced Manufacturing Research Institute, AIST in April 2001. Leader of Advanced Sintering Technology Research Group since April 2004. Currently Senior Planning Manager, Research and Innovation Promotion Office, AIST. Also stayed at the Pennsylvania State University (doctorate researcher) during 1998~1999, and worked at the R&D Division, Agency of Industrial Science and Technology, Ministry of International Trade and Industry during 1999~2000. Visiting professor at the Nagaoka University of Technology since February 2004, and Gebze Institute of Technology (Turkey) in March 2009. Advancement Award, The Ceramic Society of Japan (1997); Academic Award, The Nagai Foundation for Science and Technology (2002); Richard M. Fulrath Award, American Ceramic Society (2006); Research Advancement Award, Japan Society of Powder and Powder Metallurgy (2007); Award of Merit, Workshop on Anisotropic Science and Technology of Materials and Devices (Turkey) (2008); Certificate of Merit, The Kazuchika Okura Memorial Foundation (2008); and Best Scientific Photography Award, The Ceramic Society of Japan (2009); Best Paper Award, Journal of the Ceramic Society of Japan (2009); and others. Acted as guest editor for the MRS Bulletin (June 2001), Journal of the Ceramics Society of Japan (February, March 2008), and others. Has worked on the R&D of ceramic process technology, reactive site control process technology, and high heat conductive ceramics. In this research, was in charge of planning the whole proposal, research management and operation, and low-temperature sintering technology.Takaaki NagaokaGraduated from the Faculty of Science, Tohoku University in 1985. After working at Nihon Cement K.K. (currently Taiheiyo Cement Corporation), joined the Government Industrial Research Institute, Nagoya, Agency of Industrial Science and Technology in 1987. Worked on the next-generation core technology research project. Dispatched to Fine Ceramics Research Association during 1996~1998. Currently working on the R&D of inorganic binder at AIST since 2001. In this research, worked on inorganic binder technology.Kimiyasu SatoWithdrew from the doctorate course at the School of Science, The University of Tokyo in 1997. Became Fellow Researcher of the National Institute for Research in Inorganic Materials, Science and Technology Agency in 1997. Became CREST researcher of the Japan Science and Technology Agency in 2000. Joined AIST in 2002. Visiting researcher at the Stockholm University during 2008~2009. Currently works in Inorganic-Based Plastics Group, Advanced Manufacturing Research Institute, AIST. Doctor of Science. In this research, worked on reactive organic binder technology and inorganic and organic interface assessment technology.Yuji HottaCompleted doctorate course at the Graduate School of Science, Hokkaido University in 1997. Joined the Government Industrial Research Institute, Nagoya, Agency of Industrial Science and Technology, Ministry of International Trade and Industry (current AIST) in 1997. After being dispatched to the Fine Ceramics Center during 2000~2001, became visiting researcher at the Ytkemiska Institutet (YKI: Institute for Surface Chemistry) of Sweden during 2001~2002. Currently leader of Inorganic-Based Plastics Group, Advanced Manufacturing Research Institute, AIST. Works on nanoparticle handling technology, dispersal technology for ceramic particles, and forming process technology. In this research, was in charge of low-temperature sintering technology using nanoparticles.Discussion with Reviewers1 Energy saving and reduction of CO2 emission by the developed binderComment and question (Nobumitsu Murayama, Advanced Manufacturing Research Institute, AIST)What were the degrees of reduction in energy and CO2 emission, or how much is expected by using the inorganic binder or by reducing the organic binder?Answer (Koji Watari)By using the inorganic binder, so far we have succeeded in simple extrusion forming of alumina and silicon nitride ceramics, and the reduction in CO2 emission for manufacturing was about 70 % (see Fig. 2). In the actual production line, the amounts of reactive and inorganic binders added are different depending on the forming process, as well as the type, size, and shape complexity of the members. Also, conventional binders must be added in some cases. I have heard that the CO2 emissions were greatly reduced at the companies to which the technology was transferred, but I shall decline disclosure of specific figures and details of the reduction due to the limitation of joint research.In the future, we would like to estimate the necessary amount of binders according to the member specs (material, size, shape, etc.) at actual equipment level, and quantitatively assess the CO2 emission and the relationship of reductions based on the estimate.2 Cost increase or decrease in introducing the developed binderComment and question (Toshimi Shimizu, Research Coordinator, AIST)It is described that the cost factor of the newly developed technology is important from the perspective of “economic valley of death” in the energy-saving attempts for manufacturing process. What are the costs of introducing reactive and inorganic binders?Answer (Koji Watari)One of the advantages of the binder we developed is the low cost of introduction, in addition to its technological excellence. The reactive and inorganic binders are simply mixed

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