Mercedes Mullins
The ceramics industry has a significant impact on climate change due to its high energy consumption and greenhouse gas emissions. The production of ceramics requires a lot of energy, especially during the firing process, where clay and glazes are heated to very high temperatures, typically using natural gas, a fossil fuel. This process releases carbon dioxide (CO2) and other greenhouse gases, contributing to climate change. In addition, the extraction of raw materials and the transportation of both raw materials and finished products also contribute to the industry's carbon footprint. While ceramics may give off an earthy and natural vibe, the process of creating them can be damaging to the environment.
| Characteristics | Values |
|---|---|
| Environmental impact | Bad for the environment due to mining, shipping, and firing |
| Carbon footprint | Very high |
| Greenhouse gas emissions | High |
| Energy consumption | High |
| Fossil fuel usage | Uses fossil fuels such as coal, natural gas, liquefied petroleum gas, and fuel oil |
| Raw material extraction | Requires the extraction of raw materials such as clay, sand, and minerals |
| Manufacturing process | Requires high temperatures for firing and drying |
| Sustainable solutions | More efficient kilns, biofuels, renewable energy sources, sustainable product design, efficient recycling systems |
| Industry efforts | EU-funded DREAM and ETEKINA projects aim to develop more efficient and less polluting kilns |
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What You'll Learn
Fossil fuels used in kiln firing
The production of ceramics is highly damaging to natural and social systems, emitting significant quantities of greenhouse gases. The ceramics industry is therefore subject to emissions trading. While the emissions from clay as a raw material are unavoidable, the industry is seeking to identify alternatives to mitigate the climate effects of ceramics products and processes to make their lifecycle more sustainable.
There are three main types of energy used to fire ceramic kilns: electric, gas, and wood. Gas, such as natural gas, propane, and coal gas, is a fossil fuel and is therefore bad for the environment when burned. However, gas-fired kilns are favoured by contemporary ceramists as they do not require constant stoking and create no unburned ash residue.
Wood is another fuel used in kiln firing. While wood is a fossil fuel, it is part of the natural cycle, and wood-firing ceramists argue that the carbon footprint of wood-fired ceramics is negligible in comparison to natural wildfires. However, wood firing is very labour-intensive, requiring constant attention and an instinctual understanding of the kiln's inner workings.
Liquid fuels such as oil, kerosene, and petroleum coke are also used in kiln firing. Oil-fired kilns are widely available and inexpensive, but they are smokier than gas-fired kilns and difficult to keep lit until the kiln's temperature is above 1000°F. Solid fuels used in kiln firing include subbituminous coal, lignite, oil shale, and other low-grade solid fuels.
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Greenhouse gas emissions
The ceramics industry is highly energy-intensive and is subject to emissions trading. The production of ceramics emits significant quantities of greenhouse gases due to the necessary firing process, which requires temperatures ranging from 700 °C to 2,000 °C. Tile making, despite having comparatively low firing temperatures, is the segment with the highest CO2 emissions in the ceramics industry due to its sizeable output and substantial process-related emissions.
The greenhouse gas emissions in the ceramics industry have two main sources. Firstly, they result from naturally occurring calcium carbonate (lime, CaCO3) and the organic impurities in the clays used. Secondly, CO2 is emitted during the burning of added porosity agents, which are used as pore-forming agents in thermal insulation bricks. While emissions from clay cannot be avoided, a transition to renewable raw materials for porosification agents is underway.
The energy used to fire ceramic kilns can be electric, gas, or wood. Electric kilns are considered more environmentally friendly as they fire at lower temperatures, but this also means that additional ingredients need to be added to glazes so that they melt at lower temperatures, which encourages further mineral mining. Gas is a fossil fuel and is therefore detrimental to the environment when burned. Wood firing is labour-intensive and rarely practised, but some argue that it is part of the natural cycle and that wildfires produce a much higher carbon footprint.
The EU is mandating a 55% reduction in greenhouse gas emissions below 1990 levels by 2030 and aims to reach net zero by 2050. This means that the EU's ceramics industry must move away from processes that rely on fossil fuels. However, some ceramics executives argue that this pace of change is too quick to achieve, especially given the long lifespan of kilns, and that no cost-effective alternatives to natural gas currently exist. To achieve further carbon footprint reductions, ceramic manufacturers must invest in alternative energy sources such as hydrogen, electrification, or biofuels, as well as consider modifying raw materials and deploying carbon capture technology.
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Energy consumption
The ceramics industry is energy-intensive and has a significant carbon footprint. The production of ceramics emits substantial quantities of greenhouse gases, with the manufacturing process accounting for almost 90% of the carbon footprint of a ceramic piece. The energy hotspots in the industry are natural gas production, biscuit firing, and condensing boilers. The energy mix in the European ceramic industry is typically 80% natural gas and 20% electricity.
The high temperatures required for firing ceramic pieces, ranging from 700 °C to over 2000 °C, contribute significantly to energy consumption. The type of energy used for firing ceramics can vary, including electric, gas, and wood kilns. Electric kilns operate at lower temperatures, reducing energy demands, but may require additional ingredients in glazes to achieve the desired results. Gas kilns, while convenient, contribute directly to carbon emissions as gas is a fossil fuel. Wood-fired kilns are labour-intensive and less commonly used, but the carbon footprint associated with burning wood for ceramics is argued to be negligible compared to natural wildfires.
Initiatives to reduce energy consumption and carbon emissions in the ceramics industry are underway. The DREAM project, funded by the EU, aims to improve energy efficiency in ceramic production through waste heat recovery and the development of new materials. Innovative refractory and insulation materials have been tested to reduce heat transmission through kiln walls, lowering kiln temperatures and energy losses. Additionally, the use of microturbines eliminates the need to burn significant amounts of natural gas during kiln restarts, further reducing energy consumption and associated costs.
The transition to renewable raw materials and process optimisation is also contributing to emissions savings. While unavoidable emissions are associated with clay as a natural raw material, the industry is exploring alternatives to mitigate the climate effects of ceramic products and processes. Political and economic measures will likely be necessary to support the industry's transition to renewable energy sources and achieve its sustainability goals.
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Extraction of raw materials
The extraction of raw materials for ceramics, primarily through surface mining, has a significant environmental impact. This process involves the removal of non-renewable resources from the earth, which can lead to negative consequences such as alterations to the natural landscape. Mining operations can also result in carbon emissions, with the manufacturing of ceramics contributing to the release of CO2 into the atmosphere.
Ceramic materials are predominantly sourced through surface mining, which is considered the most detrimental form of extraction due to its extensive disruption of the environment. This method of mining removes resources that cannot be replenished, leading to long-term ecological damage. The act of mining itself, as well as the transportation of extracted materials, contributes to the carbon footprint associated with the ceramics industry.
Clay is a key raw material used in the production of ceramics, and its extraction as a natural resource is unavoidable. The process of mining and refining clay can result in emissions, specifically through the burning of organic impurities present in the clay. While efforts are being made to transition to renewable raw materials, the current extraction and use of clay contribute to the industry's carbon emissions.
Frits, another important raw material in ceramics, undergo an intensive melting and cooling process for homogenization. This energy-intensive process emits combustion products and contributes to the oxidation of atmospheric nitrogen, forming nitrous oxide, a potent greenhouse gas. The production and use of frits in ceramics, therefore, have environmental implications that must be considered.
The extraction and processing of raw materials for ceramics, including clay and frits, have direct environmental consequences. The non-renewable nature of these resources and the energy-intensive processes involved in their extraction and refinement contribute to the industry's carbon emissions and overall ecological impact. As a result, the extraction of raw materials for ceramics is a significant factor in the industry's efforts to reduce its environmental footprint and transition to more sustainable practices.
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Transport of raw materials and finished products
The transport of raw materials and finished ceramic products has environmental implications. The ceramics industry relies on the transport of raw materials, such as clay, kaolins, and feldspar, which are often shipped over long distances, contributing to carbon emissions. For example, Grolleg Kaolin, used for white porcelain clay, is sourced from England or New Zealand. Similarly, the finished ceramic products are transported to markets, with Northern Europe being a significant destination for ceramics manufacturers, utilizing road-rail transport.
The environmental impact of transporting raw materials and finished products in the ceramics industry is significant. The shipping of materials and products contributes to carbon emissions and the overall carbon footprint of the industry. This is particularly notable in the case of international shipments, where the transport of goods over long distances can result in substantial carbon dioxide emissions.
To mitigate the environmental impact of transport, some manufacturers are exploring more sustainable options. For instance, utilizing train transport instead of road transport can lead to reduced CO2 emissions, as evident in the case of shipments to Northern Europe. Additionally, the optimization of goods storage, handling, and shipment processes can contribute to environmental sustainability.
The transition to renewable raw materials for certain components, such as porosification agents, also plays a role in reducing the environmental impact of the ceramics industry. However, emissions from clay, a primary raw material, are considered unavoidable. Efforts to optimize processes and improve energy efficiency have contributed to emissions savings over the last 30 years, but further paths to decarbonization are necessary to achieve climate neutrality by 2045.
The transport of raw materials and finished products in the ceramics industry is, therefore, a critical aspect of the industry's environmental footprint. While some efforts are being made to reduce carbon emissions associated with transport, the long-distance shipping of materials and products remains a challenge for the industry's sustainability goals. The continued exploration of alternative energy sources, process optimizations, and sustainable transport options will be crucial in reducing the environmental impact of the ceramics industry.
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Frequently asked questions
No, ceramics are made from natural materials like clay, sand, and other earth minerals. However, the process of making ceramics involves firing clay, which burns fuel and releases gases and fumes into the atmosphere.
There are three types of energy used to fire ceramic kilns: electric, gas, and wood. Gas is a fossil fuel, but electric kilns are becoming more popular as they usually require lower temperatures and can use renewable energy.
Ceramics are considered more environmentally friendly than plastics, which are derived from fossil fuels. Ceramics are durable and have a long lifespan, reducing the need for replacements and resulting in less waste. They are also recyclable and biodegradable. However, the production of ceramics can be energy-intensive and emit significant quantities of greenhouse gases.
The ceramics industry is energy-intensive and contributes to carbon emissions. For example, the manufacture of ceramics in the EU emits 19 Mt of CO2 annually, while global brick manufacturing is responsible for 2.7% of carbon emissions. The industry is working towards decarbonization by adopting more low-carbon processes and exploring renewable energy sources.
