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The Ceramics and Porcelain Industry:
Improvement of Resource Efficiency and Environmental Performance

Cleaner Production Solutions    Technical Guides to Pollution Prevention     Trade Associations

The main environmental issues in this industry are energy conservation; air pollution from kilns; water pollution from grinding, molding, glazing and washing; and toxic chemical hazards from heavy metals in ceramics and in glazes.  The industry ranges from home-based pottery producers to highly advanced materials engineering firms.   Cleaner production solutions for pollution are similiar to those for clay brick production and for grinding processes.  Air pollution prevention and energy conservation is similar to glass and clay brick making.  The main cleaner production solution for chemical hazards and water pollution is substitution of non-toxic ingredients in mixes and glazes, in particular the avoidance of lead, cadmium and other heavy metals.

There are few internet resources for this industry compared to some others.   Most of them focus on energy conservation.  There do not appear to be any programs devoted specifically to environmental improvement in the industry.   Researchers seeking cleaner production solutions should study the case studies available and similar processes (grinding, water conservation, firing, air pollution control) in related industries such as glass and brick making.

The table below lists solutions to reduce waste and pollution in ceramic and porcelain manufacturing plants. Company environmental programs should demonstrate that these options have been considered thoroughly. Direct links to online guides to cleaner production for this sector follow the table.

Low-Cost Solutions to Increase Efficiency and Reduce Waste in Ceramics and Porcelain Production

Avoid or reduce the use of heavy metals in mixes and glazes

Glazes that do not contain lead or other heavy metals are commonly available.  Metals in ceramic mixes are used for their engineering properties.  Product engineers should research non-toxic ingredients.
Dry cleanup Vacuums and damp brooms can be used to clean up dust from mixes and grinding, reducing the amount of waste that goes into the wastewater from final clean up.
Water recirculation Wastewater can be stored so the suspended particles settle to the bottom, then the water can be reused for cleaning.  Sludge can be collected, dried and made into inexpensive bricks rather than disposing it.
Improve product drying before firing Extended drying time reduces fuel requirements.  Even drying throughout product stacks reduces defective firing.
Improve air flow control Stopping all air leaks and controlling the kiln opening size allows better control of air flow speed and direction to improve combustion.
Switch to propane or natural gas fuel If available and competitively priced, these fuels have significantly less emissions and can increase production quality and speed.
New kiln design Vertical shaft brick kilns allow increased production rates and significantly decreased emissions through improved combustion air flow efficiency.  Several other kiln designs have also proven to be relatively low-cost and much more efficient than traditional ovens or kilns.

LINKS

Technical Guides to Pollution Prevention Ceramics and Porcelain Associations On-Line

Profile of the Stone, Clay, Glass and Concrete Industry has general environmental and cleaner production and regulatory information.

Best practices in the ceramics industry can be found from this UK site via the selection menu for "ceramics".

Energy Conservation in the Ceramics Industry from UNIDO is a good technical report.

Energy conservation in glass and ceramics production is from the Asian Development Bank.

State of the Art Manual for the Glass and Ceramics Industry describes air pollution control requirements from New Jersey.

Pollution Prevention for Stone, Clay, Glass and Concrete is from New Jersey.

Case study on porcelain factory effluent treatment

International Ceramic Association

CeramicBulletin.Org is a trade association online magazine with an environmental department.

Ceramic Tile Institute of America

Ceramic Manufacturers Association

Porcelain Enamel Institute

American Ceramic Society

last updated 02/25/06


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