Ceramic Roadmap 'Paving the Way to 2050' - Cerame-Unie

Executive SummaryVisionStatementA strategic sector for the EUThe European ceramic industry today employsover 200,000 people in the EU-27, around 80%of them in SMEs. World-leading companies areheadquartered in the EU and the industry developshighly-skilled and trained employees.As one of mankind’s oldest industries, the Europeanceramic industry is a strategic and future-orientedsector. Through its continued commitment toinnovation, the ceramic industry has demonstratedits willingness and ability to contribute to thedevelopment of a competitive low-carbon andresource-efficient economy in the coming decades.or other ceramic products imported from lessenvironmentally-regulated countries.More than business asusual is necessaryThe transition to a competitive low-carbon andresource-efficient economy in 2050 representsa challenging target for the European ceramicindustry. As demonstrated in its long history, thesector is committed to contributing responsibly tothe achievement of such a target. This enormouschallenge means we need to build on our currentknow-how and expertise and new breakthroughtechnologies will be needed.The European ceramic industryis a strategic enabler for growth,innovation and sustainability.Therefore, a thriving ceramicindustry in the EU is vitalto achieve a competitivelow-carbon andresource-efficienteconomy by 2050.With its wide range of applications, fromconstruction to consumer goods, industrialprocesses and cutting-edge technologies, theceramic industry constantly develops innovativeand high-value solutions that improve our qualityof life and facilitate vital progress in downstreamsectors. Indeed our products play an essentialand very often indispensable role for energy andresource efficiency in other sectors. By enablingresource and energy efficiency in all these sectors,ceramics play an essential role in EU society.The need for a lifecycle approachCeramic products are designed to be durable. Thisis achieved through high-temperature firing of awide range of minerals, from locally-sourced clay tonatural or synthetic high-quality industrial minerals,to produce carefully-controlled materials.The contribution of such products to resource andenergy efficiency can only be appreciated with aholistic approach that considers the completelifecycle of the product, including its durability andimpact over the use phase. This approach shouldalso take into account all relevant environmentalindicators, such as biodiversity, ecological andhuman toxicity and water use.This holistic approach is required to ensure theresponsible promotion of ceramic productsmade in the EU instead of less durable productsThe 2050 emissions reduction targets are evenmore challenging for a capital-intensive sector withlong investment cycles like ceramics. Kilns forceramic production can last more than 40 years.Therefore, 2050 is less than the lifetime of a newkiln away. The model developed in this Roadmapshows that even in the hypothesis where half ofall kilns are converted to electricity in the period2030-2050 and the remainder retrofitted to syngasor biogas co-fired with natural gas, the emissionscould only be reduced by around 78% comparedto 1990 levels instead of the 83-87% industrytarget set by the European Commission, mainlydue to unavoidable process emissions.However, such a scenario will face significanttechnical, economic and resource constraints.Therefore, a supportive and reliable legal frameworkwill be essential to mobilise the human and financialresources needed to acquire and implement theessential further breakthrough technologies.Like many sectors, we operate in a globalmarketplace. Therefore, it is essential that theimpact of EU legislation on the internationalcompetitiveness of the industry is properlyaddressed. In particular, climate policy needs abottom-up approach which takes into accountthe technical and economic feasibility of additionalemission reductions and also the level of regulatorycommitment of non-EU countries.The year 2050 is the target of several Roadmapspublished by the European Commissionwhich set long-term strategies for a competitivelow-carbon economy, resource efficiency, energyand transport. All of these are key EU policy areas.The debate following the publication of thesedocuments has inspired a thoughtful discussionamong Cerame-Unie’s members on the currentand future role of our industry in EU society.The Ceramic Industry Roadmap represents ourcontribution to that debate.In this Roadmap, we take you on a tour of theceramic industry’s diverse sectors and demonstratethe strategic role each of them plays in societyand in enhancing life quality. We aim to presenta realistic overview of an industry that has alwaysbeen at the heart of European society and traditionand which continues to lead on the global stage.Ceramic companies across Europe are taking stepsto introduce energy-saving best practices, improveresource efficiency and move away from traditionalenergy sources. In addition, taking a lifecycleview of our products shows that they help achieveresource, water and energy savings for consumersand downstream user sectors.With a long history behind them and globalleadership, the European ceramic industry standson solid foundations and is fit for 2050 and beyond.We can enhance the international competitivenessof our industry and adapt to the shifting regulatorylandscape, provided that the appropriateregulatory framework is defined and implementedby policymakers at European and national levelworking closely with us.This is no straight road but working together, wecan pave the way for a better future for Europe,delivering on jobs and growth in a sustainablemanner. Ceramics will continue to play an excitingand critical role in the 21st century in many novelapplications.Alain DelcourtPresident, Cerame-Unie4 s Back to contents Back to contents s 5

Raw Materials and RestorationTo ensure long-term raw material supply and to encourage ongoing investment in thesector, the extraction of clay and other minerals must be carefully planned. During andafter extraction, quarries and riverbanks are restored and returned to their natural state,creating new habitats and promoting biodiversity. By restoring clay extraction sitesand protecting biodiversity, the ceramic industry plays an important role in maintainingsustainable local communities.Environmentand EmissionsA Closed LoopBeing inert due to the naturalmaterials they are made from andthe high-temperature firing theyundergo, the majority of ceramicscan be recycled and reusedwithin the ceramics industryand by other industries. Manycompanies reprocess firedceramic waste into new ceramicproducts. This creates aninternal market for waste, whichbecomes a valuable resourceand helps preserve natural stocksof virgin and important mineralsin Europe such as clay, limestoneand feldspar and also reduces theimports of minerals such as zircon,bauxite and magnesia from overseas.ProductionThe production of ceramics variesaccording to the final product,but generally includes thepreparation of raw materials,shaping, drying, glazing/decoration, firing and insome cases assembling.Investments like computercontrolledkilns, formulationswith optimised firingtemperatures and waste heatrecovery systems improveenergy efficiency. Transportand firing emissions have beenfurther reduced by technologicaladvances leading to significantweight reduction.Energy Efficiency in ProductionIn the last two decades, significant reductionsin energy consumption have been made duringproduction, for example, through better kiln designand more efficient firing. Energy-saving innovationsand materials technology have focused mainly onreplacing solid fuel with natural gas, scaling upand improving the efficiency of kiln technology,and moving, where appropriate for the scale ofoperation, from intermittent (batch) to continuous(tunnel or fast-fire roller kiln) technology. Theceramic industry is continuously improving itsenergy efficiency where economically viable.The energy used to produce the bricks for a1m² brick wall decreased by 39% from 1990 to2007. For one tonne of wall and floor tiles, theenergy used decreased by 47% from 1980 to2003. By changing from a twice-fired process atconventional firing temperatures to a single firingprocess at reduced firing temperatures, one UKhotel tableware producer reduced emissions by79% compared with similar products.High-performing and durable ceramics must befired at high temperatures. As such, the mostenergy-intensive process in ceramic manufacturingis kiln firing and in some cases the drying andshaping processes.Erik Kjær, ChiefConsultant, DanishTechnological Institute,Denmark“Back in the late 1960s,a large number of brickworks in Denmark usedcoal as fuel for firing.Today, natural gastogether with sawdust isthe fuel for approximately95% of brick productionin Denmark. This hasreduced CO 2 emissionsby approximately 40-50%. Combined with theenergy savings made inthe production process,the total CO 2 emissions inthe Danish brick industrytoday have been reducedby more than 75%.”Use PhaseOne of the main advantages of ceramics is their durability. Ceramic products require verylittle maintenance, have high resistance to environmental conditions and are extremelycost-effective. Ceramics are essential as an application in construction and many otherindustrial sectors such as automotive, power generation, steel and concrete industries.Ceramic materials fulfil the demanding hygiene specifications, chemical and mechanicalresistance required in our bathrooms. They also contribute significantly to improving theenergy and environmental profile of those sectors’ end-products.10 s Back to contents Back to contents s 11

Carbon Dioxide EmissionsThe bricks and roof tiles, refractories and wall andfloor tiles sectors together emitted a total of 19 MtCO 2 in 2010. Of these emissions, 66% were dueto fuel combustion, with electricity and processemissions accounting for 18% and 16% respectively.Existing best available technologies (BAT) arecontinually-improving, but breakthrough technologiesneed to be developed in the near future.Fuel EmissionsEnergy efficiency is the most obvious way to reducefuel emissions. Energy consumption can be furtherreduced if improved kilns, dryers, thermostats andseals are installed and by implementing automatedcontrols. Heat savings can be achieved byimproving thermal insulation through the useof novel refractory linings, coatings andother ceramic materials. As the life ofa kiln can be more than 40 years andrepresents major capital investment,it is not financially-feasible to routinelyupgrade kilns before the end of theirlife and replace them with moreenergy-efficient models.Recovery of excess heat is alsowidespread as it reduces fuelconsumption. This can be done bycapturing kiln gases in order to preheatthe combustion or dryer air. Smartdesign of manufacturing facilities is alsoa key factor because the physical distancebetween the different processes, e.g. firing anddrying, can account for energy savings.Electrification of kilns using low-carbon electricitycould be an option to reduce fuel emissions,particularly for large kilns making bricks, roof tiles,wall and floor tiles. However, this option is notcurrently economically-viable due to the significantlyhigher cost of power compared to natural gas.Alternative Energy SourcesThe continuous processes used in the ceramicindustries all require uninterrupted, secureand affordable fuel and electricity supplies asunplanned interruptions can cause severe kilndamage resulting in shutdown and production lossfor several months.Fig. 6 - CO 2 emittedduring 2010 aggregatedfor the bricks and rooftiles, refractories andwall and floor tilessectors (total emissionsof 19 Mt, representingapproximately of 90%of total ceramic industryemissions). The proportionbetween different emissiontypes, particularly forprocess emissions, canvary significantly betweendifferent processes andfactoriesThe ceramic industry predominantlyuses natural gas as it is more energyefficientat the high temperaturesrequired to fire clay and otherindustrial minerals. Today, diesel,LPG, coal or coke are only usedwhen mains gas is unavailable.Across Europe, companies arenow integrating alternative fuels andrenewable electricity into their energymix. Several countries have started usingrenewable energy for some brick, roof tile andclay pipe sites, but have encountered difficultiesin obtaining planning permission for some ofthese installations, particularly for wind turbinesand energy from waste projects. Therefore, afavourable legal framework is essential for waste toenergy projects.Cogeneration has developed in Member Stateswhere there are clear regulatory incentives forcombined heat and power (CHP) generation. In2012, there were around 250 CHP plants mainly inItaly, Portugal and Spain with an average installedcapacity of 3MW. Many are micro-generationfacilities with less than 1MW capacity. By producingelectricity in addition to the heat necessary for itslow to medium-temperature needs, the ceramicindustry contributes to the overall energy efficiencyof these Member States.In the region of Valencia, which is home to 95%of Spain’s ceramic tile industry, some ceramicfactories have solar panels. The Almeria SolarPlatform, in Andalucia in Spain, is doing researchinto solar ovens which could reach high enoughtemperatures for drying ceramics, e.g. 200-300°C.Work is ongoing into high-temperature ovens whichcould even fire some ceramics.For high-temperature firing, the most promisingway to reduce fuel emissions is to replace naturalgas by biogas or syngas from biomass or waste,modifying existing kilns through retrofitting.However, biogas today is very expensive, currently2-3 times the price of natural gas. Syngas producedby the gasification of organic waste or biomassalso has a higher potential to replace natural gasand significantly reduce emissions, particularly inthe brick and roof tile sectors. On average, the kilnrepresents 80% of the natural gas consumption ofa clay production unit. Substitution rates of up to80% syngas could technically be possible in someplants, with a potential reduction of running costs.This could reduce CO 2 emissions by over 30%.The future European public-private-partnershipof the process industries (SPIRE) will be essentialfor the development of this promising technologythat has yet to achieve full industrial reliability.Securing reliable, economic and sustainablyproducedbiomass or long-term wastesupplies is of equal importance.Process EmissionsCarbon dioxide emissions are not only related toenergy consumption, e.g. fuel-related emissions,but also to process emissions. Process emissionsare carbon dioxide emissions caused by thebreakdown of carbonates in raw materials suchas limestone, dolomite or magnesite. As theseare inherent in the raw material, these processemissions are a natural by-product of the firingprocess and cannot be avoided.The amount of process emissions from clays differsdepending on the composition of the minerals andthe local geology. The use of locally-available rawmaterials avoids long-distance transportation andconsequently higher CO 2 emissions. As such, itwould not be environmentally-sound to relocatefactories and jobs to reduce process emissions.12 s Back to contents Back to contents s 13

Current and Future TechnologiesCCSCarbon Capture and Storage (CCS) could be asolution to reduce CO 2 emissions in some sectors.However, ceramic factories are more numerous,smaller in size and more widely-dispersedgeographically than, for example, those in thesteel and cement sectors. The exhaust streamfrom ceramic plants is too CO 2 dilute, too hot andcontains too many other substances for efficient,cost-effective CCS at present. Until cost-effectivebreakthrough CCS technology is developed onan appropriate scale for the ceramic sector, theinstallation of CCS is likely to remain prohibitivelyexpensive for some time after it is installed in otherenergy-intensive sectors.Figure 7 presents an analysis of some of the key technologies whichcould be applied across the ceramic industry, highlighting bothpresent availability and future developments and taking into accountcost-effectiveness and the probability of their success in reducingemissions. Breakthrough technologies that are known today butstill require further development are also presented as they couldsignificantly reduce emissions in the near future if proven. Sometechnologies such as on-site syngas and biogas, on-site CHP andCCS, will also require significant support from regulators and/or facesupply challenges which are outside the industry’s control.Fig. 7 - Analysis of keytechnologies which couldbe applied across theceramic industryCCSEmissions Related to ElectricityConsumptionThe ceramic industry is not classed under the EUETS as electro-intensive so it does not benefit fromany electricity pass-through compensation. Forsome of the high-temperature processes in therefractories and technical ceramics sectors, such aselectric arc furnaces and electric induction furnacesoperating above 2000°C, there is a significant riskof carbon leakage outside Europe.However, the electro-intensity of the ceramicsector is expected to rise towards 2050 as someprocesses may shift from gas to electric firing.Moreover, increasing demands under the EUIndustrial Emissions Directive and other legislationmay require more use of electrically-poweredequipment. Therefore, some ceramic sectorswill have significantly more electricity usage andmay therefore become vulnerable to job andcarbon leakage as they are highly-exposed tointernational trade.TechnologiesOn-site CHPProcess optimisationClay/raw material preconditioningEnergy managementRaw materials formulation changes for more efficient firingOn-site syngas and biogasLow-temperature heat recoveryfrom kiln exhaustHeat exchanger in kiln stackNew kiln designavailable todayPilot onlyRequires SignificantDevelopmentBreakthroughTechnology14 s Back to contents Back to contents s 15

Emissions Reduction ModelThe push to decarbonise electricity in Europe will reduce theceramic industry’s indirect emissions from electricity, but will notbe sufficient to adequately decrease its emissions by 2050. Mostemissions in ceramic production arise from fuel and more radicalsteps and breakthrough technologies are required. There alsoremains the major challenge of process emissions reduction in somesectors. The cost of adaptation will significantly affect the globalcompetitiveness of the ceramic industry.As part of this Roadmap, Cerame-Uniedeveloped an emissions reduction modelto illustrate the possible emissions reductionsbetween 1990 and 2050. This is based on realemissions data from the bricks, roof tiles, wall andfloor tiles and refractories sectors which togethercomprise approximately 90% of the entire ceramicsector’s emissions.According to this model, the EU ceramic industrycan only achieve emissions reductions closeto the political targets for the EU industry withSources of CO 2Emissions:Sources of CO 2Emissions Reductions:breakthrough technologies, secure alternative fuelsources and financial assistance. This is becausethere is an unavoidable energy input to producedurable ceramics.There are additional challenges such as the factthat fossil fuels are currently used as the industry’smain energy source. Finally, in the vast majority ofcases, process emissions are unavoidable. Only atechnology such as Carbon Capture and Storage(CCS) could reduce process emissions but it istechnically more challenging and less economicallyviablethan for many other sectors.The Cerame-Unie emissions reduction modelassumes a constant level of production between2010 and 2050 with a similar product mix and thatthe emissions are for constant and near-full kilnload and production levels. It should also be notedthat the lower 2010 level of production is affectedby the consequences of the economic crisis.This model illustrates how emissions could bereduced by up to 65% between 1990 and 2050,Fig. 8 - Illustrativemodel for CO 2 emissionsreduction between 1990and 2050: A) excludingand B) including kilnelectrification. Before2010, emissions areestimated based on thereal production levelbetween 1990-2010based on an analysis of current and identifiedfuture technologies and assuming that all barriersregarding alternative fuels are overcome. Thiswould also mean that regulators treat syngas andbiogas as producing net zero emissions.Even in the hypothesis where half of all kilns areconverted to electric kilns in the period 2030-2050,and the remainder to syngas or biogas co-fired withnatural gas, the emissions could only be reduced by78% compared with 1990 levels, mainly becauseof unavoidable process emissions.This scenario would be an extremely costly step for bothcapital and running costs. Under these circumstances,the European ceramic industry could not remainfinancially-viable and internationally-competitive. Thecapital cost of this option will be approximately €90billion, assuming breakthrough technologies in electrickiln efficiency, the development of which will implysignificant further costs. In addition, we estimate acost of up to €40 billion for writing off plants before theend of their life and lost sales during downtime for plantmodifications. Furthermore, the energy bill for a typicaltile factory will most likely increase to about 2.5 timesthe current rate and the cost of biogas will be 2-3 timesthat of natural gas, even at current prices.Research and development may create opportunitiesfor further emissions reductions across the ceramicindustry through breakthrough technologies which arenot known today and have not been modelled here.Emissions (Mt)AEmissions (Mt)BProduction (Kt)150,000100,00050,000Fig. 9 - Production ofrefractories, wall andfloor tiles and bricks androof tiles sectors in thelast 20 years01990 2000 201016 s Back to contents Back to contents s 17

Ceramic Durabilityand Energy SavingsWhen assessing the impact and contribution of ceramic products,we need to look beyond the production phase. The long lifecycle ofceramic products shows how the durability, heat resistance and otherproperties of ceramics contribute to energy and resource efficiencyover the entire lifetime of the product in other sectors and during theuse phase of other applications. In everyday life, ceramics make asignificant contribution to residential energy savings. The applicationof ventilated facades and insulating blocks assure thermal stabilityin buildings, providing significant savings for heating and cooling.Ventilated facades can increase the energy efficiency of a building by40%. Innovative solutions also include new high thermal insulatingclay blocks, which can also be filled with mineral wool, perlite orpolystyrene and roof tiles with integrated photovoltaic cells.In the EU-27, there are approximately 20 billionsquare metres of residential homes. The averageheat and energy losses in residences with deficientwall insulation are significant. Replacement at arate of 1% per year with appropriate products suchas thermal insulating clay blocks or ventilated cavitywalls with clay facades could result in saving 100million tonnes CO 2 by 2050.Ceramic products are built to last and durability isone of their key benefits compared to many othermaterials. Studies show the average life of a brickhouse is more than 150 years. Vitrified clay pipescan also last for more than 150 years. In flooring,the expected lifecycle of porcelain, ceramic andmosaic tile is 50 years, far longer than carpet, vinylor natural hardwood.Innovations in refractories, abrasives and technicalceramics also contribute to significant energy andresource efficiency in other sectors and applicationsduring the use phase, multiplying significantly theirpositive impact.In recent decades, the quality and lifetime ofrefractories has increased. Fewer refractoriesare now needed: today just 10kg per tonne ofsteel compared to 50kg in 1990. As a result, theemissions per tonne of steel reduced 77% over thisperiod. To give an example, 3.15 million tonnesof CO 2 have already been saved in the annualproduction of cars due to the use of refractories.Refractories also improve the properties of thesteel itself, for example by enabling the productionof lightweight steel. Precision grinding by finerabrasives further improve engine efficiency. Hence,the overall reduction of CO 2 emissions in thetransport sector will be even higher.Water ConservationDuring manufacturing, water is used in many ways including as araw material, heat exchange vehicle and cleaning agent. Often thewater supply includes recycled water, rainwater harvesting schemesand recycled water from on-site lagoons and boreholes. Water isrecycled in many ceramic plants, often using ceramic filters. Mostcompanies in the sanitaryware and tile sectors reuse their wastewaterand almost all of the production and purification waste is reused inthe production cycle. All over Europe, companies use rainwater toreduce water consumption and many ceramic producers have theirown wastewater treatment plants.RecyclingDue to developments in the sanitaryware sector,the water consumption in homes has decreaseddramatically in the last two decades through theintroduction of new toilet and flushing mechanismdesigns. More than 30% of the water used inhomes is for toilet flushing and today all new toiletsare equipped with dual flushes, discharging lessthan 6 or 3 litres compared to earlier models whichhave a 9 litre single flush only.Innovation and ingenuity continually add new materials to the ceramicindustry’s growing portfolio of products. Brick can be crushedinto brick chips and used for landscaping or as a raw material forother products. In some British ceramic companies, up to 20% oftotal material usage in production is from alternative, recycled andsecondary source materials, with 200,000 tonnes of clay beingreplaced in one year by materials that would otherwise have beenscrapped. Unfired clay can be reused and imperfect fired bricks arecrushed and used as aggregates in the construction industry.Bricks and roof tiles are recycled throughoutEurope. Building and demolition waste includingwaste ceramics and plaster moulds used in someprocesses are used extensively in road constructionand as a secondary aggregate, while wall andfloor tiles contain more recycled material. In therefractory industry, 20% of used refractories areagain recycled into refractory applications, 27%are reused in non-refractory applications, 35%are dissolved during use and only 18% remain asunusable waste.18 s Back to contents Back to contents s 19

ApplicationsConstruction and HousingGeneral BenefitsCeramic-based building materials have an averageservice life of over a century and boast excellentresource efficiency at all lifecycle stages. Theirdurability supports the optimisation of a rawmaterial with many advantages for the constructionand housing sectors.The unique properties of ceramics provide improvedenergy efficiency and thermal comfort in both warmand cold, humid and drier climatic conditions, whiletheir resilience to corrosion and versatility acrosshundreds of applications ensures that ceramics willmaintain their fundamental role in the housing andconstruction sectors.Bricks and Roof TilesThe production of bricks and roof tiles is one ofthe most well-known applications of ceramics.Bricks and roof tiles have been used for centuriesbecause of their proven ability to protect homesfrom the elements. As an inert product made fromnatural materials, ceramic tiles and bricks are nontoxicand do not emit volatile organic compounds(VOCs), complying with the VOC restrictions in theLeadership in Energy and Environmental Design(LEED) Building Certification and providing a healthyindoor climate. Ideal for sustainable housing, bricksare highly-resistant to fire and provide insulationfrom sound and vibrations, electricity, electrostaticand ionising radiation.Timo Leukefeld, Prof.Dipl.-Ing. and energyexpert at EnergieVerbindet, Germany“Monolithic externalclay block walls, madefrom special high-techclay products, providea comfortable thermalindoor climate, both inwinter and in summer.The result is completeenergy independence for thebuilding, without needingenergy from fossil fuels orelectricity from the grid.”Wall and Floor TilesMoulded in an endless number of designs andformats, wall and floor ceramic tiles build on 2,000years of tradition to provide durability, aesthetics andtechnical solutions in private and public buildings. Nolonger just a decorative feature inside homes, wall andfloor tiles have become indispensable in the provisionof hygiene. A new generation of coatings withphotocatalytic properties (activated by UV radiation)gives tiles the ability to destroy organic matter thatsettles on their surface and encourages water toslide off, while antibacterial tiles with light-activatedantibacterial surface coatings kill hospital bacteriasuch as MRSA and other disease-causing pathogens.Other recent innovations include new forms ofceramic sheeting, including fibre-reinforced ceramics,ceramic composites containing conductive layers forheating systems, inner porous layers for thermal andacoustic insulation, and strong, lightweight thin tilesthat minimise the tiles’ environmental impact.Vitrified Clay Drainage PipesAn essential part of municipal infrastructure,vitrified clay pipes transport wastewater safely andeffectively away from buildings and roads and on totreatment plants. The raw material used in clay pipeproduction is a completely natural, inert resourceand is available in virtually unlimited reserves.Vitrified clay remains inert even when subjected toextreme temperatures or chemical attack and whenit is eventually taken out of service, it is completelyrecyclable. Currently up to 27% of the raw materialused in vitrified clay pipe production comes fromrecycled clay products.SanitarywareFavoured by architects and interior designers,ceramic washbasins, toilets, bidets and shower traysare found in homes and buildings the world over.Increasingly innovative designs in the sanitarywaresector mean that ceramics can offer a huge rangeof products covering nearly every kind of applicationrequested by the market. Ceramics’ light resistanceensures that ceramic sanitaryware does not fade orage, while the glazing process delivers smooth, easycleaning surfaces, low water-absorption, optimalhygienic characteristics and assures the indoor airquality of bathrooms. Ceramic sanitaryware hasmade a huge contribution to the reduction of diseasein general and a dramatic reduction in the waterconsumption of household appliances.Roberto Palomba,interior designer, Italy,and Klaus Leuschel,designer and author,GermanyAward-winning architectand interior designerRoberto Palomba is clearabout his preferencefor ceramic bathroommaterials, noting that“Ceramics satisfy virtuallyall demands placed ona bathroom material -better than any other.”Looking at ceramics froman art historian’s angle,author Klaus Leuscheldescribes ceramicsas “original, authenticmaterials. Their propertiesand appearance have apositive image deep inpeople’s psyches.”A Sustainable FutureAs the world’s population rises, ceramics arebeing developed to meet the growing demandfor affordable, energy-efficient and sustainablehousing in Europe and beyond. The brick and rooftile houses of tomorrow will continue to build ontheir legacy to meet the demand for sustainablesolutions. Energy-efficient buildings such as the‘zero energy house’ concept have opened newpossibilities for sustainable construction with bricksand roof tiles.Innovative model houses built with high-thermal,energy-efficient, integrated insulation clay blockenvelopes deliver significant energy savingsand meet the requirements of the EU’s Directive2010/31/EU on the energy performance of buildingsfor 2020. ‘Cool roofs’ using brightly-coloured rooftiles reduce the internal temperature in attics andhouses in regions with warmer climates and providecomfort in summer without using energy-intensivecooling systems.Shaping techniques based on the continuouscompaction of powders hold enormous potentialfor the future of low-carbon, ceramic-based floorcoverings and substrates for building facades. Themanufacturing process behind these productsallows multi-layered slabs and composite materialsto be made from recycled powders, contributing tocost savings and improved energy efficiency in thebuilt environment.Ceramic sanitaryware producers are constantlydeveloping innovative water-saving solutions, suchas flushless urinals, shallow-depth washbasins andwater-efficient toilets and cisterns.Communities are witnessing the introduction of‘intelligent ceramics’- a sustainable cities conceptwhere ceramic applications such as flooring canimprove the accessibility, comfort and safetyof citizens, preserve and regenerate the urbanenvironment and reduce maintenance costs forpublic spaces and buildings. Sensors built intoceramic flooring can detect human presenceand activate traffic signals, while wall tilingintegrated with heating systems preventsnow and ice from building up at transporthubs. Advanced ceramics hold enormousdevelopmental potential for globalresource-efficient solutions.20 s Back to contents Back to contents s 21

Industrial ApplicationsGeneral BenefitsThe ability of ceramics to withstand extremely hightemperatures, as well as their durability, strengthand non-corrosive properties make them essentialfor a number of specific applications required inmetallurgical processes, glass production and manyother key processes across all industries. Gearsused for steelmaking or quarrying often includeadvanced ceramics because their wear, corrosionand thermal resistance offer significantly longer lifecompared to conventional metal gears.AbrasivesAbrasives comprise a small but indispensableindustry. Much of the complex machinery requiredby industries, as well as the smooth finishes incountless applications, from diamonds, watchesand furniture to kitchen appliances and aircraft, isground, cut, drilled or polished with abrasives. TheEuropean abrasives industry significantly impactsproductivity in other industrial and services sectors,including steel, metal processing, automobilemanufacturing, space, glass, construction, stoneprocessing, shipbuilding, cleantech, machinebuilding,wood processing and defence industries.Maintaining and developing the abrasives industryin Europe will ensure the independence of Europe’sindustrial production.Of the wide variety of abrasives, 10% are madefrom ceramic processes, the rest being made bydifferent technologies from coating paper andtextiles to organic bonded products, pastes ordiamond coatings on steel blades.Dr Wolfgang Eder, CEOVoestAlpine, PresidentEurofer, the EuropeanSteel Association“Refractory products areindispensable for steelproduction. Thanks toinnovations in the use ofrefractories today, such asultra high power electricarc furnaces, the steelindustry has made significantadvances in recent decades,both in terms of productivity,quality, reliability andenvironmental performance.Looking to the future, weexpect to continue countingon the strong performanceand reliability of the Europeanrefractory industry to help usfurther the competitiveness ofthe steel industry in Europe.”RefractoriesRefractories are essential for all high-temperatureindustrial processes. They play the triple role ofproviding mechanical strength, protection againstcorrosion and thermal insulation. The lining ofevery single reactor, transport vessel or kiln uses awide range of refractory products including bricks,monolithics and high-temperature insulation wool.Refractory products are adapted to each specificapplication through fine-tuning and a careful choiceof the different raw materials and their processing.Innovative refractory products provide resourceefficientsolutions to downstream industries andhave been instrumental in the development of keybreakthrough processes such as the continuouscasting of steel or the production of float glass. Andlast but not least, refractories are also indispensableas kiln linings or physical support during the firing ofall ceramic products.The functionalities of technical ceramics andrefractories meet critical needs in steel, aluminium,cement, glass, the chemical industry andenvironmental applications as well as for energygeneration, all of which create some of themost corrosive high-temperature environmentsin industry today. They take advantage of theimproved energy efficiency, productivity and metalquality that refractories and technical ceramicsbring to handling smelting, melting and moltenmaterials processes.A Sustainable FutureA more efficient use of resources has becomethe key element in allowing industry to developin a sustainable way, meeting the expectations offuture generations and the low-carbon economy.Improving energy efficiency, reducing inputs andreliance on increasingly scarce raw materials,minimising waste, reducing the amount ofrefractories consumed by downstream industriesand increasing recycling are some of the solutionsEuropean refractory companies are contributing to.Abrasives, technical ceramics and refractoriesare essential solution providers that improveresource efficiency in the supply chain. Finerabrasives and superabrasives enable precisiongrinding for improved engine efficiency and thuslower vehicle emissions. Innovative abrasivesalso reduce rework and scrap by enabling coolercutting and reducing heating and waste duringindustrial processes. This results in fewer stressfractures in critical components, reinforcing themwith longer life, reduced weight and enhancedperformance in many applications, particularly inthe aerospace, automotive and defence sectors.Innovative refractories and other ceramics alsoplay a key role in the development of cleantechnologies. Ceramics contribute to low-carbonenergy generation and electricity distribution.In the recent European Commission report,‘Materials Roadmap Enabling Low CarbonEnergy Technologies’, ceramic components wereacknowledged to be critical in most technologyoptions, with applications in the production oflow-carbon technologies.22 s Back to contents Back to contents s 23

Consumer GoodsGeneral BenefitsUbiquitous in consumer goods, ceramics presenta natural, affordable and long-lasting choice ofraw materials whose transformation into an arrayof consumer goods is achieved with minimalenvironmental impact.The complex chemistry of many ceramics facilitatestheir use at high temperatures and their robustnessin coping with high speeds during manufacturingprocesses. Unique properties such as highresistance to abrasion, chemical inertness anddimensional stability ensure that ceramics todayhave the longer life and lower maintenance costsrequired to maintain the pace of technologicaladvances.Tableware and OrnamentalwareCeramic table and ornamentalware, whether madeof porcelain, stoneware or earthenware, have longbeen part of our culinary rituals. Fired in kilns usingabundant natural resources like clay and sand tocreate these stone-like substances, ceramics havehad an astonishing legacy throughout history,providing civilisation with as many varieties as thereare cultures and cuisines.Household AppliancesThe ability of ceramics to withstand very hightemperatures makes them ideal materials forcooking and heating appliances. Ceramic-coatedfrying pans are a common replacement for other,more controversial non-stick coatings.Ceramic water filters provide safe drinking waterto millions of people all over the world. The small,complex pore structure of ceramics providesgenuine sub-micron filtration. These filters arerelied upon in the most demanding situations likewar zones and natural disasters.A Sustainable FutureDining sets and ceramic art are passed fromgeneration to generation as part of our culture.Safer cookware and standalone water filtersthat provide clean drinking water in developingcommunities are all examples of the future ofceramics in consumer goods. As water becomes amore scarce resource, ceramic water filtration andliquid cleansing solutions will become more widelyused both in Europe and in developing countries.From the vases, utensils and carrying vessels ofyesteryear to the dinnerware, fine chinaware andhotel porcelain of today, the natural longevity ofceramics ensures that they will continue to evolvewith the times and remain the primary vessel ofchoice for serving food.Stephan Härdi,Executive Head Chef,Radisson Blu PlazaHotel, Norway“We have been workingwith high-end porcelainproducts since 2004. Asa market-leading hoteland Food and Beverageoperation, we arebenefitting greatly fromthe unique but practicalshapes and conceptsavailable today and theongoing cost savingsresulting from thetremendous durability ofthese porcelain-vitrifiedhotel products.”24 s Back to contents Back to contents s 25

High-Tech and InnovationGeneral BenefitsCeramics have become indispensable in cuttingedgetechnologies. Advanced technical ceramicshave unique mechanical, electrical, thermal andbiochemical properties that enable their usein a variety of applications in the automotiveindustry, electronics, medical technology, energyand environment and in general equipment andmechanical engineering.Technical Ceramics in HealthcareMedical, laboratory and pharmaceuticalinstruments as well as ceramic components areused extensively in healthcare, in blanks for theproduction of crowns, bridges and implants indentistry and also in implantable medical devicessuch as pacemakers or hip replacements.Due to their biocompatibility, wear resistanceand chemical and corrosion resistance, ceramicbiomedical implants are the optimum solution forproblems arising from disease, infections and othercomplications.With low allergenic potential, ceramic componentsare also well-suited for patients with metal allergies.Innovations in highly-advanced medical-gradeceramic applications continue to deliver improvedperformance in healthcare.Technical Ceramics in ElectronicsCeramic substrates, circuit carriers, core materialsand many other components are in use throughoutthe electronics industry. Ceramic heat-sinks providethe perfect climate for high-power electronics, whileceramics’ electrical insulation properties mean theyare used in microchips, circuit boards and circuitbreaker technology.In addition, piezoelectric ceramic components,electromechanical transducers that convertmechanical energy into electrical energy, are usedin sensors, actuators, gas ignition and powertransducers for high-power ultrasonic applications,such as transmitters and receivers in signal andinformation processing.Combined with other unique properties, ceramiccomponents are found in a wide range of demandingapplications that ensure reliable functioning inaerospace technology, the automotive industryand optoelectronics. Ceramics help keep theworld in contact and in motion in the way we havecome to expect.Security and TransportApplications of technical ceramics in security anddefence include bulletproof vests and infrared nightvision devices. The high thermal insulation andwear-resistant properties of ceramics explain theiruse in jet engine turbine blades, disc brakes andbearing components. Contributing to safety andreliability, technical ceramics are found in a vastrange of applications in rings and valve components,Combined Cycle Gas Turbine (CCGT) ceramicturbine blades, vacuum components, airbagsensors, catalytic converters, high-temperature fuelinjection systems and other specialised markets.Renewable TechnologiesMany functions in renewable technologies requirehigh-quality products that can only be manufacturedwith high-quality abrasives, refractories andtechnical ceramics. The production of the highpurityglass required for solar panels is one example,refractory products used for manufacturing siliconwafers (the semiconductor in crystalline silicon solarpanels) is another. Ceramic-based products are alsowidely used in wind turbines and other solar panelcomponents, such as anti-friction bearings, heatsinks,fuel cells, tensiometers and insulation rings.A Sustainable FutureFurther research into the use of nanoengineeredceramic materials to store energy, particularlyfrom wind turbines and solar arrays, couldprovide the solution to the so-called ‘energybottleneck’ that inhibits the widespreadadoption of wind and solar power. New nanoceramicswould be key components in the nextgeneration of capacitors that are smaller, lighter,longer-lasting and more efficient and couldbe applied to conventional energy storage aswell as for intermittent sources such as windand solar. Ceramics, one of the most ancienttechnologies in human history, could thereforebe key to unlocking next-generation energystorage and enabling future generations toharness renewable technologies.Storing energy at source is just one of manyuses for ceramics in the low-carbon economy.Next-generation capacitors could also play arole in developing more efficient electric vehiclesand other devices. Researchers are developingnew high-tech ceramics for highly-efficient solidoxide fuel cells. Ceramics are also being usedto develop new non-toxic coatings to preventmetal surfaces from rusting and to develop thenext generation of water filters.26 s Back to contents Back to contents s 27

Call to PolicymakersThe global economy is currently in transition with austerity measures beingtaken at home and abroad. And yet, with the right policy framework, wesee the future European ceramic industry being an even more innovativeand world-class industry with increasing employment, a strong supplychain and enhanced skills to meet current and emerging market needs.In line with other sectors, we call on policymakers tocreate a supportive regulatory framework to keepmanufacturing competitive in Europe and to help usmake the European Union’s objectives on smart,sustainable growth and competitiveness a reality.Our industry is world-leading yet predominantly alocal one, with significant employment in clustersand local supply chains. As a large numberof ceramic companies are SMEs, this industryprovides sustainable employment as well asleadership in innovation.Ceramics are produced all over the EU yet there isan increasing threat from imports and carbon andjob leakage to countries outside the EU.LifecycleIt takes energy to make and transport productsfrom all sectors. Our main ‘ask’ to policymakersis that they take a lifecycle view of emissionsand assess more than the carbon emitted in theproduction phase, particularly as the ceramicindustry is so interconnected with the performanceand energy efficiency of many other sectors.As shown in this Roadmap, our technologies caneven reduce overall emissions when considering thewhole lifecycle, i.e. during the use phase and at endof life. As resources become scarcer, consumersneed help to make more environmentally-responsiblechoices. Regulators can help move people awayfrom ‘throwaway’ choices and towards materialswith a sound lifecycle profile. Green publicprocurement can also encourage more sustainableconsumption patterns, for example by favouringenergy-efficient materials.Without a policy shift to measure emissionsbased on the whole lifecycle rather than duringproduction only, there is a danger that legislationwill misguidedly drive consumers to either ceramicmaterials made in less environmentally-stringentcountries or to other less durable products withhigher annualised emissions. This approach wouldbe detrimental to both the European economy andglobal emissions.Measuring resource efficiency requires appropriateindicators. The proposal in the Roadmap fora resource-efficient Europe does not take intoaccount the lifecycle, availability of raw materials,durability of the product, end-of-life emissions orenergy in the use phase. True resource efficiencycan only be based on a lifecycle approach.TradeThe European ceramic industry is affected byinternational market access issues and tradebarriers. To tackle a wide range of trade and non-tariffbarriers, we need to resort to all available trade policyinstruments, both in a bilateral and multilateral context,including negotiations and enforcement procedures.Strong action must be taken against all unfair tradepractices including counterfeiting, infringement ofintellectual property rights, dumping and subsidies.In the context of the ongoing modernisation of theTrade Defence Instruments (TDI), it is essential thatthe EU preserve an effective regulatory frameworkon Trade Defence Instruments such as anti-dumpingand anti-subsidy. Ceramics are made from a widerange of materials, from locally-sourced clay to naturalor synthetic high-quality industrial minerals. As theseindustrial minerals are to a large extent imported fromoutside the EU, secure and fair access to these rawmaterials is vital. Eliminating WTO infringementson procurement and reducing red tape as much aspossible are therefore prerequisites for a competitiveceramic industry in Europe.Investment CyclesRecognising that some of the best available andnew technologies, e.g. for energy efficiency, havesignificantly longer paybacks than shareholdersand banks will lend for, industry needs accessto affordable finance - perhaps repaid from theresulting energy savings - for capital projects withlonger payback periods.The ceramic industry today predominantly usesnatural gas. While some policymakers haveadvocated moving the industry away from gas toelectric kilns once European electricity supplies aredecarbonised, this is not an economic solution atpresent nor in the foreseeable future.If the 2050 targets are to be achieved by makinga large-scale move away from natural gas andonto biogas, syngas or other renewable energies,the ceramic industry needs to be assured of asustainable, uninterrupted and affordable supplyof these alternative fuels and proven technologythrough demonstrators. This is essential as efficientkilns must work continuously and cannot easily beswitched off due to energy supply problems.Our industry’s experience with renewables,for example wind or waste transformationplants, has not been smooth across the board.Permitting processes in the Member Statesmust support industry’s shift to renewableenergy installations if industry is to rely on asecure supply of alternative fuels.Climate and EnergyFor investment security, the ceramic industryneeds a consistent and predictable legalframework across the EU’s climate and energypolicies. The implementation of current and futuremeasures, such as the rules on new entrantsand allowance retention, must not hinder newinvestments, plant improvements and growth.The EU must continue to pursue a clear strategytowards an international legally-binding climateagreement with a comparable burden for industrybased in the major trading partners whichcompete with the European ceramic industry, suchas the BRICs, Egypt, Mexico, South-East Asiancountries and the United Arab Emirates.Equally, international agreement is neededto give equal consideration to industries mainlycomposed of small emitters like the ceramicindustry. In the absence of a multilateralagreement, free allocation of allowances andnational support schemes for indirect costs fromelectricity must apply to avoid carbon and jobleakage. Other measures such as import taxesshould be assessed.Long-term climate policy will need a broaderapproach which also takes into accountconsumed or imported emissions in productsin the EU to ensure that Europe is not simplydecarbonising by deindustrialising.Ambitious climate targets will requirebreakthrough technologies. Therefore, thetarget-setting policy must be accompanied byfinancial support to facilitate development andinvestment in low-carbon technologies. Thiscould be partly funded by recycling existingenergy taxes and CO 2 auctioning revenues.InnovationMeeting the EU’s ambitious medium and longtermclimate targets will require breakthroughtechnologies to come to market quickly to helpreduce energy use and transition to low-carbonfuel sources, particularly given the lifecycle ofceramic installations, which on average is 30 to40 years. Target-setting should be accompaniedby financial support to facilitate the transition.Developing these breakthrough technologiesrequires a supportive research and innovationpolicy framework. This Roadmap refers tosome of the technologies we believecan make a difference todayalthough the development ofother, longer-term technologiesis still essential.Process industries, includingceramics, take raw materials andtransform them into highly valueaddedproducts. Cerame-Unie is activelyinvolved in the future SPIRE public-privatepartnership (PPP) dedicated to innovation in theprocess industries. SPIRE supports the processindustries in their move to becoming moreresource and energy-efficient in line with the EU’sobjectives and Roadmaps. For example, theSPIRE roadmap recommends a 20% reductionin non-renewable, primary raw material intensityand a 30% reduction in fossil fuel intensity fromcurrent levels by 2030.Ceramic products contribute to the developmentof innovative solutions for sustainable buildings.In this context, ceramic building materials canplay a crucial role in the energy-efficiency ofbuildings public-private partnership (E2B PPP).The ceramic industry counts on policymakers tomake these PPPs a reality.The creation of a business-friendly and innovationconduciveeconomic, regulatory and legalframework to effectively support the development ofinnovative products is a priority for our industry. Weacknowledge Europe’s objectives for a competitive,low-carbon economy and Europe’s leadershipposition and ability to set the example globally.However, the sooner a level playing field can beestablished globally on emissions, the easier it willbe for all European companies to compete globallyand for real climate abatement to take place.28 s Back to contents Back to contents s 29

GlossaryAbrasive - Materials or products used to polish andfinish a workpiece through rubbing, i.e. abrasionBest Available Technology (BAT) - Best availabletechnology for achieving a high general level ofenvironmental protection, developed on a scalethat allows implementation in the relevant class ofactivity under economically-viable conditionsBiodiversity - The number and variety of organismspresent in an ecological complex in which theynaturally occur, e.g. in an ecosystemBiogas - The end-product of the breakdown oforganic feedstock by anaerobic digestion. Biogas iscomposed of methane, carbon dioxide, water andhydrogen sulphide and is used as a biofuelBiomass - A renewable energy source, materialfrom biological origin, mainly plants, that will be useddirectly or converted into other energy productsCarbon Capture and Storage (CCS) - A climatemitigation technology that allows carbon dioxideto be captured then transported and stored indepleted oil and gas reservoirs or saline aquifersCarbon and Job Leakage - The phenomenonwhen one country or region unilaterally implementsclimate legislation, resulting in the relocation ofindustries and jobs and in an increase in emissionsin a less-regulated region, with no global reductionin CO 2 emissionsCeramics - Inorganic materials, made of nonmetalliccomponents, not all including clay, andwhich become permanent after a firing processEU-27 - The European Union (EU) is an economicand political partnership between 27 Europeanmember countriesEU Emission Trading System (ETS) - Europeanpolicy to combat climate change by reducingindustrial greenhouse gas emissions costeffectively.The EU ETS has created a market toeffectively put a price on carbon emissions andtrade themFiring - The heat treatment of ceramic productsin a kiln to harden them and develop a vitreous orcrystalline bondGreenhouse Gas - Atmospheric gases thatabsorb and emit radiation within the thermal infraredrange. The burning of fossil fuels has contributedto an increased concentration of these gases in theatmosphere. Includes methane which is 25 timesmore potent than carbon dioxide as a greenhouse gasIntergovernmental Panel on Climate Change(IPCC) - A scientific intergovernmental body whosemission is to provide scientific assessments onclimate change caused by human activityKiln - High-temperature installation used forfiring ceramicsProcess Emissions - Carbon dioxide emissionsproduced during the manufacture of ceramicproducts whose raw materials contain carbonatesRestoration - Restoring degraded or damagedecosystems by human interventionRefractory - A material that retains its strength athigh temperaturesSmall and Medium Enterprise (SME) - Acompany with less than 250 employees and whereeither the turnover is less than €50m or the balancesheet total is less than €43mSPIRE - Sustainable Process Industry throughResource and Energy EfficiencySyngas (Synthesis gas) - A combustible gasmixture containing carbon monoxide, carbondioxide and hydrogen, which is an end-product ofthe gasification process of a carbon-containing fuel,such as the gasification of coal, biomass, waste toenergy gasification or steam reforming of natural gasVitreous - A ‘glassy’ application to ceramics thatas a result of a high degree of vitrification hasextremely low porosityVitrification - The progressive partial fusion of clayas a result of a firing processVolatile Organic Compounds (VOC) - Organicchemicals with high vapour pressure at roomtemperature conditions, causing large numbersof molecules to evaporate or sublimate and enterthe surrounding air. There is concern about someVOCs which are toxic30 s Back to contents Back to contents s 31