ETH material scientists have developed a new method of manufacturing ceramics that does not require the starting materials to be fired. Instead, they are compacted under high pressure at room temperature in a significantly more energy-efficient process.
The manufacture of cement, bricks, bathroom tiles and porcelain crockery normally requires a great deal of heat: a kiln is used to fire the ceramic materials at temperatures well in excess of 1,000°C. Now, material scientists from ETH Zurich have developed what seems at first glance to be an astonishingly simple method of manufacture that works at room temperature. The scientists used a calcium carbonate nanopowder as the starting material and instead of firing it, they added a small amount of water and then compacted it.
“The manufacturing process is based on the geological process of rock formation,” explains Florian Bouville, a postdoc in the group of André Studart, Professor of Complex Materials. Sedimentary rock is formed from sediment that is compressed over millions of years through the pressure exerted by overlying deposits. This process turns calcium carbonate sediment into limestone with the help of the surrounding water. As the ETH researchers used calcium carbonate with an extremely fine particle size (nanoparticles) as the starting material, their compacting process took only an hour. “Our work is the first evidence that a piece of ceramic material can be manufactured at room temperature in such a short amount of time and with relatively low pressures,” says ETH professor Studart.
Stronger than concrete
As tests have shown, the new material can withstand about ten times as much force as concrete before it breaks, and is as stiff as stone or concrete. In other words, it is just as hard to deform.
So far, the scientists have produced material samples of about the size of a one-franc piece using a conventional hydraulic press such as those normally used in industry. “The challenge is to generate a sufficiently high pressure for the compacting process. Larger workpieces require a correspondingly greater force,” says Bouville. According to the scientists, ceramic pieces the size of small bathroom tiles should theoretically be feasible.
Energy-efficient and environmentally benign
“For a long time, material scientists have been searching for a way to produce ceramic materials under mild conditions, as the firing process requires a large amount of energy,” says Studart. The new room-temperature method – which experts refer to as cold sintering – is much more energy-efficient and also enables the production of composite materials containing, for example, plastic.
The technique is also of interest with a view to a future CO2-neutral society. Specifically, the carbonate nanoparticles could conceivably be produced using CO2 captured from the atmosphere or from waste gases from thermal power stations. In this scenario, the captured CO2 is allowed to react with a suitable rock in powder form to produce carbonate, which could then be used to manufacture ceramics at room temperature. The climate-damaging CO2 would thus be stored in ceramic products in the long term. These would constitute a CO2 sink and could help thermal power stations to operate on a carbon-neutral basis.
According to the scientists, in the long term, the new approach of cold sintering even has the potential to lead to more environmentally friendly substitutes for cement-based materials. However, great research efforts are needed to reach this goal. Cement production is not only energy-intensive, but it also generates large amounts of CO2 – unlike potential cold-sintered replacement materials.
Learn more: Sustainable ceramics without a kiln
[osd_subscribe categories=’sustainable-ceramics’ placeholder=’Email Address’ button_text=’Subscribe Now for any new posts on the topic “SUSTAINABLE CERAMICS”‘]
Receive an email update when we add a new SUSTAINABLE CERAMICS article.
The Latest on: Sustainable ceramics
[google_news title=”” keyword=”sustainable ceramics” num_posts=”10″ blurb_length=”0″ show_thumb=”left”]
via Google News
The Latest on: Sustainable ceramics
- From Scrap to Style at Kohleron April 30, 2024 at 9:21 am
Kohler’s industry-leading manufacturing waste reuse business, KOHLER WasteLAB, announces its first bathroom sink, constructed of more than 70 percent recycled materials.
- Global High Temperature Ceramics Market Set to Reach US$ 9.27 Billion by 2032, Fueled by Growing Demand and Energy Efficiency Driveon April 30, 2024 at 8:13 am
The global high temperature ceramics market is poised for significant growth, with an estimated value of US$ 4.67 billion in 2022, projected to reach US$ 9.27 billion by 2032, showcasing a robust CAGR ...
- Global Glass Ceramics Market Size To Exceed USD 2,674 Million By 2031 | CAGR Of 6.5%on April 30, 2024 at 5:10 am
The key players in the global glass ceramics market are CoorsTek, Corning, Kanger Glass-ceramic, Kedi Glass-Ceramic, Kyocera, Morgan Advanced Materials, Nippon Electric Glass, Ohara, Saint Gobain, ...
- Naples’ Best Shop for Sustainable, Biophilic Home Designon April 29, 2024 at 1:57 pm
Located at Galleria Shoppes at Vanderbilt, design boutique At Faro focuses on biophilic wares and artisan-made furnishings and home goods.
- Nano-Care Deutschland AG Launches Next Generation Of Sustainable PFAS-Free Oleophobic Coatingson April 29, 2024 at 12:50 pm
Nano-Care® C0-L sets a new standard in leather care in that it not only delivers exceptional results but is also completely PFAS – free. This means that consumers can now look after their favourite ...
- A centuries-old Japanese ceramics maker has found itself at the center of the AI revolutionon April 27, 2024 at 3:53 am
Related stories This is welcome news to perhaps no one more than a centuries-old Japanese ceramics maker that got its start making dinnerware. Maruwa, which builds ceramics for circuit boards and ...
- Maine Pottery Tour set for May 4, 5on April 26, 2024 at 5:00 pm
Anyone can access the link you share with no account required. Learn more. The Maine Pottery Tour is set for Saturday, May 4, and Sunday, May 5, throughout the state. This self-guided tour ...
- Aggregate Industries getting fired up for recycled potteryon April 25, 2024 at 1:20 am
Thousands of tonnes of broken and rejected pottery is to be recycled by Aggregate Industries to help create cement at its Staffordshire plant.
- Earth Day: CCCFS promotes adoption of ceramics to fight plastic pollutionon April 23, 2024 at 2:43 am
The Centre for Climate Change & Food Security (CCCFS), a non-governmental organisation, is advocating the adoption of ceramic materials for domestic usage as the country fights the devastating ...
via Bing News