Life Cycle Assessment of Fuel Blends Integrating Green Hydrogen in Ceramic Tile Manufacturing

Main Presenter:    Vasilissa Nikonova 

Co-Authors:   Veronica Bortolotto     Serena Biella      Claudia Letizia Bianchi                                    

The ceramic tile industry is one of Europe’s most energy-intensive sectors, traditionally dependent on natural gas for firing kilns. In the context of industrial decarbonization and circular economy strategies, integrating green hydrogen as part of the thermal energy supply represents a promising pathway to reduce greenhouse gas emissions. However, limited life cycle evidence exists on the environmental trade-offs and systemic impacts of such fuel transitions at the process and product scale.
This study investigates how substituting conventional fossil fuels with varying fractions of green hydrogen affects the environmental performance of ceramic tile production. It aims to identify the blend configuration that minimizes life cycle impacts without compromising technological feasibility.
A cradle-to-gate Life Cycle Assessment (LCA) was performed following ISO 14040/14044 standards. Experimental kiln energy data and modeled hydrogen production scenarios (electrolysis powered by renewable electricity) were implemented in SimaPro using the Ecoinvent database. Scenarios include 0%, 5%, 25%, and 50% hydrogen substitution in the fuel blend. Key indicator is Global Warming Potential. Sensitivity analysis was applied to assess the influence of regional electricity mix.
Results are expected to quantify the environmental trade-offs associated with different hydrogen blend ratios. Preliminary modeling suggests potential reductions in carbon footprint with partial hydrogen integration, though the extent depends on the renewable energy source for electrolysis and system boundaries. The analysis will also identify critical parameters influencing life cycle performance, such as electricity grid mix and kiln efficiency adjustments. Final results will inform stakeholders on optimal blend configurations balancing decarbonization targets and operational feasibility.
This work provides one of the first comparative LCA insights into hydrogen-fuel integration in ceramic manufacturing, supporting decision-making for low-carbon process design within energy-intensive industries. It contributes to broader discussions on integrating green hydrogen into industrial clusters and the practical implementation of energy transition strategies aligned with EU Green Deal targets.

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