A new process called BioSintering takes advantage of plant-based bio-active molecules to fuse together particles at mild temperatures, yielding an alternative material for conventional ceramic tiles with a much lower carbon footprint. Developed by Dekiln (Manchester, U.K.; www.dekiln.com), the technology binds loose particulate materials into dense solids using ambient-temperature biologically mediated mineralization pathways, eliminating several high-energy steps from traditional ceramic processing, including kiln firing, wet milling and spray drying.
“The resulting material has many commonalities with natural materials, including seashells, tooth enamel and pearl. These materials are made from mineral particles, such as calcium carbonate or phosphate, but are assembled by biological systems into structures that are exceptionally strong, tough and durable,” explains Aled Roberts, founder and CEO of Dekiln.
In natural processes, biological binding is limited by speed, but Dekiln has engineered its process to have rapid consolidation times relative to natural systems, making it suitable for industrial production. “We are deliberately adapting BioSintering so it can run on the same upstream and downstream processing equipment used in conventional ceramic tile production, including material handling, forming, drying and finishing — just without kiln firing and a few other energy-intensive steps. This will enable a drop-in replacement for traditional tile manufacturing, allowing existing producers to adopt the technology relatively painlessly. Removing the kiln also eliminates the single largest-cost emissions source and operational bottleneck in ceramic production,” says Roberts. According to an independent lifecycle assessment conducted by Dekiln, the BioSintering process results in an overall carbon footprint reduction of approximately 94% compared to conventional ceramic tiles.
Avoiding high-temperature processing also broadens the range of feedstock materials that the process can utilize. “Because we are not constrained by firing chemistry, BioSintering can accommodate inorganic waste streams that are otherwise problematic to recycle. For instance, waste plaster (calcium sulfate) makes up over 95% of our finished tiles. This material is abundant and costly to dispose of through conventional means. This enables high-recycled content while reducing material costs and diverting waste from landfill,” adds Roberts. The technology produces no waste materials, as all organic and inorganic inputs are fully incorporated into the final product. The company is working to patent the bio-based active ingredients, as well as other natural additives that promote binding and mineralization. Dekiln is currently able to produce 1–2 m2 of tiles per day at a laboratory-scale plant, and work is underway to transition to commercial-scale equipment. Several demonstration-scale installations of the technology have also confirmed its compatibility with standard tile-handling processes.