Executive Summary
Firing kilns in the ceramics sector—tiles, bricks, roof tiles, sanitaryware, tableware—are among the most challenging loads to decarbonize. They operate at 900–1,250°C, run for thousands of hours per year, and rely overwhelmingly on natural gas. In 2026, hydrogen-ready burners, oxy-fuel concepts, and electrified preheating are moving from pilot to early deployment. At Energy Solutions, we analyze real kiln test campaigns and retrofit projects to map a credible, staged roadmap from gas to low-carbon hydrogen.
- Fuel use in typical ceramics kilns ranges from 1.8–3.0 MWh/tonne of product (tiles and bricks) with specific CO₂ emissions of 350–550 kgCO₂/tonne from fuel alone, excluding process emissions from clay.
- Efficiency upgrades—better insulation, flue-gas heat recovery, and optimized firing curves—can reduce fuel demand by 10–20% ahead of any fuel switch, often with paybacks of 3–6 years.
- Hydrogen-ready burner retrofits typically add 10–25% to burner and control CAPEX compared with gas-only designs, while full hydrogen firing can increase fuel costs by a factor of 2–4 at current green hydrogen price ranges.
- In base-case scenarios, Energy Solutions modelling suggests that by 2035, 15–30% of kiln fuel in leading EU ceramics clusters could be low-carbon hydrogen or hydrogen-rich blends, provided supporting infrastructure and policy frameworks materialize.
What You'll Learn
- Fuel Use and Emissions in Ceramics Kilns
- Benchmarks: Energy Intensity and CO₂ per Tonne
- Efficiency-First: Insulation, Heat Recovery, and Firing Curves
- Hydrogen-Ready Burner and Kiln Concepts
- Economics: CAPEX, Fuel Costs, and Abatement Curves
- Case Studies: EU Tiles, Bricks, and Sanitaryware Pilots
- Global Perspective: EU, UK, MENA, and Asia
- Devil's Advocate: Technical, Fuel, and Policy Risks
- Outlook to 2030/2035: Transition Pathways and Scenarios
- Step-by-Step Roadmap for Manufacturers
- FAQ: Hydrogen Kilns in Ceramics
Fuel Use and Emissions in Ceramics Kilns
Ceramics kilns are continuous or batch high-temperature furnaces that dry, fire, and sometimes glaze clay-based products. Tunnel kilns for tiles and bricks may operate 24/7 with firing zones at 1,050–1,200°C, while intermittent shuttle kilns for sanitaryware and technical ceramics often reach similar temperatures but with different cycle profiles.
Methodology Note
Energy Solutions combined plant-level data from more than 40 kilns in Italy, Spain, Portugal, Germany, the UK, Turkey, and the Gulf region (2018–2025). Energy intensity figures are expressed in MWh of fuel per tonne of fired product and kgCO₂ per tonne from fuel combustion, based on natural gas with 0.20 kgCO₂/kWh lower heating value. Process emissions from clay carbonates are not included.
Benchmarks: Energy Intensity and CO₂ per Tonne
Fuel Use and CO₂ Benchmarks by Product Type (Natural Gas, 2026)
| Product / Kiln Type | Fuel Use (MWh/tonne) | Fuel CO₂ (kgCO₂/tonne) | Notes |
|---|---|---|---|
| Ceramic floor/wall tiles (tunnel kiln) | 1.8–2.4 | 360–480 | Includes dryer and kiln; European best-in-class at lower end. |
| Clay bricks and roof tiles | 1.6–2.3 | 320–460 | Highly dependent on kiln age and insulation. |
| Sanitaryware (shuttle kilns) | 2.4–3.2 | 480–640 | More intermittent operation; higher losses. |
Data normalized to lower heating value of gas at 10.5 kWh/Nm³ and 0.20 kgCO₂/kWh.
Fuel CO₂ Intensity by Product Type (kgCO₂/tonne)
Efficiency-First: Insulation, Heat Recovery, and Firing Curves
Before any fuel switch, most manufacturers can cut fuel use by 10–20% via efficiency measures:
- Improved kiln insulation: Upgrading refractory linings and sealing leak points reduces shell losses and flue-gas volumes.
- Flue-gas and exhaust heat recovery: Preheating combustion air, dryer air, or incoming greenware using waste heat.
- Optimized firing curves: More precise temperature ramps and soaking times tailored to product requirements reduce over-firing and scrap.
Illustrative Savings from Efficiency Measures (Tiles Tunnel Kiln)
| Measure | Fuel Savings | Typical Payback | Notes |
|---|---|---|---|
| Insulation upgrade & sealing | 5–8% | 4–7 years | Usually implemented during major outage. |
| Combustion air preheating | 3–6% | 3–5 years | Using recuperative or regenerative burners. |
| Integrated dryer heat recovery | 2–6% | 3–6 years | Reusing kiln exhaust to dry greenware. |
Practical Tools for Project Screening
To explore headline economics for decarbonizing kilns and associated systems, you can use:
- Green Hydrogen Cost Explorer – to understand LCOH ranges and sensitivity to power prices and capacity factors.
- Waste Heat Recovery Calculator – to approximate savings and payback from flue-gas and dryer heat recovery before fuel switching.
Impact of Efficiency Package on Fuel Use (Index)
Hydrogen-Ready Burner and Kiln Concepts
Hydrogen-ready kilns are designed to operate on natural gas today while accommodating future blends or full hydrogen firing with minimal hardware changes. Key design elements include:
- Burners and manifolds sized for higher volumetric flow (hydrogen has ~1/3 the volumetric energy density of natural gas).
- Materials and controls that tolerate different flame speeds and NOx formation tendencies.
- Provision for monitoring and adjusting air-fuel ratios as blends evolve.
Energy Solutions Insight
Early hydrogen test campaigns in EU tile kilns show that up to 20–30% hydrogen by volume can often be blended into natural gas with limited modifications, though kiln tuning is essential. Moving beyond 50% typically requires hydrogen-ready burners, upgraded controls, and careful management of NOx emissions.
Economics: CAPEX, Fuel Costs, and Abatement Curves
Illustrative Economics for a Tiles Tunnel Kiln Retrofit (EU)
| Option | Incremental CAPEX | Fuel Cost Impact | CO₂ Reduction vs Gas Baseline |
|---|---|---|---|
| Efficiency package only | EUR 2–3 million | Fuel use −15–20% | −15–20% |
| Hydrogen-ready burners (0–30% blend) | +EUR 0.8–1.5 million | Fuel cost +5–15% at 30% blend* | −10–20% (fuel CO₂ component) |
| Full hydrogen firing (green H₂) | Additional piping & safety systems | Fuel cost 2–4× (depending on H₂ price)** | Up to −90–95% of fuel CO₂ |
*Assumes hydrogen at 2–3× energy cost of gas; **fuel price assumptions highly uncertain and region-specific.
Relative Fuel Cost vs CO₂ Reduction (Illustrative)
Case Studies: EU Tiles, Bricks, and Sanitaryware Pilots
Case Study: Tile Kiln Hydrogen Blend Pilot
Context
- Location: Emilia-Romagna, Italy
- Facility Type: Ceramic floor and wall tiles
- System Size: 80 m tunnel kiln, 18 t/hour
- Pilot Period: 2023–2024 heating seasons
Investment
- CAPEX: ~EUR 1.2 million for hydrogen-ready burners and controls
- Financing: EU innovation grant + corporate capital
Results
- Hydrogen Blend: Up to 30% by volume in test phases
- Fuel CO₂ Reduction: ~12–18% vs pure gas, depending on blend level
- Quality: No significant impact on tile strength or color after tuning
Lessons Learned
Detailed burner tuning and monitoring of NOx were critical. The project confirmed technical feasibility but highlighted strong dependence on future hydrogen pricing for large-scale rollout.
Case Study: Brick Kiln Efficiency and Hydrogen-Ready Retrofit
Context
- Location: North Rhine-Westphalia, Germany
- Facility Type: Clay bricks and roof tiles
- System Size: 120 m tunnel kiln
- Upgrade Date: 2022–2025
Investment
- Total CAPEX: EUR 4.5 million
- Scope: Insulation, flue-gas heat recovery, hydrogen-ready burners
Results
- Fuel Savings: 17% vs pre-retrofit baseline
- CO₂ Reduction (fuel): 17% from efficiency alone; hydrogen blend to be added later
- Simple Payback on Efficiency Portion: ~6 years at 2025 gas prices
Lessons Learned
Designing for hydrogen-readiness added modest cost at retrofit stage but avoids more expensive modifications later. However, without clear hydrogen supply timelines, financial benefits remain an option value rather than a realized return.
Global Perspective: EU, UK, MENA, and Asia
Europe is currently the focal point for hydrogen kiln pilots, driven by high carbon prices, tight regulations, and active hydrogen infrastructure planning. The UK has several industrial clusters testing hydrogen in ceramics and glass, while MENA and Asia are watching developments closely, focusing meanwhile on efficiency and fuel switching to LNG, LPG, or biomass where feasible.
Devil's Advocate: Technical, Fuel, and Policy Risks
Technical Barriers
- Flame characteristics: Hydrogen flames behave differently, requiring redesigned burners and careful control to avoid hot spots and refractory damage.
- NOx emissions: Higher flame temperatures can increase NOx unless mitigated by staged combustion or flue-gas recirculation.
Economic and Policy Constraints
- Hydrogen price uncertainty: Green hydrogen costs remain several times higher than gas on an energy basis in most markets.
- Infrastructure timing: Many ceramics clusters will not see reliable hydrogen pipelines before the early to mid-2030s.
When NOT to Adopt
For kilns near end-of-life or plants facing demand uncertainty, heavy investment in hydrogen-only infrastructure may not be justified today. Efficiency upgrades and electrification of auxiliary loads can offer lower-risk abatement while the hydrogen picture clarifies.
Outlook to 2030/2035: Transition Pathways and Scenarios
Energy Solutions scenarios suggest a staged pathway: aggressive efficiency improvements this decade, hydrogen-ready retrofits timed with major overhauls, and increasing hydrogen blends as supply, pricing, and policy incentives converge. Full hydrogen firing may remain limited to clusters with strong policy support and co-located hydrogen production.
Step-by-Step Roadmap for Manufacturers
1. Baseline and Efficiency Audit
- Quantify current energy intensity and map heat losses.
- Implement cost-effective efficiency measures first.
2. Hydrogen Readiness Assessment
- Evaluate burner and control system compatibility with hydrogen blends.
- Engage with local hydrogen infrastructure plans.
3. Phased Investment Plan
- Schedule burner and control upgrades with major kiln outages.
- Align project timelines with expected hydrogen availability.
4. Contract and Policy Alignment
- Explore long-term offtake agreements, carbon contracts for difference, and cluster-level support schemes.
5. Monitor, Test, and Iterate
- Run staged hydrogen blend tests with rigorous quality and emissions monitoring.
FAQ: Hydrogen Kilns in Ceramics
Frequently Asked Questions
1. How much can hydrogen blends reduce kiln CO₂ emissions?
Blending 20–30% hydrogen by volume into natural gas typically reduces fuel-related CO₂ emissions by roughly 10–20%, assuming the hydrogen is low-carbon. Higher blends can deliver deeper reductions but require more extensive burner and control modifications.
2. Are hydrogen-ready kilns much more expensive than conventional kilns?
Hydrogen-ready burners and associated controls generally add around 10–25% to burner and control CAPEX compared with gas-only designs. When integrated at the time of major upgrades, the incremental cost is often modest relative to total kiln investment.
3. When will hydrogen be widely available for ceramics clusters?
Timelines vary by region. In many European clusters, early hydrogen volumes for industry are expected around 2030, with more substantial availability in the early to mid-2030s. Other regions may see slower roll-out, making efficiency and electrification even more important near-term.
4. Does hydrogen firing change product quality?
Pilot tests show that with proper burner tuning and control of temperature profiles, tile and brick quality can match gas-fired baselines. However, each kiln and product mix must be validated carefully; small adjustments to glazes and firing curves may be needed.
5. How should manufacturers sequence investments?
A pragmatic sequence is to first capture low-cost efficiency gains, then integrate hydrogen-ready burners during scheduled overhauls, and only later commit to high hydrogen fractions once supply, pricing, and policy incentives are clearer.