About this Abstract |
| Meeting |
2027 TMS Annual Meeting & Exhibition
|
| Symposium
|
Advances in Ceramic Materials and Processing
|
| Presentation Title |
Factory-Scale Microwave Sintering of Alumina: Techno-Economic Viability for Industrial Decarbonization |
| Author(s) |
Samantha Mendes Castellano, Bashu Aman, Kate Whitefoot, B. Reeja Jayan, Constantine Samaras |
| On-Site Speaker (Planned) |
Samantha Mendes Castellano |
| Abstract Scope |
High-temperature (> 1000°C) ceramic sintering relies on energy-intensive convective kilns, with European ceramic installations alone responsible for approximately 19 Mt of CO2 annually. Factory-scale, economically competitive electrified alternatives are needed to achieve 2040 industrial decarbonization targets. This work reports a laboratory-to-factory transition of microwave sintering alumina ceramics, integrating a continuous 2.45 GHz microwave system into an industrial production line. We can demonstrate energy savings of up to 97% relative to a comparable gas-fired kiln. Using a process-based cost model, we decompose the production process to identify energy and cost drivers and then quantify commercial viability across four scenarios involving microwave and gas-fired sintering lines operating in the United States and China. Findings help inform manufacturers, policymakers, and investors by evaluating the commercial transition from fossil-fuel-based to electrified sintering systems. This analysis establishes the conditions under which microwave electrification is economically competitive, providing a decarbonization framework for industrial adoption at scale. |
| Proceedings Inclusion? |
Planned: |
| Keywords |
Ceramics, Process Technology, Sustainability |