Upcycling of ceramic waste to produce cabide-based ceramics

Supervisor	Prof. Karel Maca
Research Group	Advanced Multifunctional Ceramics

Grinding sludges from machining of advanced ceramics accumulate worldwide as costly and often hazardous waste streams that are rich in valuable materials (e.g., B₄C, SiC and synthetic diamonds), but contaminated by coolants, binders, and fines that hinder straightforward reuse. Landfilling or incineration of these sludges forfeits critical raw materials, carries long-term environmental liabilities, and exposes producers to tightening regulations and disposal fees. Meanwhile, demand for hard, wear- and corrosion-resistant non-oxide ceramics continues to rise, yet primary powders remain expensive and energy-intensive to produce.

The objective of this project is to find the most effective processing route to upcycle industrial waste ceramic grinding sludges into a clean, formable feedstock and then into high-performance, non-oxide (carbidic) ceramics for various applications. Upcycling sludges into high-quality powder feedstocks addresses three converging pressures — resource efficiency, compliance and risk reduction, and decarbonization — by closing material loops, reducing embodied energy and CO₂, and creating a reliable, lower-cost route to produce advanced ceramic components without compromising their performance.

This project delivers technological innovation and environmental benefits by valorising industrial waste and introducing a novel class of materials. The outcomes will be validated from laboratory to pilot scale, with attention to input variability, quality control, and readiness for industrial adoption.

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