Life cycle assessment of ceramic tiles manufactured using industrial waste fly ash

Sustainability in the ceramic tile industry is critical due to its significant resource and energy consumption. With limited life cycle assessment (LCA) studies on waste materials in tile production, a research gap exists specifically for industrial waste fly ash (IWA). Building upon previous research that has confirmed the technical feasibility of IWA as a sustainable alternative material in ceramic tile, this study explores the environmental and economic feasibility of replacing potash feldspar with IWA in ceramic tiles. A comparative LCA across scenarios with varying IWA additions from 0 % to 30 % was conducted, focusing on six key environmental impact categories: climate change, terrestrial acidification, human toxicity, terrestrial ecotoxicity, freshwater eutrophication, and fossil depletion. Additionally, a sensitivity analysis on increased production energy and an environmental life cycle cost analysis (ELCC) were performed. Results reveal significant reductions in environmental impacts with increased IWA incorporation compared to the conventional construction. Notably, the IWA30 (30 % IWA addition) scenario, which entirely substitutes potash feldspar, achieves the most substantial benefits, reducing climate change impacts by 8 %, terrestrial acidification by 10 %, and terrestrial ecotoxicity by 22 %. These reductions demonstrate that incorporating IWA significantly decreases the overall environmental footprint of ceramic tile production by reducing the reliance on non-renewable resources and mitigating pollution. IWA30 also proves to be the most cost-effective option, with an 11 % cost reduction due to IWA's availability as a waste material. Overall, adopting IWA decreases the environmental burden and enhances economic viability, providing strong incentives for industries to adopt more sustainable practices by minimising waste management challenges and raw material consumption. • Comparative LCA of ceramic tile production using industrial waste fly ash (IWA). • Assessed the environmental impacts of replacing potash feldspar with up to 30 % IWA. • Environmental impacts of IWA30 case reduced by up to 22.5 % (terrestrial ecotoxicity). • IWA30 offers the highest cost savings, with a reduction of 11.3 % compared to control. • IWA usage minimises reliance on traditional materials and waste management burdens.