Channeled PM(10), PM(2.5) and PM(1) Emission Factors Associated with the Ceramic Process and Abatement Technologies

A sampling methodology and a mathematical data treatment were developed that enable to determine not only total suspended particulates (TSP) emitted at channeled sources but also the PM(10), PM(2.5), and PM(1) mass fractions (w(10), w(2.5), and w(1)) and emission factors (E.F.), using a seven-stage cascade impactor. Moreover, a chemical analysis was performed to identify the elements present in these emissions. The proposed methodology was applied to different stages of the ceramic process, including ambient temperature (milling, shaping, glazing) and medium–high-temperature (spray-drying, drying, firing, and frit melting) stages. In total, more than 100 measurements were performed (pilot scale and industrial scale), which leads to a measurement time of 1500 h. Related to the mass fractions, in general, the mean values of w(10) after the fabric filters operated at high performance are high and with little dispersion (75–85%), and it is also observed that they are practically independent of the stage considered, i.e., they are not significantly dependent on the initial PSD of the stream to be treated. In the case of the fine fraction w(2.5), the behavior is more complex (w(2.5): 30–60%), probably because the only variable is not the cleaning system, but also the nature of the processed material. Regarding abatement measures, the use of high-efficiency cleaning systems considerably reduces the emission factors obtained for fractions PM(10), PM(2.5), and PM(1). In reference to chemical analysis, the presence of ZrO(2) and Ni in the spray-drying and pressing stages, the significant concentration of ZrO(2) in the glazing stage, the presence of Pb, As, and Zn in the firing stage, and the presence of Zn, Pb, Cd, and As compounds in the frits manufacturing should all be highlighted. Nevertheless, it should be pointed out that the use of some compounds, such as cadmium and lead, has been very limited in the last years and, therefore, presumably, the presence of these elements in the emissions should have been also reduced in the same way.