DEVELOPMENT OF NEW METHODOLOGIES AND PRACTICES TO REDUCE THE ENVIRONMENTAL IMPACT IN THE PRODUCTION OF CERAMIC MATERIALS

In response to the growing global challenges of energy security and water pollution, this thesis explores integrated electrochemical and photocatalytic approaches for sustainable hydrogen production and advanced wastewater treatment. By coupling the anodic oxidation of nitrogen- and pharmaceutical-based pollutants with cathodic hydrogen evolution, the research proposes a dual-purpose strategy that simultaneously enables pollutant removal and green energy generation. A key innovation of this work is the development and electrochemical evaluation of non-noble metal electrodes, particularly cobalt phosphide-based systems, which operate efficiently under alkaline conditions. These materials were tested in both ideal and contaminated environments, including real-matrix simulations containing diclofenac and Rhodamine B. The hydrogen production was directly quantified, providing, for the first time, a scientific assessment of the faradaic efficiency of hydrogen generation from real wastewater containing organic contaminants using non-precious electrodes. To overcome the limitations of electrochemical oxidation alone, a hybrid process integrating visible-light-active BiOCl photocatalysis was implemented, enhancing degradation kinetics and mineralization efficiency. This combined strategy offers a scalable and energy-efficient route for water remediation. Beyond laboratory scale, the study includes a case analysis of the industrial implementation of green hydrogen at Iris Ceramica Group’s H₂ Factory, where hydrogen produced via photovoltaic-powered alkaline electrolysis is blended with methane to fuel ceramic kilns. Energy balances, emission monitoring (via GC–MS), and product quality evaluations were conducted to assess the technical feasibility and environmental benefits of hydrogen integration in ceramic manufacturing. Overall, the thesis provides a multi-scale perspective—spanning materials design, process engineering, and industrial application—demonstrating how wastewater can serve as a valuable resource for both clean energy production and environmental protection. The findings contribute to advancing circular economy principles and accelerating the transition toward decarbonized, sustainable manufacturing.