Hi Gani et se
I just thought I would throw in my two cents, for what it’s worth.
I was the ceramic tech for 14 years here at the University. After getting hired on to the position, the Fire Marshal came in and threatened to close down the studio, if we couldn’t control our waste stream better. So I spent many years trying to come up with alternative ways of disposing of toxic waste.
In the Bay area nothing could go down the drain, so the glaze was collected and loaded into a 55 gallon drum at $500 a barrel and shipped out to a hazardous waste landfill where it was stored until the landfill was filled up. Then a new bigger landfill site was build and your barrel was shipped out to the new site and you would be charged $500 again for the new barrel resting site. That was known as cradle to grave waste disposal. You are responsible from the moment you produce the waste until you die.
Now a days the $500 a barrel ceramic waste is sent out to an incinerator to be turned into fly
ash to make cinder blocks or to fill another landfill.
If the students and instructors kept the glaze barrels clean of foreign materials, the waste disposal company could
sell the glaze to commercial fertilizer companies. It could be added to the fertilizer sold to farmers, to replace the metals and minerals that industrial farming and erosion has removed from the soil.
I tended to go with a low tech method of handling the glaze cycle. Get your sister three of those large blue 55 gallon drums, (steel drums rust and then you have an even bigger waste disposal problem). Get the ones that the top comes off.
The first barrel is filled with clean water and is used for cleaning the ceramic pieces before she does any glazing. She will dip the piece, removing any dust left from the greenware and bisque firing stage. This will prevent the glaze from crawling during the glaze firing. This water will be contaminated with dust and can be dumped in the yard.
Second barrel is for gross cleaning of glaze. The bottoms of her work will be sponge cleaned over this barrel, as well as cleaning work table tops, paint brushes, spray guns, spray hood filters and sponges etc. When it gets filled with a watery glaze, the barrel is left to settle out. The heavy materials sink to the bottom and the top is left cloudy water. Decant the upper water and place in the third barrel, to be used the same way as the second barrel. Final cleaning of paint brushes will be done in small containers and deposited in the second barrel; this is where most of the waste water will come from.
The remaining glaze at the bottom of the second barrel is stirred up with an electric drill and a paddle paint mixer. If the second glaze barrel wasn’t kept clean of foreign materials, it will need to be screened. She will then need to do a test firing of her new glaze. If she only uses one glaze for production runs, then her new glaze will probably fire out close to what she is already using. If she uses a variety of glazes she will probably get a dark green or black. If they turn out to be a color she doesn’t like, they can be used for glazing the inside of pots. Most of the time I got pretty respectable colored glazes. The toolroom tech would add a lot of cobalt to these glazes, and she got some pretty dreamy multi-dipped glazes. But the receipts are her secret, so your sister will have to do her own experiments. “Keep that notebook”.
No self respecting ceramicist would ever do the following, but it worked for me. The cloudy water that was floating on top of the second barrel is mostly clay and a little bit of heavy metals. Decant that water off and mix in a 5 gallon
bucket, with the scrap clay that she will be generating every day. Mix it in a pug mill and she will not be able to tell the difference between normal clay and glaze water clay.
I was mixing about ¼ glaze from the bottom of the second barrel to ¾ recycled clay and made a clay body for roof tiles for a shed, pavers for my yard and sculpture. Every once in a while during a bisque firing, I would get a little glaze spotting. But it was nothing that a coat of glaze wouldn’t cover up. She should do some test firings to see how high a firing the clay will go before it turns into a puddle.
Good luck, “Ceramics the World most fascinating hobby.”
Bill