Ceramic Sanitary Ware Research Articles

Reuse of Industrial and Agricultural Waste in the Fabrication of Geopolymeric Binders: Mechanical and Microstructural Behavior.

Resource recovery from waste is one of the most important ways to implement the so-called circular economy, and the use of alkali activated materials can become an alternative for traditional PC-based materials. These types of materials are based on waste resources involving a lower carbon footprint and present similar or high properties and good durability compared to that Portland cement (PC). This research work proposes using new waste generated in different types of industries. Four waste types were employed: fluid catalytic cracking residue (FCC) from the petrochemical industry; ceramic sanitary ware (CSW) from the construction industry; rice husk ash (RHA); diatomaceous waste from beer filtration (DB) (food industry). FCC and CSW were employed as precursor materials, and mixtures of both showed good properties of the obtained alkali activated materials generated with commercial products as activators (NaOH/waterglass). RHA and DB were herein used as an alternative silica source to prepare the alkaline activating solution. Mechanical behavior was studied by the compressive strength development of mortars. The corresponding pastes were characterized by X-ray diffraction, thermogravimetric analysis, and microscopy studies. The results were satisfactory, and demonstrated that employing these alternative activators from waste produces alkali activated materials with good mechanical properties, which were sometimes similar or even better than those obtained with commercial reagents.

Utilization of perlite as an alternative raw material in the production of ceramic sanitaryware

Perlite is an amorphous volcanic glass and an industrial mineral. Because of its relatively low price and density, perlite has a lot of commercial application. Generally, it is used in the horticultural and construction sector. Perlite is a candidate raw material for ceramic products due to its high amorphous phase. Perlite usage in ceramic sanitaryware is investigated with this work. For this purpose, albite was gradually decreased and perlite was added at rates of 3, 5, and 10% to the standard sanitaryware composition instead of albite. All tests and analyses were done under industrial conditions. The compositions were examined based on the rheological and technological properties, chemical analysis, phase analysis, and thermal analysis (thermal expansion coefficient and high-temperature deformation). According to the results, perlite addition increases fired shrinkage, fired strength, and dry shrinkage. Fired strength rose significantly up to 715 kg cm−2. Water absorption values were under 0.02% for all test samples. Besides, the thermal expansion coefficient of the bodies increased up to 10% with perlite addition and then decreased. Thermal expansion coefficient values were determined between 60.1 and 64.9 × 10−7 K−1. High-temperature deformation values decreased up to 10% with perlite addition. The composition which contains 3% perlite showed minimum deformation ( − 4.25%) at 1250 °C. As a result, it was determined that the use of perlite would be possible in ceramic sanitaryware compositions.

Investigation of Usability of Ceramic Sanitaryware Wastes in Geopolymer Mortar Production

Bu çalışmada, seramik sağlık gereci (vitrifiye) üretimi esnasında ortaya çıkan hatalı/ıskarta ürünlerin öğütülmesi ile elde edilen atık tozlar alkali ile aktive edilerek geopolimer harçlar üretilmiştir. Üretilen harçlara farklı sıvı/bağlayıcı oranı ve aktivatör molaritesinin etkisi araştırılmıştır. Bu amaçla sıvı bağlayıcı 0,45 ve 0,50 oranlarında 10, 12, 14 ve 16 M NaOH çözeltilerinde karışımlar hazırlanmıştır. Üretilen harç karışımlarına 80°C’de 24 saat ısıl kür ve 28 güne kadar havada kür uygulanmıştır. Numunelere işlenebilirlik, birim ağırlık, eğilme ve basınç dayanımı, su emme ve boşluk oranı deneyleri uygulanmıştır. Numunelerin sıvı/bağlayıcı oranı 0,50 iken molaritenin artması mekanik özelliklere olumlu etkisi olmamakta ancak işlenebilirliği iyileştirmektedir. 0,45 sıvı/bağlayıcı oranında ise molaritenin artışı dayanımda önemli gelişme göstererek 16 M NaOH konsantrasyonunda yaklaşık 34 MPa basınç dayanımı elde edilmiştir. Ancak artan dayanım, çevresel ve ekonomik koşullar açısından geopolimer harç üretimi için uygun molaritenin sıvı/bağlayıcı oranı 0,45’de 12 M NaOH olduğu belirlenmiştir.

Sanitary wares (Wash-basin) product industry situation and quality analysis

Sanitary ceramic products refer to glazed ceramic products used for sanitary installations. Sanitary wares products are divided into ceramic Sanitary wares and ceramic Sanitary wares according to different materials. According to use divide for implement kind, basin kind. The urinal type includes sit urinal, squat urinal, urinal; The basin category includes the Wash-basiner, washing tank, mop pool and so on. Among them, the Wash-basiner refers to the glazed ceramic products used for washing face and hands. It is a necessary sanitary equipment in family or public places and has become an essential sanitary appliance in people’s life.

Investigation on effect of process parameters in abrasive Jet Machining process using full factorial design

Abrasive Jet Machining (AJM) process is one of the unconventional machining process used to cut various materials including soft and hard materials. Alumina and silica are majorly used as abrasive materials due to its chemical and abrasion resistance. In this paper, abandoned Ceramic Sanitary Ware (CSW) wastes are used as abrasive materials in AJM process. Since, CSW wastes contain major amount of alumina and silica compositions. Initially, ball milling machining process is carried out to convert CSW wastes into micro particles. Then, sieving is performed to segregate the particles with its size. Stand of distance, pressure and particle size are considered as most influencing parameters in AJM process. Hence, Full Factorial design is utilized for three process parameters and three levels. The nozzle with a mixing chamber is designed and fabricated to perform drilling operation in the glass work piece. L27 experiments are carried out to evaluate Material Removal Rate (MRR) and Hole Diameter (HD) during drilling process of glass work piece. Further, the effect of each process parameters on MRR and HD is validated. From the analysis, it is found that pressure is most influencing parameters affecting MRR whereas HD greatly depends on particle size.

Preparation, microstructure studies and mechanical properties of glazes ceramic sanitary ware based on kaolin

In this paper, the use of local kaolin coming from Djebel Debbagh (denoted DD1) in the composition of ceramic glazes for sanitary ware was examined. Because of its natural abundance, low price and good characteristics, this kaolin represents an interesting economic alternative to other mineral clays. The chemical composition showed that this kaolin contains 38.49 wt.% Al2O3 and 44.85 wt.% SiO2. Two glazes based on kaolin DD1 denoted as GaDD1 and GbDD1 were prepared with conventional ceramic processing techniques at temperature 1250 oC. As a reference, another glaze (Gref) based on kaolin Remblend was also prepared in the same conditions. The samples were characterized with X-ray diffraction and Scanning Electron Microscope. The results revealed that zircon and quartz are the crystalline phases present in these glazes. In the sample GaDD1, it was found that the degree of whiteness is very high and reaches 93.30 %. However, the water absorption coefficient is low which is about 0.19 ? 0.04 %. In addition, the flexural strength and the Vickers microhardness are respectively, about 56.07 ? 5.61 MPa and 7952.80 ? 101.76 MPa. These properties are compatible with those of the glaze reference Gref and commercial sanitary ware glazes, indicating the potential use of kaolin DD1 in the production of glazed ceramic for sanitary ware applications.

Development and application of an informatization upgrade device for old equipment in ceramic sanitary ware industry

A device is proposed, which can be used to upgrade the informatization process of old equipment and information isolated island equipment of ceramic enterprises. It has the characteristics of standard, high efficiency, low cost and low risk. The universal fast interface does not interfere with the control system of the device itself when connected to the device. It can obtain data that the target device system has but is not open or the system does not have. Then, the device use the standard industrial communication protocol to transmit the data to the manufacturing execution system in accordance with the agreed data format. This method lay a good foundation for the informatization upgrade and optimization of the data. Furthermore it can be used to optimize and control production. Finally, in enterprise applications, it shows that the device has certain economic and social benefits.

Toprak Alkali Kaynağı Hammaddelerin Vitrifiye Sırlarında Ergimeye Olan Etkisinin İncelenmesi

In this study, the effect of raw materials based of alkaline earth oxides used in ceramic sanitaryware glazes was investigated on the melting behavior of the glaze. For this purpose, new raw materials based of alkaline earth oxide were included in the Seger formulation and different glaze recipes were prepared. Prepared glaze compositions were applied on fine fire clay bodies with pistole and fired at 1200-1250°C in industrial firing regime. Melting behavior of glazes were investigated with physical flow test samples. The particle size analysis for glaze compositions, thermal expansion test, Harcourt test, L *- a *- b * color measurement and stain resistance tests were applied on all glazed samples. The results showed that the variation of raw material based of alkaline earth oxides has a significant influence on the physical flow lengths and thermal expansion coefficients of glazes without degrading surface quality.

Research on Ceramic Sanitary Ware Defect Detection Method Based on Improved VGG Network

The defect detection of ceramic sanitary ware is often done manually, which is inefficient and unhealthy. The development of deep learning technology makes a non-contact and high-efficient method of inspection possible. In this paper, based on VGG-16 network, we proposed an optimized method for ceramic sanitary ware defect detection. We carried out pre-processing to denoise and enhance the original image data, improved activation function of MReLU, and used transfer learning method to train the model. The results of the test on the ceramic sanitary ware defection data set showed that the accuracy can reach 97.48%, which is 6.46% higher than that of the model using the ReLU activation function. The detection speed can reach 7 fps, which could meet the requirements of industrial online real-time production.

Pozzolanic activity of tiles, bricks and ceramic sanitary-ware in eco-friendly Portland blended cements

Reusing ceramic waste as a pozzolanic admixture may offer environmental benefits as it allows the reduction in the consumption of natural resources and energy, and the reduction of CO2 emissions associated with Portland cement (PC) production, while valorising waste materials with a long biodegradation period. This paper assessed the pozzolanic activity of three different ceramic waste types: red clay bricks (RCB), ceramic tiles (TCW) and ceramic sanitary-ware (CSW). After adapting their particle size by crushing and milling, each was used to replace 0 to 50 wt% PC (CEM I 42.5 R type). The milled powders were characterised by laser diffraction, field emission scanning electron microscopy (FESEM), X-ray fluorescence (XRF) and X-ray diffraction (XRD), and consistency and setting time tests were used to investigate the fresh behaviour of the ceramic waste/PC blended pastes. A basic sustainability analysis was performed, and the pozzolanic activity of RCB, TCW and CSW was assessed by compressive strength tests (performed in mortars cured at room temperature from 3 to 365 days) and microstructural analyses (thermogravimetry, XRD and FESEM performed in the pastes cured at 20 °C for 28 and 90 days). The pozzolanic reaction of these waste materials improved with curing time, and all the mortars prepared with up to 25 wt% RCB, TCW or CSW met the mechanical requirements set out for coal fly ashes, whatever the ceramic waste type used. Among them, these results open up the possibility of partially replacing PC with the closest available ceramic waste, which would reduce the CO2 emissions and economic cost deriving from transporting waste.

Mixed Alkali and Mixed Alkaline-Earth Effect in Ceramic Sanitaryware Bodies Incorporated with Blast Furnace Slag

Raw materials and energy are among the most important costs in ceramic sanitaryware production. With the decrease in raw material sources and increasing costs of energy in recent years, researches on alternative raw materials and energy have started to gain importance. In this study, blast furnace slag and spodumene were used to reduce both energy and raw material costs. In standard vitreous china ceramic sanitaryware, a maximum of 15% blast furnace slag and 4% spodumene was used instead of sodium feldspar. In this study, the effects of CaO, MgO, and Li2O on microstructure, technological properties such as flexure strength, water absorption, porosity, bulk density; and also, thermal properties such as sintering analysis were investigated by using a non-contact optical dilatometer and thermal expansion. The dry strength and flexure strength of fired samples increased. The increase in dry strength was approximately 47%. The increase in flexure strength was approximately 67%. The reduction in the thermal expansion coefficient values was approximately 17%, which is also important in terms of stability of the final product. As a result, the use of blast furnace slag and spodumene will result in a reduction in both energy and raw material costs. The spodumene and BFS provided a reduction in sintering temperature at a rate of approximately 60 °C. The flue gas emissions may also reduce because flue gas emissions are higher as the temperature inside the furnace is higher. The spodumene and blast furnace slag addition provide a decrease in the peak of sintering temperatures so that flue gas emissions will reduce.

Resin Mould for Ceramic Slip Rotary Moulding (CSRM) System

A type of porous resin was proposed to replace the existing plaster mould for Ceramic Slip Rotary Moulding (CSRM) system. The proposed resin is often used in high pressure casting of ceramic sanitary ware and table ware. The effect of resin mould in terms of mechanical strength (flexural properties), porosity percentage and percentage of water absorption as well as moulding process were recorded and compared with previous studies of plaster mould. Five (5) samples of porous resin were prepared according to ASTM 790 for flexural test and ASTM D570 for water absorption test. To determine the porosity percentage, mercury porosimeter test was conducted. The result shows that higher the water plaster ratio resultant in higher porosity percentage and water absorption. The result showed that, the proposed porous resin has great potential in replacing plaster mould as mould material for CSRM system. The mould has a uniform open pore to enable the filtration process to take place within the mould and the slip and has a great mechanical strength. However, porous resin is still a semi-permanent mould with definite service life.

Re-use of abandoned sanitary ware waste as abrasive particles for abrasive jet machine

In recent years, the growth in the machinery industries has emerged to produce the ceramic components which are non-bio degradable wastes. In this paper, the abrasive particles are produced through a rehash of ceramic sanitary ware wastes to machine the glass material in the abrasive jet machining process. Beforehand, computational fluid dynamics (CFD) analysis is performed on the nozzle to evaluate the flow velocity at the corresponding pressure distributions. It results that the velocity of 810 m/s is achieved at the outlet of the nozzle. The nozzle is designed based on the consequent results of flow analysis. Further, the sanitary ware wastes from washbasin urinals, sinks, bathtubs, toilets, etc are collected and renewed to the form of abrasive particles using sieving and segregation processes. The mixing chamber is fabricated and abrasive particles, dry air is made to mix in the mixing chamber. Then mixed particles are made to flow out to the working chamber through the outlet opening. The high jet velocity of the air and abrasive particle mixture has impinged through a convergent nozzle for machining the glass workpiece in the abrasive jet machining process. Moreover, the performance characteristics of abrasive particles in the abrasive jet machining process are evaluated.

Creation of a database of occupational and environmental concentrations of crystalline silica dust for the purpose of assessing past and current exposures.

«Creation of a database of occupational and environmental concentrations of crystalline silica dust for the purpose of assessing past and current exposures».Background:Professional exposure to respirable dust containing crystalline silica is of great interest for the serious lung diseases resulting from exposure.Methods:During the period 1986-2019, 3611 exposure data to crystalline silica were collected from companies in central Italy. The data were divided and statistically analyzed based on the sampling system (Cyclone Dorr Oliver, CIP 10-R, Cyclone GS3, SKC plastic selector, Cyclone Higgins-Dewell and Cyclone Lippmann) and the ATECO code (code of economic activity, Italian acronym, used to classify companies when they interface with public institutions) of the companies in which they were collected. For each ATECO code, the division was made according to the type of sampling (personal or static) and the descriptive statistics of the data were calculated.Results:Overall, for personal samples, 8.8% of the data exceeds 0.1 mg/m3, 19.6% exceeds 0.05 mg/m3 and 33.8% exceeds 0.025 mg/m3, the limit values set by the EU Directive 2019/130, suggested by the SCOEL and published by ACGIH respectively. The ATECO codes with the highest worker exposure (geometric means 0.067 and 0.069 mg/m3) were 23.31.00 (manufacture of ceramic tiles for floors and walls) and 23.42.00 (manufacture of ceramic sanitary ware), while the lowest exposure is found in 81.29.91 (cleaning and washing of public areas, removal of snow and ice including shedding of sand) with a geometric mean of 0.002 mg/m3.Discussion:Despite the general reduction over time, there are still many sectors in which data are higher than the current occupational exposure limits; especially in these sectors it is necessary to implement the measures to fully assess worker exposure.

Investigation of natural radioactivity and associated radiological hazards in ceramic sanitary ware products commercially sold in Turkey

ABSTRACT All ceramic products used in the construction of buildings contain natural radioisotopes at various rates. These radioisotopes are the main source of outdoor radiation to which people living in houses or workplaces are exposed. Therefore, it is important to determine the radioactivity levels in ceramic products used in buildings. In this study, the natural radioactivity levels (226Ra, 232Th and 40K) in forty ceramic sanitary ware products (17 closets and 23 sinks) of twelve different brands produced in Turkey were determined using a high-purity germanium detector (HPGe). In order to evaluate the radiological hazards originating from natural radionuclides of examined ceramic sanitary ware samples, radium equivalent activity (Raeq), gamma index (Iγ), external hazard index (Hex), absorbed dose rate (D), annual effective dose (AED) and excess life time cancer risk (ELCR) values were also calculated. The average activity concentrations of 226Ra, 232Th and 40K radionuclides in the investigated ceramic sanitary ware products were found as 35.47 ± 2.35, 48.80 ± 2.53, 230.44 ± 10.49 Bq/kg for closet samples and 34.64 ± 2.34, 51.25 ± 2.61, 256.23 ± 10.95 Bq/kg for sink samples, respectively. These values are less than the world average values (50, 50, 500 Bq/kg) except for the average 232Th concentration of sink samples. The average of radiological hazard parameters (Raeq, Iγ, Hex, D, AEDE and ELCR) calculated for all ceramic sanitary ware samples were found lower than the limit values recommended by international organisations.

Challenges in Performance Enhancement –Work Related Variables, Performance Link in Indian Manufacturing Sector

Producing of quality products at a reasonable cost mainly depends on the employees enhanced performance. Organizations keen in evaluating the factors most related to enhancement of performance. This study explores the link between the work related factors like work environment, organization commitment and training and development with performance of employees in ceramic sanitary ware factories in India. A sector which is unattended in the context of employee performance. It also verifies relative significance of the factors. Statistical tools were used for analysis. Findings reveal that all the three factors are positively linked to the performance enhancement and training and development is the strongest predictor and work environment is the weakest. Implications, suggestion for future research discussed.

Management of sanitary ware wastes as supplementary cementing materials in concretes

A large amount of ceramic sanitary ware wastes (SW) results from the production and after demolition processes. This study proposes the use of SW as supplementary cementing materials (SCM) in concrete to contribute with construction and demolition waste management. Experiments were carried out on concretes and pastes using different proportions of SW-replacement. Physical, mechanical, and durable behavior of concrete was evaluated and how concrete was affected by the cement hydration process. The incorporation of SW to Portland cement to make concrete reduces the permeability in the matrix and refines the capillary pores, improving the mechanical properties and the behavior in aggressive environments, such as chlorides. The results show that it is recommended the use of SW as SCM to produce concretes with mechanical properties and durability comparable to those of a conventional concrete, at 28 days.

Properties of flowable sand concrete containing ceramic wastes

This work studied the effect of recycling ceramic wastes, specifically tile ceramic waste and ceramic sanitary ware on the properties of flowable sand concrete (FSC). For this purpose, various volume fractions of sand (10%, 20%, 30%, 40%, 50%, and 60%) were substituted by the same volumes of ceramic waste aggregates. The properties in fresh state (Mini-slump flow, V-funnel flow, density, and air content) and hardened state (compressive and flexural strength, elastic modulus, water absorption, shrinkage, and fire resistance) of different FSC were studied. The results showed that the slump flow diameter decreased up to 100 and 120 mm and the flow time increased to 35 and 32 s for FSC with respectively 60% of tile ceramic waste or ceramic sanitary ware. However, the mechanical strengths of FSC are improved according to substitution of sand by ceramic wastes with an optimum of 60% and 50% respectively for ceramic tile waste and ceramic sanitary ware.

Evaluation of Production Costs Based on Reduction of Pyroplastic Deformation in Ceramic Sanitaryware Products

Seramik Saglik Gerecleri; inorganik-metalik olmayan hammaddelerin belirli oranlarda karistirilarak akiskan bir camur haline getirilmesi, daha sonra da alci ve/veya sentetik recine kaliplarda sekillendirilerek 1200-1250 o C civarinda pisirilip su emme degeri %0.5’in altinda olan urunlerdir. Kil, kaolen, kuvars, feldspat gibi inorganik hammaddeler temel yapiyi olusturur. Lavabo, ayak, klozet, rezervuar, bide, hela tasi, pisuar ve dus teknesi beyaz veya renkli olmak uzere urun yelpazesinin baslica urunleridir.[1] Bu calismada, K 2 O/Na 2 O arttirilarak SSG piroplastik deformasyonun dusurulmesi amaclanmistir. K-feldspat orani arttirarak yuksek sicaklik bunye viskozitesi uzerindeki etkisi arastirilmistir. XRD, su emme, mukavemet, pisme kuculmesi ve deformasyon analizleri yapilmistir. Artan potasyum-feldspat miktarina bagli olarak, yuksek sicaklik bunye viskozitesi yukselmekte ve deformasyona karsi direnc artmaktadir. Camsi faz miktarinin bunye deformasyonu uzerinde etkili olmadigi; ancak camsi faz kompozisyonunun onemli bir etki yarattigi belirlenmistir. Sisteme K-Feldspat ilavesinin, camsi fazda cozunen SiO 2 miktarini artirarak bunye viskozitesini yukselttigi gozlenmistir. Bunyede K-Feldspat miktari arttirilip sinterleme sicakligi dusurulmus; buna bagli olarak bunyenin deformasyon direnci artmistir. Bu degisiklerin uretim maliyeti uzerine etkisi degerlendirilmistir.

Effect of work life balance and supervisor support on employee retention in Ceramic manufacturing industries in India -An empirical evidence

Retention of talented employees has become a serious concern to organizations irrespective of their size and special attention being given to the factors motivating retention. Extant literature predicts that work life balance and supervisor support are the most relevant factors related to employee’s retention. This study examines the impact of above factors over employees of unattended ceramic sanitary ware factories in India. Statistical tools were used for analysis. Key findings reveals that work life balance and supervisor support are the factors having positive influence on retention and supervisor support gives more impact on retention. Implications to organization and suggestion for future research are also incorporated.