Production Of Ceramic Tiles Research Articles

Sulphur Dioxide Emissions during the Firing of Ceramic Bodies Based on Class C Fly Ash

Fluid fuel combustion technology in coal-fired power plants is very popular in the Czech Republic, resulting in a relatively high production of a specific by-product - fluidized fly ash (class C according to ASTM definition), which differs from the classical high-temperature fly ash in mineralogical composition with a high sulphur content of anhydrite CaSO4. Fluidized ash is not yet used in the production of fired building materials, where it could be used as a source of calcium oxide (for example, the production of porous ceramic tiles). However, high volume of sulphur dioxide emissions during the re-firing of fluidized fly ash in ceramic raw materials mixtures has been solved. The aim of the paper is definition of temperature ranges of anhydrite decomposition (formation of SO2 emission) from pure class C (fluidized) fly ashes from different sources (power plants) depending on granulometry of fly ash especially.

Development of engobe composition with the use of pharmaceutical glass waste for glazed ceramic granite

This paper reports results of research into the application of pharmaceutical glass waste, which is a mixture of medical ampoules, in the production of ceramic tiles. Disposal of such waste reduces the negative impact on the environment and contributes to saving mineral raw materials. At the same time, environmentally safe handling of ampoule forms of pharmaceutical glass waste at the disposal stage implies the removal of drugs’ residues from them. The appropriateness of using glass ampoules cleaned from drug residues as a fluxing component of engobe coatings for glazed ceramic granite is experimentally and theoretically substantiated. Comparative analysis of the charge composition of engobes of various manufacturers and of different chemical compositions of fluxing materials, which are components of these engobes, was carried out. The chemical composition of pharmaceutical glass waste was found to suggest the similarity of the basic properties of melts of these wastes and engobe glass frit. The paper considers the dependence of viscosity of the melts of engobe glass frits on the temperature. It was found that by the estimated values of viscosity of melts and experimentally determined characteristics of fusibility, glass waste can serve as substitutes for expensive engobe frits, when used with other traditional components of engobes. The chemical composition of the waste and of the basic engobe frit was determined by the method of X-ray spectrometry. Fusibility characteristics were explored using the thermoscope MISURA. Temperature coefficient of linear expansion of glass materials was determined with the use of the dilatometer LIL402PC. The research into the development of engobe coatings using pharmaceutical glass waste for the technology of glazed ceramic granite at firing temperature of 1185 °C was carried out. The rational charge composition of glazed engobe with a whiteness of 76 % was determined, which contains 30 % by weight of glass waste. The engobe tiles with water absorption of 0.3–0.4 % and the limit of flexural strength of 52–54 MPa were obtained

Identifying the Equilibrium Point between Sustainability Goals and Circular Economy Practices in an Industry 4.0 Manufacturing Context Using Eco-Design

For manufacturing companies, the transition to circular business models (CBMs) can be hampered both by the lack of relevant data and by operational tools. Eco-design, associated with Industry 4.0 IoT (Internet of Things) technologies, can be an effective methodological approach in developing products that are consistent with the principles of the circular economy. The reason is that, in the design phase, decisions are made that can significantly influence the degree of sustainability of products during their lifecycle. Therefore, in the manufacturing environment, eco-design represents an innovative approach to include sustainability among the traditional industrial variables such as functionality, aesthetics, quality, and profit. This study aimed to test eco-design as a tool to define the equilibrium point between sustainability and circular economy in the manufacturing environment of ceramic tile production, and to demonstrate how new business opportunities can be created through evolution from a linear to a circular business model, thanks to IoT and Industry 4.0 technologies used as enabling factors. The main result of this paper was the empirical validation in a manufacturing environment of sustainability paradigms through eco-design tools and digital technologies, proposing the circular business model as an operational tool to promote the competitiveness of enterprises.

Preparation and characterization of ceramic nanofiltration membrane prepared from hazardous industrial waste

AbstractKiln rollers, which are widely used in ceramic tiles production, are usually subjected to surface grinding to remove the contaminations. The resulted fine powder is considered useless waste and a hazardous source of environmental pollution particularly as it contains health‐threatening fine free silica. In the present paper, the grind waste from kiln rollers was reused as raw material in the fabrication of nanofiltration ceramic membrane. The samples of produced ceramic membranes were formed into disks by adding 15% (by weight) organic binder solution with 2% concentration, then pressed at 35 MPa, dried and fired at temperatures range from 1100°C to 1300°C for 1 hour soaking time. It was found that the best firing temperature to produce nanofiltration ceramic membrane is 1250°C, where the ceramic membrane provides high removal of turbidity and high monovalent, divalent, and trivalent salts separation percentage.

CFD Modelling of the Evaporation of Biphasic (Solid-Liquid) Individual Droplets in a Spray Dryer

An analysis of the literature shows the capability of Computational Fluid Dynamics to represent the hydrodynamics and heat transfer within spray dryers, as well as the prediction of droplet collision, agglomeration and wall deposition. The literature also reveals that no model published so far describes the drying of individual droplets, the study of which is restricted to experimental methods such as ultrasonic levitation. This article presents an Euler-Lagrange three-phase numerical set-up to simulate the drying of individual droplets within a spray dryer. The defining parameters of both phases, i.e. air and the biphasic (solid-liquid) droplets are taken from a barbotine slurry used for ceramic tile production. A single droplet size has been used—the characteristic Rosin-Rammler droplet size from the distribution generated by an actual spray injector published previously in the literature. The model predicts the theoretical linear evolution of the square diameter according to the D2-law, and the temperature and mass exchange with the environment. This unique numerical set-up allows calculating the Stokes number associated with a given trajectory path as well, providing designers with an accurate degree of control over the fate of individual droplets. The proposed model is therefore a powerful tool intended to support the design and optimization of industrial spray dryers.

The LCA Methodology for Ceramic Tiles Production by Addition of MSWI BA

Integrated waste management and sustainable use of natural resources are the basis of the Green Economy. In this context, the management of the Municipal Solid Waste Incineration Bottom Ashes (MSWI BA) is one of the current issues worldwide. This paper presents an application of the Life Cycle Assessment (LCA) procedure to the industrial production of ceramic tiles using bottom ashes in the mixture together with feldspathic sands and clays. The comparison between ashes and traditional mixture showed a similar mineralogical and rheological composition. In the reported procedure the MSWI BA, after storage, were treated to separate and recover metals. The residual ashes were added to the mixture and then they followed the traditional industrial production cycle. Samples of the different materials were taken during the experimental industrial activity and leaching tests were carried out to verify the environmental compatibility of MSWI BA use to produce ceramic tiles. The results of the LCA show large environmental and energy benefits related to the proposed reuse of BA. Metal recovery and lower use of clay in traditional mixture avoids emission of substances with a negative potential impact for environment. This study provides a sustainable alternative to the MSWI BA final disposal in landfill as MSWI BA are hazardous wastes that present complicated management and high disposal costs.

DEVELOPMENT AND EVALUATION OF CERAMIC TILES USING WASTES AND SOLID MINERALS

This paper focuses on the need for domesticating the production of building materials like tiles to address the problem of Nigeria over dependence on imported goods, despite adequate availability of mineral resources like clay, quartz and feldspar in the country. Clay, quartz and feldspar, and milled glass were respectively obtained from Ogijo in Ogun State, Okpila in Edo State and Oshodi, Lagos State of Nigeria were characterized using ASTM C71 as a guide. Samples of the ceramic tile were produced from varying mixtures of clay, quartz, feldspar and milled glass. The chemical and physio mechanical properties of the samples were also determined. The results showed that the clay sample belong to Alumino-silicate group with 59.20% silica and 21.25% alumina. The samples’ properties met the required standards; hence, the materials were found suitable for production of ceramic tiles of acceptable standards. Though, the porosity of the sample tiles increased as thepercentage weight of the clay material in the mixture decreased the proportion of quartz, feldspar and milled glass increased. The sample containing 70% Clay and 30% Feldspar had better formulation properties than others.

Probabilistic Analysis of a Ceramic Tile Production System Considering Various Redundant Subsystems and Inspection

The present paper gives analysis of a stochastic model for a ceramic tile production system considering its five main subsystems viz. Ball Mill, Spray Dryer, Hydraulic Press, Glaze Line and Kiln and a storage system, Silo. It was considered that the failure of Ball Mill and Spray Dryer subsystems depends upon Silo while failure of other subsystems are independent of Silo. Also the storage in Silo is consumed during the repair/replacement of the failed subsystems then the system goes to failure otherwise it is operative. During the occurrence of failure in subsystems Hydraulic Press, Glaze Line and Kiln, leads to the failure in other subsequent subsystem and the repairman first inspects in which redundant unit of the subsystem has a fault and then accordingly repair/replacement is carried out. The system has been analysed using Markov process and regenerative point techniques. Various conclusions for the system regarding its reliability and availability are drawn by plotting several graphs for a particular case.

Assessment of the use potential of iron ore tailings in the manufacture of ceramic tiles: From tailings-dams to “brown porcelain”

Abstract Nearly half of the total iron ore volume extracted in mining operations is rejected as tailings and disposed of in containment dams that are liable for considerable environmental impact and human hazard in case of breaching. This work aims to expand the usage possibilities of iron ore tailings and help mitigate the negative impact of tailings-dams without sacrificing the opportunities provided by mining. Materials were collected from four tailings-dams, subjected to a dry separation procedure and characterized (particle size and morphology, chemical and mineralogical composition). Besides the recovered iron ore concentrate, two other powder fractions were produced (“clay” and “sand” fractions). The sands showed the greatest uniformity (particle size and shape, mineralogy and chemical composition) and may find use as aggregates in a variety of applications. This work shows that the clays can be used on their own in the production of ceramic tiles. They present adequate plasticity and dry strength, and develop mullite and glass upon firing, showing a rather amenable processing behaviour suitable for both artisanal and full-fledged industrial production. The resulting tiles are dimensionally homogeneous and very compact (vitrified products, classified in groups BIa, BIb or BIIa), with high mechanical strength. Either industrialised or artisanal, these materials can be used in the production of “brown porcelain” tiles and ware, showing a very appealing dark brown lustre.

Building a Sustainability Benchmarking Framework of Ceramic Tiles Based on Life Cycle Sustainability Assessment (LCSA)

The purpose of this paper is to determine indices of environmental, economic and social sustainability related to the Italian production of ceramic tiles in porcelain stoneware in order to contribute to the construction of a reference benchmarking useful to decision makers, designers and end users of ceramic tiles. To achieve this goal, this paper is based on the Life Cycle Sustainability Assessment (LCSA) framework that incorporates the three dimensions of sustainability with cradle-to-grave Life Cycle Assessment (LCA), Life Cycle Costing (LCC) and Social Life Cycle Assessment (S-LCA) tools. The study has shown that in the production of porcelain stoneware one of the major environmental problems, in addition to production in the strict sense, is the distribution system of the product to end users and, to a lesser extent but always significant, the process of supplying raw materials. Finally, it was highlighted that the joint use of the three impact assessment tools (LCA, LCC, S-LCA) requires further methodological work to avoid the risk of double counting of sustainability performance. This research has adopted a detailed methodological approach, both in the collection and in the processing of data, keeping the main phases of the production process separate. In this way, it has been possible to highlight that the major environmental criticalities are just beyond the “gate” of the ceramic factories, along the logistics chain. The study also proposes for the Italian ceramic sector not only indicators of environmental sustainability but also economic and social.

Preparation of pharmaceutical glass waste for recycling in the production of ceramic tiles

Preparation of pharmaceutical glass waste for recycling in the production of ceramic tiles

Objective criterion for evaluation of the quality decoration in ceramic floor tile production prior to the sintering process

Abstract In the ceramic tile decoration process, the set of variables that can cause hue variation is quite wide and independent of the methodology used in the production. The understanding of the effects of these variables over the final expected result is of great importance to the producers, especially if it could be done before the ceramic tile’s sintering stage. The quality of the decoration is linked to the deposited dot shape and its filling with ink. It is proposed in this paper the determination of a ‘quality index’, comparing the theoretical deposition pattern and a real deposition obtained with samples. Measuring the values of the areas with and without ink, using the statistical tool of the ROC curve, it was obtained the values for sensibility=0.791, specificity=0.830, precision=0.802 and quality index=0.768. The method is intended to be used prior to the sintering step for hue variation control.

SUITABILITY OF FELDSPAR-SAND DEPOSITS AS RAW MATERIALS FOR THE PRODUCTION OF CERAMIC TILES AT WADI EL-YATIMA – WADI EL-TULEIA DISTRICT, CENTRAL EASTERN DESERT, EGYPT

The function of feldspar in ceramic bodies is that of a flux and it takes a part in physio-chemical reactions with other crystalline phases. Two formulations were studied on laboratory scale and on production simulation of tile making process, compared with standard one. The tiles made up of feldspar-sand as raw materials and fired between 1125°C (wall tile) and 1185°C (floor tiles). The properties of wall tiles were found to have the water absorption are of 13.43 - 16.25%, bulk density are of 1.65-1.68 g/cm3, apparent porosity are of 22.24-26.82%, linear shrinkage are of 0.01-0.06%, bending strength are of 18.45-23.08 kg/cm2 and loss on ignition are of 3.6-6.0% for wall tiles. Meanwhile, the results of floor tiles were found that the water absorption are of 0.88 - 6.76%, bulk density are of 1.67-1.69 g/cm3, apparent porosity are of 5.11-15.17%, linear shrinkage are of 5.24-6.8%, bending strength are of 22.7-39 kg/cm2 and loss on ignition are of 3.6-6.0%. Among the studied compositions and firing temperatures, tiles (wall & floor) made from a blend containing 29% (wall)-45% (floor) feldspar and 10% (wall) quartz, calcium carbonate 7% (wall), Aswan clay 54% (wall), ball clay 50 % (floor) and talc 5% (floor); and fired at 1125°C (wall) to 1185°C (floor), were found to have the best properties for the production of ceramic tiles. This is an indication that Wadi El-Yatima – Wadi El-Tuleia feldspar-sand deposit is suitable raw materials for the production of ceramic tiles.

Numerical and experimental characterization of the hydrodynamics and drying kinetics of a barbotine slurry spray

Spray drying is a basic unit operation in several process industries such as food, pharmaceutical, ceramic, and others. In this work, a Eulerian-Lagrangian three-phase simulation is presented to study the drying process of barbotine slurry droplets for the production of ceramic tiles. To this end, the simulated velocity field produced by a spray nozzle located at the Institute of Ceramic Technology in Castelló (Spain) is benchmarked against measurements obtained by means of laser Doppler anemometry in order to validate the numerical model. Also, the droplet size distribution generated by the nozzle is obtained at operating conditions by means of laser diffraction and the data obtained are compared qualitatively to those found in the literature. The characteristic Rosin-Rammler droplet size from the distribution is introduced thereafter in the three-phase simulation to analyse the drying kinetics of individual droplets. The model predicts the theoretical linear evolution of the square diameter (D2-law), and the temperature and mass exchange with the environment. The proposed model is intended to support the design and optimization of industrial spray dryers.

Lifecycle-oriented design of ceramic tiles in sustainable supply chains (SSCs)

Purpose The purpose of this paper is to analyse the production cycle of glazed porcelain stoneware, from the extraction of raw materials to the packaging of the finished product, with the aim of verifying the effects of integrating an environmental impact assessment into the decision-making process for managing the life cycle, to make it economically and ecologically sustainable, in a holistic approach along the supply-chain. Design/methodology/approach The research is performed using the life cycle assessment and life cycle costing methodologies, to identify environmental impacts and costs, that occur during extraction of raw materials, transportation, ceramic tiles production, material handling, distribution and end-of-life stages within a cradle to grave perspective. Findings Through the use of a comprehensive analysis of the environmental impact assessment and related externalities, three possible strategic options to improve the environmental performance and costs of ceramic tile production were formulated, leveraging sustainability as a competitive advantage. Research limitations/implications This exploratory research opens future lines of investigation, the first of which is to confirm the technological feasibility and market responsiveness to the three strategic solutions hypothesised thanks to the use of an innovative eco-design technique. Originality/value The research has allowed testing and validating the tools of environmental impact assessment (life cycle assessment) and economic impact assessment (life cycle costing as structured methodologies in a life cycle management framework, to help companies implement competitive strategies based on sustainability.

Dimensional deviation measurement of ceramic tiles according to ISO 10545-2 using the machine vision

In this paper, machine vision method is used for dimensional deviation measurement of ceramic tiles according to the International Standard Organization (ISO) 10545-2. Generally, in the ceramic tile production lines, the quality control is conducted by operators, that is, a tedious, erroneous, and time-consuming work. In this study, a stereo vision scanner was established which is not based on the judgment of human operators. Firstly, only a pair of images with two cameras of stereo vision system was taken. Then, the images were transferred to the computer and running the image-processing operations. Finally, the dimensional deviation measurement of all desired ISO parameters including the straightness of sides, rectangularity, side curvature, center curvature, and warpage was done simultaneously. The experimental results showed that the machine vision technique can be used for dimensional measurements of ceramic tiles more accurately than the desired accuracy determined by ISO 10545-2.

Attaining Natural Stone Appearance via Colored and Self-glazed Ceramics Stoneware Applied to Ceramics Tiles

There is a clear common lack of external architecture for its aesthetic appearance, and the design of the ceramic roof and the techniques applied to it are considered aesthetic input and value added to the design of ceramic surfaces in the external architecture. Also, exploiting new forming methods to produce self-glazed stone ceramic objects can be produced industrially. Likewise, the lack of a study linking the appearance of porcelain and natural stones.The research aims to legalize the relationship between stone porcelain fixtures and the aesthetic appearance of natural stones so that we reach the appearance of natural stones, which has become common in most ceramic tile products, and the link between it and stone porcelain techniques such as body coloring and self-vitrification to reach a scientific classification suitable for this relationship.The importance of the research lies in the fact that the appearance of natural stones is one of the sources of inspiration for designers in the manufacture of ceramic tiles. In the range of different shades.The research included many techniques such as the use of colored stone ceramic objects and mixing between colors, the use of the technique of glazed objects, to combine the glossy and matte surface, and the exploitation of different granular sizes to obtain the appearance of some natural stones.

Assessment on the Characterization of Mineralogical Phase of Ceramic Tiles Available in Kathmandu Valley (Nepal) Using XRD and FTIR Analyses

The mineralogical phase of eight different types of contemporary and historical ceramic tile samples used in Kathmandu valley of Nepal was analyzed using their X-ray diffraction (XRD) patterns and Fourier transform infrared (FTIR) spectra to assess their quality. Mineralogical phases existed in these eight different tile samples, i. e., three wall, three floor and two ancient tile sample specimens, used in this study are identified as quartz, feldspars, spinel, mullite and hematite including paragonite with the help of the corresponding Joint Committee for Powder Diffraction Standards (JCPDS) database files. The firing temperature applied during the time of these ceramic tiles production should be 1000° C or slightly more. The mineralogical compositions of the contemporary tile samples are found to be comparable with those of the ancient brick samples of the historical temples and monuments of Kathmandu valley of Nepal.Int. J. Appl. Sci. Biotechnol. Vol 6(3): 238-243

The use of secondary resource potential of pharmaceutical waste from glass in the pr duction of ceramic tiles

The article describes ecological aspects of pharmaceutical glass wastes. It is determined that the greatest negative impact on the environment components has wastes containing pharmaceutical residue. It was analyzed that pharmaceutical glass wastes mainly consist of used ampoules (UAs).The ecological necessity of taking away and disposing residues of pharmaceutical substances from UAs by their disposal is determined. The resource possibilities of using UAs as the secondary material in production of ceramic tiles is analyzed. Monitoring of the formation and accumulation of a mixture of ampoules in the therapeutic hospital department was carried out. The mixture consisted of ampoules containing remnants of solutions of various pharmaceuticals. To substantiate the ecological practicability and resource valuation of waste used in the process of ceramic tile production, the chemical composition and physicochemical characteristics of the mixture of UAs were experimentally determined. The chemical composition and physical and chemical characteristics of wastes are experimentally determined to justify ecological expediency and waste recoverability of UAs during ceramic tiles production. The experimentally determined values of the characteristic temperature parameters and the temperature coefficient of linear expansion of the ampoule glass mixture confirm this conclusion.

Addition of cement kiln dust in ceramic wall tile bodies

The volume of wastes generated from heavy industries, such as cement and steel industries, is increasing, and the cost of landfill disposal grows daily. Economical and eco-friendly areas of recycle are being developed to stop the growth of these waste products. Cement kiln dust (CKD) is a waste product in the cement industry. It contains very fine grains like cement in addition to finer particles of lime, silica, alumina and iron. These particles contain high concentrations of sulphates and alkalis. The aim was to study the effects of using CKD as an alternative source of CaO in ceramic wall tile production. Ceramic tiles compositions in different ratios were prepared with CKD (15 mass% max) rather than calcite. All shaped samples were sintered at 1150 °C. Optical dilatometer was used to evaluate sintering behaviour. Physical properties, such as linear firing shrinkage, bulk density, flexural strength and water absorption, were also measured. The bodies containing CKD showed a decrease in moisture expansion and were whiter than the body of a standard composition. This study showed that CKD is an effective CaO source in ceramic tile production.