Production Of Ceramic Tiles Research Articles

PROSPECTS FOR THE INTEGRATION OF QUARTZ-FELDSPAR CONCENTRATE OBTAINED FROM KAOLIN ENRICHMENT INTO CERAMIC PRODUCTION PROCESSES

ABSTRACT. The paper examin es the potential use of quartz feldspar concentrate obtained as a result of kaolin enrichment to meet the growing demand for quartz feldspar materials, which are essential components in the production of ceramic tiles, sanitary ceramics and other products. The research methodology includes laboratory tests of the chemical composition of kaolin enrichment waste and analysis of the possibility for obtaining marketa ble quartz feldspar concentrates using flotation and electrostatic separation methods. The result s showed that high quality concentrates (possessing the necessary physical and chemical properties) that are suitable for ceramic production can be obtained by flotation of such waste. The use of such waste contributes to reducing waste volumes and ensuring a stable supply of raw materials for the ceramics industry.

Shortening of fast firing in the ceramic tile production by inorganic additives - an upscale to the industry

The paper discusses the usage of additives that are protected by the European patent to enhance the features of ceramic tiles. Under laboratory conditions, various types of additives in different concentrations (0.15, 0.30 and 0.50%) were added to the ceramic mass, and changes in shrinkage, modulus of rupture and water absorption were observed. After selecting the appropriate additive and its concentration, a series of industrial tests is performed. The characteristics of regular ceramic mass and mass with the selected additive were monitored without adjusting process parameters in the industrial conditions. Furthermore, utilizing additives allowed for shortening of the fire time without distorting the characteristics of the final products. The application of additives in industrial settings has demonstrated that floor tiles can be produced with improved characteristics and increased production capacity by 6.8%. Thus, significant energy savings and a lowered CO2 footprint can be provided.

Characterization and Suitability Assessment of Ameskroud Clay Deposits for Ceramic Applications

The identification of natural clay deposit parameters is critical for the development of ceramics. This research underscores the essential role of understanding clay properties in producing high‐quality ceramics and represents a comprehensive characterization methodology, shedding light on the untapped potential of natural clay deposits for ceramic applications. This study investigates red clays from the Triassic, as well as yellow and gray clays from the Cretaceous period, collected from the western High Atlas of Morocco (Ameskroud). The characterization of clays from this geographic region is innovative, as they have not been previously investigated for their suitability within ceramic applications. The investigation encompasses an examination of the geological context, mineralogy, chemical composition, and physicochemical attributes of these clays. Furthermore, the thermal behavior, firing characteristics, and compressive strength of the clay samples were assessed when fired at 900°C, 1000°C, and 1100°C. Mineralogical analysis reveals that illite predominates with relatively low levels of kaolinite and chlorite. The primary chemical constituent is SiO2, followed by Al2O3 and Fe2O3. Notably, yellow clay exhibits a significant CaO content exceeding 10%. At 1100°C, the clay specimens exhibit reduced water absorption rates (ranging from 9.88% to 17.1%) and enhanced mechanical performance, with compressive strengths ranging from 22.33 MPa to 36.07 MPa, attributable to the sintering process. The findings affirm that the raw clays sourced from the Ameskroud region possess characteristics suitable for various ceramic applications, making them ideal candidates for the production of dense bricks and ceramic tiles.

Using glass wastes and bentonite to produce a new ceramic tile

Abstract This paper discusses the recycling of glass waste as a compound in the production of ceramic tiles. The present study aims to investigate the effects of glass waste (with two different granulometries) on the physical and mechanical properties of ceramic tiles, in order to demonstrate their suitability for the production of ceramic materials. A series of ceramic tiles was prepared based on bentonite (B) by adding 70, 65, and 60 wt% glass wastes (GW1 and GW2 with two different granulometries) into the batch composition. The ceramic tiles were sintered at a constant temperature of 900 °C following the same production protocol. The physical-mechanical properties and chemical durability of all ceramic tiles produced were evaluated. The results show that ceramic tiles can be produced from a basic mixture of 35% bentonite and 65% glass waste, with good physical, mechanical, and thermal properties (the local Algerian bentonite is considered a clay binder and has excellent plasticity).

Valorization of natural stone sawing waste as a functional additive in ceramic tile production

Valorization of natural stone sawing waste as a functional additive in ceramic tile production

Pumice and lapillus scraps: New national environmental-friendly chance for the production of ceramic tiles

Italian pumice and volcanic lapillus scraps have been used in different percentages as alternative raw materials to foreign feldspars in porcelain stoneware mixtures. The aim of this work was to create naturally colored support to limit the use of artificial dyes while maintaining the technical properties of the reference product. For this purpose, the significant presence of chromophores (Fe and Ti in particular) in by-products from extraction of Italian volcanic pumice and lapillus was exploited. The work was carried out in collaboration with a company: the products were made on a laboratory scale and then they were glazed and fired within the industrial production cycle (48 min, 1210 °C).The resulting slip and the fired samples were characterized by measuring the efflux time, density, linear shrinkage, water absorption and tensile strength to evaluate the technological performance. In addition, thermogravimetric analysis (TG), differential thermal analysis (DTA), and optical and mechanical dilatometry were performed to study the thermal behavior of the formulations.The obtained products could be classified as porcelain stoneware and belong to the BIa group (WA 0.5%, B.S.>35 MPa) in accordance with UNI EN 14411 ISO 13006.

Recycling insight into the ceramic tile manufacturing industry

The ceramic tile industry is one of the most important industrial sectors in Italy, with almost 90% of the whole production located in the Emilia-Romagna region. In this paper, the waste management and recycling practices in force among Italian ceramic tile manufacturers are reported and discussed on the basis of performance indicators determined thanks to the elaboration of a large amount of industrial data collected in the period 2013–2020. In particular, parameters such as annual water consumption (Cw) and demand (Dw), recycling factor of solid waste (Rsw) and water (Rw) and different kinds of waste generated in the process have been monitored for three different production layouts. Such indicators exhibit that recycling is a well-established practice in Italian ceramic tile production and only a minor amount of hazardous waste (exhausted lime) is land-filled.

Optimal Tunnel Dryer Operating Strategies for the Production of Ceramic Roof Tiles under Tight Quality Considerations

Optimal Tunnel Dryer Operating Strategies for the Production of Ceramic Roof Tiles under Tight Quality Considerations

Structural and Mechanical Properties of Non-Glazed Ceramic Tiles Developed from Selected Mineral Deposits in Uganda

Uganda is well endowed with clay resources; however, comprehensive knowledge about the composition, structure and suitability of these clays for ceramic tile production is lacking. In this study, we provide a comprehensive characterisation of locally sourced clays in Uganda and their suitability for ceramic tile production. In the study, we developed ceramic tiles using feldspar, kaolin, ball clay and sand from four different sites in Uganda. We focused on analysing the surface morphology, crystallographic structure and mineralogical composition of the raw materials. In addition, we examined the mechanical properties of the developed tiles with the different mixture ratios of the clay types. The surface morphology of the raw materials was analysed by using a scanning electron microscope. The structural analysis of the raw clay materials was done using X-ray diffraction. The mineralogical composition of the raw materials was investigated using energy dispersive X-ray spectroscopy and X-ray fluorescence spectroscopy. The results indicated that the strength and rapture modulus are influenced by the composition of kaolin and feldspar. We concluded that the selected mineral deposits can be used in the production of ceramic tiles in Uganda.

Studying the use of thermomechanical treated sugarcane bagasse as partial replacement of quartz and feldspar in ceramic tiles production

AbstractSugarcane bagasse ash (SCBA) is an industrial waste that consists of silicon oxides, calcium, aluminum, iron, magnesium, and alkali metal oxides. The composition and structure of thermomechanical treated SCBA was analyzed by X‐ray fluorescence (XRF), Scanning Electron Microscopy (SEM) and X‐Ray diffraction (XRD). Thermomechanical treated SCBA was mixed with clay, quartz and feldspar at different compositions according to an appropriate mixing ratio and using this mixture for the production of dry pressed ceramic tiles. The physic mechanical properties (surface quality, water absorption, modulus of rupture, linear thermal expansion and frost resistance) of the ceramic tiles were test according to ISO 13006:2018 and ISO 10545 standards. The results demonstrated that test ceramic have characteristics adequate for its use as ceramic tiles classified as BIII.

A novel dry granule preparation technology and comparison of granule properties with conventional wet system for ceramic tiles production

The ceramic tile manufacturing process uses a lot of energy, mainly thermal energy, and to a lesser extent electric energy. Total energy costs account for between 50% and 55% of average direct manufacturing costs. Fossil fuel combustion, such as natural gas combustion, produces carbon dioxide emission. Therefore, energy consumption and emissions issues are vitally important for both environmental effects and process costs in ceramic tile manufacturing. The wet process of granule production systems including wet grinding and spray drying is widely used for the production of granules. Although there is high energy consumption for the water evaporation in the spray dryer, it ensures to produce high quality tile for many years. In this study, important granule properties were introduced for a novel dry granule production system. In the successful application of a dry granulation system, the conformity of produced granules is vitally important such as particle size distribution, bulk density, flow properties, and moisture of granules and conformity for the pressing process. This paper includes the comparative studies for properties of granules produced in spray dryer and new dry granule preparation systems and the full results of the industrial trials with these granules. The cost comparison of both granule production systems was also made for the same raw material usage. The natural gas consumption and water consumption were reduced respectively from 46 to 15 m3/ton and from 540 to 95 liters/ton in the new dry granulation system while electricity consumption and maintenance costs remain almost the same in both systems.

Partial replacement of aggregate with ceramic tile in concrete

The construction industry continues to make advances in innovation and improvement, which has led to a substantial increase in the usage of natural aggregates in construction projects. Concurrently, though, the amount of solid trash generated by the demolition of structures has reached an all-time high. This is a never-before-seen phenomenon. Reusing demolished building materials such as ceramic tile and granite powder has been proposed as a way to reduce solid waste and mitigate the shortage of natural aggregates necessary to manufacture concrete as a result of these causes. This was done to reduce the amount of solid waste and the amount of solid garbage. In addition to building demolition, the manufacturing facility also contributes to the production of waste ceramic tile. Several studies indicate that between 20 and 30 percent of the raw materials handled in tile production facilities are lost as waste. This waste material should be forced to be recycled so that we may use the limited natural aggregate resource more efficiently and reduce the amount of waste generated by the construction industry. In lieu of coarse and fine aggregates, numerous types of waste ceramic tile are used, including crushed waste ceramic tile, powder made from crushed waste ceramic tile, and other waste ceramic tile. To the extent of 35 %, coarse aggregates were partially substituted with ceramic waste-based tiles. These tiles were included into the production of aggregates. In place of fine aggregate, 25 %, 30 %, and 35 % of ceramic tile powder and ceramic coarse tile were utilised, accordingly.

Using volcanic tuff wastes instead of feldspar in ceramic tile production

Using volcanic tuff wastes instead of feldspar in ceramic tile production

Evaluation of the possibility of improving the durability of tools made of X153CrMoV12 steel used in the extrusion of a clay band in ceramic roof tile production

Abstract The article presents the results of a complex comparative analysis of the abrasive wear resistance of tools made of X153CrMoV12 steel after different heat treatment variants. These investigations aimed to select the most durable material for application in tools forming a mass band in the production of ceramic roof tiles. The tests included the determination of resistance to abrasive wear in ball-on-disc tests, hardness measurements, and microstructure analysis, including the assessment of changes occurring in the subsurface area, as well as impact tests (at a working temperature for the tools of 50°C). The comprehensive test results showed that the best effects of increasing the resistance to abrasive wear can be obtained through a heat treatment that consists of hardening at 1020°C and then tempering at 200°C for about 2 hours. The next stage of research will be to compare the results obtained with another popular material for tools for the production of roof tiles - Hardox steel, which is characterized by high resistance to abrasive wear.

Evaluation of Linamon Red Clay, Salvador Black Cinder and Kapatagan Diatomaceous Earth of the Southern Philippines

The southern island of the Philippines is abundant in silicate minerals, including the province of Lanao del Norte. However, some of these resources in the region are untapped for use as raw materials in the production of various ceramic products for industrial, pharmaceutical, and nanotechnology applications. These could include tiles, sanitary ware, dinnerware, insulating bricks, porcelain, membranes and coatings. Some of the explored minerals are the red clay in the municipality of Linamon, diatomaceous earth in Kapatagan and black cinder in Salvador. It is the aim of this study that these minerals are evaluated in terms of their physical and chemical properties so that these will be used for optimum application. The properties that were determined were their specific gravities, raw and fired surface colors, Atterberg limits, particle size distribution, thermal properties, morphologies and mineralogical compositions. Pellets were formed for each raw material and fired at two temperature levels 1000 °C and 1200 °C to evaluate their physical properties. Linamon red clay has a 38.88% cumulative passing size of 150 µm, and the black cinder of Salvador and diatomaceous earth of Kapatagan have cumulative passing sizes of 96.53% and 60.12% at 150-micron sieve, respectively. The common mineral contents of the three samples are montmorillonite, quartz and andesine. Black cinder fired at 1200 °C has the darkest shade of red with a greasy quasi-submetallic luster. It attained the highest fusion coverage on the platform among the three materials, which makes it a potential supplement or replacement for feldspar in clay-based triaxial materials for ceramic production. The diatomaceous earth has the potential to be a secondary clay content source and a good source of flux for a certain temperature range. Both the red clay and diatomaceous earth were classified as plastic materials that are suitable for brick production, and the red clay is also feasible for pottery production. These are a few of the features of the clay minerals in the region that present suitable properties for application as raw materials in the production of ceramic tiles and hollow ceramic products.

Life cycle assessment in the ceramic tile industry: a review

This paper presents a comprehensive review of existing literature on the life cycle analysis (LCA) of ceramic tiles. By critically evaluating these studies, the paper aims to provide insights into controlling the factors that contribute to a more sustainable production of ceramic tiles. The study identifies the relationships between variables that impact the shaping process, and highlights the priority areas that require intervention for reducing the environmental impact of ceramic tile production. The results of the LCA analysis emphasize the significance of the manufacturing process and the dependence on non-renewable sources of fuels in the ceramic tile industry. This paper provides a hierarchical framework of the variables that have the most significant impact and offers a guide for reducing the environmental footprint of ceramic tile production.

Proposition for analysis of elastic deformation in ceramic tiles using multilevel factorial design

The production of ceramic tiles requires specific technical properties to allow a wide application, including covering floors and walls, building furniture, and decorative items. Current methods of measuring the dimensions of large ceramic tiles seem inadequate for products that exhibit elastic deformation due to their weight affecting the accuracy and precision of measurements. This paper aims to analyze the influence of format, thickness, and typology variables on the elastic deformation of ceramic tiles. Additionally, this study provides an analysis about which products can be measured by the traditional measurement system without compromising the quality of the results. Tests to determine warpage under different support conditions were performed using a laser-equipped coordinate measuring machine. This technology provided typology, thickness and size, and elastic deformation outcomes. In addition, a multilevel factorial design was carried out using analysis of variance (ANOVA) to investigate the influence of the selected variables. The results suggest that all the studied variables affect the elastic deformation due to the weight of ceramic tiles. The effect of interactions between predictor variables is significant mainly for the largest tiles sizes. The results also show that the current measurement method is indicated for tiles smaller than 30 × 30 cm. Further studies will be conducted to develop a new compatible and reliable method to determine the dimensional characteristics of larger ceramic tiles.

백제 사비기 왕궁과 사원의 기와 수급 방식과 와공의 동향

The purpose of this study is to shed light on the differences in the production and distribution of ceramic roof tiles used in the construction of the royal palaces and Buddhist temples of Baekje in the Sabi period (538-660) and the changes that occurred in the activities of the tile makers.The discussion in Chapter 2 is focused on the differing ways in which ceramic roof tiles were used in the construction of royal palaces and temples during the Sabi Baekje period. The convex roof-end tiles excavated at the sites of Baekje’s royal palaces, including those at Busosanseong Fortress, Archaeological Site in Gwanbuk-ri, Gua-ri and Ssangbuk-ri Buyeo, shared similar decorative motifs such as circular and triangular dots and waves for a long period of time. Conversely, the convex roof-end tiles discovered at temple sites dating back to the Sabi Baekje period, such as Temple Sites in Neungsa-ri and Gunsu-ri, and Wangheungsa Temple Sie in Buyeo, and Jeseoksa and Mireuksa Temples in Iksan, show that more than two new motifs were introduced at that time. The difference can be explained by the fact that new buildings continued to be added to the royal palaces, making necessary stricter management and control of the tile manufacturing facilities and equipment.In Chapter 3, the discussion deals with the ways in which roof tiles were produced and distributed for the construction of royal palaces and temples and the tendencies of tile makers. The roof tiles of new Buddhist temples built during the Sabi period were supplied by both state-run kilns and private kilns specializing in the production of roof tiles for Buddhist temples. The construction of palace buildings in the Sabi period led to continuous growth inthe size and number of tile kilns, as can be seen in the kiln sites at Geumdeok-ri, Jeongam-ri, Jeongdong-ri, Wangjin-ri and Hyeonbuk-ri. The discoveries made at the Yeondong-ri kiln site in Iksan suggest that the tile makers hired by the government-run workshops in Buyeo produced the roof tiles required for construction projects in the Iksan area. The excavation of the Wangheungsa Temple kiln site has revealed that the operator of the kiln organized temporary teams of tile makers from among workers at other kilns, suggesting a turning point in the history of tile production in Baekje. Analysis of the archaeological features has also revealed that the tile kilns of Wangjin-ri, Gwanhyeon- ri and Bonui-ri in Cheongyang were created by tile makers who had previously worked at the larger, government-financed kilns in Jangam-ri and Geumdeok-ri in Seocheon. The appearance of the convex roof-end tiles discovered at the kiln sites in Sinsan-ri of Seosan, Bunhyang-ri of Cheongyang, Sudeoksa Temple in Yesan, and Cheonho-ri of Nonsan suggests that they were produced by tile makers sent from the government-run kilns in the capital of Baekje for short-term local projects. Such changes in Baekje’s tile production system resulted from the effort to meet the need for a new system to ensure the mass production of roof tiles, effectively meeting the rapidly growing demand related with the construction of the fortified capital of Sabi in the late sixth century.

Use of Post-Flotation Solidified Tailings from Copper Production for Ceramic Tile Production

The development of the mining industry has resulted in the accumulation of large amounts of waste, which effectively degrades the environment. The aim of this study is to check whether the addition of post-flotation sludge from copper production to the typical ceramic mass of the "gress porcelanato" will allow to obtain qualified sintered or faience tiles. By adding successive amounts of post-flotation sludge to the high-quality lamellar mass, typical parameters such as firing shrinkage, water absorbability and bending strength after firing were assessed. The structure of the obtained ceramic materials, using scanning electron microscopy (SEM with EDS), was also determined. Obtaining positive results would allow not only to significantly reduce the production costs of ceramic tiles, because the sludge is finely divided and no grinding is necessary, but, above all, will allow to eliminate the environmental risk. The present study has shown that it is possible to introduce up to 20% post-flotation sludge for gres porcellanato tile production and up to 50% post-flotation slugde for faience tile production. Both types of ceramic materials with an appropriate proportion of sludge, meet the requirements of tile standards in terms of mechanical strength and water absorption.

Assessing white clays from Tabarka (Tunisia) in the production of porcelain stoneware tiles

In recent times, there has been an increasing demand for white-firing clay materials in ceramic tile production, due to a progressive shift towards porcelain stoneware bodies. Furthermore, the recent geopolitics events have challenging the industries possibilities to satisfy their clay demand for porcelain stoneware production by well-established commercial channels. In this framework, there is a need to expand the reserves of ball clays, especially in Mediterranean countries, which have a low frequency of clay deposits suitable for the production of porcelain stoneware. For this purpose, the Tabarka clays in Northern-West of Tunisia have been studied. They have already been investigated in the literature for the production of various types of ceramic tiles (but not porcelain stoneware). The technological behaviour of bodies, containing 40% clay, was assessed by simulating the industrial tile manufacturing process on a laboratory scale. Tabarka clays (TC) were compared with high and low plasticity ball clays (which define a reference range for the raw materials currently used). TC exhibit a fine grain size distribution and plasticity approaching the most plastic ball clays currently used. The behaviour of the bodies containing TC during grinding, pressing, and drying is fully suitable, with values of the technological parameters that lie within the reference range. Using TC, a slightly higher temperature was necessary during firing to get the desired water absorption (<0.5%). This was due to the kaolinite-rich composition of TC that is more refractory than ball clays taken as reference, which contain illite and illite-smectite interstratified terms, along with kaolinite. The properties of fired bodies based on TC fulfil the technical requirements for porcelain stoneware tiles.