Production Of Tiles Research Articles

Pengaruh Penambahan Limbah Serbuk Kaca dan Kapur Padam pada Pembuatan Genteng Beton Ramah Lingkungan

In Indonesia, concrete roof tiles are still relatively expensive. This can be seen from the composition of the mixture and the concrete tile production process. Based on cost considerations, the alternative is to use glass powder waste and quenched lime. Lime as an alternative choice because the chemical elements contained are almost the same as cement. Glass powder waste contains silica which is expected to increase the density of concrete roof tiles. Therefore, this research was conducted with the aim to see the effect of adding glass powder waste and slaked lime to the values of flexural load, absorption, and water seepage. The method used is the experimental method, with a mixture of cement and sand composition, namely 1: 3 and using 4 variations of the test object, namely for quenched lime with variation A 0%; B 10%; C 0%; D is 10% by weight of cement while for variations of glass powder A is 0%; B 0%; C 10%; D 10% by weight of sand. This test includes appearance, size, value of bending load, absorption, and water seepage. The result of average bending load in variations A = 1548,51 N, B = 1562,25 N, C = 1675,57 N, D = 1751,43 N. For the result of average water absorption in variations A = 9,248%, B = 6,675%, C = 9,512%, D = 7,093%. The use of glass powder waste and extinguished lime can increase the value of bending load, absorption and water seepage compared to ordinary concrete roof tiles. So as to produce concrete roof tiles that are economical and also reduce waste but still meet the quality according to SNI.

Unveiling the impact of foreign investment entry in industrial clusters: the case of Castelló and Sassuolo

ABSTRACT This paper explores the impact of foreign investment, through acquisitions and mergers of local firms, on leading industrial clusters. While previous research has highlighted the increasing involvement of cluster firms in internationalization and knowledge globalization, the role of foreign investment requires further investigation. Power asymmetries between MNEs and partner firms are prevalent in global value chains, joint ventures, and strategic alliances, shaping the contemporary global economy. By analysing two clusters specialized in ceramic tile production (Castelló, Spain, and Sassuolo, Italy), this study aims to evaluate the impact of foreign investment on leading clusters, specifically distinguishing between multinational enterprises (MNEs) and investment funds. The research examines the perceived effects through a qualitative analysis, capturing the subjective impressions of local actors involved in acquired firms, independent local firms, technological suppliers, and supporting institutions. This paper contributes to the literature by addressing contradictory findings and providing insights into the balance between knowledge absorption and spillovers from MNEs or investment funds to local firms.

Utilizing machine learning to integrate silica-based production waste material in ceramic tiles manufacturing: Progressing toward sustainable solutions

The production of ceramic tiles is an intricate process of combining modern technology with ancient craftsmanship, which creates versatile and durable finished surfaces for various construction applications. The manufacturing of ceramic tiles causes the production of significant waste during different production stages such as shaping, firing, and finishing leading to environmental degradation and depletion of resources. Therefore, this research work was planned to investigate the possibility of utilizing ceramic waste in the manufacturing of ceramic tiles. Two types of ceramic waste, namely glaze waste and body waste were used with 5–10% replacement of different materials in the production of ceramic tile. The results revealed that up to 10% of the waste produced during the manufacturing of ceramic tiles can successfully be reused in the manufacturing of ceramic tiles. The ceramic tiles produced with 10% replacement of feldspar satisfied the minimum criteria of flexural strength, shrinkage, and water absorption supported by scanning electron microscopy findings. Moreover, a machine learning model was developed using six input variables, i.e., feldspar (F), three different types of clays (C1, C2, and C3), body waste (BW) and glaze waste (GW), while three variables, i.e., firing shrinkage (SF), flexure strength (FS) and water absorption (WA), as output. Applying a machine learning approach to data revealed that the model, i.e., artificial neural network (ANN), exhibited strong and consistent performance, displaying notable generalization capabilities (with an R2 greater than 0.95 on the test set). This study aims to shape sustainable waste management approaches and establishes a blueprint for harnessing ceramic waste with the potential to be a primary resource in the production of ceramic tiles.

AN INVESTIGATION ON UTILIZATION OF DOĞANHİSAR/KONYA CLAYS IN GLAZED PORCELAIN TILE BODIES

In this study, technical properties of 3 different clays from Doğanhisar/Konya region were determined to investigate their usage potential in glazed porcelain tile production of Yurtbay Seramik Company. For this purpose, mineralogical, chemical, and thermal characterization of the clays was performed using XRD, XRF, and dilatometric analyses. Furthermore, the use of Konya clays instead of Ukrainian clay in the porcelain tile compositions was studied. Ukrainian clay was substituted gradually by Konya clays in different tile body recipes. Samples, having these new compositions, were prepared by uniaxial pressing, and exposing to a firing regime at 1190 °C for 55 min. Fired samples were then characterized based on their dry strength, fired strength, water absorption, color, and firing shrinkage properties. Experimental results proved that the use of Konya clays instead of Ukrainian clay increased the strength of fired bodies. It would be possible to use Konya clays in tile bodies up to 6 wt.% with some modifications in the body compositions and firing regime.

Chemical and mineralogical characterization to define parameters for comminution, aiming at granulometric adequacy in rock rich in feldspars extracted in Pedra Lavrada-PB

The demand for high purity feldspars with low contaminant content, especially for use in the manufacture of porcelain tiles and white crockery, poses a challenge for processing the ore. Due to the need for very low iron levels, less than 0.15%, operations must be more complex, costly and capable of providing a high purity final product. To this end, it is necessary to employ mineralogical and technological characterization to understand the ore and plan the operations of the processing plant. A sample of rock rich in feldspars collected in an extraction in the municipality of Pedra Lavrada/PB was studied, aiming to identify the chemical composition and release spectrum using XRD and SEM techniques. Aliquots were subjected to preparation, granulometric classification and high-intensity wet magnetic separation steps. The results indicate that the rock has high concentrations of feldspars, quartz and a significant content of magnetite and hornblende. The physical release of magnetic mineral phases occurs below 0.104mm, and fragmentation operations must be designed with this grain size standard in mind. Magnetic separation, with mass recovery of 14.01% in relation to the feed, satisfactorily guaranteed a reduction in the concentration of magnetic minerals in the ore

Using nano-CaCO3 and ceramic tile waste to design low-carbon ultra high performance concrete

Abstract China’s annual production of ceramic tiles inevitably produces a large amount of ceramic tile waste, which causes environmental and land occupation problems. Using a high-volume ceramic tile waste to fabricate ultra high performance concrete (UHPC) will reduce the workability and mechanical properties but increase the low-carbon properties. Motivated by such mechanical and low-carbon properties, this study introduced inexpensive, spherical, low-carbon nano-CaCO3 (NC) to improve the workability and mechanical properties of UHPC with a high volume of ceramic tile waste powder and aggregate (UHPCHCTWPA). The results of this study indicated that NC can improve the workability but shortened the setting times of UHPCHCTWPA. NC also significantly increases the mechanical properties including compressive strength, compressive work, flexural strength, fracture energy, and ratio of flexural strength to compressive strength. It is due to that NC enhances the hydration rate and hydration degree, and optimizes hydration product orientation, size, and distribution. Moreover, compared with UHPC, the UHPCHCTWPA with NC reduces energy intensity, CO2 emission, and cost by more than 20%. Therefore, adding NC can make UHPCHCTWPA with good workability, mechanical and low-carbon properties and can effectively and quickly utilize ceramic tile waste.

Programming quadric metasurfaces via infinitesimal origami maps of monohedral hexagonal tessellations: Part II

In Part I of this study, it was shown that all the three known types of monohedral hexagonal tessellations of the plane, those composed of equal irregular hexagons, have just a single deformation mode when tiles are considered as rigid bodies hinged to each other along the edges. A gallery of tessellated plates was simulated numerically to demonstrate the range of achievable deformed shapes. In Part II, the displacement field was first derived and a continuous interpolant for each type of tessellated plate. It turns out that all corresponding metasurfaces are described by quadrics. Afterwards, a parametric analysis was carried out to determine the effect of varying angles and edge lengths on the curvature, and the values of the geometric Poisson ratio of the plates. Finally, a method of fabrication is proposed based on the additive manufacturing of stiff tiles of negligible deformability and flexible connectors. Using this modular technique, it is possible to join together different monohedral tessellated plates able to deform into piece-wise quadrics. The nodal positions in the deformed configuration of the realized plates are measured after enforcing one principal curvature to assume a chosen value. The estimate of the other principal curvature confirms the analytical predictions. The presented tessellated plates permit to realize doubly curved shape-morphing metasurfaces with assorted shapes, which also can feature a certain surface roughness, and they can be employed in all applications demanding high surface accuracy and few actuators or just one.

Ceramic floor tiles with yellow pigment from Kievan Rus’: A technological study

Colored glazed ceramic tiles were widely used for paving floors of the main buildings, mostly Orthodox churches, in the Kievan Rus’ (10th-13th centuries AD). The production of ceramic floor tiles was localized near the site of construction, and the date of production can be attributed to the date of construction or renovation of the church. Therefore, the study of glazed tiles makes it possible to determine the local and chronological features of their production technology.. Local production technology in Ancient Rus' was studied using thirteen yellow glazed ceramic tiles from six cities (Kiev, Galich, Polotsk, Vladimir-Volynsky, Pereslavl-Zalessky and Novgorod). Also, two samples were selected from churches in Polotsk, Vladimir-Volynsky and Vyshgorod at different times of construction or renovation to study chronological variations in tile production technology. Chemical compositions and crystalline phases of yellow glaze and ceramic body have been analyzed by X-ray diffraction, Raman and X-ray fluorescence spectroscopy. In all cases, samples of ceramic tiles were glazed with high-lead silicate glass, and lead tin yellow type II (PbSn1-xSixO3) was used as a pigment. Local production technology in Ancient Rus' was studied using thirteen yellow glazed ceramic tiles from six cities (Kiev, Galich, Polotsk, Vladimir-Volynsky, Pereslavl-Zalessky and Novgorod). Also, two samples were selected from churches in Polotsk, Vladimir-Volynsky and Vyshgorod at different times of construction or renovation to study chronological variations in tile production technology. Most likely, the glaze layer on the ceramic tile was formed using pre-synthesized glass; this technology differs from the conventional technology for pottery, uses lead oxide or a mixture of lead oxide and quartz. Data on the chemical composition of yellow lead glazed tiles dating from the 10th-13th centuries AD can be used to determine the region of glazed ceramic production.

Economic and Industrial Development SignificantlyContribute to Acidity and Ionic Compositions of Rainwaterin China

To achieve a holistic understanding of the intricate interactions among human activities, atmospheric chemistry, and acid rain in China, a rigorous analysis of rainwater chemistry was made using a dataset comprising 2656 data points from 24 sites. The main cation and anion in the chemical composition of precipitation were Ca2+ and SO42− in China, with an average concentration of 169.9 μeq/L and 135.4 μeq/L, respectively. Acid rain generally occurs in southern cities such as Shenzhen, Guangzhou, Zhuhai, Xiamen, and Chongqing. There were evident regional disparities in acidity and ion concentrations in rainwater, with an increase in acidity and a decrease in ion concentrations from north to south across China. Utilizing positive matrix factorization, the study found that NH4+, SO42−, and NO3− mainly originated from anthropogenic sources such as fossil fuel combustion, vehicle exhaust emissions, agricultural fertilization, and industrial emissions (as reflected by F3 and F4). Ca2+ mainly stems from crustal factors, including industrial dust and natural crust (as represented by F1 and F4). Na+ and Cl− were traceable from marine sources (as reflected by F5), while Mg2+ originated from crust origin (as presented by F1). K+ was mainly derived from a mixed source of crust, marine, and biomass burning (as indicated by F2 and F3). The correlation analyses showed that SO42− and NO3− showed significant correlations with GDP and population. F− was associated with wastewater, which may be linked to the production of brick and tiles from clay with high fluoride contents. The pH was negatively related to industrial wastewater. Long-term analysis of precipitation chemistry in four cities suggested a clear decrease in the proportion of SO42− but a considerable increase in the proportion of NO3− in anions in metropolitans of Shanghai and Chongqing due to the environmental measures that targeted reducing sulfur dioxide (SO2) emissions and increase of vehicles. This showed that pollution control strategies had an impact on precipitation ion concentrations. These results can conclude that economic and industrial growth, which will increase energy consumption, utilization of coal combustion, and a subsequent rise in pollutant emissions, can contribute to the change in the chemical compositions of rainwater and the exacerbation of acid rain.

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.

Eco-efficiency of phosphogypsum waste and sisal fiber in the production of non-fired tile

Eco-efficiency of phosphogypsum waste and sisal fiber in the production of non-fired tile

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.

Technological prospects of domestic alkaline metasomatites using in the production of technical porcelain stoneware

Achieving the highest degree of sintering of porcelain stoneware (W < 0.5%) is the main condition of obtaining high­quality products with high resistance to the simultaneous action of mechanical and abrasive loads, aggressive reagents and sign­changing temperature fluctuations. The main impact in this case is dependent upon quartz­feldspathic natural material. Unfortunately, domestic Ukraine’s deposits of feldspathes are almost exhausted, while the impact of alternative fluxes is not researched on the level of technological practice. For the stable functioning of domestic industry in the market economy it is crucial to expand raw materials base and solve energy­saving problems. To solve the mentioned issues, it is required to find alternative fluxing materials, which should ensure the highest degree of sintering, and therefore complex high operational product properties, in conditions of energy­saving quick sintering of technical porcelain stoneware.
 This study justifies the forecast estimate methodology of quartz­feldspathic materials’ usage efficiency taking into the account products’ sintering conditions. A set of theoretical and experimental studies was carried out, the results of which helped to determine the usage expediency of a range of domestic alkaline metasomatites in the production of technical porcelain stoneware tiles. The used approach to predicting the behavior of alternative raw materials made it possible to obtain data on their technological properties, in particular the characteristics of the melts formed under conditions of high­speed products firing at a temperature of 1200 °C: η = 102.05 ÷ 3.07 Pa·s, s = 0.304 ÷ 314 mN/m. The results of theoretical and experimental studies of the chemical­mineral composition and properties of six different occurrences of alkaline metasomatic rocks indicate the advisability of their use as an alternative to albite concentrates imported from Turkey. Obtained new data allowed to outline the transition ways from costly feldspathic concentrates to domestic substitutes, thus allowing to eliminate of import dependence of domestic producers of porcelain stoneware tiles and large format slabs.

Optimizing raw material composition to increase sustainability in porcelain tile production: A simulation‐based approach

AbstractReducing the environmental impact of porcelain tile production while maintaining cost‐effectiveness is challenging. This work introduced a novel modeling approach for optimizing a standard composition range comprising kaolinite (15–38 wt.%), illite (0–20 wt.%), quartz (20–40 wt.%), and feldspar (20–45 wt.%) to establish a robust composition interval for porcelain stoneware tiles. The proposed study considers several factors, such as composition impact on the manufacturing sequence, production costs, and CO2 emission. A flowsheet simulation database was generated by coupling the Dyssol framework with MATLAB. This study investigated the influence of raw material composition within the process sequence, the total CO2 emissions, and production costs within the contexts of Spain and Brazil, two of the top five global producers. Granules with a higher proportion of talc and illite exhibit reduced moisture content after spray drying, and these combinations have lower green body porosity after compaction. The addition of talc allowed for decreased porosity content after compaction reduced firing temperature, and lowered costs and CO2 emissions despite the higher prices associated with talc. The proposed simulation methodology offers a powerful decision‐making tool for optimizing raw material composition to minimize cost and CO2 emissions in the porcelain tile production. This methodology represents an early stride toward integrating digital twin methodologies within the ceramic tile sector, facilitating improved process regulation, and promoting the adoption of digital technologies.

Surface defect segmentation of magnetic tiles based on cross self-attention module

The detection of magnetic tile quality is an essential link before the assembly of permanent magnet motor. In order to meet the high standard of magnetic tile surface defect detection and realize the rapid and automatic segmentation of magnetic tile defects, a magnetic tile surface defect segmentation algorithm based on cross self-attention model (CSAM) is proposed. It adopts high-low level semantic feature fusion method to build the dependency relationship between the deep and shallow features. Multiple auxiliary loss functions are used to constrain the network and reduce the noise in the deep features. In addition, an image enhancement method is also designed to solve the problem of insufficient annotated data. The experimental results show that the network can achieve 79.6% mIoU and 98.5% PA, which can meet the high standard requirements of magnetic tile manufacturing.

Statistical analysis of porcelain tiles’ technical properties: full factorial design investigation on oxide ratios and temperature

This study focuses on optimizing the composition and firing temperature of porcelain tiles using statistical analysis techniques. A full factorial design, including model adequacy checking, analysis of variance, Pareto charts, interaction plots, regression model, and response optimizer is employed. The key factors were the Seger ratios of SiO2/Al2O3, Na2O/K2O, MgO/CaO, and firing temperature. The response variables investigated were bulk density, water absorption, linear shrinkage, coefficient of thermal expansion (at 500 °C), and strength. The statistical analysis revealed highly significant results, which were further validated, confirming their reliability for practical use in the production of porcelain tiles. The study demonstrated the effectiveness of utilizing Seger formulas and properties of typical raw materials to accurately predict the final properties of ceramic tiles. By employing SiO2/Al2O3 = 5.2, Na2O/K2O = 1.50, MgO/CaO = 3.0, and firing temperature of 1180 °C, optimized properties, such as maximum strength, maximum bulk density, and minimum water absorption, was achieved with a composite desirability of 0.9821.

Optimization of physical and mechanical properties of porcelain tiles from coffee parchment husk ash

Coffee parchment husk ash (CPHA), a product from coffee processing was found to have similar fluxing oxides as are found in feldspars. CPHA is produced in large quantities through the combustion of coffee parchment in industries to produce energy for drying purposes. CPHA is commonly disposed of in landfills and open fields, causing pollution to the environment and ecosystems. In this work, response surface methodology (RSM) was used for optimization of porcelain tile bodies in which the portion of CPHA in feldspar was varied from 10 to 90 wt% and firing temperature from 800 to 1200 ℃. The response variables were linear shrinkage (LS), water absorption (WA), and flexural strength (FS). Other materials in the porcelain were maintained at 10 wt% sand, 20 wt% ball clay, and 40 wt% kaolin. Mixed proportions were dry pressed at 40 MPa and fired to respective peak temperatures at a rate of 34 ℃/min. The optimum conditions obtained were 10% of CPHA in feldspar and 1197 ℃ firing temperature. Validation experiments presented LS 8.15%, WA 0.11%, and FS 38.32 MPa. These values agree with optimum responses from RSM and therefore confirm the accuracy of developed prediction models. The test values lie within the range specified by 1SO 13006:2018 for porcelain floor tiles. These findings demonstrate that CPHA can be used as a raw material for production of porcelain floor tiles. Adoption of CPHA in ceramic production can contribute to reduction in the costs of maintaining landfills.

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