Production Of Sanitary Ware Research Articles

Performance assessment of geopolymer building bricks incorporating sanitary ware sludge waste

The sludge waste from a sanitary ware production line was used in the manufacturing of geopolymer bricks. The sludge was first dried and then fired at 800ºC. The fired powder was characterized using XRF, XRD, Particle size analysis. Caustic soda and slaked lime were used at percentages of 1% and 6 – 10% respectively. The waste was mixed with the caustic materials in molds whereby geopolymerization took place to produce the required bricks. After four weeks of curing, the produced bricks were tested for their physic-mechanical properties It was found that the compressive strength increased with the degree of geopolymerization and that the properties of the obtained bricks generally conformed to ASTM C 62 / 2017 standard for mixes consisting of 0.5% NaOH, 6% Ca(OH)2 and 45% water. These results were confirmed by SEM imaging.

Development and characterization of a sustainable process for the implementation of lightweight ceramics

Addition of hollow particles and foamed core-shell structures was evaluated to reduce density of ceramic bodies used in the production of sanitary ware, in particular Vitreous-China. Different contents of foamed ceramic beads, glass bubbles or foamed glass beads were tested, ranging from 1.5 to 10 % wt. These strategies were designed to be readily applicable to a pre-existing industrial plant, leading to a final product that retains mechanical and aesthetical properties of traditional ceramic.Mechanical properties, shrinkage, water absorption, surface finishing, and weight reduction were evaluated on dried and fired simplified samples.A moderate reduction in mechanical properties was found, numerically dependent to the overall volume of voids introduced in ceramic bulk. In particular, ceramic with a content of 3% of glass bubbles featured a flexural strength at break of 35 MPa, out of standard requirement. The highest efficiency in weight reduction was achieved with the introduction of 1.5% of cave glass bubbles resulting in a reduction of 10% in weight of fired samples, a flexural strength at break of (41 ± 4) MPa, a total linear shrinkage of (10.1 ± 0.2) %, (0.5 ± 0.1) %, water absorption of 0.5 % wt, in accordance with regulatory standard requirements.Weight reduction improved sustainability in terms of environmental impact. LCA (Life Cycle Assessment) study was conducted on optimized ceramic body (glass bubbles at 1.5 %wt, and glass bubbles at 3% with comparative purposes), evaluating the production process from transportation of raw materials to distribution of goods overseas. LCA analysis was determined using impact categories of ReCiPe Midpoint (H), ReCiPe EndPoint (H/H), and cumulative energy demand (CED). The analysis showed an overall improvement of all the impact categories, with a reduction of CED of 10%, and a reduction of ReCiPe Endpoint of 15% for optimized sample.

Investigation Of The Effect Of Vermiculite (Yıldızeli/Sivas) Addition On The Properties Of Sanitaryware Ceramic

Sanitaryware is the generic term used to describe items which traditionally were made from pottery. i.e. toilets, washbasins, pedestals, bidet, urinals, sinks, bathtubs installed within a bathroom or washroom. Sanitaryware products are primarily made of clay, kaolin, feldspar and quartz but they may also include small quantities of other raw materials. Its high gloss, stain resistant surface is ideal for use in both bath-rooms and kitchens. Vermiculite, a mineral in which the hydromicas group occurs naturally, becomes a high-efficiency thermal insulation material when heated above 300 ℃. The expanded vermiculite can be used as a filler for heat insulating materials due to its unique properties, low bulk density, low thermal conductivity, relatively high melting point, chemical inertia, durability and environmental safety. In this study, the effects of vermiculite obtained from Yıldızeli/Sivas region on sanitaryware body properties were investigated. The materials used in this study are calcined vermiculite, quartz, clay, kaolin and feldspar ceramic raw materials. Sanitaryware compositions were prepared by using kaolin-feldspar-quartz ternary equilibrium diagram according to the appropriate recipe from the raw material. In accordance with this purpose; prepared sanitaryware bodies %0, 10 and 20 by weight calcined vermiculite (1050 oC 1 hour) was added to formed the body compositions. The samples were coded as S20V1100 (S: Sanitaryware; 20V: 20% vermiculite addition and 1100: 1100 °C firing temperature). Mixtures homogenized in Alumina ball mills (60 rpm, 24 hours) were shaped by uniaxial dry pressing (100 MPa). Then, the prepared pressed samples were fired at 1050-1100 and 1150 °C for 1 hour. Microstructure (SEM), phase analysis (XRD), mechanical (hardness, 3-point bending) and physical properties (% shrinkage, water absorption, porosity and density) tests were performed on the sanitaryware bodies produced. The obtained data were presented in graphs and tables and commented. Accordingly, the properties of the vermiculite doped specimens were successfully developed and the optimum parameters were clearly shown. According to the results, it has been shown that sanitaryware properties are improved with the increase of calcined vermiculite.

Valorization of ceramic sludge waste as alternative flux: A way to clean production in the sanitary ware industry

The ceramic industry consumes a large amount of raw materials, much of which consists of fluxes. In view of the growing demand for infrastructure and sanitation, the waste valorization is a viable alternative for recycling materials, mitigating the extraction of natural resources. In this context, the present work studied the feasibility of replacing feldspathic flux by ceramic sludge waste (CS) in the sanitary ware production. The waste was characterized by particle size distribution, chemical composition, and mineralogical phases. The replacement ratios (by mass) were set in a wide range of 5, 10, 25, 50, 75, and 100%. The ceramic mass in fluid aspect was evaluated by means of density, viscosity, thixotropic index, setting rate and drying time. The hardened state was investigated through shrinkage, pyroplastic deformation, compressive and flexural strengths, water absorption and microstructure. The results showed that CS can be a stronger flux than granite. One of the proportions with total replacement (B-100) showed promising results, being the best option in terms of rheological behavior and physical-mechanical properties. An important finding concerns water absorption, which decreases with increasing the CS content. It is suggested that CS valorization on industrial scale may be sufficient to eliminate the entire volume of waste. This approach represents an eco-friendly solution, promotes the closing of waste loops and can be a way to cleaner production in the sanitary ware industry.

Thermal energy reduction in sanitary-ware industry by heat-recovering thermal engineering technologies

Ceramic industry manufacturing requires a great amount of thermal energy. Its sustainability and environmental impact demand an effort to develop more efficient technologies to reduce the consumption of fuel, mainly natural gas. In particular, the sanitary-ware production sector presents a defined special map of consumption through the manufacturing process because of the heat amounts and thermal levels of temperature. The aim of this research is to quantify the potential reduction of fuel consumption within a standard factory of sanitary-ware articles. The scope of it covers the main gas consumers, namely, kilns, dryers, heating units, or boilers. The method is based in a simulation of the process by modeling the thermophysics of the consumers, then plotting the heat recovery from one to another in order to save natural gas input. The research shows how the thermal requirement would be cut by almost a half within the factory consumption. It is consequently concluded that efficiency, environmental impact, and sustainability of this industrial sector would be improved, so as the global economy related with a potential growth of this industry, mainly in developing countries.Graphical abstractHighlightsThermal consumption reduction in a sanitary-ware factory is presented and validated.Heat recovery from kilns provides thermal energy for the rest of the thermal consumers.Energy management accounting as an extension to environmental management accounting is provided.The proposed method produces reductions of resources and economic improvements.

Effects of sintering temperature on microstructure and properties of sanitaryware ceramic produced with waste material

This paper aims at exploring the possibility of using a great percentage of recycled materials into vitreous china (VC), thus, contributing to urban waste decrease while lowering the industry’s buying costs, previously optimized, for the sanitaryware production. The recycled blend was introduced in the ceramic slip, Sanitser VC, and used in three sanitaryware production plants. This slip let to improve the environmental performances of the overall ceramic production through energy-saving and a decrease in greenhouse gas emissions. In fact, the firing temperature is 80-100 °C lower than traditional production. Therefore, the objective of this paper was to evaluate the firing behavior, technological properties, and microstructure of a typical industrial vitreous china body in comparison with Sanitser VC. The analytical results confirmed the force of this idea and highlighted the advantages of the choice made.

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.

Life cycle assessment of sanitaryware production: A case study in Italy

Abstract Sanitaryware products are one of the most diffused ceramic materials. In the present study, an environmental assessment of sanitaryware production was carried out. The Life Cycle Assessment was performed with a cradle-to-gate approach, considering the product life cycle from resource extraction to the factory gate of an Italian company and it aims to evaluate the environmental weight of sanitaryware production, identifying hotspots and comparing different energetic scenarios. The study was performed according to the current international standards and choosing, as the functional unit, 1000 kg of heterogeneous sanitaryware products. The system boundary includes raw materials extraction, transportation of raw materials and all the manufacturing activities within the factory, including electric and thermal energy supply. The results show how the study factory have implemented a mature green-based manufacturing and represents a reference point to estimate how the environmental impact can be improved by energy saving technologies and recycling water. Such technologies were compared to conventional ones and with results of other recent literature research. In addition, a potential improvement, based on cogeneration, was evaluated to consider if the economic improvement goes together with a minor environmental impact. Results show how economic benefit due to the implementation of cogeneration agrees with environmental impact, presenting only an increase in Global Warming Potential and Abiotic Depletion of fossil fuels. This is the inspiration for a further research where Life Cycle Assessment can be coupled to a Life Cycle Cost.

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.

Recycling ceramic waste as a raw material in sanitary ware production

Abstract This study characterized discarded sanitary ware waste (SWW) that could not meet quality requirements. To understand the composition of such SWW, samples were collected, processed, and characterized. This SWW was used to substitute granite in ceramic slips, and the final recycled sanitary ware compositions of 5%, 10%, 25%, 50% and 100% were obtained. Then, the mixtures were evaluated based on density, rheology, linear shrinkage, water absorption, and flexural strength. The results for viscosity and pyroplastic deformation in specimens containing the ceramic waste were better than the reference slip used in a production line. Results for density, water absorption and linear shrinkage showed no significant difference from the control samples. Although the replacement of more than 5% of granite reduced the flexural strength, no tested specimen was below the minimum value required by the industry.

Life cycle assessment and life cycle costing of sanitary ware manufacturing: A case study in China

Sanitary ware industry consumes vast amounts of energy and materials; however, little is known about the environmental impacts and economic costs associated with the production of sanitary ware. Selecting a factory of a leading Chinese sanitary ware company, Huida Co. Ltd., this paper employs a combined “cradle-to-gate” life cycle assessment (LCA) and life cycle costing (LCC) methodology to evaluate the environmental impacts and economic costs related to the production of one tonne of sanitary ware. The LCA results indicate firing and drying are the processes with the greatest environmental impacts, attributing to the combustion of coke oven gas. The LCC results show that casting, body preparation and firing are the greatest contributors to the total equipment, material and energy costs, respectively. The results of sensitivity analysis confirm that increasing fuel efficiency, natural gas usage and recycling rates can reduce the overall environmental impacts, but the total costs would be increased by 13.8% if coke oven gas is fully replaced by natural gas, even considering carbon tax. Based on the findings, recommendations such as using green materials and improving energy efficiency, are provided to promote both the environmental and economic sustainability of sanitary ware production.

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.

Incorporation of quartzite waste in mixtures used to prepare sanitary ware

Quartzite is a mineral that contains oxides that are present in the principal raw materials utilized in traditional ceramic production. However, during its extraction and processing, large amounts of waste are generated. This study, therefore, sought to investigate the incorporation of quartzite waste into the ceramic mass, replacing up to 25% of the feldspar by weight. Both, the waste and the conventional raw materials (clay, feldspar, quartz, and kaolin) were characterized. The compositions were formulated based on common industrial products. Suspensions were prepared to evaluate pH and deflocculant content. The specimens were produced using the slip casting process, dried, and fired at 1200°C. The ceramic masses containing up to 15% waste had yield strength values greater than 35MPa, water absorption in the 0.5% range and shrinkage from firing within the range recommended for sanitary ware manufacture. It was concluded that the quartzite waste can partially replace, up to 15wt%, the feldspar in ceramics for sanitary ware production.

Usage of fired wall tile wastes into fireclay sanitaryware products

In the last decade, using the waste products generated in ceramic manufacturing has been one of the important issues. Reusing the waste products is not only an environmental responsibility but also a cost reduction issue. In this study, the possibility of using fired wall tile wastes as a raw material for sanitaryware fire clay compositions was investigated. Four sanitaryware fire clay compositions were prepared by adding fired wall tile waste (FWW) into the standard fireclay composition under industrial conditions at Canakkale Kalebodur Seramik San. A. S. The results showed that addition of FWW increased the strength and decreased the water absorption and thermal expansion coefficient of the fireclay products. The thermal expansion coefficient of the products can be controlled with the addition of FWW. High-temperature deformation decreased with the addition of FWW into the fireclay composition. It can be concluded that FWW can be used in the fireclay production compositions as a raw material.

Comparative Study on Energy Saving of Low-Carbon Materials in Sanitary Ware Development

In this article, the author deeply analyzed and researched the production of wollastonite base-material sanitary ware, emphatically discussed molding method of wollastonite base-material, and established a calculation formula for whole production phase carbon emission and carbon tax of wollastonite base-material sanitary ware and common ceramic sanitary ware; made a comprehensive compare on environmental performance between common ceramic and wollastonite base-material sanitary wares, and clearly put forward the advantage on carbon emission of wollastonite base-material during production process; made a comparative research on energy consumption and carbon emission between traditional ceramic sanitary ware and low-carbon sanitary ware; finally verified the application value of low-carbon sanitary ware and provided the basis for development of it.

Hydrothermal synthesis of zeolites using sanitary ware waste as a raw material

Abstract Zeolites are extensively produced by hydrothermal treatment of different raw materials, such as kaolin. Sanitary ware (SW) is a kaolin-based ceramic ware usually found in sinks, urinals and bathtubs whose production is led by Spanish domestic clay product industry. SW production generates approximately 8% of solid waste in Spain, which increases landfills sizes and pose economic, social and technical problems. This study aims to evaluate the feasibility of solid waste of SW industry to produce zeolites once subjected to a conventional hydrothermal treatment during different times and temperatures. Ground SW was subjected to dissolution in a highly basic medium (NaOH 5 M) inside a Teflon-lined stainless steel reactors, at temperatures of 100, 150 and 200 °C for 1 to 30 days. X-ray powder diffraction (XRD), Fourier-transform infrared spectroscopy (FTIR) and scanning electron microscopy (SEM) were used to characterize both the raw material and resultant mineral phases. Quartz and mullite present in SW transform into zeolites, as temperature and time increase. Mineral assemblage at 100 °C includes zeolite P, Na-faujasite and sodalite as major component and analcime, natrolite, and zeolite A as minor, which behave as metastable phases and their relative abundance depends on aging time. Analcime and cancrinite crystallization is favored by high temperature (150 °C to 200 °C) and increasing aging time produces analcime disappearance. Cancrinite is the dominant mineral after 30 days. Conventional SW waste is an optimal raw material for zeolites synthesis under high alkaline hydrothermal conditions. Combining time and temperature it is possible to drive crystallization towards a target phase.

EPD of Novel Nanostructured Silica Coatings: Processing and Applications

Specific designed silver-doped glazes have already been used for antimicrobial coating applications in ceramic consumer oriented industry; however, comprehensive use of silver-based agents in ceramic glazes presents issues of clouding, crazing, discoloration, and other undesirable consequences to the glaze aesthetics as well as severe cost problems. Accordingly, there is a need for low-cost and high quality glazes and coatings that offer persistent built-in antimicrobial protection. Here we show that electrophoretic deposition, based on membrane templating, may answer these requests of realization of micro-topological design of glazings, while offering at the same time a wide library of available antimicrobial efficient nanomaterials to be incorporated into the micro-structured glazes. As consequence, these coatings are particularly suited for applications where interaction with pathogens in liquid solutions or gas-phase atmospheres has to be favoured. Strategies on the integration of microstructured coatings into devices with applicative purposes in consumer ceramics and sanitary ware products, are presented.

PENGARUH KUALITAS PRODUK, HARGA, PROMOSI, DAN DISTRIBUSI TERHADAP KEPUTUSAN PEMBELIAN PRODUK SANITARY WARE TOTO DI KOTA DENPASAR

Perkembangan dalam dunia bisnis sanitary sangat pesat. Berbagai inovasi dan teknologi modern digunakan oleh berbagai merek sanitary ware. Toto merupakan sebuah merek produk sanitary ternama di dunia yang menjadi salah satu pelopor yang menggunakan teknologi modern dan mesin yang canggih dalam memproduksi barang-barangnya. Penelitian ini bertujuan untuk mengetahui pengaruh kualitas produk, harga, promosi, dan distribusi secara parsial dan simultan terhadap keputusan pembelian Sanitary ware merek Toto di Kota Denpasar. Jumlah sampel yang digunakan dalam penelitian ini adalah 100 responden dengan teknik purposive sampling. Data dianalisa menggunakan analisis regresi linear berganda. Berdasarkan hasil penelitian, diperoleh bahwa bauran pemasaran yang terdiri dari produk, harga, promosi, dan distribusi secara simultan berpengaruh terhadap keputusan pembelian produk sanitary ware Toto di Kota Denpasar. Secara parsial, produk, harga, promosi, dan distribusi berpengaruh positif dan signifikan terhadap keputusan pembelian produk sanitary ware Toto di Kota Denpasar. Dengan demikian dapat disimpulkan bahwa bauran pemasaran berpengaruh terhadap keputusan pembelian produk sanitary ware Toto di Kota Denpasar.

Sanitser, an innovative sanitary ware body, formulated with waste glass and recycled materials

Abstract In the present paper, the results of “Sanitser” Life European project are presented. The aim of this study was to reduce the firing temperature for ceramic body (from 1250 to 1170 °C). This was achieved substituting feldspar and quartz with recycled blend materials and a little percentage of flux (less than 3%); in a sanitary ware vitreous china formulation a waste glass, granitic materials and fired broken ceramic pieces were introduced. Tests performed on the Sanitser formulation showed that it has the same final physical-chemical characteristics of the industrial vitreous china (VC) body. Besides, different ceramic pieces (wash basin, bidet and WC pan) were compared with VC production. The results showed that Sanitser body can replace vitreous china in the sanitary ware production. In this project, the firing temperature of the ceramic body is reduced significantly with a supposed decrease of the CO2 emissions. In Sanitser formulation, about 43.6% of recycled materials that would end in dumps were utilized.

Characterization and properties of industrial polymer matrix composite sanitarywares

Abstract Polymer matrix composites (PMCs) play an increasingly important role in everyday life from energy conservation to national security. Recently, PMCs have been found to be used for sanitaryware due to their low density, giving a sense of warmth, which allows application for broad aesthetic features, high impact resistance, the ease of shaping and the possibility to produce thin sections. It is an alternative to ceramic sanitaryware products. While thin section PMC products range in the forefront with lightness and aesthetic features, thick section PMC products are aroused interest because of the impact resistance and ease of production. Little attention is devoted to the characterization of PMC sanitarywares up to date. Therefore, in order to identify manufacturing processes and determination of the chemical and mineralogical composition, optical microscopy, scanning electron microscopy (SEM) with SE, BSE and EDX detector, X-ray diffraction (XRD), X-ray fluorescence spectroscopy (XRF) and thermogra...