Development of ceramic floor tile compositions based on quartzite and granite sludges (original) (raw)
Related papers
Incorporation of granite cutting sludge in industrial porcelain tile formulations
Journal of the European Ceramic Society, 2004
Granite wastes in the form of sludge, obtained from granite cutting industry, were incorporated in the batch formulations of porcelain tiles. The maximum possible substitution of sludge for feldspar was investigated. Samples of different formulations, in the form of pellets or extruded bars, were produced at both laboratory and pilot-plant scales and characterized throughout all the stages of the production process. The experimental results and their theoretical interpretation show that suitable incorporation of granite sludge can result in porcelain tiles with superior properties, in terms of water absorption (0.07%) and bending strength (> 50 MPa). Sludge incorporation had negligible effect on density, shrinkage and plasticity during all stages of tile-production process, anticipating no modifications in the industrial production line.
Use of Fine Wastes from Dimension Stone Industry in the Manufacture of Ceramic Tile
Large quantities of rock dust are daily discarded by dimension stone industries. These wastes can be reduced if they are selected according to their composition and used as base in other products. Two kinds of wastes (BS and OI) were mixed at different proportions with kaolinitic clay traditionally used as raw material in ceramic industry. BS has high contents of plagioclase, quartz, microcline and low biotitic; and OI has high quantities of microcline and plagioclase, besides quartz, biotitic, enstatite and edenite. At the same firing temperature, water absorption of samples with 50% BS, or less, didn't show significant differences in relation to samples with pure clay, but firing shrinkage and flexural strength decreased. On the other hand, mixtures with OI content up to 50% showed reduction of water absorption and firing shrinkage, while flexural strength was increased. Introduction The composition of red ceramics is basically common clay. Studies on characterization of clays point out that, even from the same place, they can show different particle size and variations in chemical composition due to peculiarities of deposits and their geological formation [1]. Clay minerals contain particles with diameter lower than 0.002 mm (NBR 7250) which, in contact with water, acquire plasticity. They are compound basically by hydrated aluminum silicates with laminated and elongated shape, that present cation exchange capacity. They comprise a large family of minerals classified into groups according to their crystalline structure and properties. The main groups of clay minerals, following the classification of its use in ceramics, are kaolinite, illite and montmorillonite [2, 3]. Some red ceramics, such as building blocks used in construction, has been made of mixtures of clay and industrial wastes. A very interesting way that has been studied lately is the use of dimension stone wastes. The term " dimension stone " is applied to rocky materials used for ornamentation and coating, among which the most important are those capable of being polished, such as marbles and granites [4]. Ceramics heat-treated at temperatures above 900ºC have shown good mechanical properties. According to Vieira et al. (2003), samples sintered at 1025ºC present porosity and water absorption lower than those sintered at lower temperate, while linear shrinkage and rupture tension are higher [5]. Normally, the mechanical resistance increases in function of firing temperature. In general, countries involved in production of dimension stones have tradition in this sector and are historically related to exportation of processed products. Consumption and exportation growth of dimension stones plates has increased the competition in terms of prices, markets and
Transactions of the Indian Ceramic Society, 2022
Ignimbrites (Ahlat Stone) with macro and micro-sized pores possessing independent of each other are volcanic rocks. It is mainly used as a building material because of its excellent insulation and easy to form material. The present study is aimed at producing floor tile which incorporated Ahlat stone as an alternative raw material for the ceramic industry. The effects of the increasing amount of Ahlat stone (1, 3 and 5 wt%) in the recipes on slurry rheology, physical properties of ceramic tiles, and sintering were studied. Chemical components of raw materials and Ahlat stone were determined using X-ray fluorescence spectroscopy and accordingly the recipes were created. The surface morphology of tiles was scanned using scanning electron microscope. When 3% Ahlat stone was added to the recipe, the flexural strength was calculated as 540 kgf.cm-2. This value is 22% higher than the value which is specified in the TSE standards. Therefore, tiles with a longer lifetime and more durability were developed. In addition, the increased amount of Ahlat stone in the recipe reduced the sintering temperature, thus energy saving was achieved during firing.
Application of sewage sludge in the manufacturing of ceramic tile bodies
Applied Clay Science, 2005
The substitution of clayey raw materials urban sewage sludge in the production of traditional ceramics could give place to a cost saving due to the utilisation of wastes as secondary raw material. At the same time, it can help to solve the environmental problems associated to such wastes. This research shows the results of the substitution of clay for sewage sludge in different proportions in a ceramic body. The sludge characterisation has been carried out by an analytical protocol. After that, the most suitable products were selected regarding to the chemical composition and the technological characterisation of the resulting ceramic material.
Enhancing the mechanical properties of porcelain stoneware tiles
Journal of The European Ceramic Society, 2001
This paper focuses on the complexities of the microstructure and phase development in porcelain stoneware tiles produced following industrial fast single ®ring cycles. A microstructural investigation was conducted to determine if the addition of selected low cost minerals would improve mechanical properties. The minerals tested were quartz, mullite and kyanite. Uniaxially pressed samples were submitted to the same industrial ®ring schedule and tested according to the European tile standards before further microstructural analysis. All the requirements speci®ed in UNI EN normative concerning BIa class tiles were ful®lled; moreover, mullite and kyanite added formulations showed sensible increases in mechanical properties, especially as far as¯exural strength and abrasion resistance are concerned. #
Development and Acceptability of Synthetic Granite Tiles: An Alternative Construction Material
Granite tiles are expensive construction material usually use for tiling of floor. The main focus of this study was the development of synthetic granite tiles as an alternative construction material. The development and fabrication of synthetic granite tiles underwent different procedures. It started with the design and construction of molder. Based from the experimentation of the synthetic granite tiles can be fabricated in different sizes, shapes and thickness which is comparable to the existing granite tiles. During the try-out and revision period the following were observed: The proportion of pebbles resins and hardener had a relation on the drying time of the product.
2003
On a etudie l'influence des caracteristiques mineralogiques et granulometriques de ball clays vis-a-vis des proprietes technologiques de carreaux ceramiques, en particulier de gres porcelaine. Les matieres premieres couramment employees par l'industrie des carreaux sont des argiles a grains fins, essentiellement constituees de kaolinite, quartz, illite et d'une dispersion d'illite et de smectite interstratifees, avec eventuellement de la smectite. La distribution de taille des particules affecte en particulier la plasticite et la variation dimensionnelle des carreaux a l'issue du processus, la fraction la plus fine (<0.2 μm) etant celle dont le role est le plus marque. La composition mineralogique a une forte influence sur les proprietes mecaniques et le comportement au pressage: smectite et I/S interstratifiees jouent un role essentiel, de meme que l'ordre structural de la kaolinite et de l'illite. Le frittage est, pour une large part, conditionne par...
DEVELOPMENT AND EVALUATION OF CERAMIC TILES USING WASTES AND SOLID MINERALS
The study focuses on the need for domesticating the production of building materials like tiles to address the problem of Nigeria over dependent on imported goods, despite adequate availability of mineral resources like clay, quartz and feldspar in the country. Clay, quartz and feldspar, and milled glass was 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 the percentage weight of the clay material in the mixed decreased and proportion of quartz, feldspar and milled glass increased. Sample containing 70% Clay & 30% Feldspar had better formulation properties than others.
Journal of the European Ceramic Society, 2002
Porcelainized stoneware tiles containing up to 20 wt.% of municipal incinerator grate slag have been fabricated by cold uniaxial pressing and conventional fast firing cycles. The sinterability of these samples was investigated from density and shrinkage measurements together with mechanical (Vickers microhardness and Young's modulus) and esthetical (spot resistance and colour parameters analysis) properties. The comparison with the porcelainized stoneware tiles containing no waste suggest a good compatibility between the ceramic body and the waste that does not significantly change the properties of the final products and the conditions of the firing cycle. Nevertheless, the porosity increase, proportional to the waste content, causes a decrease in density, shrinkage, spot resistance and whiteness. #
Influence of Strengthening Components on Industrial Mixture of Porcelain Stoneware Tiles
Key Engineering Materials, 2004
A typical industrial formulation for porcelain stoneware tiles was modified by adding synthetic mullite, and mullite-precursors, such as kaolin and gibbsite in order to enhance the mechanical properties by increasing the mullite content. The change in the physical properties as well as the technological and mechanical behaviour were evaluated on the basis of the phase composition modifications.