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

• Autorzy: Ergin Hasan , Taşkıran Mehmet Uğur , Pilevne Ahmet Atınç , Turgut Hatice , Kayacı Kağan

Identyfikatory

DOI

10.37190/ppmp/167498

• Języki publikacji: EN

Abstrakty

EN

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 emissions. 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.

Słowa kluczowe

EN

ceramic tile; dry granulation; energy consumption; granule characteristics

• Wydawca: Oficyna Wydawnicza Politechniki Wrocławskiej
• Czasopismo: Physicochemical Problems of Mineral Processing
• Rocznik: 2023
• Tom: Vol. 59, iss. 5
• Strony: art. no. 167498
• Opis fizyczny: Bibliogr. 13 poz., rys., tab., wykr.

Twórcy

autor

Ergin Hasan

• Istanbul Technical University, Faculty of Mines, Mining Engineering Department, Maslak, Istanbul, Türkiye

• https://orcid.org/0000-0001-6692-7456

autor

Taşkıran Mehmet Uğur

• Kaleseramik Research and Development Center, Çan, Çanakkale, Türkiye

autor

Pilevne Ahmet Atınç

• Kaleseramik Research and Development Center, Çan, Çanakkale, Türkiye

autor

Turgut Hatice

• Kaleseramik Research and Development Center, Çan, Çanakkale, Türkiye

• https://orcid.org/0009-0009-4426-6939

autor

Kayacı Kağan

• Kaleseramik Research and Development Center, Çan, Çanakkale, Türkiye

• https://orcid.org/0000-0002-9665-8338

Bibliografia

• GIL, C., SILVESTRE, D., PIQUER, J., GARCIA-TEN, J., QUEREDA, F., VICENTE, M.J., 2012. Preparation of porcelain tile granulates by more environmentally sustainable process. 12th World Congress on Ceramic Tile Quality, QUALICER 2012.
• KARAASLAN, A.K., SERT, B., 2022. Yaş Granülasyon İşleminin Toz Reometrisiyle Optimizasyonu. Journal of the Turkish Ceramics Society, 2 (1), 7-12.
• MELCHIADES, F.G., DAROS, M.T., BOSCHI, A.O., 2010. Porcelain tiles by the dry route. Boletin De La Sociedad Espanola de Ceramica y Vidrio, 49 (4), 221-226.
• MELCHIADES, F.G., DOS SANTOS, L.R., NASTRI, S., BOSCHI, A.O., 2012. Comparison between Spray-Dried and Dry Granulated Powders in the Fabrication of Porcelain Tiles. Interceram, 61, 254-258.
• MEZQUITA, A., MONFORT, E., FERRER, S., GABALDON-ESTEVAN, D., 2017. How to reduce energy and water consumption in the preparation of raw materials for ceramic tile manufacturing: Dry versus wet route. Journal of Cleaner Production, 168, 1556-1570.
• SACMI, 2005. Applied Ceramic Technology. Italy.
• SHU, Z., ZHOU, J., WANG, Y., 2010. A novel approach of preparing press-powders for cleaner production of ceramic tiles. Journal of Cleaner Production, 18, 1045-1051.
• SHU, Z., GARCIA-TEN, J., MONFORT, E., AMOROS, J.L., ZHOU, J., WANG, Y.X., 2012. Cleaner production of porcelain tile powders. Granule and green compact characterization. Ceramics International, 38, 517-526.
• SOLDATI, R., ZANELLI, C., GUARINI, G., CAVANI, G., BATTAGLIOLI, L, DONDI, M., 2020. Novel micro-granulates for porcelain stoneware tiles: preliminary data on powder rheology and compaction. 16th World Congress on Ceramic Tile Quality, QUALICER 2020.
• SOLDATI, R., ZANELLI, C., CAVANI, G., BATTAGLIOLI, L., GUARINI, MELANDRI, C., PIANCASTELLI, A., DONDI, M., 2020b. Powder rheology and compaction behaviour of novel micro-granulates for ceramic tiles. Powder Technology, 374, 111-120.
• SOLDATI, R., ZANELLI, C., CAVANI, G., BATTAGLIOLI, L., GUARINI, G., DONDI, M., 2022. Improving the sustainability of ceramic tile making by mixing spray-dried and dry granulated powders. Boletin De La Sociedad Espanola de Ceramica y Vidrio, 61, 325-335.
• SANTOMASO, A., LAZZARO, P., CANU, P., 2003. Powder flowability and density ratios: the impact of granules packing. Chemical Engineering Science, 58 (13), 2857-2874.
• VARI, A., 2004. Raw material preparation and forming of ceramic tiles. Modena.

Uwagi

Opracowanie rekordu ze środków MNiSW, umowa nr SONP/SP/546092/2022 w ramach programu "Społeczna odpowiedzialność nauki" - moduł: Popularyzacja nauki i promocja sportu (2024).