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2 Physicochemical Problems of Mineral Processing

2 2023

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Investigation of the recycling of ceramic sludge waste from wall tile production in ceramic factory

Ergin Hasan, Kayacı Kağan, Yıldırım Yıldız, Pilevne Ahmet Atınç, Keskin Aykut

Physicochemical Problems of Mineral Processing

2023

Vol. 59, iss. 5

art. no. 166262

In ceramic production, vast amount of green process waste is created. Green process waste in other words, sludge waste creates a big environmental problem. It can create water pollution as well as create environmental problems having a big physical change of the stored area., Therefore, the use of sludge waste in the process as raw material is vitally important. The research programme was carried out to use the green process wastes as raw materials in the recipes of various products in Kaleseramik Research and Development Center in Turkey. Firstly, the long term samples were taken in order to observe the fluctuation of the created waste. Then, the chemical and mineralogical characterization of sludge wastes was carried out by using XRF and XRD. Different recipes were prepared by using green process waste. The behavior and the phases of fired products were evaluated by using a double-beam optical non-contact dilatometer and XRD. SEM and EDX were carried out for microstructural and microchemical analysis. Finally; the physical, mechanical and color properties of waste added recipes; such as water absorption, linear shrinkage, breaking strength and chromatic coordinates were measured. The results showed that it is possible to develop wall tile body with suitable technological properties by using appropriate mixture of process wastes in the body composition. The usage of sludge waste eliminates environmental problems and also provides the cost advantages as a raw material input. The full results of the case study performed at Kaleseramik Factory is illustrated in details.

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

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

Physicochemical Problems of Mineral Processing

2023

Vol. 59, iss. 5

art. no. 167498

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.