The Usage of Ceramic Sanitarware Filter-press Cake Wastes in Porcelain Tile Body

Yusuf Karaca; Zahide Bayer Oztürk; Elif Ubay

Article Details

The Usage of Ceramic Sanitarware Filter-press Cake Wastes in Porcelain Tile Body

Authors:

Yusuf Karaca | Zahide Bayer Oztürk | Elif Ubay

Publisher:

Kirikkale University

Main Topics:

Materials Engineering (Other)

Journal:

International Journal of Engineering Research and Development Vol.15 Issue 2, pp.872-880

Document Type:

Article

Publication Date:

7/2023

Document Language:

Turkish

Document ID (Org No.):

2001284784

pISSN:

1308-5506

Keywords:

Abstract:

 In the context of environmental responsibility and economic production, the reuse of waste products generated in ceramic production holds significant importance. This study was carried out to evaluate the effect of using cake waste in porcelain tile composition instead of raw materials. This study was carried out to evaluate the effect of using cake waste in porcelain tile composition instead of raw materials. The cake waste is obtained by separating the semi-finished product and production residues formed in the pre-firing stages in the production of ceramic sanitary ware, removed from the water in the filter press, and accumulated in the tanks and pools of the factory. Under industrial conditions, eleven porcelain tile formulations were prepared and compared against a standard porcelain tile. The findings reveal that the incorporation of filter press cake waste to a 14 in formulation by replacing the imported clay, kaolin, and albite increase in firing strength when compared to standard, while demonstrating similar properties to the standard tile in terms of firing color and firing shrinkage. Microstructure and phase analyses conducted on samples both close to and different from the standard indicated the presence of quartz and mullite phases. These results affirm that the utilization of ceramic sanitary ware filter press cake waste presents a sustainable and technologically viable approach to the production of porcelain tiles, benefiting the economy and the environment. By employing filter press cake waste as an alternative in the ceramic tile industry, which faces clay resource scarcity, the efficient utilization of raw material resources, waste recovery, and cost-effective production can be achieved.

 In the context of environmental responsibility and economic production, the reuse of waste products generated in ceramic production holds significant importance. This study was carried out to evaluate the effect of using cake waste in porcelain tile composition instead of raw materials. This study was carried out to evaluate the effect of using cake waste in porcelain tile composition instead of raw materials. The cake waste is obtained by separating the semi-finished product and production residues formed in the pre-firing stages in the production of ceramic sanitary ware, removed from the water in the filter press, and accumulated in the tanks and pools of the factory. Under industrial conditions, eleven porcelain tile formulations were prepared and compared against a standard porcelain tile. The findings reveal that the incorporation of filter press cake waste to a 14 in formulation by replacing the imported clay, kaolin, and albite increase in firing strength when compared to standard, while demonstrating similar properties to the standard tile in terms of firing color and firing shrinkage. Microstructure and phase analyses conducted on samples both close to and different from the standard indicated the presence of quartz and mullite phases. These results affirm that the utilization of ceramic sanitary ware filter press cake waste presents a sustainable and technologically viable approach to the production of porcelain tiles, benefiting the economy and the environment. By employing filter press cake waste as an alternative in the ceramic tile industry, which faces clay resource scarcity, the efficient utilization of raw material resources, waste recovery, and cost-effective production can be achieved.

 In the context of environmental responsibility and economic production, the reuse of waste products generated in ceramic production holds significant importance. This study was carried out to evaluate the effect of using cake waste in porcelain tile composition instead of raw materials. This study was carried out to evaluate the effect of using cake waste in porcelain tile composition instead of raw materials. The cake waste is obtained by separating the semi-finished product and production residues formed in the pre-firing stages in the production of ceramic sanitary ware, removed from the water in the filter press, and accumulated in the tanks and pools of the factory. Under industrial conditions, eleven porcelain tile formulations were prepared and compared against a standard porcelain tile. The findings reveal that the incorporation of filter press cake waste to a 14 in formulation by replacing the imported clay, kaolin, and albite increase in firing strength when compared to standard, while demonstrating similar properties to the standard tile in terms of firing color and firing shrinkage. Microstructure and phase analyses conducted on samples both close to and different from the standard indicated the presence of quartz and mullite phases. These results affirm that the utilization of ceramic sanitary ware filter press cake waste presents a sustainable and technologically viable approach to the production of porcelain tiles, benefiting the economy and the environment. By employing filter press cake waste as an alternative in the ceramic tile industry, which faces clay resource scarcity, the efficient utilization of raw material resources, waste recovery, and cost-effective production can be achieved.

 Çevresel sorumluluk ve ekonomik üretim kapsamında, seramik üretiminde ortaya çıkan atık ürünlerin yeniden kullanılması oldukça önemlidir. Bu çalışma, seramik sağlık gereci üretiminde pişme öncesi aşamalarda oluşan yarı mamül ve üretim artıklarının fabrikanın tank ve havuzlarda birikip filtre-preslerde suyundan ayrılmasıyla elde edilen arıtma kekinin porselen karo bileşiminde kullanılan hammaddeler yerine kullanımının etkisini değerlendirmek amacıyla yapılmıştır. Endüstriyel koşullar altında on bir farklı porselen karo reçetesi hazırlanmış ve bir standart porselen karo ile karşılaştırılmıştır. Elde edilen sonuçlar, sağlık gereci üretiminin filtre-pres kek atığı kullanımının 14 oranında bileşimde kullanılan ithal kil, kaolen ve albit hammaddelerinin yerine kullanılması ile pişme dayanımını arttırdığını ve pişme rengi, pişme küçülmesi gibi özelliklerde standarda benzer eğilim sergilediğini göstermektedir. Standarda yakın ve standarttan farklı eğilim sergileyen numunelerin seçilmesiyle yapılan mikroyapı ve faz analizlerinde kuvars ve müllit fazları tespit edilmiştir. Bu çalışma, seramik sağlık gereci filtre-pres kek atıklarının porselen karo üretiminde sürdürülebilir ve teknolojik, ekonomik ve çevresel açıdan kullanılabileceğini göstermektedir. Seramik sağlık gereci fabrikalarının filtre-pres kek atığının özellikle kil kaynağı sıkıntısı yaşayan seramik karo endüstrisinde alternatif hammadde olarak kullanılabilirliği, hammadde kaynaklarının daha verimli kullanılmasını, atığın geri kazanımını ve ekonomik bir üretimin gerçekleşmesini sağlamaktadır.

Article Details

The Usage of Ceramic Sanitarware Filter-press Cake Wastes in Porcelain Tile Body

Authors:

Yusuf Karaca | Zahide Bayer Oztürk | Elif Ubay

Publisher:

Kirikkale University

Main Topics:

Materials Engineering (Other)

Journal:

International Journal of Engineering Research and Development Vol.15 Issue 2, pp.872-880

Document Type:

Article

Publication Date:

7/2023

Document Language:

Turkish

Document ID (Org No.):

2001284784

pISSN:

1308-5506

Ceramic tile

ceramic sanitaryware

industrial waste

technical properties.

Seramik karo

sağlık gereci

endüstriyel atık

teknik özellikler

Issues

Article Details

Authors: Yusuf Karaca | Zahide Bayer Oztürk | Elif Ubay

Publisher: Kirikkale University

Main Topics: Materials Engineering (Other)

Journal: International Journal of Engineering Research and Development Vol.15 Issue 2, pp.872-880

Document Type: Article

Publication Date: 7/2023

Document Language: Turkish

Document ID (Org No.): 2001284784

pISSN: 1308-5506

Issues

Authors:

Yusuf Karaca | Zahide Bayer Oztürk | Elif Ubay

Publisher:

Kirikkale University

Main Topics:

Materials Engineering (Other)

Journal:

International Journal of Engineering Research and Development Vol.15 Issue 2, pp.872-880

Document Type:

Article

Publication Date:

7/2023

Document Language:

Turkish

Document ID (Org No.):

2001284784

pISSN:

1308-5506