Novel approach to ensure the dimensional stability of large-format enameled porcelain stoneware tiles through water absorption control

Pinter, Jamilson; Zaccaron, Alexandre; Arcaro, Sabrina; Neto, João Batista Rodrigues; Noni, Agenor De; Raupp-Pereira, F.

doi:10.1016/j.oceram.2021.100203

Cited by 4 publications

(4 citation statements)

References 20 publications

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“…Currently, industrial facilities regulate the moisture content levels of atomized powder to ensure that it remains within a specified maximum variation range of 1 wt.%. [54][55][56][57] Yet, achieving this target can be challenging. Thus, the suggested simulations can be useful to demonstrate how this might be attained in a more straightforward method, reducing experimental trials.…”

Section: Resultsmentioning

confidence: 99%

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Optimizing raw material composition to increase sustainability in porcelain tile production: A simulation‐based approach

Alves,

Skorych,

De Noni

et al. 2023

J Am Ceram Soc.

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Reducing the environmental impact of porcelain tile production while maintaining cost‐effectiveness is challenging. This work introduced a novel modeling approach for optimizing a standard composition range comprising kaolinite (15–38 wt.%), illite (0–20 wt.%), quartz (20–40 wt.%), and feldspar (20–45 wt.%) to establish a robust composition interval for porcelain stoneware tiles. The proposed study considers several factors, such as composition impact on the manufacturing sequence, production costs, and CO2 emission. A flowsheet simulation database was generated by coupling the Dyssol framework with MATLAB. This study investigated the influence of raw material composition within the process sequence, the total CO2 emissions, and production costs within the contexts of Spain and Brazil, two of the top five global producers. Granules with a higher proportion of talc and illite exhibit reduced moisture content after spray drying, and these combinations have lower green body porosity after compaction. The addition of talc allowed for decreased porosity content after compaction reduced firing temperature, and lowered costs and CO2 emissions despite the higher prices associated with talc. The proposed simulation methodology offers a powerful decision‐making tool for optimizing raw material composition to minimize cost and CO2 emissions in the porcelain tile production. This methodology represents an early stride toward integrating digital twin methodologies within the ceramic tile sector, facilitating improved process regulation, and promoting the adoption of digital technologies.

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Section: Resultsmentioning

confidence: 99%

“…This difference does not lead to very substantial changes in the compaction of the parts. Currently, industrial facilities regulate the moisture content levels of atomized powder to ensure that it remains within a specified maximum variation range of 1 wt.% 54–57 . Yet, achieving this target can be challenging.…”

Section: Resultsmentioning

confidence: 99%

Optimizing raw material composition to increase sustainability in porcelain tile production: A simulation‐based approach

Alves,

Skorych,

De Noni

et al. 2023

J Am Ceram Soc.

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“…Os avanços tecnológicos na indústria têm experimentado um crescimento notável, impulsionando as empresas a buscarem atualização constante, não apenas para se manterem alinhadas com as tendências emergentes, mas também para aprimorar seus processos operacionais [1]. Nesse contexto, a busca por soluções que garantam precisão e confiabilidade de acordo com as normas padrões de medição dimensional tornou-se imperativa [2] [3]. Um marco fundamental nessa jornada de melhoria foi a introdução das máquinas de medição por coordenadas (CMMs) na década de 1960.…”

Section: Introductionunclassified

Estudo da viabilidade de calibração de placas padrão de duralumínio por meio de leitor automatizado

Portella,

Rosso,

Menegon

et al. 2023

Cerâm. ind.

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Atualmente, na etapa de classificação de placas na indústria de revestimentos cerâmicos, a calibração das placas padrão de duralumínio é executada por meio de um dispositivo conhecido como "dataplucômetro". Este equipamento é empregado para aferir as propriedades dimensionais das placas cerâmicas conforme estipulado na norma ISO 10545. No entanto, é importante ressaltar que o referido dispositivo vem apresentando algumas limitações e inadequações. Dentro desse cenário, o equipamento de braço articulado de medição por coordenadas surge como uma alternativa de melhora neste processo de medição. Com base nesse contexto, o objetivo deste trabalho foi investigar e validar uma nova metodologia para a calibração de placas padrão de duralumínio em braços de medição por coordenadas. Para isso, o estudo investigou medições pontuais em três placas de duralumínio de diferentes tamanhos (15 × 15, 60 × 60 e 60 × 120 cm) utilizando o braço de medição Faro modelo 14000. As medições foram realizadas em 21 pontos predefinidos em cada placa, com a participação de dois operadores durante dez dias, com o objetivo de avaliar a repetibilidade das medições e a influência da troca de operador nos resultados. Foram analisadas as características das placas, como tamanho, ortogonalidade, retitude lateral, curvatura lateral, curvatura central e empenamento. Os resultados evidenciaram uma alta repetibilidade nas medições das características de calibre nas placas, entretanto, para as propriedades relacionadas à planaridade, em particular o empenamento, observou-se um desvio padrão significativamente elevado. Portanto, o método demonstrou ser adequado somente para a avaliação do tamanho, ortogonalidade e retitude lateral das placas, enquanto a medição da curvatura lateral, central e empenamento requer uma análise mais aprofundada para fins de validação.Palavras-Chave: Braço de coordenadas; placa padrão; medição dimensional; indústria de revestimentos cerâmicos.

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“…Ceramic batch formulations usually include large quantities of feldspars (25-35 mass%) and quartz (15-25 mass%), the rest being clay (30-50 mass%) [9][10][11][12]. The formulations are related to the final application of tiles, which is primarily dependent on their water absorption and modulus of rupture.…”

Section: Introductionmentioning

confidence: 99%

Aplitic Granite Waste as Raw Material for the Production of Outdoor Ceramic Floor Tiles

2022

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One of the significant problems in the production of ceramic tiles is the very high consumption of natural resources such as clay, feldspar, and quartz. The possibility of replacing part of the formulation of ceramic batches is of great importance. In this research, the possibility of using aplitic granite waste from dimensional stone production was analyzed in detail. The waste is considered a low-cost substitute for feldspar in Serbia. The milled powdery waste was analytically tested to reveal its chemical and mineralogical contents, particle size distribution, and other important properties. The ceramic tiles containing aplitic granite waste (GW) and GW/raw clay mixture (CGW) were hydraulically pressed, and the ceramic and technological properties determined. This waste can act as a filler while forming, drying, and firing, since the high content of quartz helps to control the shrinkage and acts as a fluxing agent in high temperatures due to its feldspathic nature. The waste was found favorable in the production of ceramic tiles, as the gained values of modulus of rupture and water absorption were 28.68 MPa and 1.33%, respectively. The parameters defined in the series of standards EN ISO 10545 were tested on a semi-industrial probe, determining that this combination of materials (without the addition of quartz) may be efficiently used to produce ceramic floor tiles. The usage of what would otherwise be waste material contributes to sustainable management and environmentally friendly solutions by avoiding landfilling, while at the same time it enabling the conservation of scarce natural feldspar deposits.

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Novel approach to ensure the dimensional stability of large-format enameled porcelain stoneware tiles through water absorption control

Cited by 4 publications

References 20 publications

Optimizing raw material composition to increase sustainability in porcelain tile production: A simulation‐based approach

Optimizing raw material composition to increase sustainability in porcelain tile production: A simulation‐based approach

Estudo da viabilidade de calibração de placas padrão de duralumínio por meio de leitor automatizado

Aplitic Granite Waste as Raw Material for the Production of Outdoor Ceramic Floor Tiles

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