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Ceramic tiles reach their final microstructures and acquire their technical properties by firing process after shaping, glazing, and drying processes. The firing process is carried out continuously in roller kilns. In roller kilns, tiles pass through firing zones at different firing temperatures such as preheating, firing, and cooling zones in which different types of rollers are used. deformations such as breakage and deterioration of roller smoothness occur in the kiln roller over time due to high temperature and tile mass. For these reasons, unused kiln rollers are separated into waste and replaced with new ones. In the present study, the purpose was to transform the kiln roller into a value-added product. For this purpose, the use of kiln roller wastes in glazed porcelain tile matte-opaque glaze was investigated. Ground kiln roller waste was used instead of alumina, quartz, and zircon in a standard matte-opaque glaze composition. The developed glazes were sintered at 1190 °C for 44 min. The thermal, optical, and physical properties of the glazes were examined and compared with the standard glaze recipe. The melting behaviors of the glazes were measured with a heating microscope, and the thermal expansion coefficients were measured with a dilatometer. The phases developed in the structure were determined by XRD analysis and scanning electron microscope (SEM). According to the results, the usage of roller waste instead of alumina and quartz decreased the crystal phase development in the glaze and the opacity, causing an increase in surface glossiness. When it was used instead of zircon, anorthite and crystal phase development increased and the surface brightness decreased, but the opacity decreased significantly due to the decline of zircon crystals. Considering all these thermal and optical properties, it was determined that the use of roller waste would be possible with some optimizations in the composition of matte-opaque glaze composition.
Ceramic tiles reach their final microstructures and acquire their technical properties by firing process after shaping, glazing, and drying processes. The firing process is carried out continuously in roller kilns. In roller kilns, tiles pass through firing zones at different firing temperatures such as preheating, firing, and cooling zones in which different types of rollers are used. deformations such as breakage and deterioration of roller smoothness occur in the kiln roller over time due to high temperature and tile mass. For these reasons, unused kiln rollers are separated into waste and replaced with new ones. In the present study, the purpose was to transform the kiln roller into a value-added product. For this purpose, the use of kiln roller wastes in glazed porcelain tile matte-opaque glaze was investigated. Ground kiln roller waste was used instead of alumina, quartz, and zircon in a standard matte-opaque glaze composition. The developed glazes were sintered at 1190 °C for 44 min. The thermal, optical, and physical properties of the glazes were examined and compared with the standard glaze recipe. The melting behaviors of the glazes were measured with a heating microscope, and the thermal expansion coefficients were measured with a dilatometer. The phases developed in the structure were determined by XRD analysis and scanning electron microscope (SEM). According to the results, the usage of roller waste instead of alumina and quartz decreased the crystal phase development in the glaze and the opacity, causing an increase in surface glossiness. When it was used instead of zircon, anorthite and crystal phase development increased and the surface brightness decreased, but the opacity decreased significantly due to the decline of zircon crystals. Considering all these thermal and optical properties, it was determined that the use of roller waste would be possible with some optimizations in the composition of matte-opaque glaze composition.
Pumice, a porous rock resulting from the rapid cooling of tuff fragments during volcanic activity, exhibits a spongy texture and light color due to its low density. Found predominantly in Central Anatolia and Eastern Anatolia, it has drawn interest for industrial applications. This study delved into utilizing micronized pumice within the porcelain tile manufacturing process. Comparative analyses were conducted between formulations incorporating micronized pumice and the standard ceramic tile recipe. In place of feldspar, micronized pumice was introduced at concentrations of 3%, 5%, and 7%, while clay was substituted with micronized pumice at concentrations of 3%, 5%, 7%, and 10% by weight. The prepared bodies were fired in an industrial kiln at 1210 °C for 54 min, and various physical and mechanical properties were evaluated. These included viscosity, sieve residue, green strength pre-firing, firing shrinkage, water absorption, firing strength, and firing color after-firing. The results indicated that the samples incorporating micronized pumice closely matched the physical and mechanical properties of the standard porcelain tile. Phase and microstructural analyses revealed the presence of mullite and quartz phases. Notably, micronized pumice demonstrated promise as a substitute for clay or feldspar, with the optimal usage rate determined to be 7% in the porcelain tile recipe. This indicates that pumice has the potential to be an alternative raw material in the production of porcelain tiles.
Porous ceramics were synthesized using porcelain tile polishing residue (PTPR) and slaked lime (Ca(OH)2) as a reinforcing agent through a hydrothermal autoclaving method. The process parameters, including the quantity of slaked lime added, the hydrothermal autoclaving temperature, and the reaction duration, were optimized meticulously. The composition, structure, thermal and physical properties of the samples were thoroughly analyzed via Brunauer–Emmett–Teller (BET) measurements, powder X-ray diffraction (PXRD), and scanning electron microscopy (SEM). The results indicated that the incorporation of slaked lime and hydrothermal autoclaving led to the formation of calcium silicate hydrate, which corresponded with an enhancement in the strength of the sample. Notably, when the quantity of slaked lime added was optimized at 30 wt%, the formation of tobermorite (5CaO·6SiO2·5H2O) was detected. At a hydrothermal autoclaving temperature of 150 °C, the formation of only sheet-like calcium silicate hydrate was observed. In contrast, at an elevated temperature of 180 °C and 210 °C, needle-like tobermorite was successfully synthesized. The porous ceramic with the most favorable structure was obtained through autoclaving at 180 °C for 10 h with 30 wt% slaked lime, exhibiting a total pore volume of 0.11 mL/g, a specific surface area of 26.35 m2/g, and a mesoporous volume fraction of 90.40%.
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