KR20030091933A - Process for the production of ceramic tiles - Google Patents

Abstract

The present invention relates to an improved method for the production of ceramic tiles using industrial waste. The present invention relates in particular to an improved method for producing ceramic tiles using industrial wastes such as iron ore brine, fly ash and furnace slag.

Description

Production method of ceramic tile {PROCESS FOR THE PRODUCTION OF CERAMIC TILES}

The methods known to date produce ceramic tiles using expensive minerals such as kaolin, feldspar, quartz, talc, chloroplast (pyrophyllite) and the like. Current processes for producing ceramic tiles consist of wet mixing of raw materials, spray drying, compression molding, drying, glazing (seeding) and firing. The raw materials are wet mixed in the mill. The wet slurry obtained is filter pressed to squeeze water and then spray dried to obtain a very small raw material for better compression. The powder in preparation is compressed into tile form by hydraulic pressing, then dried and calcined to obtain a matte tile. In order to obtain a seesaw tile, an enob is first applied to hide the color of the body and then glaze is applied to the surface of the tile, which is not yet baked, and then fired. Current processes also require double firing for high quality gloss glazing of wall tiles. Another known method uses iron ore tailing in combination with other minerals such as kaolin, feldspar, quartz, talc and the like to produce ceramic tiles. The raw materials are wet mixed in a mill, filter pressed to squeeze out water and then spray dried to obtain small sintered raw materials for better compression. The preparation powder is compressed into tile form by hydraulic pressing, then dried and calcined to obtain oil-free tiles. In order to obtain a seesaw tile, the engrav is first applied to the surface of the uncured tile, then the glaze is applied and then calcined.

U. S. Patent 5,830, 251 discloses the manufacture of ceramic tiles by first melting the material to form a glass, then crushing the glass with additives, compressing it into the desired shape and devitrifying it to form the final ceramic tile.

US Pat. No. 5,558,690 discloses a process of oxidizing a waste aluminum portliner containing carbonaceous material, fluorine and glass forming material to burn carbonaceous material and partially volatilize fluorine in the glass forming material. The oxidized glass forming material is then vitrified to form a glass melt which is then shaped into a fluorine containing tile.

U. S. Patent 5,935, 885 discloses a process for oxidizing fly ash containing organic materials, metal contaminants, and glass forming materials, under conditions sufficient to burn organic materials and partially oxidize metal contaminants and glass forming materials. The oxidized glass forming material is then vitrified to form a glass melt, which is then shaped into a final tile containing metal contaminants.

This process has several disadvantages:

1. The waste material must be melted first, thereby significantly increasing energy consumption.

2. Further grinding the formed glass also requires high energy consumption.

Floors made of products of known methods cannot withstand the scratches and high wear required in many industrial applications because they have relatively low scratch hardness (about 5 in Mohs hardness) and compressive strength. The cost of producing sintered tiles made from expensive materials is relatively high. The raw materials used for the production of current ceramic floor and wall tiles require long time to grind to achieve fineness because they are formed in agglomerates, resulting in more energy consumption.

The present invention relates to an improved method for the production of ceramic tiles using industrial waste. The present invention relates in particular to an improved method for producing ceramic tiles using industrial wastes such as iron ore brine, fly ash and furnace slag.

The products produced by the process of the present invention may be of different shapes and sizes, either in glazed or unglazed form, as desired. Near impermeable, oil-free tiles will be useful for industrial laid floorboards, storage depots, buildings, etc. where floors are scratched and worn. While polished polished tile is useful for making decorative walls of buildings, polished tile with matte finish will be useful for making decorative floors.

Purpose of the Invention

It is a primary object of the present invention to provide an improved method for producing ceramic tiles in the marketed and oil free form using industrial wastes such as iron ore brine, fly ash, furnace slag and other low cost minerals.

It is yet another object of the present invention to provide an improved method for manufacturing ceramic tiles in the form of oil-free and oil-free using industrial wastes such as iron ore varnish, fly ash, furnace slag and other low cost minerals, which significantly lowers the manufacturing costs and improves the properties of the product. To provide.

It is still another object of the present invention to provide an improved method of significantly lowering energy consumption by manufacturing oil- and oil-free tiles using industrial wastes such as iron ore brine, fly ash, furnace slag.

Still another object of the present invention is to provide an improved method for producing skimmed and oil free tiles using iron ore slag, fly ash, furnace slag as industrial waste and thereby reducing environmental pollution.

Summary of the Invention

According to literature research and available information, there is currently no method available for producing ceramic tiles from energy intensive iron ore brine, fly ash, furnace slag. The objective of this development is to produce value-added products such as ceramic tiles using raw materials from large quantities of available waste, such as iron ore slag, fly ash and furnace slag, which cause environmental pollution.

Accordingly, the present invention provides an improved method for the manufacture of ceramic tiles using industrial waste comprising the following steps:

(a) iron ore slag in the range of 30-50 wt%, 10-25 wt% fly ash, 5-20 wt% blast furnace slag, 25-50 wt% aluminosilicate mineral, 5-15 wt% additive Mixing the balance intimately over a period of time ranging from 6 to 10 hours,

(b) drying the wet mixed raw material,

(c) atomizing the dried powder using an organic liquid binder

(d) compacting the particulate powder to form a tile of the desired size,

(e) slowly drying the compressed tile at a temperature in the range of 90 to 120 ° C. for a period in the range of 10 to 15 hours.

In one embodiment of the invention, the iron ore brine, fly ash, furnace slag and aluminosilicate minerals are selected from the following composition ranges.

The compressed tile obtained in one embodiment of the present invention is calcined at a temperature in the range of 1100 to 1300 ° C. for a time in the range of 30 to 60 minutes to obtain a matt tile.

In another embodiment of the present invention, the oil free tile is cooled slowly after firing.

In another embodiment of the invention, an engraved product is applied to a dried compressed tile and the tile is then glazed to obtain a seesaw tile.

In a further embodiment of the invention, the engrav is applied by spraying onto the compressed tile.

In a further embodiment of the invention, the ointment tile is calcined at a temperature in the range of 1050 to 1150 ° C. for a time in the range of 15 to 30 minutes.

In another embodiment of the present invention, the ointment tile is cooled slowly after firing.

In a further embodiment of the invention, the aluminosilicate mineral is selected from the group consisting of kaolin, bentonite, elite and chalolite.

In another embodiment of the invention, the additive is selected from the group consisting of talc, shamstone, feldspar, and any mixtures thereof.

In yet another embodiment of the invention, the organic binder is selected from the group consisting of polyvinyl alcohol, methyl cellulose, carbomethoxy cellulose and dextrin.

In a further embodiment of the invention, the binder is used in an amount in the range of 4-8% by weight.

In yet another embodiment of the invention, the compression pressure for the tile is in the range of 250-300 kg / cm ² .

In another embodiment of the present invention, drying of the compressed tiles is carried out at a temperature range of 90-120 ° C. to obtain a moisture content of less than 0.5% in the dried tiles.

Detailed description of the invention

In the process of the present invention, liquid phase sintering of iron ore brine, fly ash and furnace slag occurs in the presence of aluminosilicate minerals. Additives are added during the mixing of the raw materials to promote reaction sintering at lower temperatures (1150-1250 ° C.). The iron ore brine used in the present invention contains iron oxide and silica, and the fly ash used in the present invention contains silica, alumino and iron oxide, and the furnace slag used in the present invention contains calcium oxide, silica, alumina and magnesium oxide. It contains.

Silica is the most important component for any ceramic tile composition to form crystalline as well as the glass phase. The three waste materials used in the present invention contain silica together with alumina, iron oxide and calcium oxide and magnesium oxide. These components react together during heating and form mullite, payalite, feldspar (anotite) and other crystalline phases in the reaction sintering. The crystal phases are uniformly distributed and strengthened in the glass phase matrix. As a result, a strong, dense and compact microstructure, which causes high scratch hardness and strength, is obtained. The thermal expansion of the tile body of the present invention remains the same or barely higher than that of the glaze so that the glaze material remains under compression into the body to avoid microcracks and flaking of the glaze.

Tiles made by the present invention have the following range of properties:

Dimensional stability within 0.5% deformation

Surface properties 95% free of visible defects

2-5% for Percent Water Absorption Floor

14-16% for walls

Scratch Hardness 6-7 (Moss Hardness)

Fracture Coefficient 250 kg / cm ²

Compressive strength 350 to 500 kg / cm ²

The following examples are given by way of illustration and should not be construed as limiting the scope of the invention.

Example 1

300 g of iron ore brine, 250 g of fly ash, 80 g of furnace slag, 300 g of aluminosilicate mineral and 70 g of additives were uniformly mixed with 750 cc of water in a pot mill for a duration of 10 hours. The slurry was dried in an electric oven at 105 ° C. 60 cc of polyvinyl alcohol was evenly sprayed onto the dried powder. Commercially sized tiles of 112 × 112 × 7 mm dimensions were made by compression at 260 kg / cm ² pressure.

The tiles were then oven dried at 110 ° C. for 14 hours. The product was finally sintered at 1240 ° C. for 45 minutes to finally obtain an oil free tile. The properties obtained are given in Table 1 below.

Example 2

For nine hours in a pot mill, 370 g of iron ore brine, 200 g of fly ash, 120 g of furnace slag, 250 g of aluminosilicate mineral and 60 g of additive were mixed uniformly with 850 cc of water. Dehydration of the slurry was carried out by drying at 110 ° C. in an oven. 50 cc of carboxy-methyl cellulose were sprayed thoroughly onto the powder. Square shaped tiles of dimensions 112 × 112 × 8 mm were compressed at 300 kg / cm ² pressure.

The tiles were then dried in an oven at 110 ° C. for 15 hours. The product was finally sintered at 1225 ° C. for 1 hour to obtain a finally vitrified oil free tile. The properties are given in Table 1 below.

Example 3

In a pot mill, 320 g of iron ore brine, 150 g of fly ash, 150 g of furnace slag, 300 g of aluminosilicate mineral and 80 g of additives were thoroughly mixed with 800 cc of water. Dehydration of the slurry was carried out by drying in an oven at 110 ° C. 55 cc of polyvinyl alcohol was evenly sprayed onto the powder. 112 x 112 x 6 mm size tiles were made by compression at 250 kg / cm ² .

The tile was then dried at 110 ° C. for 15 hours. The engraved first and then the glaze were evenly sprayed onto the surface of the tile. Finally, baking was performed at 1150 ° C. for 30 minutes to obtain a glazed tile. The properties obtained are given in Table 1.

Example 4

For 10 hours in a pot mill, 400 g of iron ore brine, 150 g of fly ash, 100 g of furnace slag, 250 g of aluminosilicate mineral and 100 g of additive were mixed using 750 cc of water. Dehydration of the slurry was carried out by drying in an oven at 110 ° C. 60 cc of polyvinyl alcohol was then evenly sprayed onto the dry powder. Commercially sized tiles of 112 × 112 × 7 mm dimensions were made by compression at 280 kg / cm ² pressure. The tiles were then oven dried at 110 ° C. for 15 hours. Engraving and glaze were evenly sprayed onto the surface of the tile. Finally, sintering was performed at 1100 ° C. for 30 minutes to obtain a crude oil tile. The obtained properties are shown in Table 1.

The main advantages of the present invention are:

a) The present invention produces tiles using abundantly available industrial waste as the main raw material, thereby lowering manufacturing costs and reducing contamination compared to known processes.

b) The present invention saves energy in terms of grinding time of raw materials.

c) The products of the present invention are superior in terms of scratch hardness, fracture modulus and compressive strength to products produced by current processes.

Claims (14)

As a method for producing a ceramic tile using industrial waste, (a) iron ore slag in the range of 30-50 wt%, 10-25 wt% fly ash, 5-20 wt% blast furnace slag, 25-50 wt% aluminosilicate mineral, 5-15 wt% additive Intimately mixing the balance over a period of time ranging from 6 to 10 hours, (b) drying the wet mixed raw material, (c) atomizing the dried powder using an organic liquid binder (d) compacting the particulate powder to form a tile of the desired size, (e) slowly drying the compressed tile at a temperature in the range of 90 to 120 ° C. for a period in the range of 10 to 15 hours. 2. The method of claim 1 wherein the iron ore brine, fly ash, furnace slag and aluminosilicate minerals are selected from the following composition ranges. The method of claim 1 wherein the compressed tile as obtained is calcined at a temperature in the range of 1100 to 1300 ° C. for a time in the range of 30 to 60 minutes. 4. A method according to claim 3, wherein the oil free tile is cooled slowly after firing. The method of claim 1, wherein the engraved product is applied to the dried compressed tile and then the tile is glazed to obtain a seesaw tile. 6. The method of claim 5, wherein the application is by spraying the engraved product onto the compressed tile. 6. The method of claim 5, wherein the ointment tile is calcined at a temperature in the range of 1050 to 1150 [deg.] C. for a time in the range of 15 to 30 minutes. 6. The method of claim 5, wherein the seesaw tile is cooled slowly after firing. 2. The method of claim 1, wherein the aluminosilicate mineral is selected from the group consisting of kaolin, bentonite, elite and chalcopyrite. The method of claim 1 wherein the additive is selected from the group consisting of talc, shamstone, feldspar, and any mixtures thereof. The method of claim 1 wherein the organic binder is selected from the group consisting of polyvinyl alcohol, methyl cellulose, carbomethoxy cellulose and dextrin. The method of claim 1 wherein the binder is used in an amount in the range of 4-8% by weight. The method of claim 1 wherein the compression pressure on the tile is in the range of 250-300 kg / cm ² . The method of claim 1 wherein the drying of the compressed tile is carried out at a temperature range of 90-120 ° C. to obtain a moisture content of less than 0.5% in the dried tile.