WO2003080534A1 - Process for the production of ceramic tiles - Google Patents
Process for the production of ceramic tiles Download PDFInfo
- Publication number
- WO2003080534A1 WO2003080534A1 PCT/IN2002/000067 IN0200067W WO03080534A1 WO 2003080534 A1 WO2003080534 A1 WO 2003080534A1 IN 0200067 W IN0200067 W IN 0200067W WO 03080534 A1 WO03080534 A1 WO 03080534A1
- Authority
- WO
- WIPO (PCT)
- Prior art keywords
- tiles
- range
- weight
- compacted
- glazed
- Prior art date
Links
Classifications
-
- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B35/00—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
- C04B35/01—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on oxide ceramics
- C04B35/16—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on oxide ceramics based on silicates other than clay
- C04B35/18—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on oxide ceramics based on silicates other than clay rich in aluminium oxide
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- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B33/00—Clay-wares
- C04B33/02—Preparing or treating the raw materials individually or as batches
- C04B33/13—Compounding ingredients
- C04B33/132—Waste materials; Refuse; Residues
- C04B33/1321—Waste slurries, e.g. harbour sludge, industrial muds
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
- Y02P40/00—Technologies relating to the processing of minerals
- Y02P40/60—Production of ceramic materials or ceramic elements, e.g. substitution of clay or shale by alternative raw materials, e.g. ashes
Definitions
- the invention relates to an improved process for the production of ceramic tiles using industrial wastes.
- the invention particularly relates to an improved process for the production of ceramic tiles using industrial wastes such as iron ore slime, fly ash and blast furnace slag.
- the products produced by the process of present invention may be of different shapes and sizes, in the glazed or unglazed forms as per requirement.
- the near impervious unglazed tiles shall be useful for laying floor of industries, storage depots, buildings etc. where the floors are subjected to scratch and abrasion.
- the glazed tiles with matte finish shall be useful for making decorative floors while the glazed tiles with glossy finish shall be useful for making decorative walls of buildings. Background of the invention
- Another known process use iron ore tailings in combination with other minerals like kaolin, feldspar, quartz, talc etc. to produce ceramic tiles.
- the raw materials are wet mixed in mills, filter pressed to squeeze the water out and then spray dried to get small nodules of raw material for better compaction.
- the ready powder is compacted in tile shape by hydraulic pressing then dried and fired to get unglazed tiles. To get the glazed tiles first engob then glaze is applied on the surface of unbaked tiles and then fired.
- US Patent No. 5,830,251 discloses the manufacture of ceramic tiles by first melting material to form glass, followed by grinding the glass with additives and compacting it to the shape required and devitrifying it to form the final ceramic tiles.
- US Patent 5.558,690 discloses a process wherein spent aluminium potliner containing carbonaceous material, fluorine and glass forming materials are oxidized to combust the carbonaceous materials and partially volatilize the fluorine in the glass forming materials. The oxidized glass forming materials are then vitrified to form a glass melt which is then formed into fluorine containing tiles.
- US Patent No. 5,935,885 discloses a process wherein fly ash containing organic material metal contaminants, and glass forming materials is oxidized under conditions sufficient to combust the organic material and partially oxidize the metal contaminants and the glass forming materials. The oxidized glass forming materials are then vitrified to form a glass melt, which is then formed into the final tiles containing metallic contaminants.
- Waste materials first need to melted thereby significantly increasing energy consumption.
- the further grinding of the glass formed also requires high energy consumption.
- the main object of the present invention is to provide an improved process to produce ceramic tiles in glazed and unglazed form using industrial wastes such as iron ore slime, fly ash, blast furnace slag and other low cost minerals.
- Another object of the present invention is to provide an improved process to produce unglazed and glazed ceramic tiles using industrial wastes such as iron ore slime, fly ash, blast furnace slag and other low cost minerals whereby the cost of production is appreciably lowered and the properties of the product is improved.
- Yet another object of the present invention is to provide an improved process to produce glazed and unglazed tiles using industrial wastes such as iron ore slime fly ash and blast furnace slag whereby the energy consumption is significantly reduced.
- Still yet another object of the present invention is to provide an improved process to produce glazed and unglazed tiles using iron ore slime, fly ash and blast furnace slag which are waste materials and thereby reducing the pollution in the environment.
- the present invention provides an improved process for the production of ceramic tiles using industrial wastes which comprises:
- the iron ore slime, fly ash, blast furnace slag and alumino silicate minerals are selected from the following composition range:
- the compacted tiles as obtained are fired at a temperature in the range of 1100 to 1300°C for a period in the range of 30 to 60 minutes to obtain unglazed tiles.
- unglazed tiles are cooled slowly after firing.
- engob is applied to the dried compacted tiles and the tiles thereafter glazed to obtain glazed tiles.
- engob is applied by spraying onto compacted tiles.
- the glazed tiles are fired at a temperature in the range of 1050 to 1150°C for a period in the range of 15 to 30 minutes. In another embodiment of the invention, glazed tiles are cooled slowly after firing.
- the aluminosilicate mineral is selected from the group consisting of kaolin, bentonite, illite and pyrophillite.
- the additives are selected from the group consisting of talc, soapstone, feldspar and any mixture thereof.
- the organic binder is selected from the group consisting of polyvinyl alcohol, methyl cellulose, carbomethoxy cellulose and dextrin.
- the binder is used in an amount in the range of 4 - 8% by weight.
- the compaction pressure for the tile is in the range of 250 - 300 kg/cm 2 .
- drying of compacted tiles is done in a temperature range of 90 - 120°C to obtain moisture content of less than 0.5% in dried tiles.
- liquid phase sintering of iron ore slime, fly ash and blast furnace slag takes place in the presence of aluminosilicate minerals. Additive is added during raw material mixing to promote the reaction sintering at lower temperature (1150 to 1250°C).
- the iron ore slime, used in the present invention contain iron oxides, and silica
- the fly ash used in the present invention contains silica, alumino and iron oxide
- the blast furnace slag used in the present invention contains calcium oxide, silica, alumina and magnesium oxide.
- Silica is the most important constituent for any ceramic tile composition to form crystalline as well as glassy phase.
- the three waste materials used in the present invention contain silica along with alumina, iron oxide and calcium oxide and magnesium oxide. These constituents react together during heating and form muUite, fayalite, anorthite and other crystalline phase on reaction sintering.
- the crystalline phase is uniformly distributed and reinforced in glassy matrix. As a result, a strong, dense and compact microstructure is achieved which contribute to the high scratch hardness and strength.
- the thermal expansion of the present tile body is kept equal or marginally higher then thermal expansion of the glaze, so that glaze materials remains under compression to the body to avoid microcracking and chipping of the glaze.
- Tiles produced by the present invention have the following range of properties: Dimension stability Within 0.5% variation.
- Modulus of rupture 250 kg/cm 2 Compression strength 350 to 500 kg/cm 2
- Example 1 is given by way of illustration and should not be construed to limit the scope of invention.
- 112 x l l2 x 7mm dimensions were produced by compaction at 260 kg/cm 2 pressure.
- Example 2 The tiles were then oven dried at 110°C for 14 hours. Finally unglazed tiles were obtained by sintering product at 1240°C for 45 minutes. The properties obtained are given in Table - 1 below.
- Example 2 The properties obtained are given in Table - 1 below.
- Example 3 The tiles were then dried in oven at 110°C for 15 hours. Finally the vitrified unglazed tiles were obtained by sintering the product at 1225°C for 1 hour. The properties are given in Table - 1.
- Example 3 The properties are given in Table - 1.
- Modulus rupture 400 360 255 270 (kg/cm2)
- the main advantages of the present invention are: a) The invention utilizes abundantly available industrial wastes as major raw materials to produce tiles, thereby reducing the cost of production in comparison to the known process, and reducing pollution. 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, modulus of rupture and compressive strength then products produced by existing process.
Abstract
Description
Claims
Priority Applications (4)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
AU2002249548A AU2002249548B2 (en) | 2002-03-26 | 2002-03-26 | Process for the production of ceramic tiles |
KR10-2003-7003973A KR100525682B1 (en) | 2002-03-26 | 2002-03-26 | Process for the production of ceramic tiles |
PCT/IN2002/000067 WO2003080534A1 (en) | 2002-03-26 | 2002-03-26 | Process for the production of ceramic tiles |
US10/113,218 US6743383B2 (en) | 2002-03-26 | 2002-03-28 | Process for the production of ceramic tiles |
Applications Claiming Priority (2)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
PCT/IN2002/000067 WO2003080534A1 (en) | 2002-03-26 | 2002-03-26 | Process for the production of ceramic tiles |
US10/113,218 US6743383B2 (en) | 2002-03-26 | 2002-03-28 | Process for the production of ceramic tiles |
Publications (1)
Publication Number | Publication Date |
---|---|
WO2003080534A1 true WO2003080534A1 (en) | 2003-10-02 |
Family
ID=29781669
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
PCT/IN2002/000067 WO2003080534A1 (en) | 2002-03-26 | 2002-03-26 | Process for the production of ceramic tiles |
Country Status (1)
Country | Link |
---|---|
WO (1) | WO2003080534A1 (en) |
Cited By (2)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
CN104961435A (en) * | 2015-06-02 | 2015-10-07 | 安徽省含山瓷业股份有限公司 | Benshanlvni ceramic bowl and preparation method thereof |
CN114773032A (en) * | 2022-05-13 | 2022-07-22 | 河南城建学院 | Preparation method of red brick-imitated furring brick |
Citations (2)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US4299632A (en) * | 1980-09-22 | 1981-11-10 | Naum Gosin | Ceramic mixture |
JPH01278443A (en) * | 1988-05-02 | 1989-11-08 | Nippon Mining Co Ltd | Soil for tile and production of tile using the same soil |
-
2002
- 2002-03-26 WO PCT/IN2002/000067 patent/WO2003080534A1/en not_active Application Discontinuation
Patent Citations (2)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US4299632A (en) * | 1980-09-22 | 1981-11-10 | Naum Gosin | Ceramic mixture |
JPH01278443A (en) * | 1988-05-02 | 1989-11-08 | Nippon Mining Co Ltd | Soil for tile and production of tile using the same soil |
Non-Patent Citations (2)
Title |
---|
DATABASE WPI Week 197252, Derwent World Patents Index; AN 1972-82042T, XP002222430 * |
PATENT ABSTRACTS OF JAPAN vol. 014, no. 047 (C - 0682) 29 January 1990 (1990-01-29) * |
Cited By (3)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
CN104961435A (en) * | 2015-06-02 | 2015-10-07 | 安徽省含山瓷业股份有限公司 | Benshanlvni ceramic bowl and preparation method thereof |
CN114773032A (en) * | 2022-05-13 | 2022-07-22 | 河南城建学院 | Preparation method of red brick-imitated furring brick |
CN114773032B (en) * | 2022-05-13 | 2023-09-26 | 河南城建学院 | Preparation method of red brick-imitating veneer tile |
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