WO2022215101A1 - Procédé et installation de préparation d'un matériau adapté à la fabrication de carreaux en céramique - Google Patents

Procédé et installation de préparation d'un matériau adapté à la fabrication de carreaux en céramique Download PDF

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Publication number
WO2022215101A1
WO2022215101A1 PCT/IT2022/050090 IT2022050090W WO2022215101A1 WO 2022215101 A1 WO2022215101 A1 WO 2022215101A1 IT 2022050090 W IT2022050090 W IT 2022050090W WO 2022215101 A1 WO2022215101 A1 WO 2022215101A1
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Prior art keywords
assembly
water
tank
plant
regulator assembly
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PCT/IT2022/050090
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English (en)
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WO2022215101A4 (fr
Inventor
Aldo Tomaso BALELLI
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Balelli Aldo Tomaso
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Priority to EP22721903.7A priority Critical patent/EP4320088A1/fr
Publication of WO2022215101A1 publication Critical patent/WO2022215101A1/fr
Publication of WO2022215101A4 publication Critical patent/WO2022215101A4/fr

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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
    • C04B35/00—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
    • C04B35/622—Forming processes; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
    • C04B35/626—Preparing or treating the powders individually or as batches ; preparing or treating macroscopic reinforcing agents for ceramic products, e.g. fibres; mechanical aspects section B
    • C04B35/62605—Treating the starting powders individually or as mixtures
    • C04B35/6261—Milling
    • 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
    • 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
    • C04B35/622—Forming processes; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
    • C04B35/626—Preparing or treating the powders individually or as batches ; preparing or treating macroscopic reinforcing agents for ceramic products, e.g. fibres; mechanical aspects section B
    • C04B35/62605—Treating the starting powders individually or as mixtures
    • C04B35/62625—Wet mixtures
    • C04B35/6263—Wet mixtures characterised by their solids loadings, i.e. the percentage of solids
    • 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
    • C04B35/622—Forming processes; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
    • C04B35/626—Preparing or treating the powders individually or as batches ; preparing or treating macroscopic reinforcing agents for ceramic products, e.g. fibres; mechanical aspects section B
    • C04B35/62605—Treating the starting powders individually or as mixtures
    • C04B35/62645—Thermal treatment of powders or mixtures thereof other than sintering
    • C04B35/62655—Drying, e.g. freeze-drying, spray-drying, microwave or supercritical drying
    • 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
    • C04B35/622—Forming processes; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
    • C04B35/626—Preparing or treating the powders individually or as batches ; preparing or treating macroscopic reinforcing agents for ceramic products, e.g. fibres; mechanical aspects section B
    • C04B35/62605—Treating the starting powders individually or as mixtures
    • C04B35/62695—Granulation or pelletising

Definitions

  • the present invention relates to a method and a plant for preparing a material, in particular in powder or in granular form, suitable for manufacturing ceramic tiles.
  • Ceramic tiles are usually produced with a standardized technological system, which involves the continuous batching of raw materials to mix the different components intended to be part of the mixture. These are normally materials with very different physical and rheological characteristics: for example plastic materials, fluxes, stabilizers, etc. Each component is used to control one or more quality parameters of the product, such as stability in green, in dry, in firing, to achieve the desired quality of the fired ceramic tiles, for example made tangible by the color of the body formulation, by the water absorption capacity, dimensional regularity, the absence of surface defects and many other measurable parameters.
  • quality parameters of the product such as stability in green, in dry, in firing, to achieve the desired quality of the fired ceramic tiles, for example made tangible by the color of the body formulation, by the water absorption capacity, dimensional regularity, the absence of surface defects and many other measurable parameters.
  • the raw materials, mixed according to a specific method are milled in a roller or hammer mill, without adding water. Then, the milled body formulation is granulated, for example in a rotating drum, adding, only in this step, a specific, but reduced, amount of water.
  • the raw materials are added with a high quantity of water, usually equal to 35% of the total weight, so as to form an aqueous suspension called "slurry".
  • the amount of water added to the solid raw materials can vary depending on the body formulation, for example it can reach over 40%.
  • Wet milling usually takes place by means of mills, in which the mixture of raw materials is fed, together with a specific amount of water, and it comes out milled with residues between 3 and 8%, through a 63 micron sieve.
  • These average reference values for example, refer respectively to the production of porcelain stoneware and red-body floors.
  • wet milling has significant advantages over dry milling. In fact, it requires less frequent maintenance of the system, exploits the disintegrating power of water and, compared to dry milling, it offers the possibility of sieving at the previously mentioned fine grain sizes. Furthermore, the resulting body formulation is not subject to possible reclassification due to the difference in the specific weight of the raw materials in following transport. [09] Furthermore, while dry milling requires that the raw materials are selected from a limited number of materials, wet milling allows the widest choice of formulations, in order to obtain, as previously described, the control of the various process parameters and the desired end result.
  • wet milling is generally preferred, which achieves products of high quality and resistance.
  • wet milling it is possible to obtain highly vitrified products, even below 0.2% water absorption, with minimal surface defects, and also having large size, with no complications of the production process.
  • the spray dryer has significant economic and environmental disadvantages, due to the large consumption of energy, water, as well as the emissions of dust and CO2.
  • thermal consumption values are on average about 440 kcal/kg in the spray drying process, 90 kcal/kg in the drying process after the forming step, and 490 kcal/kg in the firing step.
  • an average product is considered in which the slurry fed into the spray dryer has a percentage of inlet water equal to 35% and outlet water equal to 8%.
  • different inlet and outlet humidity levels affect the consumption of thermal energy. For example, an increase in water in the slurry entering the spray dryer or a decrease in the moisture content in the outgoing body formulation, equal to one percentage point, can lead to an increase of about 4% in thermal energy consumption.
  • the spray dryer must extract about 27% of the initial water content from the slurry.
  • the extracted water is materially visible in the white plumes that come out of the factories and which testify to how it is substantially dispersed into the environment.
  • emission levels may be reduced, but hardly below 20 mg/Nm 3 .
  • the emission value may appear to be very low, in reality, the enormous volumes of air involved, equal for example to about 140,000 Nm 3 /h in a 14,000-liter/h spray dryer, involve a considerable introduction into the atmosphere of powders with a high content of silica, therefore of particles, as is known, very dangerous for health.
  • the powders emitted by the ceramics are mainly silicon, which effect in the lungs is known to cause both silicosis, TB and tumors, as also emerges from the study of the National Health Service entitled "Evaluation of exposure to free crystalline silica in some production sectors in Emilia Romagna, summary of the results/SSN - 2005”, in which, in particular, the high risks for workers in the ceramic tile production sector are highlighted.
  • the Sassuolo area uses approximately 442,000,000 m 3 of gas, from which combustion 1.8 kg of CO2 are obtained per m 3 of methane.
  • the rough calculation of CO2 emitted by the spray dryers is therefore about 790,000 tons/year, equal to about 2,300 tons per day.
  • patent application CN 110407587 discloses a process of dry and wet milling of materials suitable for producing ceramic tiles.
  • the aim of the present invention is to solve the aforementioned problems, devising a method and a plant for preparing a material, in particular in powder or granular form, suitable for manufacturing ceramic tiles which minimizes consumption, in particular of thermal energy and water.
  • a further object of the invention is to provide a method and a plant for preparing a material suitable for producing ceramic tiles, capable of minimizing the environmental impact, in particular with regard to the emission of dust and carbon dioxide.
  • Another purpose of the invention is to provide a method and a plant for preparing a material suitable for producing ceramic tiles that are adapted to maximize energy savings.
  • the method according to the invention makes it possible to prepare a material having a desired moisture content, preferably in the powder or granular state, therefore suitable for being formed by pressing and intended for manufacturing ceramic tiles by pressing and then firing.
  • This material is made up of a number of different substances, according to a formulation or recipe known in the ceramic production sector.
  • the method according to the invention therefore provides for preparing, according to a specific recipe, a batched quantity of solid raw materials, suitable for manufacturing ceramic tiles.
  • a recipe or formulation also called “body formulation” for producing ceramic tiles, usually includes a fraction of so-called “plastic” raw materials, for example clays, and so-called “non-plastic” raw materials, for example inert and fluxes.
  • the method then provides for wet milling or blunging at least a part of the recipe, using a wet milling or blunging apparatus known in the art, adding a certain percentage by weight of water, in order to obtain a material at the inlet, preferably a slurry, that is an aqueous suspension of particles of solid materials or in any case a "wet" material.
  • This percentage by weight corresponds to an initial moisture content of the input material, which can be for example equal to, or included in a range of a few percentage points around 35%.
  • I he solid raw materials in aqueous suspension are also called "slip" in the specific sector of the production of ceramic tiles.
  • a moisture regulator assembly comprising a tank containing a plurality of bodies freely arranged inside the tank.
  • the tank can be rotated according to a longitudinal axis and is associated with a feeding assembly for a controlled flow of an operating fluid, in particular air, to feed thermal energy to the tank to extract by evaporation an excess quantity of water from the input material.
  • the method then provides for feeding the input material into the tank of the regulator assembly and for rotating the same tank around the longitudinal axis, to obtain an output material of the regulator assembly, having a desired moisture content.
  • the aforementioned bodies can therefore perform a crushing and/or milling and/or stirring action of the substances placed inside the tank, when the tank is rotated.
  • the aforementioned regulator or stirrer assembly is a moisture regulator assembly of the fed aqueous suspension, which also comprises a feed assembly for an operating fluid, configured to exchange heat with the aqueous suspension inserted in the tank, and thus reduce its moisture content.
  • the milling and/or stirring bodies are arranged free inside the tank, so as to be dragged in rotation by the rotational motion of the tank itself, to usefully stir and crush the solid raw material preferably in aqueous suspension, introduced into the tank.
  • This crushing favors, in particular, not only a mixing action, but also an optimal heat exchange, in particular between the operating fluid and aqueous suspension, drying the latter, if required.
  • the method involves regulating, in particular correcting, the moisture content of the material entering the tank, by rotating the tank, then mixing by stirring and/or removing an excess amount of water by operating the assembly for feeding the operating fluid, preferably hot air, at a determined temperature, for example around or above 40° C.
  • the method involves stirring, then homogenizing, and crushing the incoming material, rotating the tank around the longitudinal axis, thus obtaining a material coming out from the regulator assembly, preferably in powder or granular form, having a desired moisture content.
  • the method can then provide for transferring the output material obtained from the regulator assembly to a granulator assembly, to granulate it and obtain a granular material suitable for producing ceramic tiles.
  • the abovementioned tank is therefore loaded with bodies, for example balls, preferably of sintered alumina.
  • the method can provide for extracting, or sieving, the output material coming out of the regulator assembly through filtering means, for example cyclones.
  • the tank of the regulator assembly can provide extraction means, for example made by means of a perforated sector arranged at a section of the tank, associated with suction members, to separate the flow of operating fluid heavy with moisture from the output material, obtained by stirring and crushing.
  • the ceramic body formulation or output material obtained comprises substantially the same batched quantity of solid materials initially introduced into the regulator assembly and a residual amount of water, i.e. a desired content preferably around 2 - 5%.
  • the method can therefore provide for the further step of regulating the moisture content of the input material, in particular in the slurry state, in order to obtain the desired content, by feeding the aforementioned controlled flow of operating fluid through the tank, in particular against the current, that is against the input material.
  • the introduction of the operating fluid into the tank can be controlled by control means known in the art, associated with the aforementioned feed assembly, for example as a function of the initial moisture content and/or the humidity or quantity of excess water to be extracted.
  • the method preferably provides that the aforementioned operating fluid is supplied by a heat recovery assembly, configured to recover the operating fluid produced at the outlet of a firing kiln for manufacturing ceramic tiles, set up for operation, and/or by an assembly of cogeneration arranged, in order to dry the input material, in particular the slurry or aqueous suspension, and to extract by evaporation an excess quantity of water, so as to obtain the body formulation or output material having the desired moisture content.
  • a heat recovery assembly configured to recover the operating fluid produced at the outlet of a firing kiln for manufacturing ceramic tiles, set up for operation, and/or by an assembly of cogeneration arranged, in order to dry the input material, in particular the slurry or aqueous suspension, and to extract by evaporation an excess quantity of water, so as to obtain the body formulation or output material having the desired moisture content.
  • the method can provide for separating the excess quantity of water from the input material, in particular from the slurry, by thermal separation means, through the same regulator assembly.
  • the flow of operating fluid preferably hot air, can pass through the regulator assembly, for example inside the tank and/or in a cavity made in a respective tank shell.
  • the regulator assembly preferably uses amounts of thermal energy made available through the heat recovery assembly from other steps of the tile production process, for example, and mainly, from the step of firing in the kiln.
  • the recovered thermal energy is in the form of hot air coming from the cooling areas of the firing kiln itself or from the flue gas outflow chimney.
  • the method may provide, in order to thermally extract excess water, for using thermal recovery energy produced as an alternative, if, for example, the system does not have a tiring kiln, by a cogeneration assembly set up in the system.
  • a cogeneration assembly is an electrical energy production system, comprising means such as turbines or endothermic engines, suitable for generating electrical energy, and for recovering the heat generated by them as exhaust gas and/or cooling air.
  • the method can provide, in addition or alternatively, to provide a device for feeding the thermal energy, necessary to extract the aforementioned amount of excess water, for example comprising a burner acting on the flow of operating fluid, in particular hot air, inserted for example in an independent pipe or in a pipe of the heat recovery assembly, in this case to make up for at least temporarily the possible lack of hot recovery air, due to production stops of the kiln or of the kilns connected thereto, or the temporary shutdown of the aforementioned cogeneration assembly.
  • a device for feeding the thermal energy, necessary to extract the aforementioned amount of excess water for example comprising a burner acting on the flow of operating fluid, in particular hot air, inserted for example in an independent pipe or in a pipe of the heat recovery assembly, in this case to make up for at least temporarily the possible lack of hot recovery air, due to production stops of the kiln or of the kilns connected thereto, or the temporary shutdown of the aforementioned cogeneration assembly.
  • the step of separating the excess quantity of water by thermal separation means can be preceded by an intermediate step, in which a part of the excess quantity of water to be extracted is separated, with the aid of a mechanical separation assembly.
  • the mechanical separation carried out in this intermediate step involves the reduction in the percentage of water in the slurry or initial aqueous suspension, and the obtainment of an intermediate material with an intermediate moisture content, but it may require still a following step, by the stirring assembly, of bringing the moisture content to the desired level.
  • the water mechanically extracted in the aforementioned intermediate step is rich in water-soluble substances, in particular salts.
  • the method may further include the step of shredding the body formulation with an intermediate moisture content using a shredding assembly.
  • the method can comprise the further step of recovering at least part of the aforementioned excess amount of water, extracting it by condensation from the stirrer assembly, and of using it at least in part for the initial step of preparing the slurry and/or for the step of humidifying and re-granulating the body formulation.
  • the regulator assembly includes a rotary tank, with continuous or discontinuous operation.
  • the method can advantageously provide for recovering, at least in part, preferably totally, by condensation, the excess quantity of water, possibly separated by the regulator assembly, by means of a water recovery assembly, and to reuse the condensate upstream of the process such as milling water in the apparatus for wet milling or tor blunging.
  • a considerable part of the process water for example estimated at about 60%, may be recovered in this way.
  • the method thus permits to obtain preferably a powder of suitable particle size, avoiding the use, for example, of a pin mill or similar means.
  • the method preferably provides for subsequently moisturizing the powder obtained to a suitable final moisture content, for example between 6% and 8%, and re-granulating it by means of the granulators known in the art.
  • This step makes it possible to obtain a granular mixture suitable, due to its physical shape and moisture content, for loading known forming apparatuses, such as, for example, presses for forming ceramic tiles.
  • the method may provide for storing the body formulation or granulated material in containment units, for example silos, to allow its subsequent use, according to the operating steps known in the ceramic tile production sector.
  • the method can provide for the further step of feeding into the tank of the stirring assembly a further batched quantity of raw materials in powder obtained by dry milling, thus forming in this case a semiliquid mixture with a lower moisture content.
  • the regulator assembly optimizes the energy required for mixing this semiliquid mixture.
  • the batched portion of raw materials, prepared in aqueous suspension, and the additional batched quantity pre-dry milled combine to constitute the desired formulation or recipe for the production of ceramic tiles.
  • the action of the regulator assembly is to mix and blend in an optimal way the "wet" portion, consisting of the substances introduced in aqueous suspension or in any case “wet”, with the "dry” portion, consisting of pre-dry milled substances.
  • the control of the overall moisture content of the introduced substances, made by the regulator assembly permits to obtain the outlet a material having the desired moisture content, feeding any combination of dry and wet material.
  • the method according to the invention has the advantage of avoiding the use of spray dryers, for the extraction of water from the slurry. This results in significant savings in the consumption of energy resources and water, as well as in a considerable reduction in the environmental impact of ceramic production.
  • the method permits, therefore, to reduce the emission of dust with a high silica content, which is extremely harmful, as is known, for the body, and of CO2.
  • the plant according to the invention comprises at least an apparatus for wet milling or for blunging a mixture of a specific batched quantity of solid raw materials and a percentage by weight of water, according to an initial moisture content, for producing an input material, preferably a slurry or aqueous suspension, a stirrer or regulator assembly, connected to the apparatus for wet milling or for blunging and configured to stir and crush solids in suspension in the input material.
  • the regulator assembly comprises a tank containing a plurality of grinding and/or stirring bodies, for example balls, preferably of sintered alumina, and operable around a longitudinal axis, preferably substantially horizontal, to obtain from the input material an outlet material with a desired moisture content.
  • the stirring assembly includes a feeding assembly for a controlled flow of an operating fluid, suitable for exchanging heat with the input material inserted into the tank, to extract excess moisture therefrom.
  • the tank of the regulator assembly is configured to be supplied with the operating fluid for extracting by evaporation an excess amount of water from the input material and thus obtain an output material, preferably in powder form, having the desired moisture content.
  • the plant may include control means to control the controlled flow of operating fluid.
  • the plant may also include a granulator assembly configured to receive the aforementioned body formulation from the stirring assembly, in order to obtain a granular material suitable for ceramic production.
  • the assembly for supplying operating fluid may comprise a device for producing the thermal energy used to extract the amount of excess water, for example comprising a burner acting on the flow of operating fluid, in particular hot air.
  • the plant can comprise at least one kiln for firing the body formulation, configured to produce the outlet heating operating fluid, and/or a cogeneration assembly for producing electricity, from which, preferably, thermal energy may be recovered, and a heat recovery assembly, configured to recover the outlet operating fluid produced in the firing kiln and, alternatively or in addition, in the cogeneration assembly, so as to at least partially feed the stirring assembly.
  • Said tank preferably comprises a casing, for example cylindrical, which can be rotated around said longitudinal axis, preferably horizontal.
  • the regulator assembly according to the invention can allow the regulation of the moisture of the input material, in particular of the slurry or aqueous suspension, in a dynamic way, avoiding, thanks to the action of the bodies inside the tank, the aggregation of the material and therefore, the need for further treatments for its reduction to fine dust, suitable for subsequent regranulation.
  • a further advantage is that the dynamic effect of the grinding bodies carries out a further grinding and/or, preferably, the crushing of the substances fed into the regulator assembly according to the invention. Therefore, this allows to increase the granulometry of the input material, in particular of the slurry coming out of the wet milling or blunging apparatus. Consequently, this apparatus can produce a greater quantity of slurry for the same energy consumption.
  • Said method also permits to exploit considerable quantities of recovered thermal energy, at relatively low temperatures.
  • the heating of the grinding and/or stirring bodies and of the input material, in particular the slurry, due to the preferably counter-current flow of operating fluid, according to the same particular aspect, produces the adhesion of the same material to the grinding bodies and the subsequent detachment, due to the mechanical action of the same bodies, which continually collide inside the shell.
  • the input material fed is continuously subjected, inside the regulator assembly, to the crushing action of the grinding bodies, so as to be reduced to the desired particle size.
  • the action of the grinding bodies also causes the interstitial water to escape, thus making it possible for the operating fluid to interact with the water, facilitating its evaporation.
  • the plant can also comprise mechanical separation means, functionally interposed between the apparatus for wet milling or for blunging and the stirring regulator assembly, to extract part of the aforementioned amount of excess water from the input material, obtaining an intermediate material having an intermediate moisture content.
  • the aforementioned mechanical separation means comprise a filter press or similar mechanical extraction means.
  • the plant may further comprise a shredding unit for the separate intermediate body formulation, for example a material chipper or a rotary harrow teeth or similar means.
  • a shredding unit for the separate intermediate body formulation for example a material chipper or a rotary harrow teeth or similar means.
  • the system can usefully include at least one water recovery assembly, configured to recover the aforementioned excess amount of water, in particular extracted from the regulator assembly.
  • the water recovery assembly is configured to recover, by condensation, the excess quantity of water or part of it, which can be removed by means of the regulator assembly.
  • the water recovery assembly can additionally or alternatively feed the granulator assembly.
  • the system according to the invention minimizes energy expenditure, in particular the consumption of thermal energy, and the environmental impact, thus preserving the environment and the health of the population.
  • Figure 4 schematically shows a plant for manufacturing ceramic tiles according to the invention
  • Figure 5 schematically shows a further embodiment of the plant for manufacturing ceramic tiles according to the invention.
  • Figure 6 shows a schematic view of a regulator assembly used in the plant according to the invention.
  • the method according to the invention can be implemented, for example, by a plant 10 for manufacturing ceramic tiles comprising at least an assembly 1 for batching raw materials, at least an apparatus 2 for the wet milling of raw materials or for blunging, for producing an input material S, preferably an aqueous suspension, usually called "slurry” or “slip", a moisture regulator or stirrer 3 of the input material S or of the slurry, to obtain a blended output material P, preferably in powder or granular form, having a desired moisture content.
  • a plant 10 for manufacturing ceramic tiles comprising at least an assembly 1 for batching raw materials, at least an apparatus 2 for the wet milling of raw materials or for blunging, for producing an input material S, preferably an aqueous suspension, usually called “slurry” or “slip”, a moisture regulator or stirrer 3 of the input material S or of the slurry, to obtain a blended output material P, preferably in powder or granular form, having a desired moisture content.
  • the plant also preferably comprises a heat recovery assembly 4 of thermal energy, preferably coming from a firing kiln 40 of the body formulation obtained and formed or, in addition or alternatively, from a cogeneration assembly 41 possibly provided.
  • the batching assembly 1 is configured to batch, by means of a preferably continuous weighing system, the different raw materials of a given recipe for manufacturing ceramic tiles.
  • the batching assembly 1 therefore permits to obtain a batched quantity of predetermined raw materials.
  • the apparatus 2 for wet milling or for blunging can be made up for example of a ball mill, configured to add to the batched quantity of batched raw materials or part of them a certain percentage by weight of water, so as to obtain, following milling, the incoming material, preferably slurry.
  • This percentage by weight can be equal to 35%, or it can be included in a suitable range, for example of a few percentage points, around this value.
  • a high percentage of water in the slurry allows for easier wet milling. This is convenient, in particular, if sufficient thermal energy is available for reducing afterwards, in the following steps described below, the moisture content of the slurry to the desired value for the desired body formulation. In cases in which, on the other hand, the thermal energy available to subsequently reduce the moisture content is relatively low, a lower water content in the slurry may then be introduced, for example around 30%, possibly adding deflocculating agents.
  • water is used hereinafter to also mean an aqueous solution or mixture to which additives are added, to adjust certain properties of the solution or mixture itself, or of the mixture, preferably in powder, to be obtained.
  • the apparatus 2 for wet milling or for blunging can be associated downstream with a sieving and iron removal assembly 21 of a known type, to treat the input material S in a manner suitable for the following steps.
  • the regulator assembly 3 arranged downstream of the apparatus 2 for wet milling or blunging and possibly of the assembly 21 , is configured to receive at least part of the recipe directly in the form of slurry, i.e. substances of the recipe in aqueous suspension, therefore in liquid form, with the amount of water deriving from wet milling or blunging or, as described below, with a reduced amount of water compared to that of wet milling, following an intermediate process of mechanical separation.
  • the intermediate material obtained, with a reduced amount of water can possibly be shredded, as described below, before being introduced into the regulator assembly (see Figure 5).
  • the regulator assembly 3 can be partially fed with slurry in liquid form coming from wet milling or from blunging and partially with the other substances of the same recipe, in powder form, produced in a known way by dry milling.
  • the input material S inserted altogether into the tank 30 constitutes the specific recipe for the type of ceramic tiles to be obtained.
  • the regulator assembly 3 primarily performs a stirring function, therefore mixing the liquid mixture, in particular the slurry, fed thereto.
  • the regulator assembly 3 then performs a crushing or grinding function, thanks to the action o ⁇ crushing or grinding bodies C.
  • the regulator assembly 3 performs a regulating function of the moisture content present in the mixture of substances or fed input material S. Preferably, it can provide for adjusting this parameter from an initial input content to a desired final moisture content, in particular by drying the fed mixture.
  • the regulator assembly 3 comprises a particular tank 30 which internally defines a chamber containing inside it a plurality of crushing or grinding bodies C, for example balls, preferably of sintered alumina (see Figure 6).
  • the tank that forms the regulator assembly 3 according to the invention can be rotated, advantageously and preferably according to a horizontal axis, and is configured to be crossed by a flow of an operating fluid T.
  • the regulator assembly 3 comprises a supply circuit for a controlled flow of operating fluid T, preferably hot air.
  • This flow of operating fluid T is introduced in a controlled manner by a feeding assembly, in order to extract, by removing heat, an excess quantity of water from the input material S, preferably in aqueous suspension, inserted in the tank 30.
  • the operating fluid T preferably hot air, is preferably made available by the heat recovery assembly 4, at a temperature preferably higher than 35-40 °C, to regulate the moisture content of the input material S, for example slurry, particularly in order to dry it properly.
  • the aforementioned power supply circuit can be associated with an autonomous thermal energy production device, for example made by a burner, acting on the same circuit.
  • the rotation of the tank 30 produces the effect of dragging the crushing or grinding bodies C into motion, together with the input material S inserted inside the chamber.
  • the rotation of the tank 30 with the grinding bodies C has the effect of stirring, in particular mixing, the substances S inserted in aqueous solution or slurry.
  • the dragging of the grinding bodies C can also have the advantageous effect of further milling the materials or formulation of substances S introduced into the tank 30.
  • the mechanical action of the grinding bodies C permits to obtain a perfectly amalgamated ceramic body formulation or output material P, even if the tank 30 is partially fed with product in liquid form, coming from wet milling or blunging, and partially with product in powder form, coming from dry milling, as described in detail below.
  • the regulator assembly 3 in particular, can form a first casing, preferably cylindrical, which internally defines the aforementioned containment chamber of the slurry or of the substances S to be treated.
  • the regulator assembly 3 also preferably comprises a second casing, also preferably cylindrical, arranged externally to the first casing, so as to define with it a cavity, configured for the passage of the operating fluid.
  • a second casing also preferably cylindrical, arranged externally to the first casing, so as to define with it a cavity, configured for the passage of the operating fluid.
  • the regulator assembly 3 comprises valve means, configured to maintain the tank chamber in an empty or half-empty condition.
  • a condenser device can be further provided, for the recovery of evaporated water.
  • the regulator assembly 3 can further comprise filtering means 31 , for example a bag filter like or of a cyclone-like, for sucking the operating fluid T and recovering any residual dust coming out of the regulator assembly 3.
  • filtering means 31 for example a bag filter like or of a cyclone-like, for sucking the operating fluid T and recovering any residual dust coming out of the regulator assembly 3.
  • the tank 30 of the regulator assembly 3 can provide for extraction means, for example made by means of a perforated sector F arranged at a section of the tank 30 itself, associated with suction members, to separate the flow of operating fluid T heavy with moisture from the output material P, obtained by stirring and crushing (see Figure 6).
  • I he heat recovery assembly 4 comprises means for conveying a flow of operating heating fluid T coming out of the firing kiln 40 and/or the cogeneration assembly 41 which may be present in the system.
  • the regulator assembly 3 can be advantageously associated with the aforementioned heat recovery unit 4, so as to receive, at least in part, the thermal energy accumulated in the cooling air leaving the firing kiln 40 or by other assemblies, as described below, like operating fluid T.
  • the firing kiln 40 is preferably of the known type, with rollers.
  • the heat recovery unit 4 can fully recover from the firing kiln 40 any thermal energy required by the process according to the invention.
  • the system 10 can also usefully comprise a water recovery assembly 5 that can be associated with a flow of air leaving the regulator assembly 3, configured to extract therefrom, by means of a condensing device 51 , a respective share of water.
  • the water recovery assembly 5 can be associated with the regulator assembly 3, to recover the aforementioned amount of excess water or at least part of it, for reuse, for example, in the apparatus 2 for wet milling or blunging.
  • the plant 10 can also comprise a humidifier/granulating unit 6, to bring the material P coming out from the regulator assembly 3, with the desired moisture content, to a physical form suitable for forming in known apparatuses, such as presses.
  • a humidifier/granulating unit 6 to bring the material P coming out from the regulator assembly 3, with the desired moisture content, to a physical form suitable for forming in known apparatuses, such as presses.
  • the plant 10 can also include, in the section dedicated to preparation, containment means known in the art, such as silos, in which the pulverized and granulated material can be stored until it is used in the production process.
  • containment means known in the art, such as silos, in which the pulverized and granulated material can be stored until it is used in the production process.
  • the plant 10 can further comprise a dust recovery assembly 7, configured to convey the dust recovered from the filtering means 31 or from other parts of the plant, for example from the recovery of broken and unfired tiles, from storage silos, from presses, inserting them in suitable percentages for subsequent firing during the step of mixing the slurry.
  • a dust recovery assembly 7 configured to convey the dust recovered from the filtering means 31 or from other parts of the plant, for example from the recovery of broken and unfired tiles, from storage silos, from presses, inserting them in suitable percentages for subsequent firing during the step of mixing the slurry.
  • the method according to the invention provides to prepare the apparatus 2 for wet milling or for blunging raw materials suitable for preparing a granular mixture, as well as the regulator assembly 3. Furthermore, the kiln 40 for firing ceramic products is preferably arranged for operation. Alternatively, the cogeneration assembly 41 and/or the thermal energy production device directly associated with the humidity regulator assembly 3 is preferably arranged.
  • the batched quantity of solid raw materials suitable for producing ceramic tiles is prepared according to a specific recipe.
  • At least part of the batched quantity of raw materials with the determined percentage by weight of water is then mixed and milled or blunged, by means of the apparatus 2 for wet milling or for blunging, so as to obtain the input material S, in particular the ground slurry or "slip", therefore the formulation in aqueous suspension.
  • the moisture content of the incoming material S is regulated by means of the regulating assembly 3 according to the invention, preferably using the operating fluid T, in particular hot air, preferably recovered by means of the heat recovery assembly 4 coming out of the firing kiln 40 prepared, preferably coming from the cooling zones of the firing kiln 40.
  • the stirring assembly 3 can be provided to be powered by the thermal energy production device 42, for example to compensate for the lack or variations in availability of thermal energy recovered from the kiln 40 and/or from the cogeneration assembly 41 , if present.
  • the method can provide for operating, by means of the aforementioned water recovery assembly 5, the recovery of this amount of excess water, extracting it, by condensation, during the drying process.
  • the dust recovery assembly 7 configured to convey the dust recovered from the aforementioned filtering means 31 , as well as from other steps of the plant, for example from the recovery of broken and unfired tiles, from storage silos, from presses, in percentages suitable for subsequent firing, by inserting them during the step of mixing the slip.
  • the method can preferably provide for pulverizing, humidifying and granulating the dried body formulation, that is, the material P leaving from the regulator assembly 3, through the humidifier/granulating assembly 6.
  • the dried body formulation that is, the material P leaving from the regulator assembly 3, through the humidifier/granulating assembly 6.
  • a granular body formulation suitable for subsequent forming can be obtained.
  • the method can provide for the storage of the granulated material in containment units, silos for example, to allow its subsequent use.
  • the method is implemented by a plant for the production of a material for the production of ceramic tiles, comprising, in addition or as an alternative to a firing kiln 40, a cogeneration assembly 41 , configured to produce and recover thermal energy.
  • the heat recovery assembly 4 is powered by the thermal energy produced by the cogeneration assembly 41 , to produce the drying that generates the desired output material of the regulator assembly 3.
  • the plant that can implement the method according to this alternative solution can produce the dried material, advantageously even in the absence of a firing kiln 40 in operation.
  • the plant 10' can further comprise a mechanical separation assembly 8 of at least part of the excess water, interposed between the apparatus 2 for wet milling or blunging and the regulator assembly 3.
  • the mechanical separation assembly 8 is instead configured to mechanically separate the solid part of the slurry from an excess amount of water, therefore coming out of the wet milling or blunging apparatus 2.
  • the mechanical separation assembly 8 can be made by means of a known type filter press or by an equivalent apparatus.
  • the mechanical separation assembly 8 can be configured to reduce the slurry to a body formulation in which the share by weight of water is preferably reduced to around 18%.
  • the aforementioned water recovery assembly 5 can thus also be associated with the mechanical separation assembly 8, for the recovery of a further quantity of excess water, separated from the slurry.
  • the plant 10' can further comprise a shredding assembly 9, interposed between the mechanical separation assembly 8, if provided, and the regulator assembly 3 (see Figure 3).
  • the shredding assembly 9 can be made by means of a material chipper or a rotary harrow teeth or other known apparatuses, suitable for the purpose.
  • the shredding assembly 9 reduces the intermediate material resulting from the mechanical separation of part of the excess water to a size suitable for introduction into the regulator assembly 3 according to the invention.
  • the method can advantageously provide for recovering, at least in part, the part of the excess quantity of water separated mechanically, by means of the water recovery assembly 5, and reusing it, for example, for mixing a new slurry.
  • the regulator assembly 3 can perform its own dynamic action on the mixture, obtaining an optimal mixing with minimum energy consumption.
  • the overall amount of moisture introduced into the mixture to be blended is less, so as to more easily obtain the desired final moisture content for the final mixture, intended as the final material obtained.
  • the method according to the invention therefore achieves the aim of reducing heat consumption and the environmental impact of the process of production of ceramic tiles.
  • the method for preparing a granular material for manufacturing ceramic tiles according to the present invention therefore achieves the aim of minimizing, in particular, the consumption of thermal energy and water, thus maximizing energy savings.
  • the method according to the invention and the plant that implements it are able to minimize the environmental impact, in particular by considerably reducing the emissions of dust and carbon dioxide.

Landscapes

  • Chemical & Material Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Ceramic Engineering (AREA)
  • Manufacturing & Machinery (AREA)
  • Structural Engineering (AREA)
  • Materials Engineering (AREA)
  • Organic Chemistry (AREA)
  • Inorganic Chemistry (AREA)
  • Dispersion Chemistry (AREA)
  • Physics & Mathematics (AREA)
  • Thermal Sciences (AREA)
  • Compositions Of Oxide Ceramics (AREA)
  • Preparation Of Clay, And Manufacture Of Mixtures Containing Clay Or Cement (AREA)

Abstract

Le procédé de préparation d'un matériau, en particulier sous forme pulvérulente ou sous forme granulaire, adapté à la fabrication de carreaux en céramique, comprend les étapes consistant à mettre en place au moins une quantité mesurée de matières premières solides, à ajouter un certain pourcentage en poids d'eau à la quantité mesurée de matières premières solides, à mettre en place un appareil pour le broyage humide des matières premières ou pour leur délayage en vue d'obtenir un matériau d'entrée (S) et à introduire le matériau d'entrée (S) dans un groupe régulateur (3) en vue d'obtenir un matériau de sortie (P) présentant une teneur en humidité souhaitée.
PCT/IT2022/050090 2021-04-08 2022-04-08 Procédé et installation de préparation d'un matériau adapté à la fabrication de carreaux en céramique WO2022215101A1 (fr)

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EP22721903.7A EP4320088A1 (fr) 2021-04-08 2022-04-08 Procédé et installation de préparation d'un matériau adapté à la fabrication de carreaux en céramique

Applications Claiming Priority (2)

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IT102021000008858A IT202100008858A1 (it) 2021-04-08 2021-04-08 Metodo e impianto per la preparazione di un impasto granulare per la produzione di piastrelle ceramiche
IT102021000008858 2021-04-08

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WO2022215101A1 true WO2022215101A1 (fr) 2022-10-13
WO2022215101A4 WO2022215101A4 (fr) 2022-12-08

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IT (1) IT202100008858A1 (fr)
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Citations (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN107089828A (zh) * 2017-03-21 2017-08-25 横店集团东磁股份有限公司 一种宽温宽频低比磁导率温度系数的锰锌高磁导率材料及其制备方法
CN110055486A (zh) * 2019-05-14 2019-07-26 中国人民解放军国防科技大学 双层热障/高温低红外发射率一体化涂层、带涂层的金属复合材料及其制备方法
CN110407587A (zh) * 2019-09-24 2019-11-05 佛山市博晖机电有限公司 一种建筑陶瓷干湿法制粉工艺

Patent Citations (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN107089828A (zh) * 2017-03-21 2017-08-25 横店集团东磁股份有限公司 一种宽温宽频低比磁导率温度系数的锰锌高磁导率材料及其制备方法
CN110055486A (zh) * 2019-05-14 2019-07-26 中国人民解放军国防科技大学 双层热障/高温低红外发射率一体化涂层、带涂层的金属复合材料及其制备方法
CN110407587A (zh) * 2019-09-24 2019-11-05 佛山市博晖机电有限公司 一种建筑陶瓷干湿法制粉工艺

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EP4320088A1 (fr) 2024-02-14
WO2022215101A4 (fr) 2022-12-08

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