Search Results (26)

This study proposes the utilisation of mining wastes, TG3 clay (Turoszów mining gangue) and post-flotation sludge (KGHM-Gilów), stored at a distance of about 150 km from each other in the region of Lower Silesia, Poland. From these wastes, mixtures were prepared for the production of ceramic tiles. Depending on the mutual proportions of the wastes, it is possible to obtain sintered stoneware-type ceramics with a mechanical bending strength of about 40 MPa and porous faience-type ceramics with a strength above 15 MPa. It is shown that the significant utilisation of these wastes is possible. The ceramic tiles were classified according to the applicable PN-EN 14411:2016 standard. Full article

The ceramics industry has consistently applied circular economy principles by efficiently reusing and recovering raw materials in the production process. Incorporating secondary raw materials, such as production scraps and recycled materials, reduces costs and improves sustainability. In the ceramics sector, raw materials like feldspars can be substituted with secondary raw materials from other production processes, particularly glass-based ones. This study selected waste glass, such as bottle glass or glass fiber processing scraps, to investigate its performance in a porcelain stoneware slab mixture. The behavior of this mixture was compared to a traditional porcelain stoneware mixture and a mixture containing a glass-ceramic frit, which exhibits significantly different behavior from waste glass. The study involved a comprehensive characterization of the fired samples, with a specific focus on addressing pyroplastic deformation—an issue that occurs in large slabs during the firing process. Although pyroplastic deformation has been extensively studied in the past using various waste glasses, this research work uniquely employed waste glass fiber and glass-ceramic material to mitigate pyroplastic deformation compared to the more commonly studied waste soda–lime glass. The pyroplastic deformation tests were conducted using an instrument from Expert Lab Service-MDF. Full article

Defect detection is a key element of quality control in today’s industries, and the process requires the incorporation of automated methods, including image sensors, to detect any potential defects that may occur during the manufacturing process. While there are various methods that can be used for inspecting surfaces, such as those of metal and building materials, there are only a limited number of techniques that are specifically designed to analyze specialized surfaces, such as ceramics, which can potentially reveal distinctive anomalies or characteristics that require a more precise and focused approach. This article describes a study and proposes an extended solution for defect detection on ceramic pieces within an industrial environment, utilizing a computer vision system with deep learning models. The solution includes an image acquisition process and a labeling platform to create training datasets, as well as an image preprocessing technique, to feed a machine learning algorithm based on convolutional neural networks (CNNs) capable of running in real time within a manufacturing environment. The developed solution was implemented and evaluated at a leading Portuguese company that specializes in the manufacturing of tableware and fine stoneware. The collaboration between the research team and the company resulted in the development of an automated and effective system for detecting defects in ceramic pieces, achieving an accuracy of 98.00% and an F1-Score of 97.29%. Full article

Additive manufacturing (AM), also known as three-dimensional (3D) printing, allows the fabrication of complex parts, which are impossible or very expensive to produce using traditional processes. That is the case for dinnerware and artworks (stoneware, porcelain and clay-based products). After the piece is formed, the greenware is fired at high temperatures so that these pieces gain its mechanical strength and aesthetics. The conventional (gas or resistive heating elements) firing usually requires long heating cycles, presently requiring around 10 h to reach temperatures as high as 1200 °C. Searching for faster processes, 3D-printed stoneware were fired using microwave (MW) radiation. The pieces were fired within 10% of the conventional processing time. The temperature were controlled using a pyrometer and monitored using Process Temperature Control Rings (PTCRs). An error of 1.25% was calculated between the PTCR (1207 ± 15 °C) and the pyrometer (1200 °C). Microwave-fast-fired pieces show similar mechanical strength to the references and to the electrically fast-fired pieces (41, 46 and 34 (N/mm²), respectively), presenting aesthetic features closer to the reference. Total porosities of ~4%, ~5% and ~9% were determined for microwave, electrically fast-fired and reference samples. Numerical studies have shown to be essential to better understand and improve the firing process using microwave radiation. In summary, microwave heating can be employed as an alternative to stoneware conventional firing methods, not compromising the quality and features of the processed pieces, and with gains in the heating time. Full article

The construction industry has a significant environmental impact and concrete production is responsible for a large part of CO₂ emissions and energy consumption. This study focused on the reutilisation of a specific type of tiles ceramic waste (TCW), composed only of stoneware and porcelain stoneware tiles, hereafter referred to as ceramic stoneware (CS), as recycled aggregate in concrete. Natural limestone and CS aggregates (sand and gravel) were characterised (particle size distribution, water absorption, resistance to wear, density and X-ray diffraction analyses) and recycled aggregate concrete (RAC) was prepared by replacing 20, 50 and 100 vol.% of sand and gravel, separately. Concrete workability generally improved with CW addition, especially when replacing natural gravel. Although the compressive strengths of the concrete specimens prepared with recycled sand were slightly lower than those of the reference specimens, similar or better results were recorded with the recycled CS gravel. In consonance, the RAC developed with recycled gravel obtained lower water penetration depths than the reference concrete. No significant variation in tensile strength was observed when varying CS content (values within the 2.33–2.65 MPa range). The study contributes to sustainable construction practices and circular economy by promoting the valorisation and reutilisation of industrial waste and reducing the consumption of natural resources. Full article

The aim of this research was to evaluate the possibility of reusing waste foundry sands derived from the production of cast iron as a secondary raw material for the production of building materials obtained both by high-temperature (ceramic tiles and bricks) and room-temperature (binders such as geopolymers) consolidation. This approach can reduce the current demand for quarry sand and/or aluminosilicate precursors from the construction materials industries. Samples for porcelain stoneware and bricks were produced, replacing the standard sand contained in the mixtures with waste foundry sand in percentages of 10%, 50%, and 100% by weight. For geopolymers, the sand was used as a substitution for metakaolin (30, 50, 70 wt%) as an aluminosilicate precursor rather than as an aggregate to obtain geopolymer pastes. Ceramic samples obtained using waste foundry sand were characterized by tests for linear shrinkage, water absorption, and colorimetry. Geopolymers formulations, produced with a Si/Al ratio of 1.8 and Na/Al = 1, were characterized to evaluate their chemical stability through measurements of pH and ionic conductivity, integrity in water, compressive strength, and microstructural analysis. The results show that the addition of foundry sand up to 50% did not significantly affect the chemical-physical properties of the ceramic materials. However, for geopolymers, acceptable levels of chemical stability and mechanical strength were only achieved when using samples made with 30% foundry sand as a replacement for metakaolin. Full article

Stoneware is a ceramic material with low porosity and high mechanical properties, such as the modulus of rupture. It is essentially made of clay, feldspar and quartz and is sintered to create a mixture of glass and crystalline phases. With the projected growth rate of the global ceramics market size and the country’s development plan for 2023–2028, it is imperative that alternative raw materials for the manufacture of ceramic products be sourced so that the importation of these materials, such as feldspar, be minimized, if not eliminated. Cinder in the Philippines is mainly used as a filling material in pavements and residential areas. In this study, this resource is utilized as partial and full replacement of feldspar in a typical ternary diagram for stoneware production. Bars were formed from different formulations by the slip casting method and were sintered at 1200 °C. Physical and mechanical properties of the bars, such as shrinkage, loss on ignition, water absorption, apparent porosity and modulus of rupture were determined. Thermo-physical analyses were also carried out on the raw materials and on formulated powders. Meeting the requirements of the various quality standards for ceramics, the partial replacement of feldspar with black cinder (LF, LFBQ and LFBH) is feasible for wall and roof applications while full replacement of feldspar with black cinder (LB) is suitable for wider use as wall, floor, vitrified, industrial and roof tiles. Full article

Solid solutions of ceramic pigments of red shade have been synthesized based on YAlO3 perovskite structure doped with chromium by means of conventional synthesis; that is, the “ceramic route”. To optimize this synthesis, an emphasis has been made on the study of stoichiometry, calcination conditions and mineralizer incorporation. Various studies have demonstrated the high stability of perovskite structures, which ensures stable coloration at high temperatures. This is a highly important factor in the ceramic sector, given the scarcity of red glazes functional at temperatures close to those required of porcelain stoneware and their environmental constraints. Such a limitation makes it impossible in the European community to manufacture using toxic materials such as Se and Cd (cadmium sulfoselenide) that offer interesting colors at low temperatures. Pigments have been synthesized within the Y_1−xCr_xAlO₃, YCr_xAl_1−xO₃ and Y_1−xAl_1−yCr_x+yO₃ chromium-doped systems in molar ratios between n = 0.01 molar and n = 0.10 molar. The pigments obtained have been characterized by X-ray diffraction to identify the crystalline phases responsible for the shade; that is, the formation of the perovskite crystalline structure YAlO₃ responsible for the red shade, together with lateral phases of garnet Y₃Al₅O₁₂ of lower intensity. Visible ultraviolet spectrophotometry shows absorption bands corresponding to Cr(III) in octahedral position and the appearance of Cr(IV) in both octahedral and tetrahedral positions. The morphology of the samples was studied using a scanning electron microscope, obtaining information from the secondary and back scattered electrons. The viability of its use in ceramic glazes was verified after applying them mixed at 4% by weight in a glaze to an industrial porous single-firing cycle, collecting the L*a*b* chromatic coordinates using a visible ultraviolet spectrophotometer based on the CIE L*a*b* system, giving rise to red colorations. Full article

This contribution presents the preparation and characterization of new geopolymer-based mortars obtained from recycling waste deriving from the production process and the “end-of-life” of porcelain stoneware products. Structural, morphological, and mechanical studies carried out on different kinds of mortars prepared by using several types of by-products (i.e., pressed burnt and extruded ceramic waste, raw pressed and gypsum resulting from exhausted moulds) point out that these systems can be easily cast, also in complex shapes, and show a more consistent microstructure with respect to the geopolymer paste, with a reduced amount of microcracks. Moreover, the excellent adhesion of these materials to common substrates such as pottery and earthenware, even for an elevated concentration of filler, suggests their use in the field of technical-artistic value-added applications, such as restoration, conservation, and/or rehabilitation of historic monuments, or simply as materials for building revetments. For all these reasons, the proposed materials could represent valuable candidates to try to overcome some problems experienced in the cultural heritage sector concerning the selection of environmentally friendly materials that simultaneously meet art and design technical requirements. Full article

Mining processes produce a massive amount of waste which, if not treated properly, can cause significant environmental and social impacts. Recently, some studies have focused on the use of mining waste as an alternative raw material. This work developed new sustainable ceramic formulations based on bentonite mining waste (BMW) for applications in porcelain stoneware. The BMW was incorporated into the ceramic masses in different percentages (0, 2.5, 5, 10, 15, 20, 25, and 40 wt.%), in partial replacement to feldspar and total to quartz. X-ray diffraction (XRD), differential thermal calorimetry (DTA), and thermogravimetry analysis (TGA) techniques were used to characterize bentonite waste. Samples (50 mm × 20 mm × 5 mm) were obtained by uniaxial pressing. Such samples were dried and sintered at 1150, 1200, and 1250 °C. The physical–mechanical properties (apparent porosity, water absorption, linear shrinkage, apparent density, and flexural strength) were evaluated for sintered samples. The phases formed after sintering treatments were characterized by XDR and scanning electron microscopy (SEM). The BMW presented a mineralogical composition suitable for use as ceramic raw material. In summary, our results presented that the new sustainable ceramic formulations sintered at 1250 °C have the potential for use in stoneware and porcelain stoneware. Full article

Ceramic tiles are bacteriostatic materials; however, the COVID-19 emergency has pushed tile producers to improve surfaces’ antibacterial properties. The aim of this work was to validate a silver-based antibacterial treatment applied to porcelain stoneware tiles based on natural and waste materials, thus correlating surface functionalization to tile composition and relevant physical, microstructural, and textural parameters. The treatment was applied before firing, with and without a polymeric primer. Antibacterial activity tests, stain resistance tests, and contact angle measurements were carried out on fired tiles. Further investigations were made by SEM and optical profilometry in order to study the morphological–structural profile of tile surfaces. Results showed strong antibacterial activities for all the functionalized tiles, which were mainly correlated to the morphological and textural parameters of ceramic surfaces, as well as the presence of the polymeric primer. Full article

The present work shows the path towards the industrial production of ceramic tiles containing a high amount of recycling materials in the substitution of natural raw materials. Starting from the applied research at laboratory scale, which is able to demonstrate the work feasibility, other important milestones consist of pilot scale production until the proper industrial production. Finally, when all these steps are positively achieved, the practice is consolidated and it is possible to reach the concrete sustainability benefits (social, environmental and economic). The results of an industry driven project that aimed to produce porcelain stoneware tiles containing 85% of recycled materials were selected to show this path. This innovative ceramic product—containing soda-lime scrap glass from urban-separated collection (post-consumer waste) and unfired scrap tiles from industrial ceramic process (pre-consumer waste)—was sintered about 200 °C lower than a traditional porcelain stoneware tile. It maintains high technical performances belonging to class BIa of the International Standard of ceramic tile classification (EN ISO 14411). Moreover, this product fulfils the standard requirements for dry-pressed ceramic tiles with low water absorption (≤0.5%), and it obtained the certification UNI Keymark. The LCA study was also performed and the results showed a significantly lower environmental impact of this innovative product compared to a traditional porcelain stoneware tile. Full article

Eight kaolinitic materials from the Lokoundje River at Kribi were sampled and investigated for their physical, chemical, mineralogical and thermal characteristics in order to evaluate their potential suitability as raw materials in ceramics. The Lokoundje kaolinitic materials are clayey to silty clayey and are predominantly composed of kaolinite and quartz. The alkali (Na₂O + K₂O) content ranges between 1 and 2.5 wt.%; these low values do not favor vitrification of the ceramics but may be improved through flux amendment. The presence of goethite in some samples limits their utilization in white ceramics. The minerals content, color, metallic sound, cohesion, linear shrinkage, flexural strength, bulk density, water absorption and microstructure were determined. The XRD data reveal that kaolinite and goethite were transformed, respectively, into mullite and hematite. The colors of the fired products are characteristic of their mineral assemblage. The metallic sound is indicative of low vitrification which is confirmed by the presence of cracks due to low flux contents. The cohesion is good to very good, due to the abundance of kaolinite. The physicomechanical properties increase with temperature as well as densification. The geochemical data show that the Lokoundje alluvial clays are suitable for the manufacture of white stoneware tiles. Full article

Mill scale (MS) is a iron-rich waste generated in the wire drawing process with high iron content and is still mainly disposed in landfills. The scientific community has been studied its use in other applications such as pigments, concretes, among others. This work aims to study a new added-value application for MS—the development of coloured ceramic pastes. For this purpose, the influence of the added amount (0, 1, 3, 5 and 10 wt.%), the pre-treatment (milling + sieving at 212 μ$\mathsf{\mu }$m), the maximum firing temperature (from 1043 to 1165 ${}^{°}$C) and the type of furnace (laboratory/industrial) were analysed on the sample’s characteristics. A dark grey stoneware product was obtained through the incorporation of 10 wt.% of MS and leaching tests conducted at pilot scale with cups confirmed its immobilization in the ceramic matrix. Furthermore, it was proved that the firing temperature can be reduced by about 100 ${}^{°}$C without affecting the specimen’s characteristics. This reduction leads to a considerable decrease in the energy consumption upon firing, inducing economic and environmental advantages. Therefore, this work provides a new added-value application for MS and contributes to the reduction of virgin raw materials consumption and development of more sustainable stoneware products. Full article