Microstructure-oriented porcelain stoneware tile composition design

Noni, Agenor De; Canever, Sílvia B.; Henrique, Patrick; Silva, Rodrigo Ramos

doi:10.1016/j.ceramint.2022.11.067

Cited by 6 publications

(21 citation statements)

References 20 publications

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“…The lower and upper limits for the mineral components for the optimization analysis were based on composition data from the literature [22][23][24] and industrial compositions from companies in Brazil, Italy, Spain, and Argentina. 3 Table 1 shows the range of each mineral component, average particle size (d 50,3 ), Bond Work Index (BWI), and density. The BWI defines ore grindability as crushing resistance, correlated to material mechanical properties defined as the kilowatt-hours per short ton required to break from infinite size to a product size of 80% passing through a 100 µm sieve.…”

Section: Methodsmentioning

confidence: 99%

“…This matrix incorporates quartz particles in a 10-30 wt.% ratio, mullite crystals at 4-10 wt.%, and unmelted feldspar dispersed, ranging from 0-15 wt.%. [2][3][4] This quantitatively dominant vitreous phase governs viscous flow sintering and significantly impacts the geometrical properties of tiles and their mechanical, tribological, and functional properties. 4 De Noni et al, 3 in particular, reported that 14-17 wt.% mullite is best suited for achieving a robust microstructure in porcelain tiles produced using the standard industrial-scale technology.…”

Section: Introductionmentioning

confidence: 99%

“…[2][3][4] This quantitatively dominant vitreous phase governs viscous flow sintering and significantly impacts the geometrical properties of tiles and their mechanical, tribological, and functional properties. 4 De Noni et al, 3 in particular, reported that 14-17 wt.% mullite is best suited for achieving a robust microstructure in porcelain tiles produced using the standard industrial-scale technology. To achieve this characteristic, it is necessary to prepare a mixture of compounds.…”

Section: Introductionmentioning

confidence: 99%

“…2 When raw materials are combined in the ceramic tile production, the resulting mineralogical composition typically consists of the following proportions: 20-45% kaolinite, 7-10% illite-mica, 40-50% feldspathic phases, and 15-30% quartz. [2][3][4][5] Furthermore, materials such as talc, calcite, dolomite, and diopside are added to reduce the sintering temperature. 6 Figure 1 depicts the compositions of triaxial ceramic products in which a standard composition of porcelain tile is located:…”

Section: Introductionmentioning

confidence: 99%

“…21 The impact of various compositions used in the industrial production of porcelain tiles was examined in this study using the coupling of Dyssol and MATLAB. De Noni Jr. et al 3 developed the concept of the microstructureoriented composition design for porcelain tile, which was used as the foundation for correlating the firing unit processing parameters with the various analyzed composition ranges. In the present work, the mineralogical phases under consideration included kaolinite (from 15 to 38 wt.%), illite (from 0 to 20 wt.%), quartz (from 20 to 40 wt.%), and feldspar (from 20 to 45 wt.%).…”

Section: Introductionmentioning

confidence: 99%

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Optimizing raw material composition to increase sustainability in porcelain tile production: A simulation‐based approach

Alves,

Skorych,

De Noni

et al. 2023

J Am Ceram Soc.

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Reducing the environmental impact of porcelain tile production while maintaining cost‐effectiveness is challenging. This work introduced a novel modeling approach for optimizing a standard composition range comprising kaolinite (15–38 wt.%), illite (0–20 wt.%), quartz (20–40 wt.%), and feldspar (20–45 wt.%) to establish a robust composition interval for porcelain stoneware tiles. The proposed study considers several factors, such as composition impact on the manufacturing sequence, production costs, and CO2 emission. A flowsheet simulation database was generated by coupling the Dyssol framework with MATLAB. This study investigated the influence of raw material composition within the process sequence, the total CO2 emissions, and production costs within the contexts of Spain and Brazil, two of the top five global producers. Granules with a higher proportion of talc and illite exhibit reduced moisture content after spray drying, and these combinations have lower green body porosity after compaction. The addition of talc allowed for decreased porosity content after compaction reduced firing temperature, and lowered costs and CO2 emissions despite the higher prices associated with talc. The proposed simulation methodology offers a powerful decision‐making tool for optimizing raw material composition to minimize cost and CO2 emissions in the porcelain tile production. This methodology represents an early stride toward integrating digital twin methodologies within the ceramic tile sector, facilitating improved process regulation, and promoting the adoption of digital technologies.

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