Waste recycling in ceramic tiles: a technological outlook

Zanelli, Chiara; Conte, Sonia; Molinari, Chiara; Soldati, Roberto; Dondi, Michele

doi:10.1016/j.resconrec.2020.105289

Cited by 88 publications

(29 citation statements)

References 285 publications

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“…Some recently published research works have supported these limitations for an evolution towards a circular economy. Zanelli et al [5], analysed the effects of different types of waste on technological behaviour, technical performance and environmental impact of ceramic tiles in the prospect of an industrial transfer. Dondi et al [6], shows the conflict between resource efficiency and market trends in the ceramic tile industry, and how it reflects on the supply chain raw materials.…”

Section: Introductionmentioning

confidence: 99%

“…As is highlighted in the review by Zanelli et al [5], a correct design of experiments is crucial to achieve useful results for a technological transfer to the industrial practice. In this sense, aspects such as the use of experimental conditions as close as possible to the actual industrial technology, the scale factor, the use of industrial references without waste addition and the analysis of the appropriate amount of recyclable waste in each experimental step are critical.…”

Section: Introductionmentioning

confidence: 99%

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Self-Organizing Maps to Assess the Recycling of Waste in Ceramic Construction Materials

et al. 2021

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Circular economy promotes the use of waste materials into new production processes as a key factor for resource efficiency. The construction sector, and specifically the fired clay industry, is able to assimilate large amounts of waste in their processes, without significantly altering the technical properties of products. The introduction of different waste in ceramic products at the laboratory level has been extensively studied in the literature, but most of these studies have not yet been scaled-up to industrial production. Differences in processing with respect to laboratory conditions introduces uncertainty in relation to the expected properties of the final products. This paper uses a Self-Organizing Map (SOM)-based methodology for analysing and assessing the incorporation of industrial waste, Waelz slag (WS) and foundry sand dust (FSD), in ceramic products obtained sequentially at laboratory, semi-industrial and industrial level, over technological properties and metals release. As a result, from the SOM analysis, a clustered map of the samples developed is obtained that highlights the most important parameters affecting the technological and environmental properties to be the type of clay and therefore, the firing temperature; secondly, the Waelz slag content, being independent of the foundry sand addition; and finally, the type and level of processing (laboratory-pressing, semi-industrial extruder, industrial extruder).

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Section: Introductionmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

Self-Organizing Maps to Assess the Recycling of Waste in Ceramic Construction Materials

et al. 2021

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“…The use of several kinds of waste in traditional ceramic tiles has been investigated since the late 1990s. Many works study the recycling of different wastes in traditional ceramic materials, especially porcelain stoneware tiles [17]. Waste glass (soda-lime glass) in urban collection is one of the most widely recycled forms of waste employed in traditional ceramic tile formulations, but until now it was not possible to recycle a high percentage of material (more than 20%) at an industrial level.…”

Section: Introductionmentioning

confidence: 99%

Pathway towards a High Recycling Content in Traditional Ceramics

Rambaldi

2021

Ceramics

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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.

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“…Long-term environmental impacts are critical considerations when recycling waste materials. Due to the high tolerance feature of ceramic bodies, approximately 300 papers have been published on waste recycling in ceramic tile making, with more than 56 types of waste studied for recycling in ceramic tiles [25]. Most studies have been conducted on non-hazardous waste, as the legal restrictions of recycling make the process complex and challenging [25], but some research findings have shown that the firing process can potentially immobilise the heavy metals in waste materials and encapsulate the hazardous leachate in fired tiles during the high temperatures [26].…”

Section: Introduction (Literature Review)mentioning

confidence: 99%

“…Due to the high tolerance feature of ceramic bodies, approximately 300 papers have been published on waste recycling in ceramic tile making, with more than 56 types of waste studied for recycling in ceramic tiles [25]. Most studies have been conducted on non-hazardous waste, as the legal restrictions of recycling make the process complex and challenging [25], but some research findings have shown that the firing process can potentially immobilise the heavy metals in waste materials and encapsulate the hazardous leachate in fired tiles during the high temperatures [26]. In addition, municipal waste incineration fly ash tile studies have found that the tile glazing can further reduce the leaching of heavy metals by enclosing the surface porosity [27], which is commonly applied to tiles to improve the tile performance both aesthetically and practically.…”

Section: Introduction (Literature Review)mentioning

confidence: 99%

Recycling Cigarette Butts in Ceramic Tiles

et al. 2021

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Cigarettes are one of the favoured commodities on our planet. However, the annual consumption of 5.7 trillion cigarettes and 75% littering rate results in cigarette butts (CBs) being one of the most critical environmental issues. The leachate of heavy metals and toxic chemicals is polluting our ecosystem and threatening the wildlife species. Therefore, it is crucial to find effective and efficient recycling methods to solve the growing CB waste issue. In this study, unglazed fired ceramic tiles were manufactured with 0%, 0.5%, 1.0%, and 1.5% shredded CBs by dry mass to investigate the feasibility of the proposed sustainable recycling method. The chemical and mineralogical characterisation, density, shrinkage, bulk density, breaking strength, water absorption, and modulus of rupture were investigated and compared with the Australian Standards for ceramic tiles (AS 4459). The results revealed that tiles incorporating 0.5% CBs by mass demonstrated the greatest performance compared to the other mixtures. The water absorption for all tile–CB mixtures was found to be greater than 10%, with a positive growth tendency. The addition of 0.5% CBs by mass slightly improved flexural strength from 15.56 MPa for control samples to 16.63 MPa. Tiles containing 0.5% CBs by mass satisfied the modulus of rupture and water absorption limits for group III class according to the Australian Standards (AS 13006), and they may be suitable to be used as wall tiles. The result of a simulation equation predicts that an energy savings of up to 7.79% is achievable during the firing process for ceramic tiles incorporating 1% CBs by mass.

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Waste recycling in ceramic tiles: a technological outlook

Cited by 88 publications

References 285 publications

Self-Organizing Maps to Assess the Recycling of Waste in Ceramic Construction Materials

Self-Organizing Maps to Assess the Recycling of Waste in Ceramic Construction Materials

Pathway towards a High Recycling Content in Traditional Ceramics

Recycling Cigarette Butts in Ceramic Tiles

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