Utilization of Fired Wall Tile Scraps Containing Anorthite as a Raw Material in Porcelain Stoneware Tile Body
SENCAN I. 1
1 Qua Granite R&D Laboratory Researcher , Ayd?n, Turkey; 2 Suleyman Demirel University Fine Art Institute Art and Design PhD Student, Isparta, Turkey
Fired wall tile scraps are the wastes that are usually formed during the production of wall tiles due to fracture, glazed surface defects or firing defects and they can occur 3-15% of the fired wall tile product. Fired wall tile scraps usually contain Na2O, K2O, CaO, SiO2 and Al2O3 oxides and their the loss of ignition (LOI) rate is less than 1%.
Additionally many of fired wall tile scraps can include anorthite, which is a type of calcium feldspar and also expensive ceramic raw material, it can reduces the firing temperature of ceramics when used with sodium-containing raw materials as well as it can gives superior properties like; high bending strength and improving deviation from flatness although it has a high melting point when fired alone.
This study aims to use of the fired wall tile scraps including anorthite as an alternative recycling raw material in order to increase the flexural strength and reduce the % water absorption rate in Porcelain Stoneware Tile body. For this purpose, the ratios of sodium feldspar and potassium feldspar in the STD body recipes used in Porcelain Stoneware tile production were reduced and fired wall tile scraps were used instead of them.
The prepared body recipes were ground by wet grinding method, shaped with dust pressing method and fired in 1200°C. The body recipes were tested at laboratory trials and also one of them was confirmed by the production trial.
The fired trial samples were compared with STD Porcelain Stoneware bodies with the fired shrinkage %, bending strength, water absorption %, L. a. b. color values and deviation from flatness tests. As a result of the study it has been increased bending strength and decreased in water absorption % and improving deviation from flatness, by using of fired wall tile scraps containing anorthite as a raw material in Porcelain Stoneware tile.