Semi-Wet Granule Preparation Technology for Tile Production

Abstract

The invention relates to a semi-wet granule preparation technology aimed at reducing energy and resource consumption in the production of ceramic tiles used in the field of ceramic coating materials.

Description

1 TARIFF Semi-Wet Granule Preparation Technology for Tile Production TECHNICAL FIELD The invention utilizes energy in the production of ceramic tiles, a field used in ceramic coating materials. and with semi-wet granule preparation technology aimed at reducing resource consumption 5 It is related. PREVIOUS TECHNIQUE Ceramic coating materials are widely used in the construction and decoration industries. These are basic products, and the production processes of these materials involve high energy and resource consumption. It is characterized by the following: In ceramic tile production, the appropriate composition of raw materials and 10 It is of great importance that it is prepared homogeneously with a particle size distribution. This process involves grinding, sieving, mixing-homogenization, and spray drying. It consists of a series of processes such as drying and cooking. In known techniques, particularly spray drying, the drying of shaped tiles and It requires high thermal energy consumption during the final firing stages. Ceramic 15 The preparation of raw materials is generally known as the "wet method" and involves a specific process. by spray-drying the ceramic clay formed according to the recipe This method is carried out because of the excellent quality of the granules produced. It allows the production of ceramic tiles in various formats; however, the process requires high raw materials. It is related to water and energy consumption. This situation necessitates low carbon emissions and a sustainable 20 This stands out as a factor that negatively impacts the ceramics industry's goals. The following documents were encountered during the preliminary patent search. SIPO document with application number CN111775281A specifies dry goods that do not require drying. It presents a process-based green tile short-flow preparation method. The method involves the preparation of raw materials. Crushing into pieces smaller than 40 mm, dry grinding in a Raymond mill, and 100 25 It involves obtaining powder by selecting small particles from the mesh. The resulting powder, The material is fed into a pelletizer and converted into granular material with a moisture content of 6-8%. The granules are transferred to an automatic brick press where they are transformed into semi-finished products, and then... 2 It is baked in the oven at 1120-1160 °C for 45-70 minutes. At the end of the process, the products are sorted and It is packaged using this method, which can use clay or shale with a high moisture content of 4-9%. It provides high-quality granules, thus shortening the production process and reducing costs. Preparation of ceramic raw materials in SIPO document with application number CN103056959A The process involves preparing a lot of ceramic tile molding powder using a short and dry method, lasting 5 minutes. It is suitable. The process involves crushing soft and hard raw materials to a size of 20-50 mm. crushing, then finely grinding with a grinder to a size of 0.063-0.045 mm, and It starts with mixing. The resulting lot of fine powder is then subjected to excessively wet pelleting by adding water. This process is carried out and 10-12% humidity is achieved. Then, in a fluidized bed dryer, the humidity is reduced to 6-8%. It is dried until tender, then screened, and the large particles are shaped by an optimized molding process. is corrected. Finally, the screened qualified materials are aged before profiling. It is transferred to the storage container to be left there. SIPO document with application number CN115888953A: Ceramic raw material preparation. continuous ball milling system and material grinding method used in the process The system includes multiple roughing ball mills, semi-finished slurry 15 slurry bulk tanks for temporary storage, combined continuous for fine grinding process. ball mill (consisting of first and second ball mills) and finished product slurry It consists of a tank that stores raw materials after coarse grinding into a semi-finished slurry. It is stored, mixed, and subjected to fine grinding. This process results in a homogeneous and fine mixture. It increases grinding efficiency by enabling the production of a finished product slurry in the structure and 20 It reduces energy consumption. Research into the state of the art has revealed that the current state of the art... By conducting R&D studies on the samples, the pulp-slurry density and by relatively increasing the proportion of solid matter in the solid-liquid mixture (pulp) 25 that reduces the amount of water to be evaporated, thereby reducing the amount of energy consumed and the amount of CO2. The methods need to be improved. In conclusion, all the problems mentioned above necessitate innovation in the relevant field. It has brought it to this state. 3 THE PURPOSE OF THE INVENTION The present invention aims to eliminate the aforementioned problems and provide technical solutions in the relevant field. It aims to create an innovation. The main purpose of the invention is to produce ceramic tiles used in the field of ceramic coating materials. Semi-wet granule preparation that enables reduction of energy and resource consumption in production 5 The goal is to reveal its structure. Another aim of the invention is to reduce energy consumption in spray dryers, thereby saving energy. The goal is to reduce costs. Another aim of the invention is to determine the solid content and density of the ceramic solid-liquid mixture (pulp). The aim is to ensure an efficient production process by increasing efficiency. 10 Another aim of the invention is to produce a homogeneous and high-density (high solid content) mud. The aim is to increase production efficiency by obtaining these results. Another purpose of the invention is to save energy by reducing the amount of water that needs to be evaporated. It is provided. Another aim of the invention is to reduce carbon 15 by decreasing energy consumption used for drying. The goal is to reduce emissions. A BRIEF DESCRIPTION OF THE INVENTION All the purposes mentioned above and those that will emerge from the detailed explanation below. The present invention is intended to be used in the field of ceramic coating materials. This is a semi-wet granule preparation method in ceramic tile production. Accordingly, the clay is 20 By increasing its density, the amount of water to be evaporated can be reduced by 20-30%. to reduce the amount of energy consumed by 20-25% and CO2 emissions by 20-25% a) Preparation of ceramic mixture and reducing particle size to 5-75µ grinding in a dry grinding mill (4), b) Mixing plastic clays (2) with water in the dissolving mixer (5) to form a homogeneous mud 25 bringing the uniform, c) medium and hard raw materials (3) in wet grinding mill (6) with the addition of water grinding, 4 d) Dry ground ceramic mixture in process step a, homogenized in process step b Clay brought to a mud form and processed in steps c, wet-ground medium and hard. Mixing of raw materials and removing unwanted substances from the mixture exceeding 100-175µ. from the screening unit (7) to ensure the separation of large particles passing through, 5 e) High quality of raw materials passed through the screening unit (7) in process step d. homogenizing the slurry by using a rotary solid-liquid mixer (8), f) Feeding the sludge obtained in step e into the spray dryer (9), g) The sludge fed into the spray dryer (9) in process step f is sprayed sprayed into the dryer (9) and dried to form granules 10 transformation, It includes the steps involved in the process. A preferred configuration of the invention is the ceramic mixture mentioned in method step a. as 5-10% calcite by weight, 10-20% siliceous kaolin by weight, 30-40% clay, 10-15% by weight of cooked, dry-ground tile waste, 15 The flux material should be used at a rate of 10-15% by weight. Another preferred configuration of the invention is the high-speed circuit used in process step d. The solid-liquid mixer (8) mixes the raw materials at a speed of 10-3000 rpm. A preferred configuration of the invention is that the granules obtained in process step f  5-20% by weight of 500 microns, 20  45% - 55% by weight of 250 microns,  15% - 25% by weight of 150 microns,  5% - 15% by weight of 75 microns,  1% - 10% by weight >75 microns, It has dimension distribution ranges. Another preferred configuration of the invention is grinding that takes place in process step a. The process is carried out in a dry grinding mill (4). A preferred configuration of the invention involves plastic clays occurring in process step b. The process of bringing it to a homogeneous mud form in the dissolution mixer (5) 30 It is the realization of. Another preferred configuration of the invention involves medium and hard processing occurring in step c of the process. Wet milling is the process of grinding raw materials with the addition of 30-40% water by weight. It is carried out in the mill (6). BRIEF DESCRIPTION OF THE FIGURES 5 Figure 1 shows semi-wet granules for tile production used as cladding material. The preparation technology flowchart is provided. The drawings do not necessarily need to be scaled and are useful for understanding the invention. Unnecessary details may have been omitted. Furthermore, at least the major Elements that are identical to a certain extent, or at least have substantially identical functions, are the same 10 It is indicated by a number. EXPLANATION OF REFERENCE NUMBERS IN THE FIGURES 1. Standard, alternative and secondary raw materials 2. Plastic clay 3. Medium and hard raw materials 15 4. Dry grinding mill 5. Dissolving mixer 6. Wet grinding mill 7. Screening unit 8. High-speed solid-liquid mixer 20 9. Spray dryer DETAILED DESCRIPTION OF THE INVENTION This detailed description covers the invention: Preparation of Semi-Wet Granules for Tile Production. Its technology is used solely to improve understanding of the subject, without any limiting factors. This is explained with examples that will not create a problem. 25 The invention concerns a semi-wet granule preparation technology used in the production of ceramic tiles. increasing environmental and economic efficiency by reducing energy, water and raw material consumption It is related to a method that targets [others]. 6 Ceramic coating materials are widely used in the construction and decoration industries. It has a significant area of ​​expertise. However, ceramic tile production is a highly energy and resource-intensive process. The production stages involve raw materials with a specific composition and appropriate particle size. ensuring a homogeneous distribution during preparation, and drying of the shaped tiles. and ultimately involves firing the ceramic tiles. Spray dryers, in particular, 5 It is among the devices that consume high energy during the production phase. In addition, The preparation of ceramic clay requires a large amount of water, which both This leads to undesirable consequences both economically and environmentally. Traditional ceramics In production processes, raw materials are ground using the wet milling method and this mixture... Granulating it in a spray dryer results in high energy and water consumption. 10 This situation not only increases costs, but also leads to high carbon emissions. Its emissions have negative impacts on the environment. Ceramic tile production follows a chain reaction. It consists of a series of steps, and each stage requires different amounts of energy, raw materials, and water. It requires consumption. To elaborate on this process: 1. Raw Material Preparation: In the first step, the raw materials used in ceramic tile production are prepared. 15 These raw materials are clay, kaolin, feldspar, and quartz group raw materials. Raw materials are mixed in specific proportions and then processed to be ground into a fine powder. They are ground. This process ensures that the raw materials acquire a homogeneous structure, This process is carried out to ensure the desired mineralogical and chemical composition of the tiles. During the raw material preparation phase, 0.1-0.3 kWh / m² of electrical energy is used. Electricity 20 Depending on the carbon emission factor of the source, it is estimated to be between 0.04-0.1 at this stage. kg CO₂e of carbon emissions occur. In this calculation, an average electricity emission is used. The factor is based on 0.4 kg CO₂ / kWh. The total raw material area is between 26-32 kg / m². Consumption and water usage is 1-2 liters / m². This water is used for easy grinding of the mixture and It allows for mixing. 25 2. Grinding, Mixing and Granulation: The prepared raw materials are mixed with water in the second stage. It is mixed with water to form a pulp. Water, clay and other materials are added during the granulation process. It helps the materials to come together and ensures that the granules have a homogeneous structure. This ensures that it is formed. Afterwards, it is granulated in a mud spray dryer. Granules The processed raw material becomes easier to work with during the pressing stage, and 30 The tile is shaped to the desired form. The rheology required for this process is applied. Regulating auxiliary chemicals are also used. During the mixing and granulation process, 0.2- While 0.5 kWh / m² of electrical energy is consumed, 0.5-1 liter / m² of water is used. At this stage, approximately... 7 0.08-0.2 kg CO₂e of carbon emissions are generated. The carbon footprint of electricity is the energy source's carbon footprint. It can vary depending on the fossil fuel content. 3. Pressing: The granulated raw materials are shaped into tiles at this stage. They are transformed. The granules are compressed using high pressure in special press machines. and the desired form is given. The pressing process determines the final shape and thickness of the tiles. 5 This is the given stage. During this stage, 0.1-0.2 kWh / m² of electrical energy is used. This Approximately 0.04-0.08 kg of CO₂e emissions are released during this stage. Pressing is a low-energy process. While it is a necessary step, the emissions of the electricity source used It emits carbon depending on the factor. 4. Drying: The tiles, which have been formed by the pressing process, are transferred to dryers at this stage. 10 The drying process is carried out to remove the water contained in the granules, and the final result of the tiles... It increases its shelf life before cooking. During the drying phase, 0.5-1 kWh / m² of electricity is consumed. Natural gas energy is consumed. The 0.5-1 liter / m² of water used in this process also evaporates. It is removed from the environment, thus reducing the moisture content of the tiles to a suitable level for firing. Yes. Since natural gas has an emission factor of 0.2 kg CO₂ / kWh, the estimated cost at this stage is 15. Emissions of 0.2-0.4 kg CO₂e occur. Natural gas is preferred over electricity. It provides low carbon emissions. 5. Glazing: The dried tiles undergo a surface coating process during the glazing stage. They are prepared accordingly. By applying glaze and various pigments, the tiles are given an aesthetic and A protective surface is provided. The glaze makes the tile both waterproof and durable. 20 It provides a decorative appearance. During the glazing process, 0.1-0.3 kWh / m² of electrical energy is consumed. It is used and 0.5-1 liter / m² of water is consumed. This water is used to ensure the glaze coating is applied evenly to the surface. It helps in its implementation. This process generates 0.04-0.1 kg of CO₂e carbon emissions. The emission rate in this electrically powered process varies depending on the electricity source. It can show. 25 6. Firing: Firing is the stage in ceramic tile production where the most energy is consumed. This is the stage. The tiles are vitrified by being fired at high temperatures; this makes the surface of the tiles... This allows it to harden and become non-porous. During the baking process, 4-6 kWh / m² of natural gas energy is consumed. Considering the emission factor of natural gas, During the firing stage, 0.8-1.2 kg of CO₂e is released. This stage is for ceramic tile 30 This process accounts for a significant portion of the carbon emissions in tile production. 8 It increases durability and makes the surface impervious to liquids and dirt. Baking The high temperature during the process plays a critical role in achieving the final structure of the tiles. 7. Cooling: The tiles coming out of the kiln are cooled down in a controlled manner. The cooling phase begins. This process can be avoided due to sudden temperature changes. Prevents cracks and deformations. 0.1-0.2 kWh / m² of electrical energy is consumed during cooling. It is consumed and 0.04-0.08 kg of CO₂e emissions are generated. This is powered by electricity. At this stage, carbon emissions depend on the energy source used. Controlled cooling. The process ensures that the internal and external structure of the tiles, which are hardened by baking, remains balanced. 8. Cutting and Packaging: The final stage of the production process, baking and cooling. The tiles produced from the processes are cut to the desired sizes and packaged. Cutting and 10 During packaging operations, 0.1-0.2 kWh / m² of electrical energy is used and 0.04-0.08 kg of product is consumed. CO₂e carbon emissions occur. This low-energy stage contributes to the total carbon emissions. It makes a limited contribution to emissions. At this stage, the tiles are of standard dimensions. They are brought in and made ready for use. The packaging process involves the tiles. It is important that this is done properly to prevent damage during transport. 15 The total energy consumption for all stages of ceramic tile production is 5-10 kWh / m². It varies between these levels. The total estimated carbon emissions are in the range of 1.2-2.2 kg CO₂e / m². Carbon emissions from electricity and natural gas depend on the type of energy used and the production process. This may vary depending on the technology. The average emission factor of electrical energy is 0.4. The emission factor for natural gas is accepted as kg CO₂ / kWh, while for natural gas it is accepted as 0.2 kg CO₂ / kWh. 20 The baking process, in particular, has the highest carbon footprint due to its intensive use of natural gas. It has emissions. Considering the above, the current methods are energy and Its inefficiency in terms of resources is evident. Using semi-wet granule preparation technology, the ceramic tile production process is as follows: 25 This happens in the following way; Step A: Raw Material Preparation: Dry grinding: The first step, used in the production of ceramic tiles, is a standard, alternative, and... Secondary raw materials are processed in (1) dry grinding mills. raw materials, shards of fired tile and intermediate and process waste from other sectors, etc. These are recycled materials. This step aims to increase energy efficiency and reduce water consumption. 9 This is done to reduce the amount of water used in the traditional wet method. This is eliminated in this step. Step B: Preparation and Wet Grinding of Plastic Clays: Use of dissolving mixer (5): Softer raw materials such as plastic clay (2) can be dissolved It is mixed with water using a mixer (5) and made into a liquid. 5 Wet grinding mill (6): Medium and hard raw materials (3), wet grinding together with water by grinding in the mill (6) to achieve optimum grinding conditions and suitable particle size distribution and the size is reduced until the desired size is achieved. During this process, water causes the particles to stick together. prevents and controls viscosity with additional chemicals to obtain a homogeneous mixture. This is ensured by using medium-hard raw materials, quartz, sand, kaolin, and alkali-containing fluxes. such as fired tile fragments and carbonate group raw materials (e.g., calcite and dolomite) are materials. In this step, plastic clays (2) and medium-hard raw materials (3) are used in subsequent stages. It is prepared to form a homogeneous mixture with the raw materials. Step C: Elimination and Dispersion: 15 Screening unit (7): Mixed raw materials, obtaining fine particles and It is passed through a screening unit (7) in order to remove the quantity that is not of the desired size. This step ensures the homogeneity of the mixture and the suitability of the particle size. is carried out. Step D: Homogenizing the Mixture: 20 Use of high-speed solid-liquid mixer (8): Dry ground raw materials, liquid The plastic clay and hard raw material pulp mixture is combined with the existing material. High speed. With the help of a mixer with a certain speed, these two materials with different structures are mixed into a homogeneous slurry. It is transformed into this form. This mixture has a high solid content and density. This stage, 25 is critical for ensuring a more efficient drying process in the spray dryer (9). has. The ceramic mixture obtained in step C contains 5-10% calcite by weight, and by weight... 10-20% siliceous kaolin, 30-40% clay by weight, 10-15% by weight Cooked, dried, ground tile waste, 10-15% by weight of fluxing raw material. It contains kaolin, which is approximately 30-50% by weight. Clay and kaolin are commonly used minerals in inorganic coating materials. And both materials offer properties that enhance mechanical and chemical resistance. Clay group raw materials include smectite, illite, muscovite, bentonite, montmorillonite, kaolin, haloysite, and certain It consists of complex hydrated alumina silicate minerals that do not belong to a single class. Kaolin This group, in particular, contains layered structures such as kaolinite. These different mineral structures are used in coating 5 different effects in stabilizing the rheological (flow and deformation) properties of materials This shows that the various minerals found in the clay's structure provide flexibility and durability, The layered structure of kaolinite contributes to a more regular distribution and the formation of a homogeneous structure. This ensures rheological stability. Therefore, the use of clay and kaolin in coating materials. to provide buoyancy, plasticity, baking resistance, water retention 10 It is of great importance in terms of capacity and chemical composition. Clays generally consist of Fe₂O₃ and While containing impurities like TiO₂, kaolin is in a purer form. High-purity hydrated kaolin. Kaolins, which are aluminum silicate groups, are characterized by their whiteness, low plasticity, refractory properties, and chemical resistance. They are notable for their inertness and layered tetrahedral-octahedral structures. Kaolins are soft. It is structurally sound and can be easily pulverized. 15 In conclusion, although clay and kaolin share mineralogical similarities, their purity and uses differ. They differ in terms of their areas of application. Clays are more easily dissolved by water (due to their plasticity). While (therefore) suitable for grinding, kaolins are more amenable to grinding due to their low plasticity. Step E: Granule Preparation: Spray dryer (9): The prepared homogeneous and dense mud is sprayed 20 It is fed into the dryer (9). In this dryer, the water in the mud is evaporated and the granules are formed. is obtained. The semi-wet method allows the sludge to have a higher solid content. By doing this, less water is evaporated during the drying process, and therefore energy is saved. It allows for savings. Step F: Shaping the Granules: 25 Forming of the granules: The granules obtained at the outlet of the spray dryer (9), It is used in tile forming machines within a specific granule size distribution range. This In the next step, the granules are compressed according to the desired tile sizes and formats. 11 Step G: Drying of Shaped Tiles: Tile drying: Shaped tiles are dried until they reach a low moisture content. They are dried in kilns. This stage increases the strength of the ceramic tiles and provides the final result. This is necessary to prepare it for the cooking stage. Step H: Firing Ceramic Tiles: 5 Final firing: The dried tiles are fired in high-temperature kilns. This stage, It is the final step in the ceramic tile production process and determines the hardness and durability of the tiles. It enables it to win. Previously, to ensure energy efficiency in the cooking process... The shapes, size distribution, and dimensions of the prepared granules are important. Step 1: Utilizing Waste and By-Products: 10 Integration of waste and by-products: This process involves integrating waste materials and by-products. This allows it to be incorporated into ceramic clay. This, in turn, contributes to environmental sustainability. It ensures and optimizes raw material usage. Step J Final Check: Control and quality control: The produced ceramic tiles undergo 15 quality control stages. It is subjected to testing. Parameters such as surface defects, color differences, and durability are examined. The ceramic tile production process results using semi-wet granule preparation technology. Increasing the sludge density can reduce the amount of water evaporated by 20-30%. A reduction is achieved. This reduction is due to using less water during the drying stage. This means it needs to be evaporated, resulting in a 20-25% reduction in energy consumption. This leads to savings. At the same time, thanks to reduced energy consumption. Carbon emissions are also significantly reduced, with CO₂ emissions decreasing by 20-25%. is decreasing. These results indicate that increasing energy efficiency while reducing environmental impacts. It contributes to the development of a sustainable production process aimed at achieving this goal. The scope of protection of the invention is specified in the claims attached hereto, and these detailed 25 The explanation cannot be limited to those given for illustrative purposes. Because a technically skilled person... the person, without deviating from the main theme of the invention, in light of what has been described above, similar It is clear that these structures can emerge.

Claims

12 REQUESTS 1. The invention relates to the production of ceramic tiles used in the field of ceramic coating materials. It is a semi-wet granule preparation method, characterized by increasing the mud density. Reducing the amount of water to be evaporated by 20-30%, thus saving energy. to reduce the amount of CO2 by 20-25% a) Preparation of ceramic mixture and reducing particle size to 5-75µ grinding in a dry grinding mill (4), b) Mixing plastic clays (2) with water in the dissolving mixer (5) to form a homogeneous mud bringing the uniform, c) medium and hard raw materials (3) in wet grinding mill (6) with the addition of water 10 grinding, d) Dry ground ceramic mixture in process step a, homogenized in process step b Clay brought to a mud form and processed in steps c, wet-ground medium and hard. Mixing of raw materials and removing unwanted substances from the mixture exceeding 100-175µ. 15 from the screening unit (7) to ensure the separation of large particles passing, e) High quality of raw materials passed through the screening unit (7) in process step d. homogenizing the slurry by using a rotary solid-liquid mixer (8), f) Feeding the sludge obtained in step e into the spray dryer (9), g) The sludge fed into the spray dryer (9) in step f is sprayed 20 sprayed into the dryer (9) and dried into granular form transformation, It is characterized by including the process steps.

2. This is a semi-wet granule preparation method for ceramic tile production in accordance with Claim 1, Its characteristic is; as mentioned in step a of the method, the ceramic mixture is 5-10% by weight. calcite by weight, 10-20% siliceous kaolin by weight, 30-40% clay in proportion, 10-15% by weight of cooked, dry-ground tile waste, The flux material should be used at a rate of 10-15% by weight.

3. The semi-wet granule preparation method for ceramic tile production in accordance with Claim 1, 30 The feature of the high-speed solid-liquid mixer used in step d is (8) It involves mixing raw materials at a speed of 10-3000 rpm. 13 4. This is a semi-wet granule preparation method for ceramic tile production in accordance with Claim 1, The characteristic of the granules obtained in step f of the process  5-20% by weight of 500 microns,  45% - 55% by weight of 250 microns, 5  15% - 25% by weight of 150 microns,  5% - 15% by weight of 75 microns,  1% - 10% by weight >75 microns, It has size distribution ranges. 10 5. This is a semi-wet granule preparation method for ceramic tile production in accordance with Claim 1, Its characteristic is that the grinding process that takes place in step a is dry grinding. It is carried out in the mill (4).

6. This is a semi-wet granule preparation method for ceramic tile production in accordance with Claim 1, Its characteristic is that the plastic clays formed during process step b become a homogeneous mud form. The process of bringing it is carried out in the dissolving mixer (5).

7. The semi-wet granule preparation method for ceramic tile production in accordance with Claim 1, 20 Its characteristic is that the weight of medium and hard raw materials is determined in processing step c. Grinding with the addition of 30-40% water in a wet grinding mill (6) It is the realization of.

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