A ceramic slurry composition produced from natural stone quarry waste

Abstract

The invention relates to a ceramic slurry containing natural stone waste obtained from natural stone cutting factories at a rate of 77%-83% and a bentonite additive at a rate of 17%-23%. In the invention, it is aimed to use natural stone cutting waste as a raw material in the ceramic industry by transforming it. This process reduces environmental waste problems through the utilisation of waste while enabling the production of a high-strength ceramic material that reaches porcelain strength at low temperatures. At the same time, it provides economic advantages by offering a low-cost and energy-saving production process. This invention introduces an industrial innovation by providing an environmentally friendly and sustainable solution.

Description

[0001] A CERAMIC SLURRY COMPOSITION PRODUCED FROM NATURAL STONE QUARRY WASTE

[0002] Technical Field of the Invention

[0003] The invention relates to a ceramic slurry containing waste obtained from natural stone cutting factories at a rate of 77%-83% and a bentonite additive at a rate of 17%-23%. Said natural stone cutting waste contains 40% monzonite-syenite and 60% granitegranodiorite. Through the production of the ceramic slurry that is the subject of the invention, both a contribution is made to environmental waste management and raw material costs and energy consumption are significantly reduced. This transformation enables the production of a high-strength and versatile ceramic material that reaches porcelain strength at low temperatures.

[0004] State of the Art

[0005] The ceramic industry has focused for centuries on the production and development of ceramic products used in various fields. Today, ceramic production plays an important role in various sectors such as construction, health, energy, and artistic fields. The raw materials used in this field are generally obtained from natural resources such as clay, feldspar, and quartz. However, the limited reserves of these raw materials and the need for sustainable management of natural resources constitute one of the main problems faced by the ceramic industry.

[0006] The extraction of clay and mineral raw materials used in ceramic production from nature leads to significant disadvantages in terms of environmental impacts and costs. While the tendency of clay deposits to be depleted threatens the raw material supply chain in the sector, the damage caused to natural habitats during the extraction of these raw materials also constitutes a source of concern in terms of environmental sustainability. In addition, high energy consumption during the extraction and processing of ceramic raw materials causes an increase in carbon footprint.Due to reasons such as the limitations and inadequacies of solutions in the state of the art, high energy consumption, high carbon footprint, and high costs during the extraction and processing of ceramic raw materials, it has become necessary to make a development in the field of ceramic slurry.

[0007] Brief Description and Aims of the Invention

[0008] The invention relates to a ceramic slurry containing natural stone waste including 40% monzonite-syenite and 60% granite-granodiorite obtained from natural stone cutting factories at a rate of 77%-83% and a bentonite additive at a rate of 17%-23%.

[0009] An aim of the invention is to obtain a ceramic slurry in which natural stone waste is utilised and environmental impacts are reduced. In the production of the ceramic slurry that is the subject of the invention, wastes that are released into nature in an uncontrolled manner are disposed of, thereby reducing environmental burdens. At the same time, thanks to the recycling of waste, both the need for waste storage areas is reduced and a contribution is made to the protection of natural resources.

[0010] Another aim of the invention is to obtain a low-cost ceramic slurry. The replacement of raw materials such as clay, feldspar, and quartz used in conventional production with waste enables low-cost production. In this way, the production process is made more economical by providing both energy savings and raw material savings.

[0011] In addition, it is aimed in the invention to obtain a high-strength ceramic slurry. The ceramic slurry described in the invention reaches porcelain strength at low temperatures and provides a high-strength structure. This feature enables the slurry to be used in a wide variety of fields such as floor and wall tiles, artistic objects, and industrial materials. Thus, the production of high-quality products appealing to different sectors is ensured.

[0012] Description of the Drawings

[0013] Figure 1. Mineralogical ratios of natural stone cutting wasteDetailed Description of the Invention

[0014] The invention relates to a ceramic slurry obtained by recycling natural stone quarry waste. The ceramic slurry composition that is the subject of the invention comprises, by weight, 77%-83% natural stone cutting waste containing 40% monzonite-syenite and 60% granite-granodiorite, and by weight, 23%-17% bentonite additive.

[0015] The chemical analysis of the waste used in the invention is as shown in Table 1. When these values are calculated, it is observed that the mineralogical composition consists of 14.46% clay mineral, 27% free silica, and 54.27% feldspar. When these ratios are examined in the quartz, alkali feldspar, plagioclase, feldspathoid (QAPF) diagram, it is observed that the mineralogical values of the waste are located at a point close to the soft porcelain region (Figure 1 ).

[0016] Table 1. SQX Analysis Results

[0017] No. Cmqx.»ne»t Result V«it IM limit El line Intens&ry w / onomai 1 SiO2 70.2 03899 Sl-KA 406.8905 37.0861 2 Ai2O3 16.0 0.00733 AI-KA I 31.3862. 8.4323 3 K2O 4.12 0.00790 K. -KA 18.8939 2.1 ’44 4 NB2O 3.54 i).lH598 Na-KA 16379 1.8701 .5 . CM, . 164. massM . fi.WM . Ca-KA . 11.3583. L3943 6 2.18 0,00813 Fe-KA 38.1308 1J510 7 0.667 9.0R139 Mg-KA 1.9178 0.3520 8 1102 0.178 mass% 0.01500 Ti-KA 0.2876 0.0923 9 P2O5 0410 iws% 0.90217 I* -KA 0.9335 0.0580 10 BM) tl.lOi 001893 Bti-KA 4.4259 0.0831 11 0.0943 0.00468 S -KA 0.6642 0.0498 12 MnO 0.0’35 Q.0648S Mn-KA 0.8387 0.0388 13 SrG 0.0341 BMSH 0.00178 Sr-KA 10.6493 0.0189 14 Cl 09285 990811 Cl-KA 0 1506 09150 15 Rt>2< > . 0.0166 masKK . 0.00165. RO-KA . 4.8439. 0-«? 16 ZrO2 0.0113 massM 9.00185 Zr-KA 8.6274 0.0069 17 ZaO 0.0199 mass% 9.00.215 Zn-KA 0,7599 0.0053 18 NiO 00048 9.90432 Ni-KA (OV1 0.0827 0.0026

[0018]

[0019] In order to shift the values to the porcelain region in the QAPF diagram, minerals from the clay group need to be added. The strong results obtained in terms of strength in the invention and the final product shape have been achieved with the bentonite additive. With a bentonite additive ratio of 17%— 23%, a ceramic slurry with high plasticity value that can be used in floor tiles, utilitarian goods, decorative, and artistic fields at high strength (porcelain strength) has been formed (Table 2).Table 2. Firing Tests of the Invention at 1050 Degrees

[0020] Flexur Colour Measurement Values

[0021] %

[0022] Sampl al Water

[0023] Firing AE* e and Streng Absorpti L* a* b*

[0024] Shrinka (Colour Codes th on (%) (Whitene (Redne (Yellowne

[0025] ge Differen (MPa) ss) ss) ss)

[0026] ce) Y-2

[0027] (83%

[0028] waste +

[0029] 53,63 0,008 12,5 36,64 4,36 5,36 28,28 17%

[0030] bentoni

[0031] te)

[0032] Y-3

[0033] (77%

[0034] waste +

[0035] 42,15 0,006 15,01 10,23 4,4 7,38 54,41 23%

[0036] bentoni

[0037] te)

[0038]

[0039] Porcelain tiles require higher strength due to their high density and low water absorption properties. The minimum flexural strength must be 35 MPa. Therefore, porcelain tile application areas can utilise the ceramic slurry obtained from the ceramic slurry that is the subject of the invention. It can be fired in the range of 1000-1050 °C.

[0040] Table 3. XRF Analysis Results

[0041] Components Proportions (% by weight)

[0042] Na2O 1.83

[0043] MgO 1.49

[0044] AI2O3 16.9

[0045] SiO260.85

[0046] K2O 0.77

[0047] CaO 2.62

[0048]

[0049] Fe2O33.47Table 4. XRD Analysis Results of Waste Materials

[0050] Waste Material XRD Analyses Proportions by Weight (%)

[0051] Quartz Trace

[0052] Cristobalite 8

[0053] Rock Composition Feldspar 20

[0054] Calcite 2

[0055] Total Clay Content 70

[0056] Montmorillonite (17A) 70

[0057] Montmorillonite (15A) Trace

[0058] Clay Composition Illite Trace

[0059] Chlorite -

[0060]

[0061] Kaolinite -

Claims

CLAIMS1. A ceramic slurry composition obtained by recycling natural stone quarry waste, comprising, by weight, 77%-83% natural stone cutting waste containing 40% monzonite-syenite and 60% granite-granodiorite, and by weight, 23%-17% bentonite additive.

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