Flowable Ceramic Granules for Energy-Efficient Tile Production
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Solution Overview
Problem
Current methods for producing ceramic tiles, particularly porcelain stoneware, face challenges in achieving high compactness, low water absorption, and energy efficiency, with existing processes either consuming excessive thermal energy or resulting in inhomogeneous zones leading to reduced flexure strength.
Innovation Solution
A method involving the preparation of a paste with a controlled water content, using a hybrid technique that combines wet and dry milling, followed by granulation and drying to produce flowable ceramic granules with uniform composition and reduced water usage, which can be fed directly to a ceramic press, thereby reducing energy consumption and maintaining homogeneity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If wet milling with large quantity of water is used to obtain liquid suspension for atomization, then intimate mixing of raw materials is achieved, but great thermal energy and fuel consumption are required for water evaporation
Solution Approach 1:
The invention changes the water content parameter from high (atomization process) to controlled low levels (1-10% by weight), transforming the process from wet milling with evaporation to controlled granulation with minimal drying energy requirements
Solution Approach 2:
The invention avoids the liquid-to-powder phase transition through atomization and evaporation, instead using mechanical granulation to form solid granules directly from wet slurry, eliminating the need for large-scale water evaporation
2Manufacturing precision
If atomization process is used to produce ceramic granules, then flowable powder with uniform composition is obtained, but great dimensions of atomizer are required consuming ample space
Solution Approach 1:
The invention replaces the complex thermal-mechanical atomization system with a simpler mechanical granulation system using rotating drums and binders, eliminating the need for large atomizers and associated space requirements
Solution Approach 2:
The invention introduces organic binders as intermediaries to facilitate granule formation from slurry, enabling controlled granulation without requiring the high-velocity atomization equipment and large spaces that traditional atomization demands
3Use of energy by moving object
If dry mixing of raw materials is used to granulate ceramic material, then energy consumption is reduced, but zones of insufficient homogeneity are produced affecting flexure strength
Solution Approach 1:
The invention performs preliminary wet mixing of raw materials to ensure complete homogeneity before granulation, so that when granules are formed and subsequently dried, the uniform composition is locked in place throughout the entire batch
Solution Approach 2:
The invention creates composite granules where fine clay particles are bound together with organic binders, forming homogeneous composite structures that maintain uniform composition throughout each granule and across the entire batch
4Ease of manufacture
If traditional extrusion method is used to form ceramic tiles from wetted atomized powder, then forming is achieved, but high energy consumption occurs due to re-wetting of powder
Solution Approach 1:
The invention inverts the traditional sequence by forming granules first in a wet state with controlled water content, then drying them before pressing, rather than pressing wetted powder and subsequently drying the formed product, thereby eliminating redundant energy consumption
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This method produces ceramic granules with comparable flowability, humidity, and density to atomized powders, while significantly reducing energy and water consumption, and ensuring uniform composition, enabling the production of high-quality ceramic tiles with reduced porosity and enhanced strength.
Implementation Method 1
granulated by scratching with a brush
Implementation Method 2
The rounded granules are subsequently dried
Data Source
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AI summary
A method for producing flowable ceramic material in the form of granules for manufacturing ceramic tiles comprises the steps of; preparing a paste from a mixture of raw materials, said raw materials comprising clays, inerts and fluxes and according to a defined recipe of a ceramic mix of said ceramic tiles; granulating said paste to obtain ceramic granules.