Recycling of industrial wastes in ceramic manufacturing: State of art and glass case studies

Abstract Nowadays, ceramic tile are manufactured at zero emissions permitting to recycle all by-products and part of residues derived from depuration treatments (exhausted lime, glazing sludge and polishing sludge). In addition to this environmentally friendly tendency, in the last years an increasing number of scientific studies demonstrated the feasibility to use alternative raw materials in substitution of different component of the ternary clay-feldspar-quartz system. In the first part of the paper is reported the state of the art of industrial waste recycling in the ceramic sector, with the focus on review studies related to both ceramic tiles and bricks.. In the second part of the work are reported two case studies conducted by the authors with the aim to formulate ceramic bodies using alternative raw materials. New tailored compositions were obtained replacing clays, flux and/or inert compounds (higher than 60 wt%) by scraps from packaging waste glass in tiles, and cathode ray tube glasses and packaging waste glass up to 20 wt% in the brick compositions.

[1]  F. Andreola,et al.  Management of agricultural biomass wastes: preliminary study on characterization and valorisation in clay matrix bricks. , 2013, Waste management.

[2]  G. Pellacani,et al.  Recycling of ceramic wastes in tile bodies to reduce pollution , 1993 .

[3]  José M.F. Ferreira,et al.  Incorporation of granite cutting sludge in industrial porcelain tile formulations , 2004 .

[4]  M. Raimondo,et al.  Recycling PC and TV waste glass in clay bricks and roof tiles. , 2009, Waste management.

[5]  E. Rambaldi,et al.  Use of soda-lime scrap-glass as a fluxing agent in a porcelain stoneware tile mix , 2004 .

[6]  A. Salem,et al.  Dilatometeric study of shrinkage during sintering process for porcelain stoneware body in presence of nepheline syenite , 2009 .

[7]  Vorrada Loryuenyong,et al.  Effects of recycled glass substitution on the physical and mechanical properties of clay bricks. , 2009, Waste management.

[8]  Erlangen,et al.  Light-weight cellular ceramics from biologically-derived preforms , 2000 .

[9]  C. Martínez,et al.  Recovering wastes from the paper industry: Development of ceramic materials , 2012 .

[10]  E. Karamanova,et al.  Post-treated incinerator bottom ash as alternative raw material for ceramic manufacturing , 2012 .

[11]  J. Tay,et al.  Bricks Manufactured from Sludge , 1987 .

[12]  M. Raimondo,et al.  Glass–ceramic frits for porcelain stoneware bodies: Effects on sintering, phase composition and technological properties , 2008 .

[13]  F. Andreola,et al.  Recycling of Screen Glass Into New Traditional Ceramic Materials , 2010 .

[14]  M. Hernández-Crespo,et al.  The use of a calcium carbonate residue from the stone industry in manufacturing of ceramic tile bodies. , 2009 .

[15]  M. Dondi,et al.  Zeolite–feldspar epiclastic rocks as flux in ceramic tile manufacturing , 2007 .

[16]  Michele Dondi,et al.  Recycling of industrial and urban wastes in brick production: A review (part 2) , 1997 .

[17]  A. V. Belyakov,et al.  Construction materials using tanning industry wastes , 1994 .

[18]  A. Karamanov,et al.  Ceramic material from basaltic tuffs , 2007 .

[19]  F. Andreola,et al.  TECHNICAL SOLUTIONS TO IMPROVE RECOVERY OF SCRAPS DERIVED FROM TREATING GLASS PACKAGING WASTE Extended abstract , 2013 .

[20]  M. Dondi,et al.  Influence of zeolites on the sintering and technological properties of porcelain stoneware tiles , 2003 .

[21]  C. Prasad,et al.  Effect of substitution of quartz by rice husk ash and silica fume on the properties of whiteware compositions , 2003 .

[22]  E. Karamanova,et al.  Recycling of CRT panel glass as fluxing agent in the porcelain stoneware tile production , 2008 .

[23]  A. H. Goode,et al.  Waste glass as a flux for brick clays , 1972 .

[24]  H. Alves,et al.  Inertización de lodos galvánicos para su incorporación a productos cerámicos , 1999 .

[25]  E. Karamanova,et al.  Ceramics from blast furnace slag, kaolin and quartz , 2011 .

[26]  POSSIBLE USE OF ALTERED VOLCANIC ASH IN CERAMIC TILE PRODUCTION , 1999 .

[27]  M. Al-harahsheh,et al.  Recycling of stone cutting sludge in formulations of bricks and terrazzo tiles , 2010, Waste management & research : the journal of the International Solid Wastes and Public Cleansing Association, ISWA.

[28]  C. Schmidt-Reinholz Open-air storage, soaking, and maturing of clay ceramic raw materials and bodies ― advantages and disadvantages , 1987 .

[29]  Nursev Bilgin,et al.  Use of waste marble powder in brick industry , 2012 .