Reduced Fast Firing in the Ceramic Tile Manufacturing Process with Inorganic Additives: A Step Up for the Sector.

The use of European patent-protected inorganic additives to improve the characteristics of ceramic tiles is covered in this study. Modifications in shrinkage, modulus of rupture, and water absorption were noted when different kinds of additives consisting of phosphoric acid and hydrated sodium silicate were applied to the ceramic mass at varying percentages (0.15, 0.30, and 0.50 %) in a laboratory setting. It was anticipated that using both chemicals at once would increase the slurry's viscosity and reduce the firing temperature, resulting in less energy consumption and less CO2 being released into the atmosphere. After choosing the best combination and concentration of additives, a number of industrial tests are carried out. In industrial settings, the features of both regular ceramic mass and mass containing the chosen additive were determined without modifying process parameters, while producing monoporosa floor tiles with a water absorption of below 3.0 %. It is seen that the additives in such a small percentage reduced the fire time to 55 minutes cold-to-cold without compromising the quality of the final products. By employing lower-quality raw materials, accelerating the process, lowering the maximum firing temperature, and boosting capacity by 6.8 %, the use of additives in the manufacturing of ceramic tiles creates new potential to improve the product's mechanical and physical properties and lower production costs per unit of output. As a result, considerable energy savings and a reduced carbon footprint are achieved.