Utilization of Industrial Waste

for Sanitaryware Body

Preparation
 Sanitaryware Production Process

Current
Research
Focus Area
 Sanitaryware Body Composition
 In Sanitary ware Manufacturing/Production process body preparation is the first step. In this process
Slip is produced by mixing Ball clay, Silica, China clay and feldspar. This composition is called Tri-
axial body. Consist of Body former, Filler and flux. Body former is plastic material which is required
to give strength at the green stage of the sanitary ware. Filler is non-plastic material which is going
to give strength after the firing. Flux is a non-plastic material which added to the body to reduce
the fusion temperature point of the body during firing. All raw materials are mixed at proper
position and brought to required physical parameters.

 Normally following rhelogical parameters are checked after slip preparations – Fluidity, Thixotropic
of the slip at 1 minute and 5 minute, Liter weight.

 These parameters will vary depending upon the composition, climate, Type of casting (Bench
casting, high pressure casting, Low pressure casting for sanitaryware and other) and required
casting rate.

 Supply slip will be mixture of virgin slip, run off slip & scrap slip. This composition also will vary
according to the availability of the scrap slip available and required casting rate.

 Once slip prepared according to the required parameter it will be sent to slip storage silos.
Whenever slip is required then it will be supplied to casting department for casting.
Triaxial Body Composition
Properties of Sanitaryware Body

 Water absorption should be below 0.5%.

 Can withstand minimum of 400 Kgs load.
 Good glossy surface for easy cleaning.

 Sanitary Ware is made using three main components.

1) Clay- China Clay and Ball Clay (45-55%)
2) Quartz (20-30%)
3) Feldspar (20-30%)
 Aim of the research

 To develop a low cost Sanitaryware body (Triaxial Porcelain) utilizing two

important industrial wastes (Fly ash and Blast Furnace Slag).

Ground Granulated
Fly Ash
Blast Furnace Slag
Research Articles Available
1. Innovative methodologies for the utilisation of wastes from metallurgical and allied industries,
Sanjay Kumar, Rakesh Kumar, Amitava Bandopadhyay, Resources, Conservation and
Recycling, Volume 48, Issue 4, October 2006, Pages 301–314
2. Synergistic effect of fly ash and blast furnace slag on the mechanical strength of traditional
porcelain tiles, Kausik Dana, Jayanta Dey, Swapan Kumar Das, Ceramics International, Volume
31, Issue 1, 2005, Pages 147–152
3. Partial substitution of feldspar by B.F. slag in triaxial porcelain: Phase and microstructural
evolution, Kausik Dana, Swapan Kumar Das, Journal of the European Ceramic Society, Volume
24, Issues 15–16, December 2004, Pages 3833–3839
4. Ceramics from blast furnace slag, kaolin and quartz, Emilia Karamanova, Georgi Avdeev,
Alexander Karamanov, Journal of the European Ceramic Society, Volume 31, Issue 6, June
2011, Pages 989–998
5. Effect of substitution of fly ash for quartz in triaxial kaolin–quartz–feldspar system, Kausik Dana,
Sukhen Das, Swapan Kumar Das, Journal of the European Ceramic Society, Volume 24, Issues
10–11, September 2004, Pages 3169–3175
6. The sintering kinetics of porcelain bodies made from waste glass and fly ash, Süha Yürüyen, H.
Özkan Toplan, Ceramics International, Volume 35, Issue 6, August 2009, Pages 2427–243

…… and more
Major Challenges
 Sources of industrial wastes varies from source to source.
 Usually corex process of steelmaking generates better quality of steel slag,
which is almost free of iron oxide, presence of iron oxide is detrimental for
triaxial porcelain and glaze.
 Utilization of Blast Furnace Slag develops air bubbles due the presence of
sulphur in the Slag.
 Presence of unburnt carbon in fly ash can lead to generate defect in the
body as well as in glazes.
 Presence of unwanted impurities are of challenges for making good quality
triaxial porcelain.
 Matching the properties with existing porcelain properties as well as
keeping intact the Key Properties of glazes such as: Thermal expansion,
Colour, Durability and Maturing Range in single firing.
 Mismatch between glaze and body with utilizing these industrial waste
materials.
Brief Research Plan

1. Utilization of Blast Furnace Slag (Grounded) in Body Preparation by replacing

Partially Quartz and Feldspar. (Experiment No-1).
2. Utilization of Fly Ash in Body Preparation by replacing Partially Quartz.
(Experiment No-2).
3. Utilization of both Blast Furnace Slag (Grounded) and Fly Ash in Body
Preparation by replacing Partially Quartz and Feldspar. (Experiment No-3).
4. Feasibility Study.
 Estimated Research Timeline (1 year)

0-1st 2nd 3rd 4th 5th 6th 7th 8th 9th 10th 11th 12th
Month Month Month Month Month Month Month Month Month Month Month Month

Literature
Review
Procurement
of Materials

Lab Setup

Experiment
No 1
Experiment
No 2
Experiment
No 3

Feasibility
Study
Field Trials
and Pilot
Production
Planning