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Öğe Addition of cement kiln dust in ceramic wall tile bodies(Springer, 2019) Aydin, Tuna; Tarhan, Muge; Tarhan, BaranThe volume of wastes generated from heavy industries, such as cement and steel industries, is increasing, and the cost of landfill disposal grows daily. Economical and eco-friendly areas of recycle are being developed to stop the growth of these waste products. Cement kiln dust (CKD) is a waste product in the cement industry. It contains very fine grains like cement in addition to finer particles of lime, silica, alumina and iron. These particles contain high concentrations of sulphates and alkalis. The aim was to study the effects of using CKD as an alternative source of CaO in ceramic wall tile production. Ceramic tiles compositions in different ratios were prepared with CKD (15 mass% max) rather than calcite. All shaped samples were sintered at 1150 degrees C. Optical dilatometer was used to evaluate sintering behaviour. Physical properties, such as linear firing shrinkage, bulk density, flexural strength and water absorption, were also measured. The bodies containing CKD showed a decrease in moisture expansion and were whiter than the body of a standard composition. This study showed that CKD is an effective CaO source in ceramic tile production.Öğe Development of lightweight ceramic construction materials based on fly ash(Australian Ceramic Society, 2017) Aydin, TunaThis study aims to demonstrate the suitability of using lightweight ceramics as a construction material in preference to autoclaved aerated concrete and pumice blocks or the more commonly used brick. For construction applications, ceramics show good stability under fatigue loadings and severe environmental conditions and are an economical alternative to other materials. Although bricks have better mechanical properties than the new generation construction materials, thermal insulation properties of brick are much lower. Hence, the use of bricks as a fired construction materials is becoming increasingly unfavorable; as a result, brick manufacturers are losing their market share day-by-day. This study aims to develop an alternative fired lightweight, ceramic construction material with fly ash with relatively better mechanical and thermal insulation properties.Öğe Development of Optical, Microstructural and Mechanical Properties of Porcelain Stonewares(Int Inst Science Sintering (I I S S), 2021) Aydin, Tuna; Bican, Osman; Gumruk, Recep; Kuleyin, HamdiNew production systems developed in recent years made it possible to improve different aesthetic appearance and large sizes for porcelain stonewares. In order to produce these tiles, optical and mechanical properties of the porcelain stonewares should be improved. Optical and mechanical properties also related with microstructure. In this study, spodumene, alumina and zircon were used to improve the microstructure of the porcelain stonewares and consequently their optical and mechanical properties. The wear resistance of porcelain stonewares is the one of the most important mechanical properties. In this study, a different test method was used because the existing wear test methods on the tiles were insufficient. The solid particle impingement method using alumina particles was used to determine wear resistance of the porcelain stoneware bodies.Öğe The development of porcelain foams lighter than water for heat isolation application(Springer, 2019) Aydin, TunaIn this study, technological and heat isolation properties of porous ultra-lightweight porcelain foams were investigated. Traditional construction materials such as brick show good durability against environmental conditions. Bricks are also a good alternative compared to pumice blocks and autoclaved aerated concrete which are largely used as construction materials. Bricks are also more economical than the other construction materials. But they also have poorer thermal insulation properties. Among the construction material, XPS shows the best heat isolation properties. XPS (extruded polystyrene foam) is a polymeric material. Although XPS shows best heat insulation property, it easily flames. The aim of this study is developing porous porcelain isolation materials lighter than water by using a replication method and relatively better thermal isolation properties than the other construction materials.Öğe Development of porous lightweight clay bricks using a replication method(Australian Ceramic Society, 2018) Aydin, TunaThis study focused on porous lightweight clay bricks as a construction material as opposed to autoclaved aerated concrete and pumice blocks. Traditional clay bricks exhibit good stability against environmental conditions and are an economical alternative compared to other construction materials. Furthermore, clay bricks have better mechanical properties than autoclaved aerated concrete and pumice blocks but poorer thermal insulation properties; hence, their use in buildings is becoming increasingly unfavourable. This study focused on developing porous lightweight clay bricks with relatively better thermal insulation properties using a replication method.Öğe The effect of cement raw mix waste dust on porcelain tile properties(Springer, 2019) Aydin, Tuna; Paksoy, CigdemNowadays, the recycling of industrial waste is one of the priority issues. Recycling studies related with reducing the negative effects of wastes on the environment are becoming increasingly important. It was believed that nothing was beyond recycling, and manufacturers should take greater responsibility for their part in the waste economy to apply cyclical solutions to an expanding breadth of new product categories. Cement raw mix contains silicate, alumina, iron oxide, and limestone. Raw mix contains SiO2, Al2O3, CaO, Fe2O3, MgO, Na2O, and K2O in higher ratio. The high presence of these oxides in the raw mix powder makes raw powder an alternative source of raw material for porcelain tile compositions. In this study, raw mix dust was used instead of sodium feldspar in a standard porcelain tile composition, at a rate of 1, 5, 10, and 15% by weight. The specimens were sintered at 1210 A degrees C. Flexural strength, firing shrinkage, water absorption, porosity, and other technological properties were investigated. It has been determined that the body containing 1% of the raw mix powder improved its physical and mechanical properties compared to the standard body.Öğe The Effect of Nepheline Syenite Addition on Pyroplastic Deformation of Sanitarywares(Int Inst Science Sintering (I I S S), 2018) Aydin, Tuna; Kunduraci, Nazim; Akbay, AtamerNepheline syenite is used instead of feldspars as fluxing in ceramics. In this study, three ceramic bodies were prepared. Nepheline syenite was substituted by Na feldspar in the ratio of maximum 30 wt.%. The pyroplastic deformation was evaluated together with technological properties, including linear shrinkage, water absorption and strength. Phase and microstructural characteristics were also investigated. Results showed that the addition of nepheline syenite provided a decrease in viscosity. The decrease in viscosity caused an increase in the tendency for pyroplastic deformation in bodies containing nepheline syenite; however, this result shows that bodies containing nepheline syenite can be sintered at a lower temperature than the standard body. The addition of nepheline syenite also decreased water absorption and increased strength.Öğe The Effect of Nepheline Syenite Addition on the Sintering Behaviour of Sanitaryware Bodies(Australian Ceramic Society, 2016) Kunduraci, Nazim; Aydin, Tuna; Akbay, AtamerIn this study, the effect of nepheline syenite addition on the sintering and material properties of sanitaryware porcelain bodies was investigated. Three ceramic sanitaryware bodies were prepared by substituting Na feldspar (max. 30 wt %) with nepheline syenite. The sintering behaviour was evaluated using an optical dilatometer. Samples were sintered at 1300 degrees C using step-by-step processing. In addition the linear shrinkage, water absorption and bending strength were measured. Results showed that the addition of nepheline syenite enhanced the material properties of sanitaryware bodies, had a positive effect on the formation of the liquid phase during sintering and improved overall the sintering and mechanical properties.Öğe Effect of spodumene addition on pyroplastic deformation of porcelain stoneware(Korean Assoc Crystal Growth, Inc, 2014) Aydin, Tuna; Kara, AlpagutLithium aluminosilicates, such as spodumene, have been used as raw materials in the production of thermal shock resistant whiteware and sanitaryware. The presence of spodumene causes enhancement of mullitization and imparts better physical and mechanical properties to ceramics. In this study, the influence of Li2O-content on the properties of a standard porcelain stoneware body was investigated. Sodium feldspar was replaced by the spodumene in varying amounts (up to 4 wt. %). The results showed a significant microstructural improvement, the presence of spodumene which, during firing, allows the development of a low viscosity liquid phase with a decrease of closed porosity, also with increasing bulk density and bending strength.Öğe Effects of Alumina on Porcelain Insulators(Australian Ceramic Society, 2016) Aydin, Tuna; Kara, AlpagutThis study was conducted under both industrial and laboratory conditions for improving material properties (i.e. mechanical and electrical) of electroporcelain bodies produced by porcelain insulator factories in Turkey. To achieve this aim, the quartz content of a standard electroporcelain body was substituted by alpha-alumina. The technical and sintering behaviours of quartz and the alumina-substituted bodies were investigated. Results showed that the addition of alumina increased the mechanical and electrical strength of the materials.Öğe The effects of fine fire clay sanitaryware wastes on ceramic wall tiles(Elsevier Sci Ltd, 2016) Tarhan, Muge; Tarhan, Baran; Aydin, TunaIn the last decade, environmental preservation has become an important issue. Specifically, recycling of sanitaryware fine fire clay (FFC) waste is important for reducing costs. In this study, the use of FFC waste as an alternative raw material in the production of ceramic wall tiles was investigated. Five ceramic wall tile bodies were prepared by substituting kaolin (max. 15 wt%) with FFC wastes. All formulations were mixed, pressed into pellets and sintered at 1145 degrees C. The sintering behaviour was evaluated using an optical dilatometer. Water absorption, linear shrinkage and bending strength were also measured. This study revealed that FFC wastes are good alternative raw materials, and the corresponding formulations were shown to be viable in the manufacturing of ceramic tiles. The most remarkable conclusion from this study was that the addition of FFC waste decreased moisture expansion. (C) 2016 Elsevier Ltd and Techna Group S.r.l. All rights reserved.Öğe Investigation of the effect of type and grain size of feldspar on thermal properties of ceramic sanitaryware(Springer, 2023) Gunbay, Asli Aydin; Kunduraci, Nazim; Aydin, Tuna; Sari, HasanCeramic sanitaryware products are produced using inorganic and non-metallic raw materials such as clay, kaolin, quartz and feldspar at certain rates. After mixing and grounding process, the slip is obtained. The products are shaped in gypsum or synthetic resin moulds. Green bodies are fired at 1250 & DEG;C for 16-18 h, and their water absorption values are less than 0.5%. Nowadays the most important issues are raw materials and energy costs. In this study, the sintering behaviour of Na-feldspar and K-feldspar, which are widely used in ceramic sanitaryware, is analysed by reducing to different grain sizes. The grain sizes of the samples containing Na-feldspar were reduced under 63 & mu;m. It was found that the decrease in grain size of Na-feldspar contributed to the decrease in sintering temperature. Potassium feldspar was also added instead of Na-feldspar in order to develop deformation behaviour at higher temperature. The increase in the amount of K-feldspar contributed to the decrease in deformation values. However, the flexural strength of the bodies decreased. A decrease in grain size of Na-feldspar resulted in a reduction of 10 & DEG;C at the sintering temperature. The decrease in sintering temperature will provide a cost advantage of around 3%. It was also found that technical properties such as firing shrinkage, bulk density, and flexure strength increased as the grain size of Na-feldspar decreased.Öğe Investigation of wear resistance of the porcelain tile bodies by solid particle impingement using alumina particles(SPRINGER, 2020) Aydin, Tuna; Bican, Osman; Gumruk, RecepWear resistance is of great importance for many industries related with minerals. The particles seen in these industries may cause erosion. These particles may have various sizes, shapes, and hardness, and may also impact the surface at various angles and speeds. Wear resistance is also important for the ceramic tile industry because the materials, which are also used in building facades, must withstand all kinds of weather conditions. In this study, the wear resistance of the porcelain tile bodies was investigated by solid particle impingement using alumina particles. The effects of technological, mechanical, and microstructural properties on wear resistance were also investigated. It was determined that the technological, mechanical, and microstructural properties were improved with the addition of spodumene, which also caused that the wear rates were reduced.Öğe Mixed Alkali and Mixed Alkaline-Earth Effect in Ceramic Sanitaryware Bodies Incorporated with Blast Furnace Slag(SPRINGER, 2020) Aydin, Tuna; Casin, ErayRaw materials and energy are among the most important costs in ceramic sanitaryware production. With the decrease in raw material sources and increasing costs of energy in recent years, researches on alternative raw materials and energy have started to gain importance. In this study, blast furnace slag and spodumene were used to reduce both energy and raw material costs. In standard vitreous china ceramic sanitaryware, a maximum of 15% blast furnace slag and 4% spodumene was used instead of sodium feldspar. In this study, the effects of CaO, MgO, and Li2O on microstructure, technological properties such as flexure strength, water absorption, porosity, bulk density; and also, thermal properties such as sintering analysis were investigated by using a non-contact optical dilatometer and thermal expansion. The dry strength and flexure strength of fired samples increased. The increase in dry strength was approximately 47%. The increase in flexure strength was approximately 67%. The reduction in the thermal expansion coefficient values was approximately 17%, which is also important in terms of stability of the final product. As a result, the use of blast furnace slag and spodumene will result in a reduction in both energy and raw material costs. The spodumene and BFS provided a reduction in sintering temperature at a rate of approximately 60 degrees C. The flue gas emissions may also reduce because flue gas emissions are higher as the temperature inside the furnace is higher. The spodumene and blast furnace slag addition provide a decrease in the peak of sintering temperatures so that flue gas emissions will reduce. [GRAPHICS] .Öğe Reusing sanitaryware waste products in glazed porcelain tile production(Elsevier Sci Ltd, 2017) Tarhan, Baran; Tarhan, Muge; Aydin, TunaReusing the waste products generated in ceramic manufacturing is an environmentally responsible and sustainable approach. This study aims to protect natural resources, minimise raw material costs and manage waste-generated pollution by reusing the vitrified sanitaryware waste (VSW) products from Canakkale Kalebodur Seramik San. A. S. Six sample formulations were prepared under industrial conditions and compared with a standard tile body. The results indicated that using VSW in place of feldspar results in an increased firing shrinkage and decreased bending strength, whereas using VSW in place of pegmatite results in an increased bending strength and reduced thermal expansion coefficients. The reduction in the thermal expansion coefficients is an important finding that aids in meeting the dimensional and deformation requirements of porcelain tiles and also results in a slight lightening of the tile colour. This study shows that the fired VSW products can be used in glazed porcelain tile production as a sustainable and technologically, economically and environmentally suitable approach.Öğe The effects of cement raw mix waste dust on thermal properties of ceramic wall tile bodies(Springer, 2021) Aydin, TunaThe recycling of industrial wastes has in recent years become a priority issue. The relevant work on reducing the adverse effects of industrial wastes is becoming more important. Farina (raw mix) is a crude mixture obtained by grinding the raw materials used in cement production. The oxides at a high rate ensure that the cement raw mix waste dust is a good source of raw material in ceramic wall tile body production. This study used 2%, 3%, 5% and 10% cement raw mix waste dust instead of calcite, which is used in a standard wall tile recipe. Another industrial waste, marble dust, was also used as a source of CaCO3. The physical and mechanical properties of prepared samples such as firing shrinkage, dry and fired strength, and water absorption were examined. And firing behavior using a non-contact optical dilatometer was also studied. The study showed that the addition of cement waste raw mix dust improves physical and mechanical properties. Dry strength and bending strength increased as the amount of cement waste raw mix dust increase. Bulk density also increased with the addition of cement waste raw mix dust. Especially, 50% increase in dry strength was achieved with the addition of cement waste raw mix dust instead of calcite. The sintering rate (dy/dt) was negatively affected, and sintering slowed down when the higher amount of the addition cement waste raw mix dust. The study showed that cement waste raw mix waste dust and marble dust can be used as alternative raw materials for ceramic wall tiles up to 5 wt % instead of CaCO3.Öğe The Effects of Silicon Carbide Usage on Strength, Electrical Conductivity, and Durability in Cement Composites(Springer Science and Business Media B.V., 2024) Filazi, Ahmet; Şenses, Ahmet Mustafa; Aydin, TunaThis study investigates the effect of silicon carbide (SiC) powder on cement pastes. SiC was added in various percentages by weight of cement (1%, 2%, 4%, 8%, 12%, and 16%). The spread diameter, mechanical strength, chloride permeability, capillary water absorption, and electrical conductivity of each mixture were determined, and microstructural analyses (SEM and EDX) were conducted. The results indicate that SiC decreases the spread diameter of the mortar while increasing its mechanical strength and electrical conductivity. Specifically, 2% and 4% SiC additions resulted in the highest strength improvements. Chloride permeability tests showed that the resistance of concrete to chloride ions improved over time, with permeability levels significantly decreasing. Microstructural analyses revealed that SiC influences the formation of C-S–H and C-H structures in the cement matrix, enhancing mechanical strength and overall durability. This study highlights the potential of SiC to improve the mechanical properties and electrical conductivity of cement in the industry, suggesting avenues for future research to explore different SiC concentrations and application methods in greater detail. © The Author(s), under exclusive licence to Springer Nature B.V. 2024.
