Şeker pancarı melasının sırlı porselen seramik yer karosu gövdelerinde mukavemet artırıcı olarak kullanımı ve karakterizasyonu

Abstract

Arka plan—Şeker fabrikaları yan ürün olarak büyük miktarlarda şeker pancarı melası üretmektedir. Melas bazı endüstriyel sektörlerde kullanılsa da, araştırmalarımız seramik pres makineleri için sırlı porselen seramik yer karosu gövde çamuru granüllerinde mukavemet artırıcı olarak kullanılmadığını göstermiştir.

Amaç—Bu makalenin amacı, seramik fabrikalarındaki seramik pres makinelerinde kullanılan seramik yer karosu gövde çamuru granüllerinde şeker pancarı melasının mukavemet artırıcı olarak kullanımını araştırmak ve literatürdeki bu boşluğu doldurmaktır.

Yöntem—Pres makineleri seramik yer karosu üretiminde şekillendirme işleminde kullanılır. Granüllerin gerekenden düşük nem içeriği ve kuru mukavemet değerleri nedeniyle, seramik karo üretiminde sırlama sırasında ve sonrasında ve pişirme aşamasında yaklaşık %10 kayıp meydana gelir. Bu kayıpları en aza indirmek ve bunu mümkün olan en düşük maliyetle başarmak için, şeker fabrikalarının bir yan ürünü olan şeker pancarı melası, mukavemetini artırmak amacıyla standart yer karosu gövde çamuruna ağırlıkça %0,1, %0,2, %0,3, %0,4 ve %0,5 oranlarında eklenmiştir. Daha sonra, eklemeden önce ve sonra meydana gelen değişiklikler X-ışını floresans (XRF) spektroskopisi, SEM analizi, termogravimetrik analiz (DTA-TG) ve fiziksel özellikler (mukavemet, renk ölçümü, yoğunluk, akış süresi, elek kalıntısı, partikül boyutu, kuru mukavemet, pişmiş mukavemet, büzülme, su emme vb.) kullanılarak analiz edilmiş ve sürece dahil edilmiştir. Analiz, %0,3 oranında şeker pancarı melası içeren standart karo gövde çamurunun, melas içermeyen standart karo gövde çamuruna göre daha yüksek mukavemete sahip olduğunu göstermiştir.

Bulgular—Günde yaklaşık 250 ton granül tüketen ve seramik pres makineleri kullanan bir seramik fabrikasında, aylık ortalama 7500 ton sırlı porselen seramik yer karosu hamuru granülü kullanılmaktadır. Seramik pres makinesi üretiminde mukavemet kaybından kaynaklanan %10'luk kaybın geri kazanılabileceği göz önüne alındığında, aylık 750 ton granül israfı önlenecektir. Çalışmalar, seramik pres makinelerinde sırlı porselen seramik yer karosu hamuru granüllerinde mukavemet artırıcı olarak atık şeker pancarı melası kullanımının, şirkete önemli ekonomik faydalar sağlayacağını ve sektörde sürdürülebilirliği destekleyeceğini göstermiştir.

Sonuç—Şeker pancarı melasının kullanımı, seramik ve şeker endüstrilerinin sürdürülebilir gelişimine katkıda bulunacak, çevre kirliliğini önleyecek ve aynı zamanda seramik karoların maliyetini düşürecektir. Atık melası yeniden kullanarak şirket, önemli ekonomik kazanımlar elde edecek ve çevre dostu üretim uygulamalarına öncülük edecektir.

Keywords

• Seramik bünye çamuru
• seramik karo
• şeker pancarı
• melas.

Use and characterization of sugar beet molasses as a strength enhancer in glazed porcelain ceramic floor tile bodies

Abstract

Context—Sugar factories produce large quantities of sugar beet molasses as a byproduct. Although molasses is used in some industrial sectors, our research has shown that it has not been used as a strength enhancer in glazed porcelain ceramic floor tile body sludge granules for ceramic press machines.

Objective—The aim of this article is to investigate the use of sugar beet molasses as a strength enhancer in ceramic floor tile body sludge granules for ceramic press machines in ceramic factories, and to fill this gap in the literature.

Method—Press machines are used in the shaping process of ceramic floor tile production. Due to the lower-than-required moisture content and dry strength values of the granules, approximately 10% losses occur in ceramic tile production during and after glazing, and at the firing stage. To minimize these losses and achieve this at the lowest possible cost, sugar beet molasses, a byproduct of sugar factories, were added to standard floor tile body sludge at weight percentages of 0.1%, 0.2%, 0.3%, 0.4%, and 0.5% to increase its strength. Subsequently, the changes occurring before and after the addition were analyzed using X-ray fluorescence (XRF) spectroscopy, SEM analysis, thermogravimetric analysis (DTA-TG), and physical properties (strength, color measurement, density, flow time, sieve residue, particle size, dry strength, fired strength, shrinkage, water absorption, etc.) and incorporated into the process. The analysis showed that standard floor tile body sludge containing 0.3% sugar beet molasses had higher strength than standard body floor tile sludge without molasses.

Results—In a ceramic factory that consumes approximately 250 tons of granules per day with ceramic press machines, an average of 7500 tons of glazed porcelain ceramic floor tile body granules are used monthly. Considering that the 10% loss due to strength loss in ceramic press machine production can be recovered, the waste of 750 tons of granules per month will be prevented. The studies have shown that using waste sugar beet molasses as a strength enhancer in glazed porcelain ceramic floor tile body slurry granules in ceramic press machines will provide significant economic benefits to the company as well as support sustainability in the sector.

Conclusion—The use of sugar beet molasses will contribute to the sustainable development of the ceramics and sugar industries, prevent environmental pollution, and simultaneously reduce the cost of ceramic tiles. By reusing waste molasses, the company will achieve significant economic gains and will pioneer environmentally friendly production practices.

Keywords

• Ceramic body sludge
• ceramic tile
• sugar beet
• molasses

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