MANFREDINI & SCHIANCHI Srl Via G.M. Dallari, 2 - 41049 Sassuolo (MO) - Italy - Tel. +39-0536-801207 Fax: +39-0536-807248 Web: http://www.manfredinieschianchi.com - Email: [email protected]1/9 REPORT ON THE EFFECT OF DRY GRINDING & COLOURING PROPOSED BY MANFREDINI & SCHIANCHI ON THE CHARACTERISTICS OF POWDERS TO BE UTILIZED FOR THE PRODUCTION OF PORCELAIN STONEWARE Manfredini & Schianchi have been active since 2002 in the research for obtaining winning solutions for the production of porcelain stoneware tiles with valuable and abundant laboratory and industrial tests, optimization of their Dry Preparation Plants, and with the realization and completion of productive units utilizing our technology with success. In view of the constant demands for energetic & water savings, as well as safeguarding environmental conditions, our Company, undisputed leader in the sector of the dry preparation of raw materials, has acquired such knowledge enabling us to propose to National & International manufacturers and investors personalized lines based on the raw materials available and quantity desired. In this present report we would like to reintroduce a study conducted with the prestigious contribution of the University of Modena (Department of Materials Engineering). In conclusion to the study here below, we indicate the qualitative parameters reached on a finished product with our exclusive technology of the Dry Preparation of raw materials through dry grinding & colouring and with suitable machinery to manage all processes up to press loading, obtaining production results of porcelain stoneware tiles with characteristics identical to those obtained with the usual wet technology. Alessandro Manfredini
REPORT ON THE EFFECT OF DRY GRINDING & COLOURING PROPOSED BY
MANFREDINI & SCHIANCHI ON THE CHARACTERISTICS OF POWDERS TO BE
UTILIZED FOR THE PRODUCTION OF PORCELAIN STONEWARE
Manfredini & Schianchi have been active since 2002 in the research for obtaining winning solutions for the production of porcelain stoneware tiles with valuable and abundant laboratory and industrial tests, optimization of their Dry Preparation Plants, and with the realization and completion of productive units utilizing our technology with success.
In view of the constant demands for energetic & water savings, as well as safeguarding environmental conditions, our Company, undisputed leader in the sector of the dry preparation of raw materials, has acquired such knowledge enabling us to propose to National & International manufacturers and investors personalized lines based on the raw materials available and quantity desired. In this present report we would like to reintroduce a study conducted with the prestigious contribution of the University of Modena (Department of Materials Engineering).
In conclusion to the study here below, we indicate the qualitative parameters reached on a finished product with our exclusive technology of the Dry Preparation of raw materials through dry grinding & colouring and with suitable machinery to manage all processes up to press loading, obtaining production results of porcelain stoneware tiles with characteristics identical to those obtained with the usual wet technology.
ACHIEVEMENT OF LOW POROSITY CERAMIC PORCELAIN STONEWARE TILES FROM MIXTURES GROUND & DRY PROCESSED WITH THE TECHNOLOGY OF MANFREDINI & SCHIANCHI.
Research contract between the Department of Materials Engineering at the University of Modena & Reggio Emilia and Manfredini & Schianchi Srl.
Purpose of the research:
Contribution to establish the best dry grinding conditions (type of mills & variable operations) such as:
• Wetting systems & granulation of powders.
• Press adjustment (homogeneity in moulds loading, advancing press car speed, press axle and punch drop, etc)
• Successive working phases (drying, glazing, firing & sorting).
Reaching the optimal conditions for tiles (such as porcelain stoneware) by means of dry grinding, with consolidated characteristics utilizing the usual wet technology.
Foreseen activities:
• The achievement of dry ground mixtures for the production of compositions destined to the production of tiles with characteristics of porcelain stoneware.
• Verification of mineralogical, chemical, morphological and particle size characteristics and sintering of mixtures obtained.
• Verification of macroscopic and normative characteristics of products obtainable from mixtures (linear shrinkage, water absorption, mechanical resistance, black core defects).
• Contribution to the compilation of the reports. Contribution to the organization of seminaries, venues, publications and diffusion activity of the initiative.
Materials:
• Mixtures for the production of ceramic tiles to be dry ground with the technology of Manfredini & Schianchi.
• Reference mixture obtained for wet grinding.
Test to be carried out:
• Measurement of particle size distribution of the powders in the compositions.
• Chemical characteristics of the powders in the compositions.
• Mineralogical characterization of the powders in the compositions.
• Morphological characterization of the powders in the compositions.
• Firing characteristics (RL, AA) of products obtained from the powders in the compositions.
CHARACTERIZATION OF REPRESENTATIVE PRODUCTS ALREADY IN USE IN CERAMIC INDUSTRIES IN ORDER TO IDENTIFY THE PROPERTIES AND THE CHEMICAL & MINERALOGICAL COMPOSITION. FORMULATION OF
SOME NEW COMPOSITIONS UTILIZING DIFFERENT RAW MATERIALS, SEMI-PROCESSED & WORKING REJECTS (NATIONAL & NON)
Two types of mixtures were formulated. Based on a series of preliminary tests, whose results are omitted, a composition was realized suitable for the production of sintered floor tiles in porcelain stoneware.
The composition developed was made following the classic criteria of formulas for ceramic mixtures and by carrying out the opportune modifications rendered necessary from the various reactivity of the dry ground powders. In the successive section the significant results of the experiment are reported.
In particular, so as to optimize the composition, the characteristics from the porcelain stoneware mixture designed and realized through dry grinding are compared to a typical porcelain stoneware mixture obtained from wet grinding.
LABORATORY TESTS TO EVALUATE THE APPLICATIVE POTENTIALITY OF THE NEW FORMULAS FOR OBTAINING DIFFERENT TYPES OF PRODUCTS WITH PREDETERMINED REQUISITES
Successively, after the foreseen activities in the combined research had been concluded, the essential results emerged that permit the acquisition of knowledge sufficient to reach and/or verify and validate the objectives of the project.
Mineralogical and particle size analysis of the powders
Mixture for porcelain stoneware production by
means of MS DRY-TECH
Mixture for porcelain stoneware production by
means of wet method
Diffractometer analysis
(Predominant crystalline stages: quartz, sodium feldspar, potassium feldspar, minerals of a clayey kaolinite nature and minerals of an illite clayey nature)
Mixture for porcelain stoneware production by means of MS DRY-TECH – Sintering
X-ray diffractometer on powders and micrographs of a mixture for porcelain stoneware fired at 1150°C (A), 1175°C (B) & 1210°C (C). The main peaks of quartz are indicated (square), Feldspars (triangle) & mullite
Mixture for porcelain stoneware production by means of MS-DRY-TECH – Fluidity of the powders.
Effect of the dimensions of the possible
agglomerates on fluidity.
Effect of the humidity on the fluidity of the
powders.
The formulas that were projected, studied and applied permit the attainment of types of products with the same characteristics as those obtained with the usual technology of wet grinding and successive spray drying.
With the proposed process and development of grinding, the particle sizes obtained are ideal for the production of porcelain stoneware.
In particular the developed process allows excellent reactivity to the system, perfect for obtaining porcelain stoneware with kinetics (temperature & process time) higher than current ones.
With the aforesaid mixture realized for dry-process method Manfredini & Schianchi and utilizing raw materials that are both easy to find and with contained costs, the following technical results on the finished product were obtained:
Technical parameters for Porcelain Stoneware through MS DRY-TECH process
Humidity of mixture at the press 6,5 - 7%
Working pressure of press 370 kg/cm2
Number of press cycles per minute 16
Firing cycle 1210°C / 33'
Daily production 10.000 mq
Shrinkage 6,0 %
Absorption < 0,1 %
Green M.O.R 16 kg/cm2
Dried M.O.R. 34 kg/cm2
Fired M.O.R 590 kg/cm2
Coefficient of linear dilation F 24 400°c 78,5 x 10-7
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