Utilizing waste zirconia nozzles for eco-friendly ceramic tile production
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The ceramic industry is increasingly focused on sustainability, seeking alternatives to reduce the environmental impactof raw material extraction and consumption. Recycling initiatives and waste reduction strategies have proven essential inconserving resources and minimizing waste. Zirconia nozzles, commonly used in continuous steel casting for molten metalflow control, are typically made from high-purity zirconia powder. Despite their critical industrial role, waste zirconia nozzlesremain an underutilized source of zircon oxide, a valuable and costly raw material used in white floor and porcelain tileproduction. This study explores the potential of repurposing waste zirconia nozzles from the Iron Steel Company (Bilecik,Turkey) for ceramic tile manufacturing. Comparative analysis of color properties between standard zircon and waste zirconiamaterials was conducted, followed by extensive physical and mechanical assessments of the final tile products. Crystalphaseanalysis (XRD), chemical composition analysis (XRF), and microstructural evaluation (SEM-EDS) were performed toevaluate the feasibility of this sustainable approach. The results demonstrate the viability of using waste zirconia nozzles as acost-effective, environmentally responsible alternative in ceramic tile production without compromising product quality. Thisstudy highlights the potential for significant waste reduction and cost savings in the ceramic industry.
Abstract
The ceramic industry is increasingly focused on sustainability, seeking alternatives to reduce the environmental impactof raw material extraction and consumption. Recycling initiatives and waste reduction strategies have proven essential inconserving resources and minimizing waste. Zirconia nozzles, commonly used in continuous steel casting for molten metalflow control, are typically made from high-purity zirconia powder. Despite their critical industrial role, waste zirconia nozzlesremain an underutilized source of zircon oxide, a valuable and costly raw material used in white floor and porcelain tileproduction. This study explores the potential of repurposing waste zirconia nozzles from the Iron Steel Company (Bilecik,Turkey) for ceramic tile manufacturing. Comparative analysis of color properties between standard zircon and waste zirconiamaterials was conducted, followed by extensive physical and mechanical assessments of the final tile products. Crystalphaseanalysis (XRD), chemical composition analysis (XRF), and microstructural evaluation (SEM-EDS) were performed toevaluate the feasibility of this sustainable approach. The results demonstrate the viability of using waste zirconia nozzles as acost-effective, environmentally responsible alternative in ceramic tile production without compromising product quality. Thisstudy highlights the potential for significant waste reduction and cost savings in the ceramic industry.