Production of Large-Sized Ceramic Stones Based on Screenings from Waste Heap Processing Using the Technology of Stiff Extrusion for Molding Products

Abstract

This article discusses the prospects for using large-format ceramic stones in the construction of contemporary homes, as well as an overview of raw materials and technologies for production. The most promising technology is stiff extrusion with the ability to load the raw products on firing trolleys and accelerate the processes of firing and drying. Characteristics of Eastern Donbass waste heaps processing screenings are given, which are coal mining by-products and are considered to be main raw material for the production of large-sized ceramic stone. It is shown that as a result of introduction of waste heaps into the production of ceramic stones with the lowest prime cost, the density of the resulting products will be less than 800 kg/m3, the thermal conductivity will be less than 0.20 m·°C/W, and the strength grade will be M150 and higher. Thus, the use of ceramic stones in total volume of wall products for residential construction will reach the level of 80% and will increase the competitiveness of the material, especially when compared with gas silicate products, as used in Western Europe. High economic feasibility of the production of such materials based on by-products of waste heap processing is shown as well.