Use of Post-Flotation Solidified Tailings from Copper Production for Ceramic Tile Production

Abstract

The development of the mining industry has resulted in the accumulation of large amounts of waste, which effectively degrades the environment. The aim of this study is to check whether the addition of post-flotation sludge from copper production to the typical ceramic mass of the “gress porcelanato” will allow to obtain qualified sintered or faience tiles. By adding successive amounts of post-flotation sludge to the high-quality lamellar mass, typical parameters such as firing shrinkage, water absorbability and bending strength after firing were assessed. The structure of the obtained ceramic materials, using scanning electron microscopy (SEM with EDS), was also determined. Obtaining positive results would allow not only to significantly reduce the production costs of ceramic tiles, because the sludge is finely divided and no grinding is necessary, but, above all, will allow to eliminate the environmental risk. The present study has shown that it is possible to introduce up to 20% post-flotation sludge for gres porcellanato tile production and up to 50% post-flotation slugde for faience tile production. Both types of ceramic materials with an appropriate proportion of sludge, meet the requirements of tile standards in terms of mechanical strength and water absorption.