Effects of composition changes on sanitary ware sintering

In this thesis, the effects of composition of the glassy phase and particle size on the sintering temperature and deformation were investigated by using a standard recipe and sieve residue. As a result of the experimental studies it was determined that there is an optimum Na2O/K2O value to decrease the sintering temperature. Sintering temperature and deformation ratio were slightly decreased by the addition of rare earth alkali oxides (CaO and MgO) but when fine grained raw materials were used, sharp reduction were observed at both sintering temperature and deformation ratio. Sintering tempearture was decreased down to 1120 OC from 1250 OC by the addition of Li (Lithium). Sintering was ensured at 1100 OC, the lowest sintering temperature known at the open literature, by using a lithium, nephelin syenite and talc combination. New recipes were designed which provides a 50 % decrease in the deformation ratio according to the standard product. This improvement assure an advantage to produce thinner cross sectioned products. It is predicted that 30 % energy savings was achieved via 100 OC temperature decrease in the sanitaryware production. This industry has a high energy consumption, due to this fact it is very important to carry out energy focused projects both to supply the intense requirements and to decrease the amount of energy, an input of international commerce.