Development of FFC ceramic sanitaryware bodies with reduced chammotte content

Sanitaryware ceramics are products manufactured by mixing inorganic, non-metallic raw materials in specific proportions to form a casting slip. This slip is then shaped in plaster and/or synthetic resin molds and subsequently fired at temperatures around 1200–1250°C. Fine Fire Clay (FFC) bodies are characterized by higher water absorption and lower deformation ratio compared to vitreous china bodies. Due to the low deformation requirement, 30-40% chamotte is used in the composition of these bodies. Chamotte, which is a significant factor in the production costs of FFC products, is an expensive semi-finished product produced as a result of thermal processes carried out at high temperatures and is also a negative factor in terms of CO₂ emissions and carbon footprint during the production process. The aim of this study is to develop low-cost recipe compositions that are parallel to the technical properties of the standard FFC recipe and suitable for CSW production in terms of rheology by removing chamotte from FFC recipes and/or reducing the recipe usage rate. In this regard, feldspar use was systematically eliminated from the compositions, the proportion of plastic raw materials was increased instead of chamotte, and wollastonite was added to the recipes. As a result of the compositional changes made, the formation of anorthite and cristobalite phases in the microstructure was observed, and the pyroplastic index value of the material was reduced. As a result of the study, FFC recipes that do not contain chamotte but comply according to industrial standards have been developed.