Kağan Kayacı

R&D CENTER, ÇANAKKALE-TURKEY · Materials

The ceramic tile manufacturing process uses a lot of energy, mainly thermal energy, and to a lesser extent electric energy. Total energy costs account for between 50% and 55% of average direct manufacturing costs. Fossil fuel combustion, such as natural gas combustion, produces carbon dioxide emission. Therefore, energy consumption and emissions is...

Konya clay occurrence is the biggest clay mine of Turkey, except for the Şile region (İstanbul, Turkey) clays, and crop out near the Doğanhisar (Konya, Central Turkey). It was formed by alteration of the Na- and K-feldspars, and muscovitic micas; additionally, direct transportation of the sericitic/illitic clays from the metapelitic rocks of metamo...

In the production of wall tiles, trends are moving toward larger-format wall tiles. Moisture expansion of larger-format wall tiles is one of the most important technological parameter that determine the quality of their service life. Clay, kaolin, quartz, carbonate and less fluxing materials are generally used in monoporosa tile recipes. In this st...

In this study, the effect of perlite from NW Turkey on the physical properties of ceramic tile bodies was investigated. The phases present in the raw materials were measured by X-ray diffraction while chemical analysis of the raw materials were determined by X-ray flouresence. Colour, water absorption and firing shrinkage of the raw materials were...

The Istanbul and Ukrainian clays, Aydın-Çine albite, and Düvertepe (Balıkesir, Turkey) or some local kaolines are the main components of the Turkish ceramic tile products. Increasing in the ceramic production is leading to a fast consumption of the available raw materials. On the other hand, transportation of raw materials from long distances cause...

The in-situ kaolinitic clay occurrence of Doğanhisar region is in the quartz sericite-muscovite schists/phyllites and quartzites of the late Devonian aged Engilli formation of Sultandağı unit. These rocks are white colored, likely to talc, very soft in nature. Geological data revealed that these rocks were formed by the hydrothermal alteration of m...

In this study, the cake and the ceramic sanitary ware wastes utilization for the manufacturing of porcelain tile bodies were examined. Firstly, physical, chemical and mineralogical properties of these wastes were determined. Then, porcelain tile body formulations containing the different rates of the wates were formed. Shrinkage (%), water absorpti...

In this study, Zeolitic Tuffites in Biga Peninsula region were investigated by using in wall tile bodies. Firstly, chemical-mineralogical and thermal properties of Zeolitic Tuffites were determined and characterization studies were performed. Afterwards clay, kaolin, calcite and zeolite materials were mixed by grinding in laboratory type ceramic ba...

Porcelain ceramic tiles are produced from a mixture of ball clay, kaolin, quartz and Na- and K-Feldspars. Gradually increase in this type production, the consumption of the natural raw materials increases rapidly. This situation leads the ceramic tile producers to look for alternative raw materials close to the plants. In this context, a series of...

Increasing of porcelain tile production in ceramic industry caused the more usage of feldspar minerals as fluxing material. The increase in raw material costs led to the ceramic tile producers to look for local alternative fluxing alkaline raw materials. In this context, the geological, chemical, mineralogical and technological features of the Biga...

This research addresses the residual stresses phenomenon taking place during the manufacture of porcelain tiles. Residual stresses were quantified by the strain relaxation slotting method. The method is based on the fact that stresses are released when a slot is made leading to a curvature change. Once the method was validated, the impact of proces...

In this research an analysis of firing deformation tendency in porcelain stoneware tile compositions was carried out based on pyroplastic deformation measurements. The effect of the amount and nature of some fluxing additives as well as some process variables were addressed. Firing diagram, pyroplastic deformation and microstructure examination of...

Inkjet printing is obviously the leading technology for ceramic tiles decoration and it is also a common practice to protect the applied decoration with a transparent glaze to avoid abrasion. A protection glaze based on Sr-Al-Si (Zn, Ca, Ba) glass ceramic system with high transparency, abrasion resistance, chemical resistance and matt aspect after...

Resumo A impressao por jato de tinta e a tecnologia lider para decoracao de placas cerâmicas, sendo uma pratica comum proteger a decoracao aplicada com um vidrado transparente para evitar abrasao. Neste trabalho foi desenvolvido um vidrado protetivo baseado no sistema vitrocerâmico Sr-Al-Si (Zn, Ca, Ba) com grande transparencia, resistencia a abras...

In ceramic tile manufacturing industry, the wet process includes wet grinding and spray drying, is widely used for preparing granule. However, due to the high energy consumption for the water evaporation in spray dryer has become a major problem in wet process. In recent years, there have been vast amount researches for developing of dry granulatio...

In this study, a ceramic water filter with micron sized pores was developed based on diatomite raw material. The slip with diatomite earth which has tubular shaped particles was prepared by using agar. Agar is a gelatinous material derived from sea alges and used as a gelling agent in order to form ceramic filters by gel casting method. Rheology of...

In ceramic tile manufacturing industry, the wet process includes wet grinding and spray drying, is widely used for preparing granule. However, due to the high energy consumption for the water evaporation in spray dryer has become a major problem in wet process. In recent years, there have been vast amount researches for developing of dry granulatio...

In this study, the effect of alternative additives on the properties spred diameter, setting time, bending strength and water absorption of sanitaryware plaster moulds was investigated. The plaster was partially replaced by the alternative additives such as perlite, diatomite and glass beads. Microstructural features of the resultant compositions w...

In ceramic production, there are around 5-8 % of floor tile defects occurred due to unsuitable body compositions or operational failure. The reuse of those fired products creates problems due to the difficult grindability features. These kinds of wastes are stored near factories and create vital environmental problems. There are some attempts to ut...

Cement manufacture is a very energy intensive process and causes large amounts of CO2 emissions in the production. Worldwide cement industry is responsible for around 7% of total CO2 emissions, of which 65% of the CO2 emission comes from the calcination of limestone. The use of different industrial by-products and wastes as clinker replacement mate...

We have discovered a felsic intrusive unit (the Karaköy granite; 125±4.2 M.A.), which was emplaced into the Triassic metamorphic rocks of the Sakarya Zone as small stocks and dikes in the north of the Bozüyük Town of NW Turkey. This area is close to the İzmir-Ankara Suture which is the remnant of northern branch of Neo-Tethys Ocean. The Karaköy gra...

Agacli-Kemerburgaz area, NW of Istanbul, is one of the most important underclay deposits of Turkey. This area is composed of Paleozoic sedimentary sequence, Upper Cretaceous volcanic rocks, Neogene sediments and Quaternary alluvium deposits. The calc-alkaline volcanic rocks are the parent rocks of the underclays in this area. In this work, mineralo...

The investigations on the usage of alternative raw materials have been always popular for porcelain tile production. Manufacturers have been interested in this subject for both increasing product quality and decreasing production costs. In the study, the possibility to use granite, as fluxing agent, in a body recipe used for porcelain tile, was det...

Characterization of underclays from Agaçli-Kemerburgaz region of Istanbul/Turkey and their evaluation for porcelain tile production gacli-Kemerburgaz area, NW of Istanbul, is one of the most important underclay deposits of Turkey. This area is composed of Paleozoic sedimentary sequence, Upper Cretaceous volcanic rocks, Neogene sediments and Quatern...

Turkey is the fifth biggest ceramic tile exporter of the world. Considering the expectation that the Turkish tile sector continues to expand, further studies both on the improvement and the development of the tile formulations are necessary in order to make the producers advantaged in the world market while maintaining the capital and running costs...

The aim of this study is to determine the properties of metarhyolites from llgin-Konya (Turkey) area and to decide whether or not metarhyolites are suitable as a flux agent for porcelain stoneware tile production. For this aim, the chemical and mineralogical properties of metarhyolite were determined by chemical analyses, XRD and SEM studies. Start...

In the production of ceramic tiles, composition of body and firing conditions determine the phase transformations and in turn affect the final properties of the product Thus, selection of relevant raw materials and characterisation of their individual physico-mechanical and chemical characteristics are very important In this study, sintering behavi...

Starting from an industrial body mix for porcelain stoneware tiles, part of its fluxing agent, sodium feldspar was replaced by a fine-grained microgranite. Sintering behaviour of the studied porcelain stoneware bodies with and without microgranite was investigated using a double beam optical non-contact dilatometer according to the corresponding in...

The use of rhyolite from a local source as an alternative fluxing agent in a commercial porcelain stoneware formulation was investigated. The experimental work was achieved in two parts: in the first part, standard tests were applied to the porcelain tiles obtained from the experimental bodies incorporated with varying amounts of rhyolite (up to 12...

We have discovered a felsic intrusive unit (the Karaköy granite; 125±4.2 M.A.), which was emplaced into the Triassic metamorphic rocks of the Sakarya Zone as small stocks and dikes in the north of the Bozüyük Town of NW Turkey. This area is close to the İzmir-Ankara Suture which is the remnant of northern branch of Neo-Tethys Ocean. The Karaköy gra...

During ceramic tile production (wall, floor and porcelain stoneware), wet milling process for the preparation of ceramic slurries is widely used. The currently preferred wet grinding machines are discontinuous and/or continuous ball mills, where grinding occurs when a particle is crushed between two pieces of grinding media. Ball milling is, howeve...

Sile Region, northeastern Istanbul, includes the most important underclay deposit of Turkey. In the area, Upper Cretaceous calc-alkaline volcanic rocks are the major parent rocks of the Neogene sequence composed of plastic clays, underclays, sands, gravels and Quaternary alluvial deposits. The Sile Region consists of discontinuous cyclic thin coal...

Sile Region, northeastern Istanbul, includes the most important underday deposit of Turkey. These days are composed of disordered kaolinite, illite, mixed-layer illite-smectite, smectite, gibbsite, quartz, pyrite, anatase, K-feldspar, goethite and organic matter. The underclays have been studied because this area is the biggest sedimentary industri...

In this study, an attempt was made in order to develop a multipurpose tile body using a single formulation. In order to achieve this, several body recipes were prepared using mainly local raw materials with clearly defined physical and chemical properties at different sieve residues and single fast fired under industrial conditions in the first par...

The possible use of trachyte as an alternative fluxing agent in a commercial floor tile body was investigated. The experiments were carried out in two parts: In the first part, standard tests were applied to the products obtained from the experimental tile bodies modified with varying amounts (0-40 wt. %) of non-magnetic trachyte following single f...

The possible use of trachyte as an alternative fluxing agent in a commercial floor tile body was investigated. The experiments were carried out two parts: In the first part, standard tests were applied to the products obtained from the experimental tile bodies modified with varying amounts (0-40 wt. %) of non-magnetic trachyte following single fast...

Turkey is the fifth biggest ceramic tile exporter in the world. Considering the expectation that the Turkish tile sector continues to expand, further studies both on the improvement and the development of tile formulations are necessary in order to make the producers advantaged in the world market while maintaining the capital and running costs at...

The use of rhyolite from a local source as an alternative fluxing agent in a commercial porcelain stoneware formulation was investigated. The experimental work was achieved in two parts: in the first part, standard tests were applied to the porcelain tiles obtained from the experimental bodies incorporated with varying amounts of rhyolite (up to 12...

ZET Bu çalışmada, Bilecik-Söğüt civarındaki Yakacık kumlu kilinin zenginleştirilerek duvar karosu bünyelerinde kullanımı araştırılmıştır. Bu bağlamda, Yakacık kumlu kili ilk olarak zenginleştirme işlemleriyle silisli kum (+106 µm) ve kil (–106 µm) olarak iki kısıma ayrılmıştır. Daha sonra, bu ürünlerin duvar karosu yapımında kullanılabilirliğinin b...