Ceramic process cost

and tile flexibility

Range of binders/plasticizers
for ceramic body composition
 Range of binders / plasticizers for ceramic body composition

What Tenagreen is and does?

Products designed to enhance It combines production

mechanical characteristics benefit for output quantity
of the body before firing. and sustainable solutions.

It‘s a blend of new generation

resin from Lamberti technology.
 Range of binders / plasticizers for ceramic body composition

Tenagreen
Action Areas
Binding Black Core
Action Absence

Plasticity Efficiency
Flexibility Cost optimization

Rheological
Sustainability
Stability
 Range of binders / plasticizers for ceramic body composition

Tenagreen
Action Areas
Binder/plasticizer for the body
to increase mechanical strength.

Binding Action Plasticity Flexibility Black Core Absence

High mechanical strength values High green strength values Low impact on black core
(high binding action ): (high Plasticity): permits:

• Less breakage • Less breakage • Low organic matter content

• Higher productivity • Body Riformulation • Complete burning of Tenagreen
• Thinner tiles • Punch/mould pressure reduction
• Slabs production
 Range of binders / plasticizers for ceramic body composition

Tenagreen
Action Areas
Binder/plasticizer for the body
to increase mechanical strength.

Efficiency Cost Rheological Stability Eco –compatibility

Optimization
A better rheological control Tenagreen brings :
brings:
By the choice of the right
• Acid emission reduction
Tenagreen is possible to:
• Low slip Viscosity • V.O.C. reduction
• Low slip yeld point • Low odorigenous emission
Increase the ceramic process
• Low Thixotropy
efficiency increasing the
productivity reducing the body
formula cost
 Range of binders / plasticizers for ceramic body composition

Tenagreen
for all needs

Tenagreen FL Tenagreen N
Blend of liquid binders Liquid Binders/Plasticizers
and deflocculants

Tenagreen P Tenagreen S
Binders/Plasticizers Liquid Binders/Plasticizers
in powder for particular production
necessities and for high frit
content body
 Range of binders / plasticizers for ceramic body composition

What can be done

with Tenagreen S?

Optimize ceramic process cost

and increase productivity yield
enhancing working density.

Increase tile Flexibility allowing

production to be more stable
and reducing scraps.
 Range of binders / plasticizers for ceramic body composition

Tenagreen S serie
Effect on ceramic process

How tenagreen optimise costs

and reduce environmental impact

Plastic clays are one of the main components These additives achieve a number of goals:
of a ceramic body. However, although they
ensure suitable mechanical properties, their • lower raw materials costs
presence limits production yield as they require • higher working density
larger quantities of milling water. • lower energy costs
Plasticizers are used to reduce the plastic • reduced CO2 emissions
component and increase the content of lean
clays, which are often cheaper and more readily
available.
 Range of binders / plasticizers for ceramic body composition

Tenagreen S serie
Effect on ceramic process

Let’s look at a practical example involving the introduction

of a plasticizer from Lamberti’s Tenagreen series (fig.1). MOD1 MOD2

Plastic clay (%) 24 8 8

The most important targets:
Other clays (%) 16 31 31

❶ Tenagreen S (%) - - 0,6

Reduction in the cost of the ceramic body from 58 to 54 €/ton. Body Cost (€/t) 58 51 54

Density (gr/l) 1710 1750 1750

❷ Spray dryer CH4 saving (ton/year) -360 ton/year

Natural gas savings of around 360 tons/year Spray dryer CO2 saving (ton/year) -905 ton/year

(about 490,000 m3/year) and a reduction in CO2 emissions 22 sec 22 sec 22 sec
Viscosity (FC4mm)
of about 900 tons/year; in addition to the economic savings
8,2 7,6 7,6
(around €149,000 per year), the industrial-scale reduction
Green Mor (kg/cm2)

in CO2 emissions is also consistent with global decarbonisation Dry Mor (kg/cm2) 35,0 20,0 35,0

climate plans.

❸
Fig.1 Comparison between the composition
Reduction in milling water consumption of 6,000 tons/ year. of a standard body and one containing Tenagreen S
 Range of binders / plasticizers for ceramic body composition

Tenagreen S serie
Effect on ceramic process

The graph (fig.2) shows how increasing slip density,

reduces CH4 and CO2 consumption keeping an equal rate
of productivity, on a year basis.
We considered a production of spray-dried material
of 140,000 tons/year with a 6% moisture content.
Fig.2 How density variation affects CH4 Consumed CH4 Tons/Year
Produced CO2 Tons/Year
consumption and CO2production

CO2 emissions

Density
are reduced

g/l
1750

1700

Working Energy costs

1650
density are reduced
increase
by using less methan
for the water evaporation
in the atomization phase 0 1000 2000 3000 4000 5000 6000 7000 8000 9000 10000

Tons/Year
 Range of binders / plasticizers for ceramic body composition

Tenagreen S serie
Effect on ceramic process
Let’s sum up what is means increasing
the working density for a ceramic process

Water Saving Methane CH4 saving

We use less water into We use less Methane gas
the milling process. for the water evaporation.
DENSITY
CO2 emissions INCREASE Money saving
decreasing
We save money as the
We produce less CO2
usage of Methane gas
as we decrease keeping
is lower.
a steady productivity.
 Range of binders / plasticizers for ceramic body composition

Tenagreen S
Effect on Flexibility
Deformation before breakage

By universal testig machine (picture

on the right) it‘s possible to collect data
on deformation before breakage, mechanical
strength, modulus of elasticity and integrate
them into a graph. All the samples have to be
prepared by using accurately the same method
(samples with the same moisture, mould
pressure , drying temperature, storage time etc.)
 Range of binders / plasticizers for ceramic body composition

Tenagreen S
Effect on Flexibility
Deformation before breakage

Tiles more flexible accept a bigger SL 0,4%

deformation before breaking, avoiding

S0800 0,4%
Bentonite 4%
STD

defects as ruptures and cracks. 55

Strength applied
50

45

(N)
40

35

30

25

20

Tenagreen S 15
STD Bentonite 4% Sulfonates 0,4%
0800 0,4%
10
Strength applied (N) 26,17 36,49 43,91 40,54
5

Deformation before breakage (%) 1,02 1,13 (+11%) 1,04 (+2%) 1,37 (+34%)
0

0 0,025 0,05 0,075 0,1

Deformation (mm)
 Range of binders / plasticizers for ceramic body composition

Tenagreen S
Effect on Flexibility
Deformation before breakage

On the way to get the mechanical strength measurements, it’s Strenght (n)

possible to obtain the deformation before breakage as well. (fig. 3 )

1600
This deformation is calculated by detecting the displacement
of a static extensiometer applied to the specimen; this
1200
measurement is taken form the first Strength applied, thus
the first movement of the specimen. The deformation before
800
breakage is calculated by the following expression:
400

d* 0

D = — . 100 1 1.05 1.1 1.15 1.2 1.25

e** Deformation(mm)

* Deformation before breakage Fig.3 Relationship between growing strength applied

** Thickness of the sample and the consequent deformation of the specimen.
 Range of binders / plasticizers for ceramic body composition

Tenagreen S
What technological changes
can be supported?

Replacing partially plastic clays Reduce thickness

Tenagreen can help in recover part of Tenagreen can help this technical
the plasticity if a technologist reduces change; the mechanical strength downs
the content of plastic clay; no side effect along with the tickness if all the other
are found as variations in dimension, working parameters are the same.
water adsorption or planarity.

Produce Slabs
The internal slab strains can be reduced
by supporting the body recipe with
a plasticizer.
 Range of binders / plasticizers for ceramic body composition

Conclusions

Let’s underline the targets by using The Flexibility of tiles and slabs
Tenagreen S is enhanced facilitating
the technological innovation

The ceramic process can be optimized

increasing productivity with low
environmental impact