THERMO PHYSICAL CHARACTERISTICS OF VITRIFIED TILE POLISHING WASTE FOR USE IN TRADITIONAL CERAMICS-AN INITIATIVE OF CGCRI, NARODA CENTRE

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1 International Conference on Ceramics, Bikaner, India International Journal of Modern Physics: Conference Series Vol. 22 (213) World Scientific Publishing Company DOI: /S THERMO PHYSICAL CHARACTERISTICS OF VITRIFIED TILE POLISHING WASTE FOR USE IN TRADITIONAL CERAMICS-AN INITIATIVE OF CGCRI, NARODA CENTRE S. N. MISRA *1 B. B. MACHHOYA *2 R. M. SAVSANI *3 This paper reports the thermo physical characteristics of Vitrified tile polishing waste materials. As such growing production of vitrified tiles in the country generate large volume of this waste obtained during processing, polishing and cutting of the vitrified tiles to the tune of nearly 1-15 tonnes per day from each plant. The characteristic features of these materials are being studied and investigated to develop suitable technology for finding its gainful use especially in the traditional ceramics. It is known that ceramic as such building materials industry could be a large raw materials consumer and being heterogeneous and thus could utilize this vast quantity as the raw materials. However, the main problem would be it s firing nature as it showed thermal deformation after a particular temperature. Interestingly, the production process of most of the traditional ceramics follows a similar pattern starting from the raw materials processing up to a level of firing. Hence, to suggest suitable utility in the traditional ceramics as raw materials, it was the prime requisite that these waste must be thoroughly studied w.r.t various thermo physical characteristics to make use in this sectors. Hence, the present paper interestingly gone up to various study such as raw materials nature, particle size distribution, chemistry, XRD and DTA study for understanding typical physico chemical properties, and finally thermal properties to make it suitable for use in traditional ceramic industries. The higher fineness of the waste materials indicates its usefulness without extra grinding. The chemistry of typical sludge shows contamination from abrasive particles, sorrel cement bonding materials etc. originated from the polishing wheel and needs special precaution while suggesting use in the ceramic sectors. The firing characteristics of the sludge materials produces a foamy and spongy shapes and this could be the main guiding parameters in selecting the end use of the waste materials w.r.t temperature. The present study only shows various characteristic features of this waste and focuses its important properties to be used as a raw material in large quantity in the ceramic industries. Keywords: Vitrified tile; polishing sludge; sorrel cement; traditional ceramic; deformation. 1. Scientist in Charge; 2. Sr. Tech off.; 3.Prin.Tech Off.; * CSIR-Central Glass & Ceramic Research Institute, Naroda Centre, (Council of Scientific & Industrial Research, Govt. of India), Ahmedabad, Gujarat-38233, India. 118

2 Thermo Physical Characteristics of Vitrified Tile Polishing Waste Introduction Ceramic materials are one of the largest constituents of the construction industries primarily used as building materials. These include bricks, ceramic tiles, sanitary wares, mortars, cements, plaster of paris, paint materials etc. In recent times, the use of industrial products and growth has stepped up many folds in some developing countries. India is not far away from the growth path in the industrial sectors. In this aspect, the building sectors have progressed at a steady pace. When considering the productivity and volume of production, this sector of industries consume huge amount of raw materials to make finished products through a step of different manufacturing processes. In general, manufacturing of ceramic products are associated ultimately with firing process and so highly energy intensive. Thus, any ceramic production unit would be more benefited if the cost of energy goes down, else the cost of firing of such products requires less temperatures. Hence, any process and technology which help in reducing costly raw materials, lower firing temperature and green manufacturing or rather low cost of manufacturing would be the actual answer for the present day production problems. All such innovation leads to cost savings and wide acceptability by the industries. Also, the growing consumption and consequent increasing of industrial production has lead to a fast decrease of the available natural resources. 1 Industries utilize natural raw materials, extract the component needed and expels the by product as the waste 2. The accumulation of such waste put pressure to the environment and researcher needs to focus its recyclable possibilities in these sectors. Therefore, alternative ways to reuse several types of waste materials has been attempted and special attempt is made to incorporate this waste in clay based ceramic products 3-8. It is always an accepted norm and consideration to find gainful utilization of such waste in building materials industries.9. Now a day, industries are looking for alternative and less expensive materials to optimize the process and minimize waste. Thus, recycling this waste will benefit the industries and the environment 1. A major problem with the incorporation of waste materials lies with its inherent non homogeneity and inconsistent characteristics leading to continuous changes in the formulation. Otherwise, there could be wide variation in the properties of the finished products made out of these waste materials. This may result in lower quality product. Hence, a thorough understanding of the physico chemical behavior of the raw materials containing waste w.r.t consistent finished product quality is essential for their commercial viability. In the present work, a research study has been undertaken to evaluate physiochemical characteristics of the waste materials generated from the vitrified tile industries. Vitrified tiles have been found extensive use nowadays in the building sectors due to its inherent mechanical properties much higher and wide acceptability owing to its advantageous surface features. Slowly marble, granite and glazed floor tiles have been replaced with this unique tile In India and abroad. There are huge demands of these tiles and every year new industries are coming up to meet the growing need in the consumer market. However, with the production of vitrified floor tiles, there is a growing environmental nuisance created due to the generation of tile polishing waste materials. These waste

3 12 S. N. Misra, B. B. Machhoya & R. M. Savsani materials are obtained in tonnages during grinding and polishing operation of vitrified tiles. As most of the floor tiles are polished in this operation resulting removal of at least.4 to.8 mm ground materials weighing around gms of solid materials from each 2 feet by 2 feet size tile surface depending on the polishing requirement of finished products. With a production capacity of 1 sq mt. tiles, there could be a minimum of 15-2 tonnes of this waste material produced regularly from each of the plant It is estimated that out of nearly 6 vitrified tiles units, every day production of these waste materials could be in the tune of nearly 1-12 tonnes. The materials have been contaminated with many impurities especially abrasive particles mostly consisting of silicon carbide and magnesia and calcia based sorrel cement materials. Mostly these are retained along with some soluble materials in the slurry form and non plastic in nature. In this paper, an attempts has been made to evaluate various characteristics of these waste to find it s future scope in traditional ceramic applications. 2. Experimental 2.1. Procurement of Vitrified Tile Polishing Sludge Total six nos. of samples of Vitrified Tile Polishing Sludge which is here after denoted as VTPS were collected from different vitrified tile producing units of Morbi and Kadi regions of Gujarat. The samples of VTPS were marked as W1, W2, W3, W4, W5 and W Characterization of VTPS General Characteristics All the VTPS samples were visually observed for physical appearance. Presence of physical water in the sample was determined using IR moisture balance and the dried sample was used for the observation of raw color. Presence of carbonaceous matter was checked by acid test. Grit contents were determined by passing the sample through 3 mesh sieve with the help of water jet. Particle Size Distribution (PSD) in the range of.3 to 4 micron was determined by laser based particle size analyzer, model 92L of CILAS, France. All the samples were characterized for complete chemical analysis by standard laboratory method Thermo Mechanical Properties To determine the thermo physical properties, the test specimens in the form of cylindrical tablet of size 2 mm diameter and 1 mm height were prepared by pressing the granule of VTPS containing about 7% moisture in Carver press. The pressed test specimens were dried at 11 ± 5 C in an air oven. The dried samples were fired in gradient furnace at the maximum temperature of 115 o C. Total nine nos. of test specimens were fired at a time in the gradient furnace and the peak temperature of each segment of the furnace was

4 Thermo Physical Characteristics of Vitrified Tile Polishing Waste 121 observed at 1125 C, 198 C, 163 C, 127 C, 985 C, 948 C, 912 C, 873 C and 823 C. Test specimens were visually observed after firing and its effect on shrinkage property with respect to temperatures. Both the vertical and horizontal linear change of the test specimens were determined by measuring the height and diameter of the fired samples. Similarly change in mass due to firing was determined by weighing the fired test specimens. To evaluate it s reproducibility in a different condition, the dried test specimens were again fired in a lab type roller kiln at 15, 11 & 112 C with firing cycle of 45 minutes. The fired samples were characterized for vertical & horizontal linear change, weight loss/gain on heating and maturity. The maturity in terms of water absorption & apparent volume porosity as well as compactness in terms of bulk density was determined by boiling method through Archimedes principles Mineralogical Characterization To determine the physico chemical characteristics, the unfired and pre-fired sample of typical VTPS marked W-4 was subjected to thermo gravimetric and differential thermal analyses (TG/DTA) using TG/DTA63 model instrument of Sieko Instruments Ltd, Japan on 2 mesh fine powder of the sample by heating them up to 12 o C at a heating rate of 1 o C.min -1 and using calcined alumina powder as reference inert material. Crystalline Phases formation at different temperature in the VTPS was identified by X- ray diffractometry. The X-ray diffraction study was carried out on VTPS samples fired at 912, 985, 168, 198, 1125 and 117 O C, using Phillips PW-171 equipment with Ni filter and CuKα radiation. The micro structural features were studied by Scanning Electron Microscopy (SEM) on fractured surface for pore morphology and the existence of various phases in the fired samples. Different vibrational spectra such as Stretching / bending vibrations present in unfired and fired samples were identified by Fourier Transform Infrared (FTIR) spectrometry using FTIR spectrometer model Spectrum-1 of Perkin Elmer in the range of 4 to 4 cm -1. The linear thermal expansion up to 7 o C of cylindrical specimen (~1 mm dia. and 25.4 mm length) was measured using dilatometer Orton-212 STD model of Orton, USA at a heating rate of 3 o C.min Results and Discussion Table 1 showed the general characteristics of VTPS samples and indicated the presence of moisture in the range of 11 to 15 %. The VTPS is a typical waste material and generated in the form of thick slurry during polishing operation of fired vitrified tiles. In actual practice, this slurry either is dumped in the open area or in some cases dewatered by filter pressing and then kept in the open place. Hence, the moisture content of the VTPS may vary from lot to lot and source to source. Presence of inherent moisture in the VTPS suggests that either proper drying or adjustment of moisture would be needed by calculation prior to its utilization in any specific applications. The dried VTPS samples

5 122 S. N. Misra, B. B. Machhoya & R. M. Savsani were dull white to light gray colored, agglomerated and light weight soft lumps representing the colour of the parent body. During Acid test, all the samples showed no effervescence indicating absence of free carbonaceous matters. The residue (retained mass) on 3 mesh sieve was observed to contain about 4. to 5. % coarse materials indicating presence of foreign impurities as contamination. Table 1. General Characteristics of VTPS Samples. Visual Observation W 1 W 2 W 3 W 4 W 5 W-6 Gray coloured agglomerated soft lumps Gray coloured agglomerated soft lumps Gray coloured agglomerated soft lumps Gray coloured agglomerated soft lumps Gray coloured agglomerated soft lumps Gray coloured agglomerated soft lumps Raw colour Dull White Dull White Dull White Dull White Dull White Dull White Moisture (% by mass) Acid Test Residue on 3# Volume Percent No Effervescence No Effervescence No Effervescence No Effervescence No Effervescence No Effervescence W-1 W-2 W-3 W-4 W-5 W-6 <1 mu <5 mu <2 mu <1 mu Particle Size 1 Paricle Size (mu) Fig. 1. Particle Size distribution of VTPS samples. W-1 W-2 W-3 W-4 W-5 W-6 d1 d5 d9 d1 Mean d - Value Dia. The results of the particle size distribution showed in Fig 1. The study revealed that mean diameter of the particles for all the VTPS samples falls in the range of 11 to 13 micron and concentration of the particles lies in the range of 2 to 1 micron. This confirms the presence of fine particles in the VTPS samples. This could be an advantageous and indicates that no further grinding of the material would be required for it s future use in traditional ceramics. Thus, it can be used directly followed by proper blunging in ceramic body preparation. From the results of chemical analysis of VTPS samples furnished in Table 2, it is noted that the sludge samples contained SiO 2 in the range of 6 to 67 wt.% as major constituent and Al 2 O 3 present in the range of 18 to 24 wt.%. The coloring impurities like Fe 2 O 3 and TiO 2 were found in the range of 1. to 1.5 wt. percent. MgO content was on slightly higher side (2 to 5 wt. %), which might have contaminated during wear & tear of

6 Thermo Physical Characteristics of Vitrified Tile Polishing Waste 123 the abrasive wheels being used in polishing operation. The total alkalies content in the sludge were in the range of 5 to 7 wt. percent. Being heterogeneous, VTPS is a mixture consisting of fine powder of fired scrap of vitrified porcelain tiles as major constituent along with abrasive particles, binding/cementing materials, carbonaceous/organic mass like resin etc. as minor ingredients. It showed LOI in the range of 2 to 4 wt. % due to oxidation of carbonaceous/organic mass. Table 2. Chemical Analysis of VTPS Samples Constituents W 1 W 2 W 3 W 4 W 5 W-6 % Constituents SiO Al 2 O Fe 2 O TiO CaO MgO Na 2 O K 2 O Li 2 O L.O.I On visual observation it was found that the fired color of the VTPS darkened with the increase in firing temperature indicating gradual increase in maturity (Fig. 2). Beyond 15 o C, change in fired color was significant. Also, change in volume was also noticed with the rise in temperature. Up to 163 o C, the test specimens showed a gradual contraction in the volume. The maximum value of shrinkage as measured was up to 8 to 13 % and 6 to 12 % horizontally and vertically respectively (Fig. 3 & 4). All the VTPS sample showed a significant expansion in volume along with deformation of shape beyond 198 o C and indicating swelling due to high evolution of gases. However, tendency of over firing has been observed when the test specimens fired at a temperature of 1125 o C. W-1 W-2 W-3 W-4 W-5 Fig. 2. Firing behavior at different temperatures of VTPS samples (fired in gradient furnace)

7 124 S. N. Misra, B. B. Machhoya & R. M. Savsani Linear Change (%) Linear Change (Horizontal) (%) v/s W 1 W 2 W 3 W 4 W Fig. 3. Effects of heat on horizontal linear change of VTPS samples (fired in gradient furnace). Linear Change (%) Linear Change (Vertical) (%) v/s W 1 W 2 W 3 W 4 W Fig. 4. Effects of heat on vertical linear change of VTPS samples (fired in gradient furnace). Weight loss (%) Weight loss (%) v/s W 1 W 2 W 3 W 4 W Fig. 5. Effects of heat on weight loss of VTPS samples (fired in gradient furnace).

8 Thermo Physical Characteristics of Vitrified Tile Polishing Waste 125 All the samples of VTPS showed loss in weight with the increase in temperature and slowly increased up to the maximum value of 3.5 to 6 % depending on the characteristics of the samples up to 11 o C and beyond a marginal change in the weight loss was noted. Although the VTPS is a fired material respective loss in weight could be attributed to the presence of organic impurities like resin binder, sorrel cement bonding materials, other carbonaceous impurities etc in it (Fig. 5). W-1 W-2 W-3 W-4 W-5 Fig. 6. Firing behavior at different temperatures of VTPS samples (fired in roller kiln) On visual observation of the specimens fired in roller kiln at 15 o, 11 o and 112 o C, there was a gradual increase in maturity and the same was reflected by the fired color which become more darker at higher temperature. Beyond 15 o C, change in fired color was significant. Fig. 6 showed similar observation of over firing and significant shape deformation in all the samples as shown in earlier case (Fig.2.). Again this phenomena could be attributed to the froathing due to the oxidation of silicon carbide, contaminated as an impurity during polishing process. The presence of silicon carbide resulted from the the wear and tear of the polishing wheel. The maximum cotraction was noted at 15 o C and beyond this temperature, an expansion of the sample was observed. At 15 o C the maximum value of shrinkage of 7 to 15 % and 9 to 19 % horizontally and vertically respectively was attained and then beyond 15 o C, the entire VTPS samples showed a significant increase in volume along with deformation of shapes (Figs. 7 & 8) Linear Change (%) Linear Change (Horizontal) (%) v/s W 1 W 2 W 3 W 4 W Fig. 7. Effects of heat on horizontal linear change of VTPS samples (fired in roller kiln).

9 126 S. N. Misra, B. B. Machhoya & R. M. Savsani Linear Change (%) Linear Change (vertical) (%) v/s 5 4 W 1 W 2 3 W 3 W 4 2 W Weight Loss (%) Fig. 8. Effects of heat on vertical linear change of VTPS samples (fired in roller kiln) Weight Loss (%) v/s 2 1 W 1 W 2 W 3 W 4 W Fig. 9. Effects of heat on weight loss of VTPS samples (fired in roller kiln). The value of weight loss on heating VTPS in roller kiln was slightly decreased up to the temperature of 11 o C and then showed a marginal increase at the temperature of 112 o C. The total weight loss was about 3 to 6.5 % which might be resulted due to presence of organic impurities like resin binder, abrasive particles and other carbonaceous impurities (fig. 9). The graphical results of maturity in terms of water absorption, porosity and bulk density revealed that the water absorption and porosity of VTPS samples gradually increased with increase in temperature and then a sudden steep rise was observed at 112 o C. In the case of bulk density, the reverse trend was observed. The maximum densification was observed at 15 o C and then further heating of the samples at high temperature, the resultant bulk density decreased. These particular phenomena of significant increase in apparent volume porosity & water absorption with simultaneous decrease in bulk density and resultant swelling of the samples is attributed to the oxidation of silicon carbide present in sludge material with gas evolution (fig. 1-12).

10 Thermo Physical Characteristics of Vitrified Tile Polishing Waste 127 Water Absorption (%) Apparent Volume Porosity (%) Water Absorption (%) v/s W 1 W 2 W 3 W 4 W Fig. 1. Effects of heat on water absorption of VTPS samples (fired in roller kiln) W1 W 2 W 3 W 4 Apparent Volume Porosity (%) v/s Fig. 11. Effects of heat on apparent volume porosity of VTPS samples (fired in roller kiln). 2.5 Bulk Density (gm.cm -3 ) Bulk Density (gm.cm -3 ) v/s W 1 W 2 W 3 W 4 W Fig. 12. Effects of heat on bulk density of VTPS samples (fired in roller kiln).

11 128 S. N. Misra, B. B. Machhoya & R. M. Savsani DTA/TGA results furnished in figs. 13 & 14, showed peak of quartz inversion at 577 o C in both unfired and fired samples of the VTPS. TGA curve revealed.4% weight loss due to removal of absorbed water in the temperature range of about 54 to 247 o C. Further a weight loss of.5% was observed in the range of 375 to 712 o C indicating decomposition of marginal amount of decomposable impurities in the VTPS. It may be noted that results of chemical analysis also showed presence of MgO in the sample. Fig. 13. DTA of unfired and fired VTPS samples Fig. 14. TGA of unfired fired VTPS samples The XRD peaks (Fig. 15) of the VTPS samples showed the presence of quartz as a major phase. Mullite was present as minor phase. However Silicon Carbide has been found to be present in trace quantity. Silicon Carbide may have come from the polishing operation and observed as traces in the VTPS. During firing of the vitrified tiles, there could be formation of mullite phase after vitrification near 12 o C, whereby some amount of quartz, feldspar got into molten state and clay dissolution takes place. At this stage, the resultant product comprised of quartz as predominant phase with the formation of mullite and certain amount of glassy phase in the porcelain body. The samples fired at higher temperature showed decrease in intensity of quartz indicating dissolution of it in presence of fluxing material with the increase in amorphous phase formation at higher temperature. Correspondingly, the more intense mullite phase is also observed at higher temperature, however, still it remained as minor phase. In the high temperature region, oxidation of Silicon Carbide takes place leading to formation of more siliceous glass phase and predominantly forming glassy phase insitu with other fluxing material.

12 Thermo Physical Characteristics of Vitrified Tile Polishing Waste 129 Q/M M Q M Q-QUARTZ M-MULLITE M M M Q M Q Q Q M Q Q 117 o C 1125 o C COUNTS 912 o C Theta (degree) Fig. 15. XRD pattern of VTPS samples 198 o C 163 o C 985 o C The Scanning Electron Microscopy of the VTPS samples after firing at different temperatures showed that a gradual increase in the vitrification of the constituents with the increase in the temperature. Scattered crystals of the mullite were observed in all the samples. However needle shape crystals formed insitu becoming prominent at higher temperature. With the increase in temperature, amorphous phase formation increased due to quartz dissolution in the matrix. An amount as well as size of the voids due to evolution of gases was found to be increased with increase in the firing temperature (fig. 16).

13 13 S. N. Misra, B. B. Machhoya & R. M. Savsani 127 o C 163 o C 198 o C Fig. 16. SEM of VTPS Samples 1125 o C The FTIR spectra of unfired VTPS samples furnished in Table 3 and Fig. 17, showed stretching vibration and bending vibration of Si-O-Si bond. The sample showed presence of H-O-H bond indicating the presence of structural water. % T W 4-A F W 4-B F C m -1 Fig. 17. FTIR spectra of VTPS samples

14 Thermo Physical Characteristics of Vitrified Tile Polishing Waste 131 Table 3. Results of FTIR of VTPS Samples UNFIRED VTPS FIRED VTPS Wave number (cm -1 ) Remarks Wave number (cm -1 ) Remarks Si O Si Bending Si O Si Bending Si O Al Bending Vibration Si O Quartz Si O Quartz Si O Quartz & Fe O Str Si O Quartz & Fe O Str H O H Bending Si O Si Str O H Str H O H Bending Aliphatic CH 2 & CH Groups O H Str. Similarly from the FTIR spectra of fired VTPS samples furnished in Table-3 & Fig. 17, the stretching vibration and bending vibration of Si-O-Si bond as well as presence of H-O-H bond were found. Also, the presence of quartz in the vtps could be substantiated corresponding bands at and cm -1 and verified by the XRD peaks.there is a significant reduction in vibration band in case of fired VTPS samples. Absence of organic groups ( such as CH 2 and CH 3 ) could be seen very clearly in the fired sample obviously due to its removal during heat treatment. Co-Efficient of thermal Expansion of the typical VTPS samples showed 6.79x1-6/ o C from 3 to 5 o C and 7.26x1-6/ o C from 3 to 6 o C (Table-4 & Fig. 18). This expansion curve of the VTPS as a typical sample reflected quite similar property observed in traditional ceramic system. However, further expansion w.r.t increase in temperature could not be measured due to some abrupt change in the shrinkage curve as observed during firing of the pellet sample shown in earlier case (fig. 6). Fig. 18. Thermal expansion of Washed VTPS samples

15 132 S. N. Misra, B. B. Machhoya & R. M. Savsani Table 4. Results of Thermal expansion VTPS Samples 4. Conclusions Temp. ( o C) Time (min.) PLC ACE (1E-6in/inC) DCE (1E-6in/inC) From the above results of characterization of different samples of VTPS sourced from different vitrified tile units, a marginal difference in composition of parent vitrified body was observed. The colour of raw VTPS collected from different plants in Morbi and elsewhere showed as dull white to light grey colored agglomerates containing 11 to 15 % moisture and 4 to 5 % grits. This aspect needs consideration while selecting the VTPS as a source of raw materials for further processing in the traditional ceramics application. Also, the generation of VTPS from various vitrified tile units are very fine in nature as shown from it particle size distribution across various plants with d 5 value near to 7 to 1 micron & mean diameter 1 to 13 micron. Hence, in future ceramic use, this waste material could be suggested to put to use directly without any grinding. Due to variation in the moisture level of the VTPS as observed from different plants and therefore, the moisture content of the VTPS should be predetermined and taken into consideration while formulating of suitable ceramic body mix in future. Chemical analysis showed that VTPS is an Alumino Silicate system with constituents remain as 6 to 67 % silica (as quartz), and around 18 to 24 % Al 2 O 3 along with other impurities and alkalies. It also contains MgO in the range of 2 to 5 %. Mineralogical analysis suggested that it possessed quartz as major phase and mullite as minor phase. Few percent of silicon carbide present in the VTPS, which might have originated from

16 Thermo Physical Characteristics of Vitrified Tile Polishing Waste 133 the polishing operation of the abrasive wheels. However, due to oxidation of this silicon carbide at higher temperatures, there were frothing and swelling phenomena observed from the firing of VTPS. This type of swelling from the VTPS could be attributed to the evolution of tremendous amount of gas. This has resulted in volume expansion along with deformation of shape, lightweight with a bulk density nearing one and even lesser. Thus this swelling tendency of the sludge at above 11 C restricted its use at higher temperature. For all practical applications of the VTPS, efforts are needed to establish temperature dependent properties of various sources of VTPS for it s ultimate utility. Thus this study on vitrified tile polishing sludge has been significant due to over generation of vast quantity of these materials in all the vitrified tile units. An attempt has been made to characterize systematically the thermo physical properties of sludge material to understand chemistry and reactive phase formation at high temperature to focus development of these waste materials for gainful use in traditional ceramic industries. Acknowledgment The authors are thankful to Director, CSIR-Central Glass & Ceramic Research Institute, Kolkata for his kind permission to present the paper. Authors are also thankful to Deptt. Of Sci & Tech, Govt. of India for sponsoring this project for it s fruitful use in ceramic industries. Authors also thank the management of M/S Somany Ceramics for being the industry sponsor of this project and providing facilities and all the necessary help for industrial as well as plant trials at Somany Cearmics Ltd, Kadi. The authors also wish to thank the staff members of CGCRI, Naroda Centre for various support extended in this project. References 1. J. M. F. Ferreira, P.M.C Torres, M. S. Silva, J. A. Labrincha; Recycling of Granite sludges in brick type and floor tile type ceramic formulations, Euroceram News 14, 1, (23). 2. A. A. Mustafa, W. M. N. Nour, D. M. Ibrahim, M. A. Abou-Matty; Granite waste as the main constituent in Tile Recipes, Interceram, 57(1), 26, (28). 3. J. H. Tray; Bricks manufacture from sludge, J. Environ. Engg, 113, 278, (1987). 4. M. Churchill; Aspects of Sewage sludge utilization and its impact on brick making, Global Ceram. Review, 1, 18, (1994). 5. J. A. Perez, R. Terradas, M. R. Manent, M. Seijas, and S. Martinez; Inertization of Industrial wastes in Ceramic materials, Industrial ceramics, 16, 7, (1996). 6. S. A. Komissarov, T. M. Korchuganova and A. V. Belyakov; Construction materials using tanning industry wastes, Glass & Ceramics, 51, 32, (1994). 7. D. A. Pereira, D. M. Couto and J. A. Labrincha; Incorporation of aluminium rich residues in refractory bricks, CFI-Ceramic Forum International, 77, 21, (2). 8. I. Pavlova; Use of Industrial waste in brick manufacture, Tile & Brick Intl, 12, 224, (1996). 9. M. Dondi, M. Marsigli and B. Fabbri; Recycling of industrial wastes in Brick production- A Review, Tile & Brick Intl, 13, 218, (1997). 1. A. M. Segadaes. and M. A. W. Carvalho; Using Marble and Granite rejects enhance the process wing of Clay, Appl. Clay. Sci, 3, 42, (25).