US 12,291,486 B2
Porcelain stoneware production process and products
Francesco Borgomeo, Rome (IT)
Assigned to SAXA GRESTONE S.P.A., Roccasecca (IT)
Appl. No. 17/049,313
Filed by SAXA GRESTONE S.P.A., Roccasecca (IT)
PCT Filed Apr. 18, 2019, PCT No. PCT/IB2019/053224
§ 371(c)(1), (2) Date Oct. 20, 2020,
PCT Pub. No. WO2019/207433, PCT Pub. Date Oct. 31, 2019.
Claims priority of application No. 102018000004789 (IT), filed on Apr. 23, 2018.
Prior Publication US 2021/0347695 A1, Nov. 11, 2021
Int. Cl. C04B 33/135 (2006.01); B03B 9/04 (2006.01); B09B 3/00 (2022.01); B09B 3/25 (2022.01); B09B 3/40 (2022.01); B28B 3/02 (2006.01); B28B 3/20 (2006.01); C04B 33/24 (2006.01); C04B 33/32 (2006.01); C04B 35/626 (2006.01); C22B 7/00 (2006.01); B09B 101/30 (2022.01)
CPC C04B 33/1355 (2013.01) [B03B 9/04 (2013.01); B09B 3/25 (2022.01); B09B 3/40 (2022.01); B28B 3/02 (2013.01); B28B 3/20 (2013.01); C04B 33/24 (2013.01); C04B 33/32 (2013.01); C04B 35/6261 (2013.01); C22B 7/005 (2013.01); B09B 2101/30 (2022.01); C04B 2235/349 (2013.01); C04B 2235/5436 (2013.01); C04B 2235/6021 (2013.01); C04B 2235/604 (2013.01); C04B 2235/6567 (2013.01)] 12 Claims
OG exemplary drawing
 
1. A process for preparing a porcelain stoneware product comprising:
treating ashes with carbonation reactions for at least 20 days to lower a pH of the ashes, wherein the ashes are residual from combustion of urban waste;
performing deferrization and de-metallization of the ashes;
combining the ashes with a plurality of raw materials for preparing porcelain stoneware to provide a mixture, wherein the mixture comprises between 1% and 40% by volume of the ashes;
grinding a dose of the mixture to provide a particle size of less than 150 m; and
homogenizing the mixture with wetting during a rotation phase to provide a humidity rate between 4% and 8%,
wherein the porcelain stoneware product comprises a tread surface, a base surface, and an average thickness extending from the tread surface to the base surface of greater than or equal to 4.5 cm, and
wherein said ashes have a composition of:
 
 
 Na2O MgO Al2O3 SiO2 P2O5 SO3 Cl2O
 
% 2.84 2.75 17.08 36.08 1.23 0.85 1.12
 
 
 
 K2O CaO TiO2 Fe2O3 CuO ZnO
 
 
 % 1.06 30.21 1.74 4.03 0.45 0.56.