A novel approach of preparing press-powders for cleaner production of ceramic tiles

China produces almost half of ceramic tiles in the world. However, serious air pollution and high energy consumption in the preparation of ceramic press-powders by traditional wet process (WP) have become major barriers for the sustainable development of ceramic tile manufacturing industry. A novel cleaner production process, named by the authors as Droplet-Powder Granulation Process (DPGP), was proposed and tested in this work. Droplet-powder granulator, a key facility of DPGP, was designed. In the granulator, ceramic suspension was directly sprayed to form fine suspension droplets and ceramic dry powder was simultaneously jetted and dispersed to enwrap, insulate and adsorb the suspension droplets so as to form coarse granules that were then rolled, tamped and dried into press-powders. Lab experiments of preparing press-powders by DPGP were carried out. The as-prepared DPGP press-powders consist of solid granules with nearly spherical shape and approximately normal grain size distribution, and present favorable flowability and relatively high bulk density, with the similar properties of the press-powders as those prepared by WP. Moreover, as compared with WP, DPGP can reduce both pollutant emission of 98% dust, 65% sulfur oxides and 71% nitrogen oxides and resource consumption of 24% energy and 69% water. Therefore, DPGP is an innovative approach for cleaner production of ceramic press-powders.