Utilizing waste zirconia nozzles for eco-friendly ceramic tile production

Abstract

The ceramic industry is increasingly focused on sustainability, seeking alternatives to reduce the environmental impact of raw material extraction and consumption. Recycling initiatives and waste reduction strategies have proven essential in conserving resources and minimizing waste. Zirconia nozzles, commonly used in continuous steel casting for molten metal flow control, are typically made from high-purity zirconia powder. Despite their critical industrial role, waste zirconia nozzles remain an underutilized source of zircon oxide, a valuable and costly raw material used in white floor and porcelain tile production. This study explores the potential of repurposing waste zirconia nozzles from the Iron Steel Company (Bilecik, Turkey) for ceramic tile manufacturing. Comparative analysis of color properties between standard zircon and waste zirconia materials was conducted, followed by extensive physical and mechanical assessments of the final tile products. Crystal- phase analysis (XRD), chemical composition analysis (XRF), and microstructural evaluation (SEM-EDS) were performed to evaluate the feasibility of this sustainable approach. The results demonstrate the viability of using waste zirconia nozzles as a cost-effective, environmentally responsible alternative in ceramic tile production without compromising product quality. This study highlights the potential for significant waste reduction and cost savings in the ceramic industry.