Fine Fireclay (FC) technological properties and mineralogy by tuning body composition and raw materials particle size distribution

The Fire-Clay (FC) technology is being revised to cope with challenges involving difficulties in the supplying chains and need to optimize the reuse of waste from production. In this view, the effects induced onto the fundamental FC-ceramic reactions by the introduction of waste from Fire-Clay and Vitreous-China productions are investigated, as a function of the secondary raw materials’ particle size (s) in partial replacement of traditional chamotte. Complex interwoven reactions take place upon changing s, pointing to a general improvement of greification with a reduction of s and increase of the glass content. The role of small nepheline syenite contents (<5 wt%) is also analyzed, leading to relevant effects on greification and thermal expansion. All this opens a chance of introducing waste up to 20–25 wt%, thus providing a relevant contribution to a sustainable production and mitigation of natural resources exploitation.