Claims:
WE CLAIM,

1. A composition for preparing recycled ceramic composite, wherein said composition comprises:
• A Pulverized ceramic waste,
• A Binder,
• A Deflocculating agent,
• Water;
Wherein,

Said pulverized ceramic waste is in the range of 30-70% by weight and is the primary raw material utilizing the waste and reducing the energy consumption during firing;
Said binder is in the range of 30-70% by weight and is configured to provide plasticity to the composite and providing structure to make products from the composition;
Said deflocculating agent in the range 0.10%-0.50% is configured to prevent the raw material and binder particles from sedimentation;
Said water in the range of 30-50% is the medium for uniform dispersion of raw material and binder particles and maintaining the optimum viscosity of the composite.
2. The composition for preparing recycled ceramic composite as claimed in claim 1, wherein said pulverized ceramic waste raw material include use of stoneware waste, porcelain waste, bone china waste, terracotta waste, post-industrial or post-consumer in the range of 30%-70% by weight.
3. The composition for preparing recycled ceramic composite as claimed in claim 1 and 2, wherein said pulverized ceramic waste raw material in said composition is 60% by weight.

4. The composition for preparing recycled ceramic composite as claimed in claim 1, wherein said binder include use of fire clay, ball clay, china clay, feldspar, talc, silica (quartz), bentonite, CMC either individually or in combination of two or more in the range of 30%-70% by weight.

5. The composition for preparing recycled ceramic composite as claimed in claim 1 and 4, wherein said binder in said composition is 40% by weight.

6. The composition for preparing recycled ceramic composite as claimed in claim 1, wherein said deflocculating agent consists of sodium silicate, soda ash in the range of 0.10%-0.50% by weight.

7. The composition for preparing recycled ceramic composite as claimed in claim 1 and claim 6, wherein said deflocculating agent in said composition is 0.20% by weight.

8. The composition for preparing recycled ceramic composite as claimed in claim 1, wherein said water in the composition is 40% by weight.

9. A process for preparing recycled ceramic composite, wherein the recyclable process comprises steps of :

• Crushing of ceramic waste into fine powder;
• Preparing the homogeneous mixture of said composition;
• Molding said mixture and obtaining the molded products;
• Firing of said molded products at 900°C to 1000°C;
• Applying glaze over the fired product through spraying, dipping and/or pouring methods;
• Placing the glaze applied products inside the furnace at 1120 °C to 1180 °C;
• Repeating the above steps;
Dated this 3rd day of May, 2021.

GOPI TRIVEDI (Ms.)
IN/PA 993
Authorized Agent of Applicant

To,
The Controller of Patents
The Patent Office
At Mumbai. , Description:Form 2

The Patents Act, 1970
(39 of 1970)

COMPLETE SPECIFICATION
(Section 10; Rule 13)

“A COMPOSITION FOR PREPARING RECYCLED CERAMIC COMPOSITE AND PROCESS THEREOF”

EARTH TATVA INNOVATION PRIVATE LIMITED
8, Indraprasth apt., Opp. St. Xavier’s School, Near Adarsh Society, Ghod Dod Road, Surat – 395 001, Gujarat, India.

SHASHANK NIMKAR
8, Indraprasth apt., Opp. St. Xavier’s School, Near Adarsh Society, Ghod Dod Road, Surat – 395 001, Gujarat, India.

The following specification particularly describes the nature of the invention and the manner in which it is to be performed:
FIELD OF INVENTION:

The present invention relates to a composition for preparing recycled ceramic composite and a process for preparing the same. More particularly, it provides the composite having higher strength and the process requiring lower energy consumption during firing.

BACKGROUND OF INVENTION:

With social economy and the fast development of ceramic industry, a large amount of industrial waste is generated. Among industrial wastes, ceramic wastes have been increasing in recent years. Ceramic waste is generated in large quantities due to the aging and redevelopment of buildings and rejections in ceramic production line, fired at a high temperature exceeding 1200 ° C and vitrified. Currently, it is being disposed of in large quantities.

Further, as the Compound Annual Growth Rate (CAGR) for the ceramic industry worldwide increases, it requires more raw materials to fulfil the requirements of the consumer market. This directly impacts the amount of mining activities undertaken at various sites around the world to extract and process the required raw materials. These mines at such extraction rate can provide the materials only for a countable number of decades.
Additionally, in most other industries, we can fix any defects from manufacturing or at the least sell those products at a lower price. But with ceramics, most often we cannot fix a product bearing cracks and unfortunately the value becomes negligible.
Therefore, the development of so-called recycled products that reuse these industrial wastes is actively performed in various industrial fields, and the ceramics field is no exception and many ceramic products that reuse industrial wastes need to be disclosed.

PRIORART AND ITS DISADVANTAGES:

The Japanese patent application JP2005263601A relates to the composition of ceramic waste as raw materials to make new products. The invention further relates to composition as using many types of waste containing silica such as
ceramic waste, cement waste, blast furnace slag, sewage sludge, and garbage incineration ash in 70%-90% of proportion of the composite. The invention uses glassy material, binder and metal salts to reduce the firing temperature and composition strength, firing in the range of 950 °C or more and 1200 °C or less. The pulverized size of the ceramic waste can be at least 2mm or less, preferably 1mm or less to obtain a high-quality ceramic product.
However, the cited prior art relates to making of ceramic products from high proportion of ceramic waste containing silica with multiple types of waste such as ceramic waste, cement waste, blast furnace slag, sewage sludge, and garbage incineration ash which defies the purpose of using high quantity of ceramic industrial rejects after firing. Further, the obtained recycled product demonstrates the same strength and hardness as conventional products after the firing process, thus does not provide advancement in durability of the products. The strength is only increased for the unfired pieces to have convenient handling for unfired pieces. This requires an addition of metal salt powder. Further, said invention uses glass powder or sludge as a binder it is cutting down the recyclability and life cycle of glass. Thus, failing to provide longevity for the material and thus limiting the application of the invention to building and decorative products.
Another patent application CN102584179A relates to blank formula of the ceramic product comprising 32-36 parts of waste ceramic powder by dry weight proportion. Using large amount of waste ceramic powder for the base glaze formula, and the technological difficulties of waste ceramic powder compounding, grain composition, sintering and decoration are overcome.
However, the glaze firing temperature of said invention is in the range of 1060°C -1100 °C which may not necessarily be able to accommodate food safe glazes, thus, allowing the invention to be used only for decorative applications. Moreover, the invention uses red lead as a major ingredient for its glaze which is known to be a toxic element to be used for food consumption products. Further, the mentioned process uses porcelain waste and may not be able to accommodate other kinds of ceramic waste like stoneware, bone china and terracotta. Overall, the use of this invention has a narrow industrial application and does not efficiently solve the purpose of using waste ceramic to reduce material consumption yet make safe products for varied use.
Another Chinese patent application CN110357584A, relates to a method of preparing ceramic mud by recycling ceramic waste water. It turns ceramic waste water containing 3%-10% of ceramic mud to 90%-97%, ball mills it with certain amount of water and degumming agent. Iron is removed after the ball milling process through sieving. Said process eliminates squeezing process while directly using ceramic waste water recycling ball milling. This method is said to save squeezing, cost of wheeling, while efficiently solving mud viscosity, thixotroping and easily causes glaze pin hole.
However, said prior art fails to provide a solution for post-firing waste. The composition uses various potassium and sodium sand which may not be stocked by most of the industries causing them to increase their investment in added inventory. Further, the invention uses porcelain mud and may not be applicable to other types of ceramics. It also mentions the occurrence of spot impurity in glaze through the pin hole effect. This defect may cause further rejection in the production line after glaze firing. Thus, is inefficient in saving resources by the end of the production and is incapable of addressing the waste after the firing process.
Another patent application JP2013227188A, relates to a method for manufacturing building material using ceramic waste and organic combustible material, ceramic hardening agent, glass binder and water. The building material is fired at 600°C - 1000°C. It uses saw dust, leaf and wood waste, resins as organic combustible material. While flax, cathode ray tube, liquid crystal glass is used as a glass-based binder.
However, the surface of the material in said invention is rough and can only be used for applications like tiles, outer wall, road pavements and water retaining bricks most having outdoor applications. Thus, it cannot be used for making smooth and safe products for indoor use by individuals. Further, as the material is porous one cannot use it to make food safe containers. Thus, limiting the applications of the composite to few industries. Additionally, the glass-based binder may cut down on the natural recyclability of the glass, making it inefficient to be a recyclable material composite and building materials with small specific gravity are likely to be reduced in strength which is dependent on the size and amount of organic combustible material which may be inconsistent hampering the production specifications.

DISADVANTAGES OF PRIOR ART:

The existing prior art suffers from all/any of the following disadvantages:
• Most of the prior art fail to provide a solution for post-firing waste.
• Most of them use glass as a binder. Glass and ceramics are from the same silica based family of materials but have different properties. Mixing them together hinders the recyclability of the ceramic waste material.
• None of the prior art provides the technical advancement in terms of strength and hardness.
• Said prior art uses red lead as a major component for glaze, which is not safe for both people and environment.
• Said prior arts fail to provide recyclability of the composite after its end of life, thus failing to offer a closed-loop circular solution.
• Said prior art fails to provide the composite for food safe applications.
Thus, there is an unmet need of the invention that eliminates the disadvantages of the prior art and provides recycled ceramic composite that is food safe, recyclable and having high strength.

OBJECTS OF THE INVENTION:
The primary object of the present invention is to provide a composition for preparing the recycled ceramic composite.
Another object of the present invention is to provide a process for preparing the recycled ceramic composite.
Yet another object of the present invention is to provide the recycled ceramic composite, which reduces the need for mining of natural resources by using the ceramic waste as a primary raw material to manufacture functional and decorative products.
Another object of the present invention is to provide the recycled ceramic composite with higher strength and durability even after the firing process.
Yet another object of the present invention is to provide the recycled ceramic composite that utilizes clay as a natural binder to turn recycled ceramic into a mono-material after the firing process and thus can be recycled for multiple production cycles.
Another object of the present invention is to provide the recycled ceramic composite that eliminates the use of glass as a binder and uses ceramic waste itself to add strength to the composite.
Yet another object of the present invention is to provide the recycled ceramic composite that gets fired at up to 100 °C lower or further lower than conventional firing of ceramics to reduce the energy consumption.
Another object of the present invention is to provide the recycled ceramic composite that can be molded into smooth surface food safe tableware products.
Yet another object of the present invention is to provide the recycled ceramic composite that can be used to make any ceramic, decorative, and food safe products.
Another object of the present invention is to provide the recycled ceramic composite that makes products with thin walls to offer light weight products with optimum use of materials.
Yet another object of the present invention is to provide the process for preparing recycled ceramic composite that facilitates equal and uniform dispersion of waste and binding particles for stable and higher strength of the material.
Another object of the present invention is to provide the process for preparing recycled ceramic composite that facilitates closed-loop zero-waste manufacturing through repeated use of waste ceramics, water, glazes and unfired clay.

SUMMARY OF THE INVENTION:
The present invention provides a composition for preparing recycled ceramic composite and a process thereof. Said composition comprises of: 30%-70% by weight pulverized ceramic waste (250-400 mesh), 30%-70% by weight binder,
0.10%-0.50% by weight deflocculating agent and
30%-50% by weight water. The process for preparing said composite comprises steps of:1. Crushing of ceramic waste into small pieces2. Preparing homogeneous mixture of said composition 3. Molding said mixture for obtaining the molded products 4. Firing of said molded products at 900°C to 1000°C5. Applying glaze over the fired product through spraying, dipping and/or pouring methods 6. Placing the glaze applied products inside the furnace at 1120 °C to 1180 °C7. Repeating the above steps in case of damage or rejection of the composite products. The present invention provides zero-waste manufacturing process for preparing the recycle ceramic composite.

DETAILED DESCRIPTION OF THE INVENTION:
The present invention provides a composition for recycled ceramic composite and a process of preparing the same. It provides utilization of high proportion of ceramic waste as a primary raw material to make composite that has higher strength and durability and lower energy consumption during the firing process. It provides the recycled ceramic composite with recyclability at its end of life by replacing various industrial wastes like cement and other building waste with ceramic rejects. Said composite is used in manufacturing of tableware/dinnerware products, architectural elements like tiles, furniture, planters, vases, paver blocks and gifting products.
Said recycled ceramic composite comprises of:
• Pulverized Ceramic waste
• Binder
• Deflocculating agent
• Water
Ingredients of composition
Weight percentage
Pulverized ceramic waste (250-400 mesh) 30%-70%
Binder 30%-70%
Deflocculating agent 0.10%-0.50%
Water 30%-50%
Table 1: Ingredients of composition with weight percentage of the present invention
As shown in table 1, said pulverized ceramic waste includes but does not limit to the use of stoneware waste, porcelain waste, bone china waste, terracotta waste, post-industrial or post-consumer and alike in the range of 30%-70% by weight and more preferably 60%. Said Ceramic waste is provided to utilize waste as a primary raw material, which reduces the energy consumption during firing in which the glaze particles facilitate sintering and act as reinforcement in the structure of clay to increase the strength of the composition.
Said binder includes but does not limit to the use of fire clay, ball clay, china clay, feldspar, talc, silica (quartz), bentonite, CMC and alike either individually or in combination of two or more in the range of 30%-70% by weight and more preferably 40%. The binders used whether individually or in combination add plasticity to the composite and give structure to make products from the composition.
Said deflocculating agent is used to prevent the raw material and binder particles from sedimentation. It consist of but does not limit to the use of sodium silicate, soda ash and alike in the range of 0.10%-0.50% by weight and more preferably 0.20% either individually or in combination of two or more. The deflocculating agents provide even dispersion of the raw material and binder particles to achieve a smooth surface and comfortable working with the material by keeping the particles suspended in water.
Further, the water in the present composition is used as a medium for uniform dispersion of the raw material and binder particles within the composition in the range of 30%-50% by weight and more preferably 40%. The use of water further maintains the optimum viscosity of the composite for various applications that includes but not limits to casting.
The present invention further provides the process for preparing the aforesaid recycled ceramic composite and the combinations of the raw material and binder composite taking into account the following key features:
a) It utilizes ceramic waste in combination of clay as a natural binder turning it into a mono-material composite after firing that enables recycling of the composite for multiple production cycles.
b) Producing products with a smooth surface and eliminating the use of heavy metal oxides to facilitate the use of the composite for food safe products.
c) It provides optimum combination of materials and thereby increases the strength and reduces water absorption thus substantially increasing the shelf life of the composite products.
d) It lowers the maturing temperature of the composite thus reducing the energy consumption during the firing process.
The process for preparing the recycled ceramic composite comprises of following steps:
1. Crushing of ceramic waste into fine powder
2. Preparing the homogeneous mixture of said composition
3. Molding said mixture for obtaining the molded products
4. Firing of said molded products at 900°C to 1000°C
5. Applying glaze over the fired product through spraying, dipping and/or pouring methods
6. Placing the glaze applied products inside the furnace at 1120 °C to 1180 °C
7. Repeating the above steps in case of damage or rejection of the composite products
Step 1: Crushing of ceramic waste into fine powder
First, the rejected or broken ceramic products whether from ceramic manufacturing industries or consumers are crushed into small pieces. It is then fed as input to pitcher machine or ball mill for pulverization. The volume of the input depends on the capacity of the respective machines. If crushed in a ball mill, it may require 6-8 hours of running the machine.
Step 2: Preparing the homogeneous mixture of said composition
For preparing the homogeneous mixture, 30%-70% by weight pulverized ceramic waste, 30%-70% by weight binder, 0.10%-0.50% by weight of deflocculating agents and 30%-50% by weight water is used. These are added as charge in the ball mill and mixed for 6 hours, thus, a homogenous mixture is prepared.
Step 3: Molding said mixture for obtaining the molded products
Said homogeneous mixture is molded into different products through various methods. The mixture takes a dough form, after draining the excess moisture. Further, the dough of the mixture can be used in various production techniques like but does not limit to the use of jigger jolly, press molding, wheel throwing, hand building and alike. The mixture in liquid form can be casted into plaster/gypsum molds to produce various functional and decorative products. The composition of each ingredient is decided arbitrarily in the aforementioned range to be used for a decided application of said composite.
The casting time of this material is quicker than conventional material and thus increases the productivity and profitability of the industry.
Step 4: Firing of said molded products at 900°C to 1000°C
The product is fired in a furnace at a temperature 900°C-1000°C preferably taking 8-12 hours to reach the mentioned temperature. The furnace could be but does not limit the use of electric, gas fired and alike. These bisque fired pieces are naturally allowed to cool down to room temperature inside the furnace to avoid any breakages due to thermal shock from cool air outside the furnace. This step turns the composite hard which facilitates easier handling of the pieces.
Step 5: Applying glaze over the fired product through spraying, dipping and/or pouring methods
After the bisque fired pieces are cooled down, they are cleaned with a damp sponge. Glaze is applied to these pieces through various techniques but does not limit to the use of spraying, dipping, pouring, painting and alike. The present invention uses in any combination but not limited to China clay, silica, feldspar, ball clay, talc, fire clay for base glaze with a combination of non-toxic metal oxides as colouring agents. This step adds aesthetic decorations to the pieces and eliminates the use of heavy metal oxides making the products food safe.
Step 6: Placing the glaze applied products inside the furnace at 1120 °C to 1180 °C
The glaze applied products are carefully placed inside the furnace, fired between 1120°C to 1180°C and reaching the said temperature in 12-14 hours. This step makes the composite stronger and harder, also sintering the glaze that adds aesthetic values and turns it food safe. Said composite saves energy consumption by reducing the firing temperature by up to 100°C or more.
Step 7: Repeating the above steps in case of damage or rejection of the composite products
After the glaze firing, some pieces may bear defects like cracks, warpage, glaze rolling, unmelted glaze and alike. These pieces under usual circumstances do not serve their original purpose and hold very little or no commercial value. Such pieces are pulverized again to turn into raw material and then repeat the process from step 1. Thus, turning the linear ceramic production into a closed-loop, zero-waste manufacturing process.

WORKING EXAMPLES:
The present invention and the manner in which it is performed is described in detail below with working examples and is by the way of illustrations only. Therefore, these examples should not be constructed to limit the scope of the present invention as illustrated below.
Example 1:
Said recycled ceramic composite is prepared using a combination of pulverized ceramic waste, binder, deflocculating agents and water. Glazed ceramic waste pieces are pulverized in pitcher machine or ball mill. Ball mill is charged with pulverized ceramic waste 60% by weight with fire clay as a binder used 40% by weight. Water is added in 40% by weight along with deflocculating agents like sodium silicate and soda ash in a proportion of 0.20% and 0.15% respectively to the mix. Ball mill is operated for 6 hours to make a homogenous liquid. The material composite is molded into products through various techniques like casting, press molding, jigger jolly, wheel throwing, hand building and alike. The pieces are bisque fired at 900°C to 1000°C preferably reaching the mentioned temperature in 8-12 hours. After naturally cooling to room temperature, the pieces are cleaned and glaze is applied. The pieces are fired at 1120°C to 1180°C. If there are any rejections the pieces are pulverized again and are used as raw material.
Example 2:
Said recycled ceramic composite is prepared using a combination of pulverized ceramic waste, binder, deflocculating agents and water. Glazed ceramic waste pieces are pulverized in pitcher machine or ball mill. Ball mill is charged with pulverized ceramic waste 60% by weight with ball clay as a binder used 40% by weight. Water is added in 40% by weight along with deflocculating agents like sodium silicate and soda ash in a proportion of 0.20% and 0.15% respectively to the mix. Ball mill is operated for 6 hours to make a homogenous liquid. The material composite is moulded into products through various techniques like casting, press moulding, jigger jolly, wheel throwing, hand building and alike. The pieces are bisque fired at 900°C to 1000°C preferably reaching the mentioned temperature in 8-12 hours. After naturally cooling to room temperature, the pieces are cleaned and glaze is applied. The pieces are fired at 1120°C to 1180°C. If there are any rejections the pieces are pulverized again and are used as raw material.

Example 3:
Said recycled ceramic composite is prepared using a combination of pulverized ceramic waste, binder, deflocculating agents and water. Glazed ceramic waste pieces are pulverized in pitcher machine or ball mill. Ball clay and fire clay are mixed in ratio 2:3 respectively forming the binder in ball mill or rapid grinder. Ball mill is charged with pulverized ceramic waste 60% by weight with the combination of binder used 40% by weight. Water is added in 40% by weight along with deflocculating agents like sodium silicate and soda ash in a proportion of 0.20% and 0.15% respectively to the mix. Ball mill is operated for 6 hours to make a homogenous liquid. The material composite is moulded into products through various techniques like casting, press moulding, jigger jolly, wheel throwing, hand building and alike. The pieces are bisque fired at 900°C to 1000°C preferably reaching the mentioned temperature in 8-12 hours. After naturally cooling to room temperature, the pieces are cleaned and glaze is applied. The pieces are fired at 1120°C to 1180°C. If there are any rejections the pieces are pulverized again and are used as raw material.
Example 4:
Said recycled ceramic composite is prepared using a combination of pulverized ceramic waste, binder, deflocculating agents and water. Glazed ceramic waste pieces are pulverized in pitcher machine or ball mill. Ball clay, china clay, fire clay, feldspar, talc, silica are mixed together in a ratio 30:20:10:16:10:14 respectively by weight forming the binder in a ball mill or rapid grinder. Ball mill is charged with pulverized ceramic waste 60% by weight with a combination of binder used 40% by weight. Water is added in 40% by weight along with deflocculating agents like sodium silicate and soda ash in a proportion of 0.20% and 0.15% respectively to the mix. Ball mill is operated for 6 hours to make a homogenous liquid. The material composite is moulded into products through various techniques like casting, press moulding, jigger jolly, wheel throwing, hand building and alike. The pieces are bisque fired at 900°C to 1000°C preferably reaching the mentioned temperature in 8-12 hours. After naturally cooling to room temperature, the pieces are cleaned and glaze is applied. The pieces are fired at 1120°C to 1180°C. If there are any rejections the pieces are pulverized again and are used as raw material.
Said recycled ceramic composite of the present invention is food safe and recyclable as it replaces cement and other building material waste and organic waste with ceramic waste and yet provides higher strength, lower firing temperature, high aesthetics, affordability of the products made from recycled ceramic composite.

ADVANTAGES OF THE INVENTION:

There are many advantages of the present invention over the prior arts:
• The present invention provides the composition for recycled ceramic waste and process for preparing the same.
• The composite uses clay as a natural binder thus is environment-friendly.
• It reduces the need for mining of natural resources by using the ceramic waste as a primary raw material to manufacture the functional and decorative products.
• It provides the recycle ceramic composite with higher strength and durability after the firing process.
• The process for preparing the recycled ceramic composite requires lower energy consumption.
• It provides the recycle ceramic composite that can be moulded into smooth surface food safe tableware products.
• The present invention provides zero waste manufacturing process because we can reuse the composite for multiple production cycles.