TITLE OF THE INVENTION: "SMOG RELIEF TILES"

BACKGROUND OF THE INVENTION:

1. FIELD OF INVENTION:

The invention discloses an innovation on a ceramic tile body composed of inherent Titanium dioxide from 0.2 to 0.5% along with other ingredients like Si02, Al203, Fe03, CaO, MgO, Na20, K20 etc. On which

1) A primary coating called Engobe composed of Titanium dioxide (0.5 to 1%) along with other chemical components,

2) A secondary coating called Base Glaze composed of Barium carbonate(1 to 5%) and Titanium Dioxide (1 to 4%) along with other chemical components and

3) A final aesthetic coating in the form of design printing ink composed of a base containing Barium Carbonate (1 to 5%) and Titanium dioxide (2 to 5%) along with other chemical components.

Thus, formed ceramic glaze tile Body with triple layer coating, will be fired at a very high temperature in a Roller hearth kiln between 1150 to 1180°C and the resultant tile will have the potential to absorb smog and neutralize the chemical from smog providing relief from etching of exterior tiles from 'SMOG'.

Background of Invention

Most commonly building exteriors are covered with paints, bricks, clay tiles, natural granites, ceramic exterior tiles etc. These exterior are exposed to air pollution caused due to heavy traffic of vehicles. These vehicles use Fossil fuels such as oil, natural gas and coal and burning of these fossil fuels results NOx. Ground level ozone is produced by reaction between Nitrogen Oxides(NOx) and volatile organic compounds(VOC) in the atmosphere. VOC comes mainly from the evaporation ofliquid fuels, solvents and organic chemicals and from gasoline burning.Because smog forming reaction depends upon temperature and sunlight. Smog problems are generally more acute on hot, sunny summer days.

What is so bad about SMOG?
Smog can be a powerful and irritating pollutant. Even short term exposure of only one or two hours can irritate our nose and throat and cause respiratory problems such as coughing and painful deep breathing, Exercising outdoors increases the likely hood of respiratory difficulties due to Smog, since more air is inhaled during physical activities. In addition, ground level ozone increases our susceptibility to other respiratory illness and may results in premature aging of the lungs.

The higher levels of ground level ozone that contribute the smog often damages the building exteriors, agricultural crops and vegetation. How to absorb this dangerous smog and neutralizing this chemical to a useful fertilizer is the key behind the invention.

Exteriors of the building face the Smog 24hrs 365 days and the chemicals NOx from the smog deposits on the exteriors and react gradually and eat the surface gradually. This invention has helped to prevent this dangerous eating etching of exteriors and providing relief to worried citizens across the world.

Basics of Smog and its effect in the Environment:
The term SMOG was first coined many years ago to describe the combination of smoke and fog in the atmosphere. Today, the main components of smog in many cities are ground level ozone.

Photochemical smog is a harmful mixture of gasses primarily formed whensunlight interacts with certain industrial pollutants and exhaust from cars, trucks, generators and all type of vehicles on roads.

Where does SMOG, come from?
Ground level ozone occurs as the results of reaction between naturally occurring NitrogenOxide (NOx) and oxygen in the air. However, human created NOx and Volatile organic compounds (VOC) accelerate the ozone formation process, resulting in excessive amounts of ground level ozone.NOx results from the burning of fossil fuels such as gasoline, natural gas, oil and coals. VOC comes mainly from the evaporation of liquid fuels, solvent and organic chemicals as well as from gasoline burning. Because smog forming reactions depend in temperature and sunlight, smog problems are particularly acute an hot sunny summer days.

SMOG LEVELS DEPENDENCY:
The frequency and severity of smog depends on the size of a city, itspopulation and vehicle density and the kind of industry it supports. Smog is not just a city problem, it flows in to rural area as well. Since ozone NOx and VOC can be transported by air currents, the extent of a smog problem in a particular area can be affected by smog levels in location up to several hundred kilometers away.

Climate and topography can also affect smog levels. For instance, although rain can clean the air of the pollutants that cause smog, this may result in acidic rain water. Wind can also blow smog away, but if cities are surrounded by hills or mountains, the reduced air flow can cause smog levels to increase.

Ozone layer: while ozone is everywhere in the atmosphere, higher levels are concentrated in two main areasie the stratosphere, located between 15Km and 40Km above the earth's surface, and at ground level where we live and breathe. Ozone occurs naturally in both of these areas, but at certain times of the year the natural balance is disturbed by too much ozone at ground level and too little in the stratosphere.

Stratosphere ozone:
Stratospheric ozone plays an important role in the atmosphere; it forms a protective layer around the earth as it absorbs the intense ultra-violet radiation from the sun and prevents most of it from reaching the Earth's surface. The consequences of more intense radiation reaching the earth are more serious.

Although some ultra violet radiation is needed to sustain life and help plants grow, too much radiation increases risk of skin cancer andeye cataracts and reduces yields of important agricultural crops such as wheat, rice, corn and soyabeans. Therefore it's important that we ensure levels of this beneficial stratospheric ozone don't continue to diminish.

Ground level Ozone: Ground level ozone occurs naturally but only in low concentrations. These concentrations increase when pollutant in the air reacts in the presence of sunlight under warm temperature and result in harmful level of ozone.

Controlling NOx and VOC is one of the best ways to limit ground level ozone to acceptable levels. When level of smog reaches harmful proportions, it is wise to change our outdoor activities like.

1) Avoid strenuousoutdoor exercise, especially during the afternoon and early evening when ground level ozone levels are at their highest. Opt for indoor activities whenever possible at these times.

2) Avoid exercising near heavy traffic areas, at least during rush hour, to minimize exposure to smog.

What can we do to help reduce SMOG?

People can limit the production of smog.Become Travel Smart - use alternative transportation methods such as walking, cycling, and using public transit systems. A full 12 meterbus holds enough people to replace 50cars in rush hour.

- Share riders two/four persons in a vehicle cuts the fuel consumption per person in half or quarter.

- Drive with in the speed limit - Reducing speed from 100 to 80Km/hr reduces fuel consumption by 15 to 20 percent.

- Maintenance of vehicle timely results in smoother running of engine and less energy waste.

- Reduce idling of vehicles.

- Turn off engines while waiting at signals 8t railway crossing

- Avoid unnecessary travelling by attending teleconferencing.

At Home:-
- When buying a home, choose an energy efficient model.
- Use Solar Reflective Index tiles/ COOL TILESto cover the roof to keep the home cool.
- Use fans instead of air conditioners as fans use much less energy.
- Use florescent or energy saving incandescent lighting which use less energy and helps reduce emissions.
- Avoid firing wood and dried leaves or plastic waste.

When shopping:- consider the environmental impacts of products before purchasing. Use the Ecology as a guide to products that are less harmful to the environment.

- While buying a car, consider its fuel efficiency.
- Buy small cars to help reduce pollution as well as travel costs.
- Buy energy efficient appliances with the help of energyguide label since smog is primarily a result of fuel burning, reducing energy use and making wise buying decisions all contribute to cleaner air.

After mentioning about reduction of smog in the environment by human beings, let us mention on treatment to absorb/ neutralize smog.

- Titanium Dioxide Nanoparticles spray used as a variety of surfaces such as roads, roof tops, building exteriors, fabrics, solar panels and windows to reduce smog effects.

- Paints created with Titanium dioxide to filter out Nitrogen Oxide are being applied on the walls which process is also called "Smog scrubbing paints".

- There are some varieties of cement concrete with smog eating effects.

Summary of the invention

The summary mainly involves a development of ceramic exterior tile product which absorbs Air pollutant,ie SMOG.

What is Air pollution?
Air pollution is the presence in the air of any substance in high enough concentration to be harmful to the environment or the human health.

Human activities (eg: combustion of Fossil fuels and industrial flue gases) are the main source of most pollutants, although pollutants can also come from Natural sources (Fire, windblown dust, volcanoes).

The main air pollutants are:-
1) Nitrous Oxides (NOx), which are produced during the combustion of Fossil fuels, arepollutants themselves but also react with water vapour to form fine acidic droplets and react with VOCs to generate Ozone.

2) SulphurDioxide (S02), which is generated by industrial process and combustion of fossil fuels, is a pollutant itself, but also reacts with water vapour to form the acidic droplets(eg.sulphuric acid). S02 is not a GHG (Green House Gas).

3) Carbon Monoxide (CO) is generated by combustion of Fossil Fuels (primarily from automobiles), but is also released by wild fires and volcanic eruptions. CO is not a GHG.

4) Volatile Organic Compounds (VOCs) are a group of carbon containing compounds (both natural and synthetic) released primarily but the evaporation of petroleum products (eg: gasoline, Natural gas), solvents and other volatile products(eg:Paints) VOCs reacts with NOx in the presence of sunlight to form ground level Ozone. Some VOCs are carcinogenic (eg.Benzene, Formaldehyde). VOCs by themselves do not contribute to the Green-house effect.

5) Ground level Ozone is formed by the chemical reaction between VOCs and NOxs, in the presence of sunlight. Ground level ozone is of the main components of smog. Because the reaction that generates Ozone accelerates at higher temperatures, global warming is expected to increase concentrations of ground level ozone and lead to more smog. Ground level ozone is also a GHG.

6) Airborneparticles (Particulate matter-PM) include both solids and droplets form a variety of natural sources and human activities. In most cases, coarse particles (2.5 to 10 microns) are emitted directly into the air(dust pollen, diesel soot, smoke) and fine particles(less than 2.5 microns) are formed through chemical reaction involvingNOx, S02> water vapor, VOCs and ammonia. Particulate matter is one of the main components of smog, but does not contribute to the green-house effect.

7) Various heavy metals (lead, mercury, cadmium, manganese) and persistent organic compounds (eg PCBs, Dioxins) are also found in air pollution. Heavy metals and persistent organic compounds do not contribute to the greenhouse effect.

Good Ozone and Bad Ozone
Stratospheric Ozone- the Good ozone layer is located 16-50Kms above the ground. It has a cooling effect on the earth and protects humans and other life from Ultraviolet radiation(UV). When scientists refer to holes in the Ozone layer (caused primarily by chlorofluorocarbons or CFCs) they are referring to the stratospheric ozone layer which is not a pollutant.

Ground level Ozone - The bad ozone is formed when VOCs and NOx react in sunlight. (NOx + VOx + sunlight =GLO) Ground Level Ozone is toxic to humans, contributes to Smog and Climate change and does not protect us from UV radiation.

Cycle of Smog
The Main Motto Behind the invention is to absorb these ambient air particulates and neutralize the harmful chemical into a useful fertilizer.

The invention has considered the de polluting properties of Titanium dioxide and Barium Carbonate, and these compounds are used in the process of Ceramic exterior tiles exclusively designed for absorbing the smog.

2. DESCRIPTION OF THE PRIOR ART;
Prior Art No.GB2425075,describes aconcrete roof tile comprising one or more base layers and a topmost layer of discrete photo catalytic particles. The photo catalytic layer is capable of oxidizing pollutants such as NOx and SOx. The initial activity of the fresh photo catalytic layer or layers may be enhanced through etching which may be mechanical such as by blasting with abrasive grits or synthetic abrasives or solid CO2 (dry ice) or chemically.

Prior art No.MXPA05000846A, describes Ceramic or refractory materials being commonly used, among other applications, in the form of blocks as linings of furnaces. When it is necessary to re-line a furnace, the ceramic blocks are removed and typically discarded to a landfill and replaced with new ceramic blocks made from a ceramic material such as alumina oxide, zircon, silica, or magnesia oxide. Sometimes, the ceramic blocks may be recycled by crushing them to form gravel which is then pulverized, and new ceramic blocks made therefrom. Gunite materials, in the form of high pressure concrete mixes of cement, sand or crushed slag, and water, and the like have been sprayed over reinforcements.

In the prior art No. US7892997describes a boron containing compositions for use in glaze compositions. The composition is obtainable by a process which comprises heating to a temperature sufficiently high that calcination occurs but insufficient for the formation of a homogeneous melt a mixture comprising components capable, under the conditions of heating, of forming the oxides B203, Si02, A1203, Na20 and optionally CaO in proportions such that the relative percentages by weight of the said oxides, based on the total weight of the said oxides, are as follows: 10 to 18% B203, 40 to 65% Si02, 17 to 32% A1203, 4 to 9% Na20, and 0 to 10% CaO. The boron-containing compositions according to the present invention may be used in glaze compositions, suitably frit-free or boron free frit containing glaze compositions.

In order to overcome from the difficulties of prior art invention, many ceramics that is used and describes the material and compositions in order to obtain the glaze tiles which provides the different tile qualities. But the reference invention is prepared by taking few compositions from prior art to obtain the glaze or engobe, but here, other different raw materials are also mixed and processed in different technique to obtain a smog free tile.

Details of the invention;
The invention particularly relate to the development of ceramic exterior tiles which can absorb smog and neutralize the dangerous effects of smog. So called Smog relief tiles production process involves 3 steps.
1) Body preparation and formation of green tiles.
2) Glaze preparation and application of glaze on green body and decoration.
3) Firing of glaze decorated body.

Brief Process:
a) Body Preparation;
Raw materials from different sources received by trucks. The materials are unloaded at their designated bins. From raw materials bins materials are shifted to Weighing Hopper by JCB for weight. Materials are taken as per the recipe. Then materials are put inside the Ball Mills. The materials from weighing hopper to Ball Mill are transfer by conveyor belts. Water (45-55%) andDeflocculating agents (like STPP, Sodium Silicate etc) are added in the Ball Mill. Ball Mill is a cylindrical cell. There are alumina balls inside the ball mills. When it rotates it serves us two purposes, Size reduction and mixing. After 3-4 hours grinding the slurry (called slip) are taken out from the Mills, passed through vibro sieve and stored in a tank with continuous stirring to avoid settling.

Weighing of the materials are done according to the Body recipe

Body Recipe
Constituent's %
Red Clays- 55 - 65
Ball Clays- 10-20%
Feldspar- 10-15%
Calcite- 10-15%
Deflocculating Agent- 0.5-0.7%
TiO2 0.2 - 0.5 %

Then Slip is Spray Dried and form granular Powder containing about 5-6 % of moisture. In spray dryer slips are sprayed inside the chamber as a fine mist from bottom and hot air is given from the top. As liquid slip come in contact with the hot air, it dries and form solid granule. Spray dried powder is then stored in the silos. From silos Powder is fed to the press hopper by conveyor belt.

Pressing: Purpose of the press in to give shape of the tiles. Powder are fed into the press cavity and pressed by hydraulic press and green tiles are produced. After Pressing Tiles are dried in the drier and sent to glaze line for coating ofEngobe and Glaze.

b) Engobeft Glaze Preparation: Here, the Engobe, Glaze and Printing paste, etcare prepared. Raw materials are weighed according to the recipe and put in to the Ball Mill. Water and other chemicals also added in Ball Mill. The Ball Mills are lined with High Alumina Bricks and Alumina Balls are used as grinding media. After grinding,Materials slurry is stored in tank with continuous stirring to avoid settling. Glaze/Engobe slurry is supplied to glaze line for coating on green tile surface. For Decoration Printing base is prepared by mixing Printing Base,Medium, Ceramic Stain and Titanium Dioxide in Euro Mills.

Glazing; Here tiles are coated with engobe/glaze. Tiles are 1st passed through engobe fall and then glaze fall. After glazing if required there is decoration on tiles as per required design. After coating tiles are passed through the pre kiln dryer.

C) Firing of decorated Glazed Tiles:Here tiles are heat treated up to 1150 °C. Tiles move on the ceramic roller and pass through different temperature Zone (Pre heating, Heating,Cooling). The Typical temperature profile of the kiln

Sorting: At the last stage of operation tiles are classified based on different visual Faults as well as dimensional differences

Claims:
What is claimed is:
1. A smog relief ceramic tile body composed of titanium dioxide, silicon dioxide, aluminium
oxide, Iron oxide, calcium oxide, magnesium oxide, sodium oxide, potassium oxide which comprising:
a) A primary coating of engobe composed of titanium dioxide;

b) A secondary coating of base glaze of barium carbonate and titanium dioxide;

c) A final aesthetic coating in the form of printing ink composed of a base containing barium carbonate and titanium dioxide;

d) The ceramic glaze tile body with triple layer coating is fired at a very high temperature.

2. A smog relief tile according to claim 1 wherein said body recipe further composed of red clays from about 55 to 65% by weight, ball clays from 10 to 20% by weight, feldspar from 10 to 15% by weight, calcite from 10 to 15% by weight, deflocculating agent from about 0.5 to 0.7% by weight and titanium dioxide from about 0.2 to 0.5% by weight.

3. A smog relief tile according to claim 1, wherein said primary coating of engobe composed recipe of frit FI-65 from about 12 to 15% by weight, frit FZI 209 is from about 8 to 10% by weight, frit FZI 6000 is from about 6 to 8% by weight, quartz is from about 3 to 5% by weight, china clay is from about 40 to 45% by weight, soda feldspar is from 20 to 25% by weight, titanium dioxide is from 0.5 to 1.0% by weight and STTP is from 0.2 to 0.5% by weight.

4. A smog relief tile according to claim 1, wherein said secondary coating of base glaze recipe composed of frit KBB 7 20C 15 to 18% by weight, frit 9330 is from about22 to 28% by weight, soda feldspar is from about 20 to 25% by weight, china clay is from 8 to 10% by weight, calcite powder is from 13 to 16% by weight, dolomite is from 4 to 6% by weight, barium carbonate is from 1 to 3% by weight, cal alumina HGRM 30 is from 1 to 3% by weight, zinc oxide is from 1 to 3% by weight, zirconium silicate is from 4 to 6% by weight, titanium dioxide is from 1 to 4% by weight, CMC is from 0.1 to 0.3% by weight, STPP is from 0.2 to 0.5% by weight.

5. A smog relief tile according to claim 1, wherein said printing ink base for decorating composed of printing base is from about 40 to 60% by weight, printing medium is from 30 to 40% by weight, stain is from 5 to 15% by weight, barium carbonate is from 1 to 5% by weight, and titanium dioxide is from 2 to 5% by weight.

6. The method of smog relief tile comprising the steps of:

a) Body preparation and formation of green tiles;
b) Glaze preparation and application of glaze on green body and decoration;
c) Firing of glaze decorated body.

7. The method of smog relief tile according to claim 6, wherein said body preparation and formation of green tiles comprising the steps of:

a) loading the body raw materials to designated bins;

b) shifting the raw materials from bin to weighing Hooper and materials are taken as per the recipe;

c) putting the materials inside the ball mills from weighing hooper that are transferred by conveyer belts;

d) water from about 45 to 55% and other deflocculating agents like STTP, sodium silicate are added in the ball mill;

e) grinding the slip for at least three to four hours, taken out from mills and passed through vibro sieve and stored in a tank with continuous stirring to avoid settling;

f) spray drying the slip and form as granular powder containing about 5 to 6% of moisture and spray dryer slips are sprayed inside the chamber as a fine mist from bottom and hot air is given from the top, as liquid slip come in contact with the hot air, it dries and form solid granule, spray dried powder is stored in the silos and from silos powder is fed to the press hopper by conveyor belt;

g) feeding the powder into the press cavity and pressed by hydraulic press to form as green tiles, tiles are pressed and dried in the drier and sent to glaze line for coating of engobe and glaze.

8. The method of smog relief tile according to claim 6, wherein said engobe or glaze preparation
and application on green tile comprising the steps of:

a) Weighing the raw materials as per the recipe and put into the ball mill along with water and other chemicals;

b) grinding the raw materials inside the ball mill, slurry is stored in tank with continuous stirring and engobe slurry is supplied to glaze line for coating on green tile surface.

9. The method of smog relief tile according to claim 8, wherein said glazed tile is for decorating printing base is prepared by mixing printing base, medium, ceramic stain and titanium dioxide in euro mills.

10. The method engobe or glaze preparation and application on green tile according to claim 8 and 9, wherein application of glaze on tile is coated when the tiles are passed through engobe fall and then glaze fall and coated tiles are passed through the pre kiln dryer.

11. The method of smog relief tile according to claim 6, wherein firing of decorated glaze tiles are prepared when tiles are heated up at least between 1150 to 1180 degree centigrade and passes through different temperature zone in the kiln.

12. The method of smog relief tile according to claim 11, wherein said tiles are passes through kiln is sent to rectification, sorting and packing.