Foundry by-products: Alternative materials for ceramic tiles. Technical, radiological and environmental assessment

The aim of this study is to assess the feasibility of using foundry by-products in porcelain tiles. This feasibility has been evaluated by three different perspectives: technical, radiological and environmental. Firstly, given that the main impurities in foundry by-products are carbon and organic compounds, thermal treatments that successfully reduce carbon and organic compounds have been evaluated. Subsequently, both calcined and uncalcined byproducts have been characterised from a technological and radiological point of view and finally, porcelain tile compositions with both calcined and uncalcined by-products have been obtained. These compositions were fully characterised and their performance in the manufacturing process has been evaluated. The environmental impacts of this recycling process were also assessed by means of a life cycle assessment. The results confirm that foundry by-products can partially replace sand in porcelain tile bodies.