Optimization of the Process of Producing Porcelain Stoneware from Mineral Raw Materials and Microsilica as a Secondary Raw Material

The development of the ceramic industry requires the creation of new innovative products with improved properties. Given the growing demand for high-quality finishing materials and the limited availability of traditional raw materials, the search for more efficient technologies for porcelain stoneware production is a relevant challenge. The aim of this study was to develop porcelain stoneware with enhanced performance characteristics. The research presents the results of a study aimed at improving the production technology of porcelain stoneware in Kazakhstan using local raw materials and microsilica. The raw materials from the Turkestan region were examined for their suitability for porcelain stoneware production. The influence of technological parameters (firing temperature, particle size) on the properties of porcelain stoneware was studied. New ceramic compositions with various microsilica contents, a by-product of silicon production, were investigated. Different compositions with varying raw material mixtures and microsilica content were prepared and fired at temperatures of 1100, 1150, and 1200 °C. The optimization of process parameters for producing porcelain stoneware in different compositions showed the degree of yield dependence on firing temperature and time as well as the effect of microsilica content. The temperature, time, and visually determined parameters at which different yield values were achieved were highlighted in different colors. The results showed that changes in the mixture composition and sintering temperature affect the quality of ceramic tiles. The final experimental conclusions demonstrated that the production of ceramic tiles containing up to 3% microsilica at a firing temperature of 1200 °C. The addition of microsilica increases the flexural strength of porcelain stoneware to 41 MPa (exceeding the standard), reduces water absorption to 0.023%, increases frost resistance to 107 cycles, and also enhances shrinkage. These findings open new prospects for the development of the domestic ceramic industry, the expansion of the product range, and the resolution of environmental issues.