Production of ceramic tiles by combining Moroccan phosphate mine tailings with abundant local clays

Abstract

This study offers an easy, economical, and ecological solution to manufacture a ceramic faience product with excellent mechanical properties by combining Moroccan phosphate mine tailings and two abundant local clays. The use of these clays alone was inconceivable because they do not generate a material that meets the mechanical requirements. A mixture design strategy conducted the optimization of the formulation. Therefore, ten tests were carried out. The ceramic tiles produced are characterized by their physical properties (water absorption, shrinkage), mechanical properties (flexural strength), and surface properties (observation by scanning electron microscopy). The results show that phosphate mine tailings improve the mechanical properties of ceramic tiles. Industrial use at a rate of 33% in formulas based on abundant local clays could, therefore, be envisaged to design faience products, conforming to the mechanical and technical requirements. This mode of production contributes to saving non-renewable natural resources, preserving the environment, and aligns with the principle of sustainable development.