Ceramic Insulator and Waste Management

Tugas Mata Kuliah Limbah Industri Manufaktur
Dosen Pengampu: Dr. Arif Zulkifli Nasution

Nama Mahasiswa: Verry Surya Hendrawan
Nomer Mahasiswa: 16510501
Ceramic Insulator Industry and Their Waste Management
At PT WIKA-NGK Insulator, Kawasan Industri WIKA, Jl. Raya Narogong KM 26

Cileungsi, Gunung Putri, Bogor, West Java Province
Background
PT WIKA-NGK Insulator is a joint venture ceramic insulator

manufacturing, between PT WIKA (Indonesia) and NGK Cooperation (Japan),
established in 1987
Our Products
Electrical insulators are devices used in electricity supply networks, and porcelain
has long been used as an electrical insulator. The advantages of porcelain
insulators include superior electrical properties, good mechanical properties
(especially tensile strength), good creep resistance at room temperature and high
corrosion resistance
Waste Management in Porcelain Insulator Manufacturing Page 1

Our Process Flow Diagram
Materials
The mineral raw materials used in this industry are mainly inorganic, non-metallic,
crystalline solids formed by geologic process. Porcelain is mainly made out of China
Clay, a material that contains the alumina silica. The different raw materials are as
follows:

1. China Clay Minerals

2. Feldspar
3. Quartz
4. Alumina
5. Talk
6. Brown Glaze
7. Pyrophylite
8. Felcite
9. Pebbles
Clays have the ability to form clay-water composition and to maintain their shape and
strength, during drying and firing
Quartz Feldspar Ceramic Soil
Production Processes

Ball mills have been used for decades to

grind and mix materials used in the
ceramic industry, for preparing the
slurry. A slurry is a thin sloppy mud or
cement or, in extended use, any fluid
mixture of a pulverized solid with a
liquid (usually water), often used as a
convenient way of handling solids in
bulk.[1] Slurries behave in some ways
like thick fluids, flowing under gravity
but are also capable of being pumped if
not too thick. A ball mill is a type of
grinder used to grind and blend
materials for use in mineral dressing
processes, paints, pyrotechnics,
ceramics and selective laser sintering. It
works on the principle of impact and
attrition: size reduction is done by
impact as the balls drop from near the
top of the shell
VibroScreen Machine. The slurry produced by ball mill would be then delivered to this
vibroscreen machine, for ensuring that all big particle/sand/stone and ferromagnetic
particles are screened, before the cleaned slurry goes into the Filter Pressing

The Service Tank. This tank rotates continuously, to keep the slurry always in low
viscous mode
Filter Pressing. Filter Presses used to dewater slip consist of an iron frame with nylon
filters. Hydraulic pressure is used to close the filter press over the slip. What is left after
pressing is called a filter cake

Pugging. A process called pugging is

often used to remove air bubbles from the
cake and further refine the clay body. The
cake is fed into the pug mill is shredded
by rotating auger blades. The clay is then
extruded. The worms that are produced
are cut in short lengths
CNC Shaping. Its a process to

shape the worms into the final
shape of the insulator, as per-the
engineering drawing. Once its
done, the green body of this
insulator would be dried in a
controlled room, enough to get the
Moisture Content are stabilized

Spray Drying. Spray drying is another method for reducing the amount of water in slip.
Keeping the amount of water, binder, and lubricant to a minimum is important because
these elements are burned out when the product is fired thereby resulting in shrinkage. It
commonly called as a Bisque Firing. After being formed, the porcelain parts are generally
bisque-fired, which entails heating them at a relatively low temperature to vaporize
volatile contaminants and minimize shrinkage during firing
Spray drying is used to produce granular Glazing process. The raw materials for the
particles with a moisture content of 7 % or glaze are mixed with water. Like the body
less. The solid granules do not contain any slurry, the glaze slurry is screened and
air bubbles or dust passed through magnetic filters to remove
contaminants. It is then applied to the ware
by means of painting, pouring, dipping, or
spraying. Different types of glazes can be
produced by varying the proportions of the
ingredients, i.e. alumina, silica, and calcia.
I.e. increasing the alumina and decreasing
the silica produces a matte glaze

Firing. Firing is a further heating step that During the firing process, a variety of
can be done in one of two types of oven, or reactions take place. First, carbon-based
kiln. A periodic kiln consists of a single, impurities burn out, chemical water
refractory-lined, sealed chamber with burner evolves (at 215 to 395 degrees Fahrenheit
ports and flues (or electric heating or 100 to 200 degrees Celsius), and
elements). It can fire only one batch of ware carbonates and sulfates begin to
at a time, but it is more flexible since the decompose (at 755 to 1,295 degrees
firing cycle can be adjusted for each Fahrenheit or 400 to 700 degrees Celsius).
product. A tunnel kiln is a refractory Gases are produced that must escape from
chamber several hundred feet or more in the ware. On further heating, some of the
length. It maintains certain temperature minerals break down into other phases,
zones continuously, with the ware being and the fluxes present (feldspar and flint)
pushed from one zone to another. Typically, react with the decomposing minerals to
the ware will enter a preheating zone and form liquid glasses (at 1,295 to 2,015
move through a central firing zone before degrees Fahrenheit or 700 to 1,100
leaving the kiln via a cooling zone. This degrees Celsius). These glass phases are
type of kiln is usually more economical and necessary for shrinking and bonding the
energy efficient than a periodic kiln grains. After the desired density is
achieved (greater than 2,195 degrees
Fahrenheit or 1,200 degrees Celsius), the
ware is cooled, which causes the liquid
glass to solidify, thereby forming a strong
bond between the remaining crystalline
grains. After cooling, the porcelain is
complete

The electrical insulator must undergo the following tests

Flashover tests of insulator (electrical)
Performance tests (mechanical)
Routine tests
Waste Management
Waste Management could be done, physically, biologically and

chemically. Chemically treatment means to manage the waste through these
processes; either and/or oxidase, reduction, electrolyze, neutralize, sedimentation,
solidification, stabilization, absorption, ion exchanging and pyrolysis. Those
treatments are form-changing, characteristic-changing or waste chemical
composition analysis with the proper processes. The goal is also to reutilize all
waste that still has the economic value, and recycle it into other commercialized
products
On the ceramic industry, the waste control and management is designated

for the secondary material and secondary product, those with the commercial
value, and to produce the material those are environmental friendly

Based on the type, waste could be categorized into three:
1. Liquid Waste
2. Gas Waste
3. Solid Waste
Based on the content, could be classified into
1. Organic Waste
2. Inorganic Waste
While based on the source, waste could also be grouped into 3:
1. Industrial
2. Domestic
In this industry, we have 4 types of waste:
1. Wet/Liquid Waste those generated during the process. This basically all
waste generated BEFORE the firing process
2. Gas Waste those generated DURING the firing process
3. Dried/Solid Waste (AFTER the firing process) due to the broken units
during failure testing/handling
4. B3 Waste

Above chart illustrates the type of waste generated from ceramic/porcelain

insulator industry. All red square block means waste to be managed
Wet/Liquid Waste
Wet/Liquid Waste is disposed in diluted water of liquid. Please find below

table for all Wet/Liquid Waste generated by PT Wika-NGK Insulator
No. Waste Source Type Remarks
1 Equipment Cleaning Water Treatment
2 Mixing & Crushing Water Treatment
Wet Waste
3 Glazing & decoration Water Treatment
4 Office & Toilet Septic tank
This wet/liquid waste would be water treated in the IPAL, to ensure that
those produced waste would NOT be exceeding the acceptance limit
a. Water/contaminated water

Ceramic/Porcelain industries consume huge volume of water in their

processes, i.e. to dilute the clay & other materials, to clean the equipment
etc. Therefore, huge amount of water would be re-circulated and re-use
b. Slurry
c. Cake
d. Jiggering
e. Glaze
Heavy metals are dense metals used in glazes to produce a particular
colour or texture. Glaze components are more likely to be leached into the
environment when non-recycled ceramic products are exposed to warm or
acidic water. Leaching of heavy metals occurs when ceramic products are
glazed incorrectly or damaged. Lead and chromium are two heavy metals
commonly used in ceramic glazes that are heavily monitored by
government agencies due to their toxicity and ability to bio-accumulate
Ceramic industry generates glaze wastewater and clay waste. Glaze
wastewater contains heavy metal from ceramic painting process which can
potentially cause severe pollution problem. Glaze wastewater from PT.X
typically contains Cd (0.013 mg/L); Cu (0.033 mg/L); Pb (1.20 mg/L); and
Zn (7.00 mg/L). Clay waste could be used as adsorbent to reduce heavy
metal amount in glaze wastewater. The present study investigates in bench
scale and uses batch adsorption method to determine effective adsorbent
amount and contact time in removing heavy metals in glaze wastewater in
order to fulfil the discharge requirement based on regulation of Minister of
Environment No.16/2008 concerning effluent water standard for ceramic
industries. The results showed that the effective adsorbent amount and
contact time respectively are 5 g/L and 15 minutes with pH 8 and stirring
speed of 150 rpm. Concentration of heavy metal adsorbed are 0,614 mg/L
and 2.07 mg/L for lead (Pb) and zinc (Zn) with removal efficiency up to
61.0% for Pb and 9.8% for Zn. From this study clay waste could be

potentially used as an adsorbent to reduce heavy metal amount in glaze

wastewater
f. Wet Body
Waste Water
Waste Water processed came from the Glaze (Body Preparation Step)
Waste Management in the Ceramic Industry, and their regulations
Waste Water Characteristic

1. Physics, including the temperature, color, smell and solid content.
Temperature is important parameter in operating the waste water
treatment, as it influences to both biological and physical. Smell is a
subjective parameter. The smell measurement depends on the sensitivity of
the auditor. The presence of other smells shows of other components
inside the waste water. For example: bad egg smell indicates the presence
of hydrogen sulfide generated by the organic elements in anaerobic status.
Color commonly due to the presence of the dissolved, suspended and
colloidal materials, which could be seen from the color spectrum
happened. The incoming waste water in PT WIKA-NGK is odorless but
muddy. The average temperature is between 24 27oC
2. Chemicals, including organic and inorganic compound

3. Waste Water Treatment Design. Based on the waste water character in PT

WIKA-NGK, the treatment is conducted by both physics and chemicals.
Biological treatment is not needed, since the raw materials used are
inorganic minerals, and the organic materials would be evaporated due to
the firing process.
3.1. Physical Treatment consists of equalizing and sedimentation
3.2. Chemical Treatment consists of coagulation, flocculation and PH
controlling
3.1.1. Equalizing
This is the 1st step. In this stage, waste with various debit and
qualities, would be mixed together so that results in a homogeneous
and constant debit. Or in other words, the purpose of this process is to
ease for the next process. Another process happened in this step is the
sedimentation. The suspended sediment is settle-able.
Waste water from production would be accommodated in this unit
for 24 hours, depend on the volume. The transfer from the equalizing
tank to the coagulation tank is conducted mechanically by using a
pump unit. It works by using the different air pressure (Air-Operated
Double Diaphragm/AODD) in both tanks
3.1.2. Coagulation
In this process, we add coagulant solvent. This is a
chemical material that has the ability to neutralize the colloid
content and to tie those particles so that theyre easily molded as a
flock or blobs. Chemicals used as a coagulant agent is calcium,
alumina sulfide and poly-electrolyte (synthetic organic), inorganic
coagulant (poly aluminium chloride PAC), and ferric-chloride and
iron sulfide. PT. WIKA-NGK uses the alumina sulfide as the
coagulant. This material is easily found in Indonesia, in industry or

for water purifying as its effectively and economically used, as

well as to easily stored
The mixing process between the coagulant and waste water
is conducted mechanically by using mixer for 1-2 minutes. PT
WIKA-NGK uses mixer with the 1400 rpm. This speed would be
then reduced into 200 300 rpm by enlarging the turbine mixer
utilized. The width of the turbine mixer is 70 cm with 40 cm
height. This is a anti rusted steel turbine mixer
3.1.3. Sedimentation
This is a mechanical suspension process to segregate the
slurry and supernatant. Slurry is a part with the biggest particle
concentrate, while Supernatant is the clean/transparent part. This
process utilizes the gravity, by letting the suspended waste, split
into both sedimentation and clean/transparent parts. In this
sedimentation tank the suspended residual (flock) and
clean/transparent part would be segregated, due to the gravity.
Those flocks would be in the bottom of the tank
Sedimentation process would be in a range of 15 20
minutes. Time consumed would really be depending on the
characteristic of the inlet, i.e. from Glaze, this input would takes
longer time for the sedimentation process. This process would
result the clean water outlet and to make it easier for the mud
handling. In this process, only particles those are heavier than
water could be separated, such as flock (result from the chemical
process) and mud
Mud would be re-processed by using the filter press. Its
transferred by using the pump mechanism. Filter press used here is
the variable volume filter press type. In this type, water would goes
through the cloth, while the solid content would remain stay and
build the cake. 10-20% out of the result from this filter press (or

commonly named as sludge cake), would be recycled by PT

WIKA-NGK in the production process. Outlet supernatant would
be transferred to the flocculation process
3.2.1. Flocculation
After the sedimentation process, the water would be
transferred to the flocculation tank. This unit would build the bigger
flock. There would be a slow mixing process. The flocculation unit
used here is the baffle type. In this process, waste water would be
drained and got injected by the NaOH
3.2.2. PH Controlling
NaOH has 2 functions; both to increase the PH and also to
tie to SiO2 (one of the compound needed to build the clay). This
process would generates the sludge which would be loaded into the
bag and thrown away

Gas Waste
Gas Waste is disposed into the air, in the shape of gas. Please find below
table for all Gas Waste generated by PT Wika-NGK Insulator
1 Filing
Reduced by using Dust
2 Drying
Air Pollution Collector and disposed
3 Griding
out through chimney
4 Pressing
Dried/Solid Waste
Dried/Solid Waste is disposed into the environment in the shape of solid.

Please find below table for all Solid Waste generated by PT Wika-NGK Insulator
1 Forming/Pressing Sold or recycle
2 Sorting Solid Waste Sold of recycle
3 Office Disposed
Around 2 10% of the solid waste would be recycled as the raw materials for the
new production line. Majority of the rest would be either sold to the local buyer

(as they still have an economical value) or to be processed through the land-filing,
or being developed as the future coral in the deep ocean (please see below)
Solid waste Used for the coral in the deep ocean
B3 Waste

1 Forming
2 Electronic Devices Stored in B3 Waste Area,
B3 Waste
3 Production Process then to be disposed out
4 Offices
B3 Waste would be loaded into the drum and sealed, and located on a particular
area. These sealed drums would periodically be taken by the certified 3 rd party
who would do the final process in accordance to the law and regulation
Thank you,
Verry Surya Hendrawan
08111111141

Ceramic Insulator and Waste Management

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Tugas Mata Kuliah Limbah Industri Manufaktur

Dosen Pengampu: Dr. Arif Zulkifli Nasution

Ceramic Insulator Industry and Their Waste Management

At PT WIKA-NGK Insulator, Kawasan Industri WIKA, Jl. Raya Narogong KM 26

PT WIKA-NGK Insulator is a joint venture ceramic insulator

Waste Management in Porcelain Insulator Manufacturing Page 1

Our Process Flow Diagram

Waste Management in Porcelain Insulator Manufacturing Page 2

1. China Clay Minerals

Quartz Feldspar Ceramic Soil

Waste Management in Porcelain Insulator Manufacturing Page 3

Ball mills have been used for decades to

Waste Management in Porcelain Insulator Manufacturing Page 4

Waste Management in Porcelain Insulator Manufacturing Page 5

Pugging. A process called pugging is

CNC Shaping. Its a process to

Waste Management in Porcelain Insulator Manufacturing Page 6

Waste Management in Porcelain Insulator Manufacturing Page 7

Waste Management in Porcelain Insulator Manufacturing Page 8

The electrical insulator must undergo the following tests

Waste Management could be done, physically, biologically and

On the ceramic industry, the waste control and management is designated

Waste Management in Porcelain Insulator Manufacturing Page 9

Based on the type, waste could be categorized into three:

Based on the content, could be classified into

While based on the source, waste could also be grouped into 3:

In this industry, we have 4 types of waste:

Waste Management in Porcelain Insulator Manufacturing Page 10

Above chart illustrates the type of waste generated from ceramic/porcelain

Wet/Liquid Waste is disposed in diluted water of liquid. Please find below

Waste Management in Porcelain Insulator Manufacturing Page 11

Ceramic/Porcelain industries consume huge volume of water in their

Waste Management in Porcelain Insulator Manufacturing Page 12

potentially used as an adsorbent to reduce heavy metal amount in glaze

Waste Management in the Ceramic Industry, and their regulations

Waste Water Characteristic

Waste Management in Porcelain Insulator Manufacturing Page 13

3. Waste Water Treatment Design. Based on the waste water character in PT

Waste Management in Porcelain Insulator Manufacturing Page 14

for water purifying as its effectively and economically used, as

Waste Management in Porcelain Insulator Manufacturing Page 15

commonly named as sludge cake), would be recycled by PT

Waste Management in Porcelain Insulator Manufacturing Page 16

Dried/Solid Waste is disposed into the environment in the shape of solid.

Waste Management in Porcelain Insulator Manufacturing Page 17

Solid waste Used for the coral in the deep ocean

No. Waste Source Type Remarks

Verry Surya Hendrawan

Waste Management in Porcelain Insulator Manufacturing Page 18

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