Artificial intelligence-based predictive model for utilization of industrial coal ash in the production of sustainable ceramic tiles

The recycling of waste materials and the promotion of sustainable practices to utilize these waste materials in product development have become imperative in addressing environmental concerns. This study presents a novel approach to utilize waste ashes in the production of sustainable ceramic tiles using an integrated artificial intelligence (AI) model. Experimental investigation was carried out on ceramic tiles using waste ashes produced during the manufacturing process. More than 35 different ceramic tile mixtures incorporating different proportions of waste ashes were prepared at a temperature of 1120 °C using different percentages of waste ashes. The ceramic tiles were evaluated using X-ray diffraction (XRD), flexural strength, water absorption, shrinkage, visual index, and scanning electron microscopy (SEM). The results revealed that up to 5% of waste ashes can be used to manufacture ceramic tile satisfying the minimum specified limits of EN-ISO 10545. Moreover, ceramic tile specimen using waste ashes showed more compact and integrated structure. Further, an AI model was proposed to predict the optimal composition of waste ashes, considering factors such as chemical properties, particle size distribution, and sintering behavior. The results demonstrated that the incorporation of waste ashes in ceramic tile production not only offers environmental benefits, but also proves economically viable. The AI model provides accurate predictions, facilitating the optimization of waste ash composition and ensuring the desired physical and mechanical properties of the tiles. The findings of this study provide valuable insights for policymakers, industry stakeholders, and researchers seeking innovative solutions for sustainable waste management and product development.