NEWS
Focus On High-Quality Silicate (Ceramic) Materials
How to Reduce Water Content in Ceramic Body Slurry by 1–2%
By Goway Chemical Technical Team | Updated July 2026 | Ceramic Body Slip & Spray Drying
Key Takeaways
- 1–2% water reduction = 1.5–3 tonnes less water per day on a 100 ton/day slurry line. At ~800–1000 kcal per kg water evaporated in the spray dryer, this is a six-figure annual energy saving. (Industry-typical reference)
- FG-N203B is the primary water-reduction grade. With SiO₂ 30–33% (highest in series) and L.O.I 45–50% (lowest in series), it provides superior viscosity buffering at elevated solid content for spray-drying slurries. (Source: Goway TDS, FG-N203B)
- Incremental solid increase in 0.5% steps is mandatory. Jumping solid content by 2% in one step almost always causes viscosity excursions, spray dryer nozzle blockage, or granule quality issues. Each step requires deflocculant dosage re-optimisation.
- Three savings streams combine: (a) additive cost savings (FG-series is 30–40% of STPP price), (b) spray dryer energy savings, (c) capacity increase revenue. (Source: Goway product page, /products_detail/6.html)
- FG-ZM01 binder compensates for green strength loss. Higher solid content can marginally reduce green body strength; adding FG-ZM01 at 0.15–0.3% increases green strength by 30–70% while improving slurry flow by 5–10 seconds. (Source: Goway TDS, FG-ZM01)
§1 Why Water Content Matters — Energy, Capacity, and Granule Quality
In ceramic tile manufacturing, the spray dryer is the single largest energy consumer in body preparation. Its job is to evaporate water from the slurry to produce free-flowing granules. Every kilogram of water in the slurry that is not strictly necessary represents wasted energy, reduced capacity, and potentially compromised granule quality. Understanding the cost of excess water is the first step in building the business case for a water reduction programme.
The Energy Cost of Evaporating Water
The energy required to evaporate water in a spray dryer is substantial. The latent heat of vaporisation of water at 100°C is approximately 540 kcal/kg, and in practice — accounting for heating the slurry, radiation losses, exhaust heat, and the efficiency of the spray dryer — the total energy consumed per kilogram of water removed is typically 800–1000 kcal. (Industry-typical reference)
For a typical ceramic tile body slurry at 32% solid content, every tonne of slurry contains 680 kg of water. If the solid content can be raised to 34%, the water drops to 660 kg — a reduction of 20 kg per tonne of slurry. On a 100 ton/day slurry line, that is 2,000 kg less water per day, or approximately 1.6–2.0 million kcal of energy saved daily.
Cost Impact Table: 1–2% Water Reduction
The table below translates water reduction into energy savings and capacity increases. The values are illustrative — actual figures depend on your spray dryer specifications, fuel type, and energy costs.
| Scenario | Solid Content | Water per tonne slurry | Daily water reduction (100 t/day) | Est. energy saving (kcal/day) | Est. spray dryer capacity increase |
|---|---|---|---|---|---|
| Baseline | 32% | 680 kg | — | — | — |
| 1% reduction (33% solid) | 33% | 670 kg | 1,000 kg | ~800,000–1,000,000 | +5–8% |
| 1.5% reduction (33.5% solid) | 33.5% | 665 kg | 1,500 kg | ~1,200,000–1,500,000 | +8–12% |
| 2% reduction (34% solid) | 34% | 660 kg | 2,000 kg | ~1,600,000–2,000,000 | +10–15% |
| Energy values based on industry-typical 800–1000 kcal per kg water evaporated in a spray dryer. Capacity increase estimates assume the spray dryer evaporation rate is the bottleneck. Actual savings are plant-specific and must be validated with your spray dryer energy audit data. | |||||
Three Impacts of Excess Water
| # | Impact Area | What Happens with Higher Water Content | What 1–2% Reduction Delivers |
|---|---|---|---|
| 1 | Energy cost | More water to evaporate = more fuel (natural gas, LPG, or coal) consumed per tonne of powder produced. Spray dryer energy is typically 15–25% of total tile manufacturing energy. (Industry-typical reference) | 3–8% reduction in energy consumption per tonne of spray-dried powder. Direct fuel cost saving. |
| 2 | Spray dryer capacity | The spray dryer's evaporation rate is the bottleneck. More water per tonne of slurry means lower powder throughput — the dryer is spending time evaporating water, not producing granules. | 5–15% increase in powder production rate, enabling higher daily tile output without capital investment in a larger dryer. |
| 3 | Granule quality | Higher water content can produce lighter, more hollow granules with lower bulk density, affecting press feeding uniformity and green tile density. Moisture distribution across granule sizes is also less uniform. | Denser, more spherical granules with better flowability and more uniform moisture distribution — improving press consistency and reducing lamination risk. |
| Capacity and granule quality impacts are industry-typical reference ranges. Actual results depend on spray dryer design (co-current vs. counter-current), atomisation type (nozzle vs. centrifugal), and operating parameters. | |||
§2 The Physics of Water Reduction — Solids, Viscosity, and Zeta Potential
Water reduction in ceramic slurry is fundamentally a problem of viscosity management. You can only reduce water (increase solid content) to the point where the slurry remains pumpable and sprayable. Understanding the relationship between solid content, viscosity, and deflocculant mechanism is essential to pushing the solid content higher without crossing the viscosity threshold.
The Solid Content – Viscosity Relationship
In a ceramic body slurry, viscosity increases non-linearly with solid content. At low solid content (below ~25%), the slurry behaves almost like water — particles are far apart and inter-particle forces are weak. As solid content increases, particles pack more closely, and two forces dominate:
- Attractive forces (van der Waals, edge-to-face flocculation) pull particles together into flocs, trapping water in the floc structure and increasing viscosity.
- Repulsive forces (electrostatic double-layer repulsion, steric hindrance) keep particles dispersed, releasing trapped water and maintaining low viscosity.
A deflocculant's job is to maximise the repulsive forces so that particles remain dispersed even at high solid content. The stronger and more stable the repulsion, the higher the solid content achievable at a given viscosity.
How Deflocculants Increase Zeta Potential
The electrostatic repulsion between clay particles is quantified by the zeta potential — the electrical potential at the shear plane around a particle in suspension. A higher (more negative) zeta potential means stronger repulsion and better dispersion.
FG-series deflocculants increase zeta potential through two mechanisms, depending on their Na₂O:SiO₂ ratio:
| Mechanism | How It Works | FG Grades Using This Mechanism |
|---|---|---|
| Na⁺ ion exchange | Sodium ions (Na⁺) from the deflocculant exchange with Ca²⁺ and Mg²⁺ ions on clay particle edges. This eliminates flocculation bridges and increases the negative surface charge, raising zeta potential. | FG-2017 (Na₂O 30–32%) — highest Na⁺ availability for rapid ion exchange. (Source: Goway TDS) |
| Silicate layer adsorption | Silicate anions (from SiO₂) adsorb onto clay particle surfaces, forming a protective hydrated layer that provides both electrostatic and partial steric repulsion. This is more stable over time than pure ion exchange. | FG-N203B (SiO₂ 30–33%), FG-MK03 (SiO₂ 20–22%), FG-SL01A (SiO₂ 18–20%). (Source: Goway TDS) |
For a deeper understanding of zeta potential and its measurement in ceramic slurries, see our beginner's guide to zeta potential in ceramic slurries.
The Core Formula: Lower Viscosity at Higher Solids
This formula describes the conceptual relationship. The actual achievable solid content increase must be determined experimentally via the five-phase protocol in §4. The key insight: water reduction is achieved by increasing zeta potential, not by simply adding more deflocculant — beyond the plateau, additional deflocculant causes re-flocculation and viscosity increase.
§3 FG-Series Deflocculants for Water Reduction — Product Comparison
All four FG-series deflocculants can contribute to water reduction, but their effectiveness varies with application. For spray-drying body slurries where maximum solid content is the goal, FG-N203B is the standout product due to its high SiO₂ content and low L.O.I. The table below compares all four grades from the perspective of water reduction capability.
FG-Series Comparison for Water Reduction
| Parameter | FG-2017 | FG-MK03 | FG-N203B | FG-SL01A |
|---|---|---|---|---|
| Na₂O (%) | 30–32 | 12–15 | 15–18 | 18–20 |
| SiO₂ (%) | 0 | 20–22 | 30–33 | 18–20 |
| P₂O₅ (%) | 0–1 | 1–2 | 0–1 | 1–2 |
| L.O.I (%) | 55–60 | 55–65 | 45–50 | 55–60 |
| Optimal solid content achievable | Medium-high | Medium-high | Highest | Medium |
| Viscosity at target solid (rel.) | Low (fast onset) | Low (stable) | Lowest at high solids | Medium-low |
| Recommended application | Fast dispersion; wall/floor tile | Long-term stability; stored slurry | Spray-drying slurry; high-solid | Universal; multi-body |
| Dosage range (% dry body) | 0.2–0.5 | 0.2–0.5 | 0.2–0.5 | 0.2–0.5 |
| Source: Goway Technical Data Sheet (v2.1, 2026-05-14), validated by Goway Product Team. "Optimal solid content achievable" is a relative ranking based on Goway internal testing — actual performance depends on body formulation and process conditions. All FG products are 100% STPP replacements priced at 30–40% of STPP cost. | ||||
Product Detail Cards — Water Reduction Perspective
FG-2017 Fast Dispersion
Highest Na₂O (30–32%), zero SiO₂. Achieves rapid viscosity reduction through concentrated Na⁺ ion exchange. Effective for moderate water reduction in fast-throughput single-body lines.
- Water reduction role: Quick viscosity drop enables 0.5–1.0% solid content increase in simple body formulations
- Best for: Wall tile and floor tile body slurry; high-throughput ball mill lines where fast dispersion is prioritised over maximum solid content
- Limitation for water reduction: No SiO₂ buffer means narrower dosage plateau at elevated solids — less tolerance to variation
- Dosage: 0.2–0.5% on dry body weight (Source: Goway TDS)
FG-MK03 Long-Term Stability
Balanced Na₂O (12–15%) + SiO₂ (20–22%). Silicate layer adsorption provides stable viscosity at higher solid content over extended storage — critical when slurry is stored before spray drying.
- Water reduction role: Maintains viscosity stability at elevated solid content during 12–48 hour storage, preventing re-flocculation that would otherwise force dilution
- Best for: Slurry stored 12–48 hours before use; weekend storage; hard water conditions; high-clay-content bodies
- Advantage for water reduction: Prevents the "viscosity creep" that often forces operators to add water back into stored slurry
- Dosage: 0.2–0.5% on dry body weight (Source: Goway TDS)
FG-N203B Spray-Drying Optimised
Highest SiO₂ (30–33%) and lowest L.O.I (45–50%) in the series. The densest active ingredient concentration provides the strongest silicate protective layer at high solid content — the primary water-reduction product.
- Water reduction role: Engineered for maximum solid content in spray-drying slurries. SiO₂-rich composition maintains low viscosity at the highest achievable solid content
- Best for: Spray-drying body lines targeting 1–2% water reduction; large-format porcelain tile; vitrified tile; high-solid slurry (>60 wt%)
- Advantage for water reduction: Low L.O.I means higher active ingredient density per kg — more deflocculating power per unit dosage
- Dosage: 0.2–0.5% on dry body weight (Source: Goway TDS)
FG-SL01A Universal / Multi-Body
Symmetrical Na₂O/SiO₂ ratio (both 18–20%). Triple-action mechanism (electrostatic + steric + phosphate complexation) provides moderate water reduction across diverse body types.
- Water reduction role: Predictable solid content improvement across multiple body formulations — ideal for factories running various recipes on one line
- Best for: Multi-product ceramic factories; combined wall/floor tile lines; factories with variable water quality and raw materials
- Advantage for water reduction: Broadest tolerance to body recipe variation — maintains performance when raw material batches change
- Dosage: 0.2–0.5% on dry body weight (Source: Goway TDS)
Product Selection for Water Reduction
| Factory Scenario | Recommended FG Grade | Expected Water Reduction | Key Reason |
|---|---|---|---|
| Spray-drying body slurry; target maximum solid content | FG-N203B | 1.5–2.0% | Highest SiO₂ (30–33%), lowest L.O.I — strongest viscosity buffering at high solids |
| Slurry stored 12–48 h before spray drying; viscosity creep forces re-dilution | FG-MK03 | 1.0–1.5% | Silicate layer prevents storage viscosity drift, maintaining high solids without re-dilution |
| Wall/floor tile; fast throughput; single body type | FG-2017 | 0.5–1.0% | Rapid Na⁺ exchange for quick viscosity drop, but narrower plateau limits maximum solids |
| Multi-product factory; variable body recipes | FG-SL01A | 0.5–1.5% | Triple-action mechanism maintains performance across formulation changes |
| Hard water (>100 mg/L Ca²⁺) + spray drying line | FG-N203B + FG-MK03 blend | 1.0–1.5% | SiO₂ buffer against ionic contamination combined with long-term stability |
| Expected water reduction ranges are relative estimates based on Goway internal testing and customer feedback. Actual reduction depends on your body formulation, clay mineralogy, water chemistry, and equipment. All FG products: 100% STPP replacement, 30–40% of STPP cost. Product details: /products_detail/6.html | |||
§4 Step-by-Step Water Reduction Protocol — Five Phases
Water reduction is not achieved by a single change. It requires a structured five-phase protocol that gradually increases solid content while re-optimising deflocculant dosage at each step. Skipping phases or increasing solid content too quickly almost always results in viscosity excursions, spray dryer issues, or quality defects. This protocol has been developed from Goway field experience across multiple ceramic factories.
-
Phase 1: Baseline Measurement (Days 1–3)
Before changing anything, document your current system comprehensively. This is your reference point — without it, you cannot measure improvement or diagnose problems.
Measure and record:
- Slurry solid content — dry 100 g slurry at 110°C to constant weight, calculate %. Record for 5 consecutive batches.
- Ford Cup #4 flow time — measure at 25°C, 3 times per batch, record average. This is your viscosity baseline.
- Current deflocculant type and dosage — record actual addition rate (kg per tonne dry body) over 5 batches.
- Spray dryer parameters — inlet temperature, outlet temperature, powder moisture, powder bulk density, granule size distribution (40/60/80 mesh).
- Process water — hardness (mg/L Ca²⁺), pH, conductivity. These affect deflocculant performance.
- Daily production volume — tonnes of slurry and tonnes of spray-dried powder per day.
-
Phase 2: Lab Dosage Curve Test (Days 4–7)
Using your actual body recipe and process water, run a five-point dosage curve for 2–3 FG grades (recommended: FG-N203B plus one other based on §3 decision matrix). For each grade, prepare samples at 0.15%, 0.25%, 0.35%, 0.45%, and 0.55% dosage. Measure Ford Cup flow time at 30 min, 2 h, and 24 h. Plot the dosage-viscosity curve and identify the plateau minimum and width.
Selection criteria:
- Lowest plateau viscosity at your current solid content
- Widest plateau (dosage tolerance band) — indicates robustness to variation
- Lowest 24-hour viscosity drift — indicates storage stability
The grade with the widest plateau and lowest 24 h drift is your primary candidate for water reduction. For spray-drying slurries, this is typically FG-N203B. (Source: Goway TDS, FG-N203B)
-
Phase 3: Incremental Solid Content Increase (Days 8–14)
This is the core of the water reduction process. Starting from your current solid content, increase in 0.5% steps. At each step, re-optimise the FG-series dosage to maintain the target Ford Cup flow time.
Step protocol:
- Increase solid content by 0.5% (reduce water addition by the corresponding amount)
- Measure Ford Cup flow time — if it exceeds target by >5 seconds, increase FG dosage by 0.02–0.05%
- Allow 30 minutes equilibration, re-measure
- If flow time is within target ±5 s: proceed to next 0.5% increment
- If flow time cannot be brought within target by dosage adjustment: you have reached the maximum solid content for this grade. Stop and record.
Critical rule: Never increase solid content by more than 0.5% in a single step. Larger jumps destabilise the slurry and cause unpredictable viscosity behaviour. Each 0.5% increment requires full dosage re-optimisation.
For each increment, also measure 24-hour viscosity drift. If drift exceeds 15%, either increase dosage or switch to a higher-SiO₂ grade (FG-MK03 or FG-N203B) for better long-term stability.
-
Phase 4: Pilot Trial — 200–500 kg Batch (Days 15–21)
Once the lab has identified the maximum achievable solid content and corresponding FG dosage, validate at pilot scale. Charge a 200–500 kg batch in a production ball mill with actual raw materials and process water.
Monitor at pilot scale:
- Ford Cup flow time at 0 h, 4 h, 8 h, 24 h — compare to lab results (production mills run hotter, which can affect viscosity)
- Verify solid content is at the new target (±0.3%)
- Spray-dry the pilot batch and compare to baseline: inlet/outlet temp, powder moisture, bulk density, granule size distribution
- Press test tiles and measure green MOR — if green strength drops below 90% of baseline, add FG-ZM01 binder at 0.15–0.3% (Source: Goway TDS, FG-ZM01)
Go/No-Go criteria: Ford Cup within ±5 s of target, solid content at new target, spray dryer powder bulk density within ±5% of baseline, green MOR ≥ 90% of baseline. If any criterion fails, return to Phase 3 and reduce the solid content target.
-
Phase 5: Production Validation (Days 22–35)
Transition the validated parameters to full-scale production. Run the new solid content and FG dosage for 5 consecutive production days with continuous monitoring.
Monitor daily:
- Ford Cup flow time every 4 hours — must stay within ±5 s of target
- Solid content every 8 hours — must stay within ±0.5% of target
- Spray dryer powder bulk density every 4 hours — within ±5% of baseline
- 24 h viscosity drift — ≤ 15%
- Green body MOR — daily, 5 samples
After 5 stable production days, fire tiles through the standard kiln cycle and evaluate fired shrinkage, warpage, whiteness, and MOR. If all fired body parameters are within tolerance (shrinkage ±0.2%, warpage ±0.3 mm, whiteness ±1.0 L*, MOR ±5%), the new solid content is validated for ongoing production.
Protocol Summary Table with Go/No-Go Criteria
| Phase | Timeline | Key Activity | Go Criteria (Proceed) | No-Go Criteria (Investigate) |
|---|---|---|---|---|
| 1. Baseline | Days 1–3 | Measure current solid content, Ford Cup, spray dryer parameters | Complete data set for 5 batches | Missing or inconsistent data |
| 2. Lab dosage curve | Days 4–7 | 5-point dosage curve for 2–3 FG grades | Clear plateau identified; grade selected | No plateau; all grades fail |
| 3. Incremental increase | Days 8–14 | 0.5% solid content steps with dosage re-optimisation | 1–2% solid increase achieved at target viscosity | Viscosity exceeds target at <1% increase |
| 4. Pilot trial | Days 15–21 | 200–500 kg batch through spray dryer | Ford Cup ±5 s; bulk density ±5%; green MOR ≥90% | Viscosity excursion; bulk density >10% drop; MOR <85% |
| 5. Production validation | Days 22–35 | 5-day production run + fired body evaluation | 5 days stable; fired body within tolerance | Viscosity excursions; fired defects |
| If a No-Go is encountered at any phase, return to the previous phase and adjust. Do not proceed to the next phase until all Go criteria are met. Rushing the protocol is the most common cause of failed water reduction programmes. | ||||
§5 Before/After Case Data — Factory Trial Example
The following case study illustrates a typical water reduction result achieved by transitioning from STPP to FG-N203B in a spray-drying body slurry line. The data is presented as an industry-typical reference based on composite results from multiple factory trials — individual results will vary.
Factory Trial Case Study: STPP → FG-N203B with Solid Content Increase
| Parameter | Before (Baseline — STPP) | After (FG-N203B + Water Reduction) | Change |
|---|---|---|---|
| Deflocculant type | STPP (FG-1003) | FG-N203B | 100% replacement |
| Deflocculant dosage (% dry body) | 0.40% | 0.35% | −0.05% |
| Slurry solid content (%) | 32.0% | 34.0% | +2.0% |
| Water content (%) | 68.0% | 66.0% | −2.0% |
| Ford Cup #4 flow time (s) | 35 s | 33 s | −2 s (improved) |
| 24 h viscosity drift (%) | 18% | 10% | −8% (improved) |
| Slurry temperature (°C) | 30°C | 30°C | No change |
| Process water hardness (mg/L Ca²⁺) | 85 | 85 | No change |
Spray Dryer Parameters — Before/After
| Spray Dryer Parameter | Before (32% solid) | After (34% solid) | Change |
|---|---|---|---|
| Inlet temperature (°C) | 580 | 580 | No change |
| Outlet temperature (°C) | 92 | 95 | +3°C (less water to evaporate) |
| Granule moisture (%) | 6.0% | 5.5% | −0.5% (more uniform) |
| Powder bulk density (g/cm³) | 0.82 | 0.85 | +3.7% (denser granules) |
| Granule size: 40 mesh fraction (%) | 28% | 31% | +3% (better distribution) |
| Granule size: 60 mesh fraction (%) | 45% | 46% | +1% |
| Granule size: 80 mesh fraction (%) | 18% | 15% | −3% (less fines) |
| Production rate (tonne powder/day) | 68 | 76 | +11.8% capacity |
| Energy per tonne powder (relative) | 100 (baseline) | 93 | −7% energy |
| Industry-typical reference — composite data based on multiple Goway factory trial results. Actual results depend on spray dryer model, body formulation, and process conditions. This data is illustrative and not a performance guarantee. | |||
Green and Fired Body Properties — Before/After
| Property | Before (STPP, 32% solid) | After (FG-N203B, 34% solid) | Assessment |
|---|---|---|---|
| Green body MOR (MPa) | 2.4 | 2.3 | −4% (within tolerance) |
| Green density (g/cm³) | 1.82 | 1.85 | +1.6% (improved) |
| Fired shrinkage (%) | 7.8 | 7.9 | +0.1% (within ±0.2% tolerance) |
| Fired whiteness (L*) | 72.3 | 72.1 | −0.2 (within ±1.0 tolerance) |
| Fired MOR (MPa) | 38.5 | 39.0 | +1.3% (within ±5% tolerance) |
| Warpage (mm) | 0.4 | 0.4 | No change |
| Industry-typical reference. The small green MOR decrease (−4%) is typical when solid content increases — water-mediated particle bonding is reduced. If green MOR drops below 90% of baseline, add FG-ZM01 binder at 0.15–0.3%. (Source: Goway TDS, FG-ZM01) | |||
For a comprehensive guide to the STPP replacement process that forms the foundation of this water reduction programme, see our STPP replacement factory trial guide.
§6 Spray Dryer Performance Impact — Granule Quality and Throughput
Reducing water content in the slurry has direct, measurable impacts on spray dryer performance. The spray dryer is designed to evaporate water and produce granules of a specific size, moisture, and density. Less water in the feed slurry means the dryer can produce more powder per unit time, with better granule characteristics.
How Reduced Water Content Improves Spray Dryer Performance
| Performance Parameter | Mechanism of Improvement | Typical Improvement (1–2% water reduction) |
|---|---|---|
| Granule morphology | Higher solid content produces denser, more spherical granules with thinner shell walls. Less water means less steam expansion inside the droplet during atomisation, reducing hollow granule formation. | More spherical granules; bulk density +3–5%; hollow granule rate reduced |
| Granule flowability | Denser, more uniform granules flow better in the powder silo and press feeder, improving die fill consistency. | Improved flow index; reduced bridging in silos |
| Granule moisture uniformity | Less water to evaporate means the outlet temperature can be maintained higher, producing more consistent residual moisture across the granule size distribution. | Moisture spread across size fractions reduced by 30–50% |
| Spray dryer throughput | The dryer's evaporation capacity is the bottleneck. Less water per tonne of slurry means more tonnes of powder produced per hour at the same evaporation rate. | +5–15% capacity increase |
| Energy consumption per tonne powder | Less water evaporated per tonne of powder produced directly reduces fuel consumption per unit output. | −3–8% energy per tonne powder |
| Outlet temperature stability | With less water to evaporate, the outlet temperature is more stable, reducing thermal cycling stress on the dryer and improving control precision. | Outlet temperature variance reduced; fewer control interventions |
| Improvement ranges are industry-typical reference values based on published spray dryer performance data and Goway field observations. Actual improvements depend on spray dryer design, atomisation type, and operating parameters. | ||
Spray Dryer Comparison: Baseline vs. Water-Reduced Slurry
| Parameter | Baseline Slurry (32% solid) | Water-Reduced Slurry (34% solid) | Direction |
|---|---|---|---|
| Slurry feed rate (t/day) | 100 | 100 | Same feed rate |
| Water to evaporate (t/day) | 68 | 66 | −2 t/day less evaporation |
| Powder output (t/day) | ~68 | ~76 | +8 t/day more powder |
| Fuel consumption per t powder | Baseline (100%) | ~93% | −7% fuel per tonne |
| Granule bulk density | Baseline | +3–5% | Denser granules |
| Hollow granule rate | Baseline | Reduced | Improved press feed quality |
For a comprehensive guide to optimising spray dryer output and granule morphology — including atomisation pressure, inlet/outlet temperature control, and granule size distribution management — see our guide on maximizing spray dryer output.
§7 Cost-Benefit Analysis — Annual Savings Calculation
A 1–2% water reduction programme generates three distinct savings streams: (a) deflocculant cost savings from switching to FG-series, (b) spray dryer energy savings from evaporating less water, and (c) capacity increase revenue from higher powder throughput. Combined, these typically deliver a compelling ROI for the 3–5 week programme investment.
Three Savings Streams
| Savings Stream | Mechanism | Annual Savings (100 t/day line, illustrative) |
|---|---|---|
| (a) Additive cost savings | FG-series deflocculants are priced at 30–40% of STPP cost, while achieving 100% replacement at similar or slightly lower dosage. (Source: Goway product page, /products_detail/6.html) | 60–70% reduction in deflocculant procurement cost |
| (b) Spray dryer energy savings | 1.5% water reduction = ~1.5 t/day less water to evaporate. At 800–1000 kcal/kg, that is 1.2–1.5 million kcal/day saved. (Industry-typical reference) | 3–8% reduction in spray dryer fuel cost per tonne powder |
| (c) Capacity increase revenue | 5–15% more powder per day = more tiles produced without capital investment in a larger spray dryer. (Industry-typical reference) | 5–15% additional daily production capacity |
| Savings (a) is a Goway product page claim; savings (b) and (c) are industry-typical reference estimates. Actual savings require plant-specific calculation using your energy cost, production volume, and product margin data. | ||
ROI Calculation Formula
Annual Savings Calculation
The example assumes a 100 t/day body slurry line with 1.5% water reduction. Actual savings depend on your STPP price, FG price (request quotation), fuel type and cost, product margin, and operating schedule. Goway's technical team can provide a customised ROI calculation based on your specific parameters.
Illustrative Annual Savings Breakdown
| Savings Component | Calculation Basis | Est. Annual Savings (CNY) |
|---|---|---|
| Additive cost (STPP → FG) | 100 t/day × 0.35% × 300 days × (STPP − FG price differential) | Significant — request quotation |
| Spray dryer energy | 1.5 t/day × 900 kcal/kg × 300 days × fuel cost | Plant-specific |
| Capacity increase | 6.5 t/day additional powder × product margin × 300 days | Plant-specific |
| Indirect savings | Reduced scrap from improved viscosity stability; reduced wastewater phosphorus treatment; reduced operator intervention | Plant-specific |
| Goway does not publish product prices publicly. For a customised savings calculation, provide your current STPP price and dosage, daily production volume, fuel type and cost, and product margin. Visit /products_detail/6.html to request a quotation. | ||
§8 Common Pitfalls and Troubleshooting
Water reduction programmes fail most often not because the deflocculant is wrong, but because the transition was rushed or a specific side effect was not anticipated. These troubleshooting cards address the six most common issues encountered when increasing solid content in ceramic body slurry.
Problem: Viscosity too high after solid content increase
Likely cause: The 0.5% solid content increment was too large for the current deflocculant dosage, or the FG dosage is at the edge of its plateau and cannot buffer the additional solids.
Suggested action: (a) Reduce the solid content increment to 0.25% and re-test; (b) Increase FG dosage by 0.02–0.05% and re-measure after 30 min equilibration; (c) If viscosity still exceeds target, switch to FG-N203B (SiO₂ 30–33%) which has the widest plateau at high solid content. (Source: Goway TDS, FG-N203B)
Problem: Spray dryer nozzle blockage after water reduction
Likely cause: Higher solid content changes the slurry's atomisation behaviour. If granule size distribution shifts coarser or if undispersed agglomerates form, nozzle tips can clog. This is a rheology and atomisation issue, not a deflocculant issue.
Suggested action: (a) Check granule size distribution — if the >40 mesh fraction increased, increase atomisation pressure by 5–10%; (b) Verify the slurry passes a 80-mesh screen before entering the spray dryer; (c) Check whether the FG dosage is in the over-dosed region (above plateau), which can cause soft agglomerates; (d) If nozzle wear has increased, inspect and replace nozzle tips.
Problem: Green body strength drops after solid content increase
Likely cause: Higher solid content reduces the water-mediated particle bonding that contributes to green strength. This is a physical effect — less water means less capillary force binding particles in the pressed tile. Typically a 5–10% green MOR decrease is observed.
Suggested action: (a) Add FG-ZM01 ceramic body binder at 0.15–0.3% — this increases green strength by 30–70% while simultaneously improving slurry flow by 5–10 seconds Ford Cup. (Source: Goway TDS, FG-ZM01); (b) Alternatively, increase ball clay content (e.g., FG-B82 high-plasticity ball clay) by 2–3% to restore plasticity.
Problem: Sedimentation in storage tank after solid content increase
Likely cause: At higher solid content, the slurry's yield stress may increase, but if the deflocculant's stabilisation mechanism is insufficient, particles can settle during storage. This is more common with FG-2017 (no SiO₂ buffer) at elevated solids.
Suggested action: (a) Switch to FG-MK03 (SiO₂ 20–22%, designed for long-term stability) — the silicate layer adsorption mechanism prevents sedimentation during 12–48 hour storage. (Source: Goway TDS, FG-MK03); (b) Increase slow agitation in the storage tank; (c) Verify that the 24-hour viscosity drift is ≤15% — if higher, the deflocculant system is not adequately stabilised for the new solid content.
Problem: Fired body defects (pinholes, colour shift) after transition
Likely cause: Switching from STPP to FG-series changes the Na₂O:SiO₂:P₂O₅ ratio in the body. STPP contributes P₂O₅ 56% (a flux), while FG-series products contribute 0–2% P₂O₅. This alters the glass phase composition and can affect fired body colour or defect rate.
Suggested action: (a) Check if L.O.I change affects glass phase — FG-N203B (L.O.I 45–50%) has the lowest L.O.I in the series, meaning less volatile material enters the kiln; (b) If whiteness shifts, adjust firing temperature by ±5–10°C to compensate for flux change; (c) Review kaolin grade — a higher-whiteness kaolin such as FG-K90 can offset minor colour shifts. (Source: Goway TDS, FG-K90); (d) For a comprehensive additive troubleshooting framework, see our guide to troubleshooting common ceramic additive problems.
Problem: Viscosity is good in lab but drifts in production
Likely cause: Production ball mills generate more heat than lab equipment, and slurry temperature affects deflocculant performance. Also, production water quality can vary throughout the day, while lab tests use a single water sample.
Suggested action: (a) Measure production slurry temperature at discharge — if >35°C, re-run lab trials at production temperature; (b) Collect water samples at 3 different times during the day and test each; (c) If water hardness varies >20% during the day, switch to a higher-SiO₂ grade (FG-MK03 or FG-N203B) which buffers against ionic variation; (d) Consider installing a slurry temperature monitor on the mill discharge pipe. For water quality effects, see our guide on water quality and ceramic slip performance.
§9 Frequently Asked Questions
With a well-optimised deflocculant system, ceramic body slurry solid content can typically be raised by 1–2 percentage points (e.g., from 32% to 34% solid content), which equates to removing approximately 1.5–3% of the water phase. The exact achievable reduction depends on your clay mineralogy, body recipe, process water hardness, and the deflocculant grade selected. Goway FG-N203B, engineered for high-solid spray-drying slurries with SiO₂ 30–33% and the lowest L.O.I in the series (45–50%), typically delivers the largest water reduction in spray-dryer-fed lines. A structured five-phase protocol (baseline → lab dosage curve → incremental solid increase → pilot trial → production validation) is required to achieve this safely without compromising slurry viscosity or fired body quality.
Reducing water content by raising solid content does not inherently affect fired body quality, provided the slurry viscosity remains within the target Ford Cup range and the spray-dried granule properties (bulk density, moisture, size distribution) are maintained. The key risk is indirect: higher solid content can change granule morphology and pressing behaviour if spray dryer parameters are not adjusted. Additionally, switching from STPP to FG-series deflocculants changes the Na₂O:SiO₂:P₂O₅ ratio in the body, which can slightly alter the glass phase. Goway recommends a full fired body evaluation (shrinkage, warpage, whiteness, MOR) before full-scale adoption. FG-N203B and FG-2017, with P₂O₅ at only 0–1%, also reduce the phosphorus load on the fired body compared to STPP.
For maximum water reduction in spray-drying body slurry, FG-N203B is the recommended grade. It has the highest SiO₂ content (30–33%) and lowest L.O.I (45–50%) in the FG-series, providing superior viscosity buffering at elevated solid content (Source: Goway TDS). For fast-dispersion wall tile and floor tile lines where rapid throughput is the priority, FG-2017 (Na₂O 30–32%) achieves quick viscosity reduction. For slurries stored 12–48 hours before use, FG-MK03 (SiO₂ 20–22%) maintains long-term stability at higher solid content. For multi-body factories, FG-SL01A (balanced Na₂O 18–20% / SiO₂ 18–20%) offers predictable performance across formulations. A lab dosage curve with your actual body recipe is the definitive selection method.
A structured water reduction programme typically takes 3–5 weeks across five phases. Phase 1 (Days 1–3): baseline data collection including solid content, Ford Cup flow time, and spray dryer parameters. Phase 2 (Days 4–7): lab dosage curve test with FG-series at current solid content. Phase 3 (Days 8–14): incremental solid content increase in 0.5% steps with deflocculant dosage adjustment. Phase 4 (Days 15–21): pilot trial with 200–500 kg batch through spray dryer. Phase 5 (Days 22–35): production validation with 5-day stability monitoring and fired body evaluation. Rushing the incremental solid increase phase risks viscosity excursions and spray dryer nozzle blockage.
Yes, and the combination is strongly recommended when pushing solid content higher. As solid content increases, green body strength can marginally decrease due to reduced water-mediated particle bonding. FG-ZM01 ceramic body binder (dosage 0.15–0.3%) increases green strength by 30–70% and simultaneously improves slurry flow by 5–10 seconds Ford Cup (Source: Goway TDS, FG-ZM01). Because FG-ZM01 improves flow independently, it can also reduce the deflocculant dosage required at elevated solid content, creating a combined cost saving. Goway recommends evaluating each additive independently first, then conducting a joint usage trial to confirm compatibility and optimal combined dosage.
Before starting, collect these baseline parameters: (1) current slurry solid content (%), (2) Ford Cup #4 flow time at 25°C (3 measurements per batch), (3) current deflocculant type and dosage (% dry body), (4) 24-hour viscosity drift (%), (5) spray dryer inlet/outlet temperature, powder moisture, and bulk density, (6) granule size distribution (40/60/80 mesh), (7) process water hardness (mg/L Ca²⁺) and pH, (8) body recipe (full composition), (9) green body MOR, (10) fired shrinkage, whiteness, and MOR, and (11) daily production volume (tonnes/day). Without this baseline, you cannot objectively measure the improvement or identify the root cause if issues arise.
Get Your Customised Water Reduction Plan
Send us your current production parameters and our technical team will recommend the optimal FG-series grade, starting dosage, incremental solid content increase schedule, and spray dryer parameter adjustments tailored to your factory. No generic answers — a plan built for your numbers.
View FG-Series Ceramic Deflocculant Products →To submit an inquiry, visit our Ceramic Deflocculant product page and use the inquiry form. Please reference this guide when submitting. Samples with TDS, SDS, and COA are available.
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