Suitability and characterization of pumice, bauxite, and ferrochrome slag as alternative raw materials in vitrified ceramic industry

• Autorzy: Benkli Yunus Emre , Koca Kazım

Identyfikatory

DOI

10.37190/ppmp/187967

• Języki publikacji: EN

Abstrakty

EN

Since the natural raw materials used in the manufacture of clay-based ceramic products vary greatly in the sintering stage, the resulting products are quite heterogeneous. In addition, different types of waste could be used to make ceramic tiles and bricks. Therefore, this study aimed to investigate the effects of pumice, bauxite, and ferrochrome slag on the vitrified ceramic body. In this context, firstly, binary slip mixtures were prepared by composing 40% clay with 60% pumice, bauxite, and ferrochrome slag one by one, which was reduced to 150 μm in particle size. Then, the mixtures were shaped by slip casting method and sintered at 1000°C, 1100°C, 1200°C, and 1250°C. The qualitative XRD analysis was performed in order to see the phase variation, and physical properties were determined with shrinkage and water adsorption measurements. Since pumice transformed into a glassy phase after sintering at 1100°C, an amorphous phase was observed in all samples produced with pumice. In addition, the mullite development occurred in clay-pumice body composition with the temperature increment. However, tridymite and cristobalite phases were analysed in clay bauxite and ferrochrome body compositions. The shrinkage and water adsorption values, which were high in the samples sintered at 1000°C, began to reduce from 1100°C to 1250°C significantly. In particular, water adsorption reached 0% in the clay-pumice system which was suitable for a fully vitrified-high density standard (ISO13006-10545/98). Besides, the brighter colour was reached in the clay-pumice system while brown and black colour was seen in clay-bauxite and clay-ferrochrome bodies, respectively.

Słowa kluczowe

EN

vitrified ceramics; pumice; ferrochrome slag; bauxite; industrial waste

• Wydawca: Oficyna Wydawnicza Politechniki Wrocławskiej
• Czasopismo: Physicochemical Problems of Mineral Processing
• Rocznik: 2024
• Tom: Vol. 60, iss. 2
• Strony: art. no. 187967
• Opis fizyczny: Bibliogr. 50 poz., rys., tab., wykr.

Twórcy

autor

Benkli Yunus Emre

• Atatürk University, Faculty of Engineering, Department of Metallurgical and Materials Engineering, Erzurum, TÜRKİYE

autor

Koca Kazım

• Atatürk University, Faculty of Engineering, Department of Metallurgical and Materials Engineering, Erzurum, TÜRKİYE

Bibliografia

• ANDREEV, D.V., ZAKHAROV, A.I., 2009. Deformation of porcelain articles. Glass and Ceramics, 66(1), 8-10.
• ANDREOLA, F., BARBIERI, L., KARAMANOVA, E., LANCELLOTTI, I., PELINO, M., 2008. Recycling of CRT panel glass as fluxing agent in the porcelain stoneware tile production. Ceramics International, 34(5), 1289-1295.
• ANDREOLA, F., BARBIERI, L., BONDIOLI, F., FERRARI, A.M., LANCELLOTTI, I., MISELLI, P., 2010. Recycling screen glass into new traditional ceramic materials. International Journal of Applied Ceramic Technology, 7(6), 909-917.
• ANDREOLA, F., BARBIERI, L., LANCELLOTTI, I., LEONELLI, C., MANFREDINI, T., 2016. Recycling of industrial wastes in ceramic manufacturing, state of art and glass case studies. Ceramics International, 42(12), 13333-13338.
• ARCASOY, A., 1983. Ceramic Technology, Marmara University, Faculty of Fine Arts Publications, No, 2, Istanbul, 19, p, 228
• ATEŞER, H.O., 2010. Investigation of sintering and mechanical properties of amorphous silica ceramics with andalusite addition. Thesis (M.Sc.), Istanbul Technical University, Institute of Science and Technology.
• CANDURAN, K., URAL, M., 2019. Apparatus used to prevent deformation in the production of ceramic sanitary ware. Academic Art, 4(8), 66-79.
• CARBONCHI, G., DONDI, M., MORANDI, N., TATEO, F., 1999. Possible use of altered volcanic ash in ceramic tile production. Industrial Ceramics, 19(2), 67-75.
• CARTY, W.M., SENEPATI, U., 1998. Porcelain-raw materials, processing, phase evolution, and mechanical behaviour. Journal of the American Ceramic Society, 81, 3-20.
• ÇELIK, M.Y., YILMAZ, S., 2018. The effect of static, salty and acidic aqueous environments on the capillary water absorption potential of porous building stones used as building stones in the Afyonkarahisar region. Journal of the Faculty of Engineering and Architecture of Gazi University, 33(2), 591-607.
• ÇEVIKEL, Ü.İ., 2010. Comparison of PVC, glass mosaic and ceramic tiles in terms of application as coating materials in private reinforced concrete swimming pools. Thesis (M.Sc.), Istanbul Technical University, Institute of Science and Technology.
• DARKEN, L.S., 1948. Melting points of iron oxides on silica; phase equilibria in the system Fe-Si-O as a function of gas composition and temperature. Journal of the American Chemical Society. 70(6), 2046-2053.
• DAVILA, L.P., RISBUT, S.H., SHACKELFORD, J.F., 2008. Quartz and Silicas. Ceramic and Glass Materials, 71–86., Editors, Shackelford, J.F., Doremus, R.H.
• DENIZ, V., UMUCU, Y., YILMAZ, I., 2004. Evaluation of jig performances in the pumice enrichment facility of Soylu Industrial Minerals Inc. 5 Endüstriyel Hammaddeler Sempozyumu, 307-312.
• DURGUT, E., PALA, C.Y., KAYACI, K., ALTINTAS, A., YILDIRIM, Y., ERGIN, H., 2015. Development of a semi-wet process for ceramic wall tile granule production. J. Ceram. Process. Res., 16(5), 596–600.
• DURGUT, E., CINAR, M., OZDEMIR, O., 2022. Effect of calcite and mica contents in nepheline syenite samples on the ceramic body sintering behaviours and surface roughness. Physicochemical Problems of Mineral Processing, 58(5), 149179.
• EL-SHIMY, Y.N., AMIN, K., EL-SHERBINY, S.A., ABADIR, M.F., 2014. The use of cullet in the manufacture of vitrified clay pipes. Construction and Building Materials, 73, 452-457.
• ERGUL, S., AKYILDIZ, M., KARAMANOV, A., 2007. Ceramic material from basaltic tuffs. Industrial Ceramics, 27(2), 211-217.
• FORTUNO, D., 2000. Firing. Ceramic Technology Sanitaryware, Gruppo Editorialle Feanza Editrice S.P.A, Feanza, Italy, 125–126.
• GAJEK, M., PARTYKA, J., KMITA, A.R., GASEK, K., 2017. Development of anorthite based white porcelain glaze without zrsio4 content. Ceramics International, 43(2), 1703-1709.
• GENNARO, R., CAPPELLETTI, P., CERRI, G., GENNARO, M., DONDI, M., GUARINI, G., LANGELLA, A., NAIMO, D., 2003. Influence of zeolites on the sintering and technological properties of porcelain stoneware tiles. Journal of the European Ceramic Society, 23(13), 2237-2245.
• GENNARO, R., DONDI, M., CAPPELLETTIC, P., CERRID, G., GENNARO, M., GUARINI, G., LANGELLA, A., PARLATOC, L., ZANELLI, C., 2007. Zeolite-feldspar epiclastic rocks as flux in ceramic tile manufacturing mesoporous microporous mater. Microporous and Mesoporous Materials, 105(3), 273-278.
• HILLIG, W.B., 1993. A methodology for estimating the mechanical properties of oxides at high temperatures. Journal of the American Ceramic Society 76(1), 129-138.
• HOSENY, N.F., AMIN, S.K., FOUAD, M.M.K., ABADIR, M.F., 2018. Reuse of ceramic sludge in the production of vitrified clay pipes. Ceramics International, 44(11), 12420-12425.
• ISLAM, G.M.S., RAHMAN, M.H., KAZI, N., 2017. Waste glass powder as partial replacement of cement for sustainable concrete practice. Journal of Environmental Chemical Engineering, (3), 1767-1775.
• JACKSON, P.R., HANCOCK, P., CARTLIDGE, D., MUKESH, C., LIMBACHIYA, J., ROBERTS, J., 2015. Recycled bottle glass as a component of ceramic sanitary ware. Sustainable Waste Management And Recycling, Glass Waste, ICE Publishing, 313-320.
• JANI, Y., HOGLAND, W., 2014. Waste glass in the production of cement and concrete – A review. Journal of Environmental Chemical Engineering, 2(3), 1767-1775.
• KARAMANOVA, E., AVDEEV, G., KARAMANOV, A., 2011. Ceramics from blast furnace slag. kaolin and quartz. Journal of the European Ceramic Society, 31(6), 989-998.
• KIATTISAKSOPHON, P., THIANSEM, S., 2008. The preparation of cordierite-mullite composite for thermal shock resistance material. Chiang Mai J. Sci. 2008; 35(1), 6-10.
• KOBAYASHI, Y., SUMI, K., KATO, E., 2000. Preparation of dense cordierite ceramics from magnesium compounds and kaolinite without additives. Ceramics International, 26(7), 739-743.
• LIU, C., LIU, L., TAN, K., ZHANG, L., TANG, K., SHI, X. 2016. Fabrication and characterization of porous cordierite ceramics prepared from ferrochromium slag. Ceramics International, 42(1), 734-742.
• NIIBORI, Y., KUNITA, M., TOCHIYAMA, O., CHIDA, T., 2000. Dissolution rates of amorphous silica in highly alkaline solution, Journal of Nuclear Science and Technology, 37(4), 349-357.
• PRASAD, C.S., MAITI, K.N., VENUGOPAL, R. 2003. Effect of the substitution of quartz by rha and silica fume on the properties of whiteware compositions. Ceramics International, 29(8), 907-914.
• RAMBALDI, E., ESPOSITO, L., TUCCI, A., TIMELLINI, G., 2007. Recycling of polishing porcelain stoneware residues in ceramic tiles. Journal of the European Ceramic Society, 27(12), 3509-3515.
• ROMERO, M., PÉREZ, J.M., 2015. Relation between the microstructure and technological properties of porcelain stoneware. A review. Mater. Construcc. 65 [320], e065.
• SAHU, N., BISWAS, A., KAPURE, G.U., 2016. A short review on utilization of ferrochromium slag. Mineral Processing and Extractive Metallurgy Review 37(4), 211-219.
• SALEM, A., JAZAYERI, S.H., RASTELLI, E., TIMELLINI, G., 2009. Dilatometric study of shrinkage during sintering process for porcelain stoneware body in presence of nepheline syenite. Journal of Materials Processing Technology, 209(3), 1240-1246.
• SALLAM, E.M.H., CHAKLADER, A.C.D., 1978. Sintering characteristics of porcelain. Ceramurgia International, 4 (4), 151-161.
• SATO, T., SAWABE, Y., OHYA, Y., SUGAI, M., NAKAGAWA, Z., 2000. Cracking in a cristobalite-containing mullite body during cooling. Journal of the Ceramic Society of Japan 108(4), 345-349.
• SCHABBACH, L.M., ANDREOLA, F., BARBIERI, L., LANCELLOTTI, I, KARAMANOVA, E., RANGUELOV, B., KARAMANOV, A., 2012. Post-treated bottom incinerator bottom ash as alternative raw material for ceramic manufacturing. Journal of the European Ceramic Society, 32(11), 2843-2852.
• SHUTE, R.L., BADGER, A.E., 1942. Effect of iron oxide on melting of glass. Journal of the American Ceramic Society. 25(12), 355-357.
• TARVORNPANICH, T., SOUZA, G.P., LEE, W.E., 2005. Micro-structural evolution on firing soda-lime-silica glass fluxed white-wares. Journal of the American Ceramic Society, 88(5), 1302-1308.
• TORE, I., 2013. Uses of pumice as alternative flux for floor tile products. International Journal of Science and Modern Engineering. 1(11), 16, 19.
• TORRES, P., FERNANDES, H.R., AGATHOPOULOS, S., TULYAGANOV, D.U., FERREIRA, J,M., 2004. Incorporation of granite cutting sludge in industrial porcelain tile formulations. Journal of the European Ceramic Society, 24(10–11), 3177-3185.
• TUCCI, A., ESPOSITO, L., RASTELLI, E., PALMONARI, C., RAMBALDI, E., 2004. Use of soda-lime scrap-glass as a fluxing agent in a porcelain stoneware tile mix. Journal of the European Ceramic Society, 24(1), 83-92.
• URAL, M., 2017. Deformations occurring in vitrified ware production and their elimination. Sakarya University, Institute of Social Sciences, Department of Ceramics and Glass (Master's Thesis), 141 pages, Sakarya, Türkiye.
• WEILL, D.F., KUDO, A.H., 1968. Initial melting in alkali feldspar-plagioclase-quartz systems. Geological Magazine. 105(4), 325-337.
• WYPYCH, G., 2016. 2 - Fillers – Origin, Chemical Composition, Properties, and Morphology. Editor(s), George Wypych, Handbook of Fillers (Fourth Edition), ChemTec Publishing, Pages 13-266, ISBN 9781895198911.
• YUAN, S., HAN, Y., LI, Y., GAO, P., YU, J., 2018. Effect of calcination temperature on activation behaviors of coal-series kaolin by fluidized bed calcination. Physicochemical Problems of Mineral Processing, 54(2), 590-600.
• ZANELLI, C., BALDI, G., DONDI, M., ERCOLANI, G., GUARINI, G., RAIMONDO, M., 2008. Glass ceramic frits for porcelain stoneware bodies, effects on sintering, phase composition and technological properties. Ceramics International, 34(3), 455-465.