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Abstract
This study aims to optimize the composition (body formulation) and firing temperature of sustainable ceramic clay-based ceramics incorporated with electric arc furnace (EAF) steel slag waste using general full factorial design (GFFD). The optimization is necessary to minimize drawbacks of high iron oxide’s fluxing agent (originated from electric arc furnace, EAF steel slag waste), which led to severe surface defects and high closed porosity issue of the ceramics. Statistical analysis of GFFD including model adequacy checking, analysis of variance (ANOVA), interaction plots, regression model, contour plot and response optimizer were conducted in the study. The responses (final properties of ceramics) investigated were firing shrinkage, water absorption, apparent porosity, bulk density and modulus of rupture (MOR). Meanwhile, the factors employed in experimental parameters were weight percentage (wt.%) of EAF slag added and firing temperature. Upon statistical analysis, GFFD has deduced that wt.% amount of EAF slag added and firing temperatures are proven to significantly influence the final properties of the clay-based ceramic incorporated with EAF slag. The results of conducted statistical analysis were also highly significant and proven valid for the ceramics. Optimized properties (maximum MOR, minimum water absorption and apparent porosity) of the ceramic were attained at 50 wt.% of EAF slag added and firing temperature of 1180 °C.
Highlights
In recent years, the development of sustainable clay-based ceramics is becoming notable and attracting worldwide researchers to explore on it
General full factorial design (GFFD) with two independent variables or operating factors was used to statistically analyze effects of different operating factors and their interactions on predicted responses or properties of clay-based ceramics incorporated with the electric arc furnace (EAF) slag
At the end of this research work, the general full factorial design (GFFD) statistical experimental design’s approach successfully optimized EAF slag added and firing temperature for the development of sustainable clay-based ceramic incorporated with EAF slag
Summary
The development of sustainable clay-based ceramics is becoming notable and attracting worldwide researchers to explore on it. The EAF slag is suitable as a fluxing agent, the formulation of clay-based ceramics is still very crucial to avoid the drawbacks highlighted such as surface defects and closed porosity issues which could deteriorate properties (water absorption and MOR) of the tile. Considering this concern, proper formulation and firing temperature assisted by general full factorial design, which is one of a statistical experimental design approaches, could minimize the aforementioned drawbacks of clay-based ceramic incorporated with EAF slag
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