Production Of Ceramic Bricks Research Articles

Characterization of Jurassic mudstones of the Northwest Caucasus as a raw material for clinker tile production

The article characterizes Jurassic mudstones of the North-West Caucasus as a potential raw material for the production of clinker tiles with water absorption of less than 3%. It is noted that traditional for the south of Russia raw materials for the production of ceramic bricks and tiles in the last centuries were various types of loams, which are widely distributed almost throughout the territory. However, for a number of reasons, they cannot be considered as raw materials for the production of clinker tiles, for which there has been a steady demand in recent years, especially on the Black Sea coast. Geographically, the Jurassic sediments in the Krasnodar region are traced in a wide strip (50–100 km) at a distance of 20 to 60 km from the coast. These are the oldest rocks in the region. The thickness of numerous mudstones varies from a few to many tens of meters. The chemical composition of mudstones is characterized by the content of aluminum oxide from 17 to 22 %, increased content of potassium oxide and iron oxides. The mineral composition is represented by hydrous mica, kaolinite and chlorite with admixture of quartz and feldspars. Pre-firing properties of argillites can be regulated by the degree of grinding. In terms of sinterability, argillites are qualified as a strong-medium sintering raw material of low-temperature sintering with high strength of ceramic stone. The results and analysis of the obtained data allow us to assert that the Jurassic mudstones of the North-West Caucasus are potentially suitable raw materials for production of clinker tiles with a wide range of physical and technical properties using a simplified technology.

Humidity-Controlling Ceramic Bricks: Enhancing Evaporative Cooling Efficiency to Mitigate Urban Heat Island Effect

Passive evaporative cooling technology using the building envelope is a crucial measure to mitigate the urban heat island effect. This study aims to enhance the cooling efficiency of the surface of enclosure structures by utilizing volcanic ash, potassium–sodium stone powder, and silica-based mesoporous oxide (SMO) as primary materials. These components are incorporated into the ceramic brick production process to create innovative humidity-controlling ceramic bricks (HCCTs). This study extensively investigates the impact of SMO and the amount of applied glaze on the physical and mechanical characteristics of these HCCTs. Additionally, it examines the water absorption and evaporative cooling properties of the studied materials under optimal substitution conditions. Numerical calculations are used to determine the heat and moisture transfer properties of HCCTs. The results indicate that incorporating 2% SMO and applying 70 g/m2 of glaze results in a moisture absorption capacity of 385 g/m2 and a moisture discharge capacity of 370 g/m2. These conditions also yield a notable flexural strength of 15.2 MPa. Importantly, the HCCTs exhibit significantly enhanced capillary water absorption and water retention capabilities. Increased water absorption reduces surface temperature by 2–3 °C, maintaining the evaporative cooling effect for 20 to 30 h. It is also found that the temperature of HCCTs decreases linearly with increasing water content and porosity, while the temperature difference gradually decreases with thickness. Water migration in HCCTs with greater thickness is notably influenced by gravity, with water moving from top to bottom. Therefore, it is recommended that brick thickness does not exceed 15 mm.

Production of ceramic bricks using nickel slags as contribution to decarbonization

PurposeThe study suggests that the high concentration of mining and metallurgical enterprises on the territory of the Russian Ural region determines the need to consider industrial waste, including nickel slag, as a possible raw material for the production of ceramic bricks. The article describes the properties of clays and nickel slag obtained at metallurgical enterprises in the Orenburg region and the features of their use as components in the composition of ceramic bricks.Design/methodology/approachTo achieve this purpose, such tasks as determining the technological parameters of production, conducting the X-ray phase and microstructural analysis of the obtained samples were solved.FindingsCompositions of ceramic mass using clay from the Khalilovsky deposit (Orenburg region) with the addition of nickel slag (20 and 40% by weight) have been developed, and their physical and mechanical properties (compressive strength, bending strength, water absorption and density) have been determined. With the help of modern research methods involving high-tech equipment, the microstructure is considered and the phase composition of the finished samples is determined. As a result of the conducted research, it was found that the composition of the selected clay and nickel slag in the obtained rational composition ensures the production of ceramic bricks of grades M175 and M200.Originality/valueThis is the first study on the use of nickel slag for the production of ceramic bricks. The results relate primarily to Russian feedstocks, but a methodology is presented that can be applied to other countries as well as to other silica-containing feedstocks.

ИССЛЕДОВАНИЕ СВОЙСТВ КЕРАМИЧЕСКОГО РЯДОВОГО КИРПИЧА НА ОСНОВЕ ОТХОДОВ БУРЕНИЯ НЕФТЕДОБЫВАЮЩЕЙ ОТРАСЛИ

The purpose of these studies is to determine the possibility of using drill cuttings from the oil fields of the Southern Fed-eral District as a source for the production of ceramic ordinary bricks with their maximum content in the initial mixture to take into account their physical and chemical properties. The objects of study were: drill cuttings from the Slavyanskoye oil field (Krasnodar region) and clay (VKV-2) from of the Vladimirskiy quarry (Rostov region). Based on the research results, a working hypothesis has been formulated, which is that complex processing of the composition of the mineral component of drilling waste and plastic clay at the stages of preparation, molding, and drying ensures, under low-temperature firing conditions, compliance of the physical and chemical properties of brick with the requirements of GOST 530–2018 and their preservation during long-term operation

Assessment and Characteristics of Molding Masses Based on Loam during Production Soft Molded Ceramic Brick

опThe article discusses the issues of assessing the properties of loams and selecting the composition of molding compounds based on them for the production of ceramic bricks using the soft molding method. It is noted that for soft molding technology, to date, no recommendations have been developed for the evaluation of raw materials with the establishment of relationships between the composition, technological properties, molding features and aesthetic features of the front edges of products. According to technological features, the method of soft molding of ceramic bricks is conventionally divided into 4 methods: manual molding, accelerated molding, pressing method and vibration molding method. The results of our work made it possible to identify the main indicators when assessing clay raw materials and to develop the basic principles for selecting the composition of molding masses. Thus, the critical compression stress and the degree of deformation of the workpieces should be on average 0.2–0.8 kg/cm2 and 3–5 units, respectively. In this case, the molding masses should have the minimum possible water content and stickiness, have minimal air shrinkage (less than 6–7%), and be slightly or moderately sensitive to drying. An algorithm has been developed for selecting molding compounds, including determination, in addition to generally accepted indicators, such as the degree of deformation and critical compressive stress at different water contents, specific penetration resistance, determination of the optimal electrolyte content, and stickiness. For typical loams, the dependences of the degree of deformation of the samples and the critical compressive stress on the water content of the molding masses are shown, as well as the influence of electrolytes on the water content. It has been shown that the introduction of electrolytes can significantly reduce the water content of molding masses. It is noted that the genesis of loams, their variable composition and the frequent presence of undesirable harmful impurities predetermined the situation that high-quality loams that meet the necessary requirements are quite rare and the only alternative can be the selection of compositions of molding compounds based on correct scientific and methodological

Study of clay raw materials with Korolek technogenic waste for the production of ceramic bricks

The use of industrial waste in the production of building materials is an urgent task at present. Studies on the use of mineral wool waste in the manufacture of ceramic bricks have been carried out. For the preparation of experimental samples of ceramic bricks used clay deposit, as heaters and intensifiers of sintering – waste production of mineral wool. Chemical composition of investigated components is given. The study of mineralogical and phase composition of raw materials was carried out by petrographic, X-ray phase, IR-spectroscopic, electron-microscopic methods of analysis and DTA. During the experiment such properties of samples as cracking temperature; end shrinkage moisture; relative shrinkage; drying time to residual moisture content of 8%; mechanical strength in compression were tested. As a result of the tests, the influence of Korolek on the drying properties of ceramic samples was established. Thus, an increase in the content of Korolek in the samples, improved the crack resistance, relative shrinkage, drying time to residual moisture. The results of the research showed a non-linear dependence of physical and mechanical properties of the samples on the content of Korolek. The best values of mechanical strength were achieved when the Korolek content was 40% of the total mass of the manufactured sample. The proposed composition corresponds to the properties of ceramic bricks above grade M150-175.

Wood Waste Management from the Furniture Industry: The Environmental Performances of Recycling, Energy Recovery, and Landfill Treatments

Proper management of wood waste (WW) from the furniture industry has become an important issue. Life-cycle assessment (LCA) is a tool that is widely used for identifying environmental gains in WW management strategies. Thus, the aim of this research was to perform a comparative LCA, analyzing the environmental aspects and impacts of different WW management scenarios generated in the furniture industry in the state of Espirito Santo, Brazil. To conduct the study, five scenarios were designed: medium-density fiberboard (MDF) production (Scenario 1), medium-density particleboard (MDP) production (Scenario 2), solid ceramic brick production (Scenario 3), heat production in the ceramics industry (Scenario 4), and landfill disposal (Scenario 5). The results showed that compared to Scenarios 3 and 4, Scenarios 1 and 2 are potentially more favorable for disposing of WW. Scenario 1 achieved more environmental benefits in all of the impact categories evaluated. Notably, 1 m3 of MDF stores 1080 kg CO2 eq/m3, which results in a net impact of −849 kg CO2 eq/m3 of MDF. Scenario 5 is the least favorable practice. This research designs scenarios that contribute to reductions in the demand for virgin sources and increases in environmental gains.

Experiences in the Production of Wall Ceramics with the Addition of Carbonate-containing Wastes

The use of mining and metallurgical industry wastes containing calcium, magnesium, and strontium carbonates is described. The initial compositions and transformations occurring during the firing are considered. The best composition was chosen according to the results of laboratory studies, and based on that, ceramic brick was studied in real production conditions. The possibility of using mining and metallurgical industry wastes (dolomite and cake) as coloring pigments in the production of ceramic bricks has been theoretically substantiated and experimentally proven. Magnesium and strontium carbonates, along with calcium carbonates, participate in the formation of multicomponent systems, on the basis of which it is possible to obtain wall ceramics that meet modern requirements.

To the question of structure optimization for producing high-strength ceramics

The article outlines the principles that ensure the production of high-strength ceramic bricks. The change in the phase composition of clay raw materials during firing is analyzed. The role of the calculation method for determining the amount and composition of the melt formed during firing is determined. The value of the glass phase in the strengthening of the ceramic shard has been determined. Taking into account the properties of neoplasms, various types of structures were analyzed. The optimal structures for increasing the strength of fired ceramics are determined. The main factors that increase the strength of ceramic bricks and methods for their implementation were established. The factors that increase the strength of ceramic bricks are determined. Implementation methods are recommended.

THE EFFECT OF MODIFYING ADDITIVES ON THE PROPERTIES OF THE CERAMIC COMPOSITION

The results of studies of the effect of modifying additives on the properties of ceramic masses are presented. It is shown that the complex activation of the ceramic mass by plasticizing additives in the form of bentonite and surfactants and using rice straw leads to a decrease in molding humidity and an improvement in the physical and mechanical properties of ceramics while reducing the firing temperature by 50-100 °C. The optimal composition of a ceramic composition containing low-plastic loam, bentonite, rice straw and surfactants for the production of ceramic bricks by plastic molding has been determined.

Effect of the incorporation of Neem (Azadirachta indica) wood ash in Kodeck ceramic materials for the manufacture of fired bricks (Far-North Cameroon)

The current study evaluates the suitability of Neem (Azadirachta Indica) wood ash as raw material in the production of ceramic bricks for their application in construction. Accordingly, for the fabrication of bricks, compositions were prepared by adding increasing amounts of Neem wood ash (0%, 5%, and 10% in wt.). The specimens were manufactured by mixing clay with a Neem wood ash amendment and subsequently compacted and fired at 850 °C, 950 °C, and 1050 °C. The fired samples were characterized to determine their technological properties. The results indicate that brick formulations containing Neem wood ash decreased the bulk density up to 8%. Water absorption increased up to 10% and porosity also increased up to 20% with wood of ash. These values meet the Turkish TS EN standards for masonry structures. Due to the interesting performances observed, the potential used up to 10 wt% of Neem Wood ash in ceramic formulations of industrial interest was confirmed. Therefore, incorporating ash into a clay material reduces environmental problems and the total cost of raw material disposition. This is very important in the Sahelian zone and it provides a great opportunity for the inhabitants of this zone.

Low-Quality Brick Clays and Ash and Slag Waste in the Production of Ceramic Bricks

Low-Quality Brick Clays and Ash and Slag Waste in the Production of Ceramic Bricks

Use of bottom ash in the production of ceramic brick

The influence of the addition of ash residues from the processing of solid household waste from the Balakhani Industrial Zone in Baku on the properties of ceramic bricks in the Khirdalan and Karadag regions of Azerbaijan was studied. Ash residues were added in the amount of 10-50% of the mass. The physical properties of ash residues were studied - fractional, granulometric, radiological and toxicological compositions, as well as water absorption of ash bricks at different firing temperatures. The positive role of waste for obtaining wall ceramics with high performance properties was revealed, which corresponds to the regulatory requirements of GOST. It should be noted that the introduction of mineral additives has a positive effect on the characteristics of the ash brick. Among other ash-containing bricks at firing temperatures of 900 and 1100, the highest strength (22 MPa) is observed at 1100 °C with an ash content of up to 10%. As the ash content increases, the compressive strength at 900 °C and 1100 °C decreases.

Synthetic Wollastonite is a Promising Additive in the Production of Light-Colored Facing Ceramic Bricks

Synthetic Wollastonite is a Promising Additive in the Production of Light-Colored Facing Ceramic Bricks

Ceramic products based on modified agricultural waste

The current production status of building ceramics is based on the following realities. First, due to market conditions, the number of ceramics factories in operation has decreased significantly. Second, from 2019, taking into account the pace of housing construction related to the transition to new financing mechanisms, the production of ceramic bricks increased by 2-3% from 2019. Growth opportunities are associated with an increase in the thermal efficiency of ceramic products and masonry based on them. The aim of the research described in the article was the development of compositions for wall heat-efficient ceramics on the basis of loess-like low-quality clay using rice straw as a burnout additive and in particular to determine the optimal consumption of processed rice straw. The scientific novelty of the research consisted in the development of methods for selecting the composition of ceramic mixtures, optimizing their composition and demonstrating the influence of rice straw and rice straw ash on the properties of ceramic mixtures and the properties of products. Rice straw. 5–15% by weight of lint rice straw, which is incorporated into clay masses at the stage of their production and burns at a temperature of 200–300 ° C, burns out the mass and makes it porous, prevents shrinkage phenomena and ash contains up to 20% amorphous silica. Carbonates contained in clay dissociate during firing, interacting with amorphous silicon dioxide and forming various calcium silicates that strengthen the structure of the chip industry.

Assessment of Mineralogical Characteristics of Clays and the Effect of Waste Materials on Their Index Properties for the Production of Bricks.

Significant research investigations on the characteristics of unexplored clay deposits are being conducted in light of the growing need for clay in the ceramic industry and the variable chemistry of clays. Parallel to this, the generation of waste materials like fly ash, ferrochrome slag, and silica fume is also increasing, responsible for environmental degradation. This paper aims to study the mineralogical properties of pure clays (one specimen from Siberia and five specimens from different locations in Turkey), and the effect of mentioned waste materials on the index properties of clays obtained. This study is divided into two phases, wherein in the first phase, the pure clay specimens are analyzed against mineralogical properties (i.e., chemical composition, thermal analysis, and particle size distribution). While in the second phase, index properties of pure clay specimens and clay specimens modified with 0-50% fly ash, ferrochrome slag, and silica fume are analyzed. The results reveal that the clay specimens from Turkey (USCS classification: CL) are fit for the ceramic industry and bricks production, and incorporation of waste materials can further improve their index properties. It is also observed that incorporation of 10-30% fly ash and ferrochrome slag have higher efficiency in reducing the plasticity index of clays studied as compared to the addition of silica fume.

Determination of approaches to the development of ceramic compositions for the manufacture of facial bricks

This paper considers the principles of designing a composite mixture for the production of ceramic facing bricks based on clay materials. The complex of conducted researches allows establishing rational technological parameters of molding and firing of ceramic products to achieve high values of operational properties. Composite charges were obtained based on clays from Druzhkovsky and Zalyutinsky deposits, as well as on clay wastes of zircon-ilmenite sand enrichment from Vilnohirsk Mining and Metallurgical Plant. It was established that based on these materials by forming via the method of rigid extrusion and application of firing at temperatures of 1020–10400С, it is possible to fabricate a ceramic brick of grade not lower than M225.

Utilization of Spent Sorbent in the Production of Ceramic Bricks

The composition and technology for the production of semi-dry ceramic bricks using a nanostructured complex sorbent based on bentonite clay of the 11th horizon of the Tagan deposit of the Republic of Kazakhstan and basalt fiber (gabbro-diabase) of the Karauzek deposit of East Kazakhstan have been developed. The characteristics, chemical composition, and structure of the spent sorbent are given based on electron microscopic and X-ray phase analyses. A number of physical and mechanical parameters have been studied to evaluate the spent sorbent as a raw material for the production of ceramic products. The microstructures of fired ceramic samples with loam and spent sorbent have been studied, and the features of their structure have been revealed. The environmental safety of waste sorbents utilization by extraction in acidic, alkaline, and neutral media with the determination of the content of chromium, zinc, and iron ions has been studied. Experimentally obtained data indicate an insignificant concentration of chromium and zinc ions, not exceeding 3.5 µg/L. Relatively high concentrations of iron ions in ceramic bricks are associated with their high content in the feedstock and in the spent sorbent. It has been established that the introduction of the spent sorbent in the amount of 25% of the total mass increases the strength of the final product from 10.8 to 15.8 MPa, which corresponds to the M125 ceramic brick grade.

Production of water-permeable ceramic bricks derived from fly ash via a simple pellet method: Mechanism of mechanical strength and permeability

• Water-permeable ceramic bricks were prepared from fly ash via a simple pellet method. • The consumption of fly ash in the ceramic brick was up to 80 wt%. • Average pore size of water-permeable ceramic bricks reached 123.9 μm. • Anorthite phases generated at high temperature contributed to strength of bricks. • The water-permeable ceramic bricks had a low heavy metal leaching toxicity. Rising with the sponge city construction, water-permeable bricks as emerging materials, are receiving more and more attentions. It is a beneficial way to produce water-permeable bricks using industrial solid wastes as raw materials, which could not only eliminate the adverse effect of solid wastes, but also produce sustainable products. Herein, water-permeable ceramic bricks were produced by recycling fly ash as the main material with consumption up to 80 wt% via a simple pellet method. Fly ash was firstly mixed evenly with tailings at a mass ratio of 4:1 to adjust plasticity to prepare pellets. Pellets were then pressed under low forming pressure to obtain raw bricks, which were dried and sintered at high temperature to prepare water-permeable ceramic bricks. Effects of size and water content of pellets, forming pressure, and sintering temperature on the performance of water-permeable ceramic bricks were investigated. Under optimized conditions, ceramic bricks with compressive strength of 48.6 MPa, bending strength of 6.1 MPa and water permeability of 2.83 × 10 -2 cm/s were produced. Average pore size of optimized bricks reached 123.9 μm, which guaranteed excellent water permeability. The generated anorthite phases at high temperature contributed to the high mechanical strength of water-permeable bricks. The evaluation of heavy metal leaching toxicity indicated that the prepared bricks were environmentally-friendly. This study provides a strategy to produce water-permeable ceramic bricks derived from industrial solid wastes.

Переработка земли формовочной горелой

At present, the metallurgical industry occupies one of the leading positions in the economy of many countries. At the same time, a large amount of solid wastes is generated in the metallurgical industry. The most large-tonnage includes burnt molding earth, which is formed at the stage of knocking out castings from foundry molds. The properties of burnt molding earth (humidity, loss on ignition, elemental, phase and grain composition) were studied and the possibility of its regeneration was confirmed. The simplest and cheapest is the dry mechanical method of regeneration, which is used in most enterprises of the Republic of Belarus. The paper shows that when this method is implemented, about 80 % of the burnt molding earth is returned to the technological process at the stage of casting molds, and about 20 % is converted into a fine pulverized fraction, which is a waste product and is currently being disposed of for disposal. On the basis of experimental studies, it has been established that this fraction of burnt molding earth can be used in the production of ceramic bricks as a lean additive. Were obtained samples of ceramic bricks containing 80 wt. % clay field «Lukoml», as well as sand and a fine fraction of the molding burnt earth in various proportions. The properties of the obtained samples, their structure and phase composition have been studied. It has been established that with an increase in the content of waste, the properties of ceramic bricks change insignificantly. Therefore, it is proposed to use 20 wt. % of the finely dispersed fraction of the burnt molding earth, i.e., completely replace the quartz sand with waste. On the basis of experimental studies, firing at a temperature of 1000 °C with isothermal holding for 60 minutes was chosen. It has been established that the obtained samples of ceramic bricks correspond to GOST 530-2012 «Ceramic brick and stone. General Specifications», stamp 300.