Manufacture Of Ceramic Bricks Research Articles

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.

Technological behaviour and leaching tests in ceramic tile bodies obtained by recycling of copper slag and MSW fly ash wastes

The substitution of standard clays to residues, in this case copper smelter slag and fly ashes coming from the incineration process of MSW in traditional ceramics manufacturing, could suppose cost savings due to the use of recycling by-products as raw materials and reduce firing temperatures. However, these residues are considered a factor of air, soil and water contamination when its stabilization is not viable. The aim of this paper is to evaluate the feasibility of adding this residue in manufacturing of ceramic bricks, as well as tested the immobilization of Pb and As in ceramic tile bodies obtained. Water absorption, linear contraction, and bending strength have been accomplished. The decrease in water absorption with the increase of waste added was tested. The incorporation of these wastes gives rise to an increase in strength. The results showed the viability of replacing up to 40% of clay with these residues, with an improvement in the resistance of pieces compared to ceramics made without adding residues. The immobilization of As and Pb was also observed in the ceramic bodies obtained. Leaching tests show that immobilization of both elements (As and Pb) improves with increasing firing temperature.

Production of high-strength ceramics from ash and slag waste

In the analytical part of the article, a review of domestic and foreign experience in the use of ash and slag waste (ASW) of coal-fired power plants in the manufacture of ceramic products was made. The practical part provides information on the technology of extracting the ash fraction suitable for the manufacture of ceramic products from the dump ash of Primorskaya SDPP. A method for the manufacture of ceramic bricks with a 100% ash and slag waste content is described, some physical characteristics of the products obtained are determined, and the characteristics of the products obtained are compared in accordance with GOST 530-2012.

USE OF TECHOGENIC RAW MATERIALS IN THE TECHNOLOGY OF CERAMIC BRICKS PRODUCTION

The article presents the results of a study of burnt rocks of mine dumps, ash and slag waste and clay raw materials for the purpose of their use in the technology of manufacturing ceramic bricks. Indicators of their quality are given. In terms of properties and composition, this raw material is close to clay. Compositions and technological modes for the manufacture of ceramic bricks using burnt rocks of mine dumps and ash and slag waste have been developed. The results of laboratory research and industrial tests are presented. The possibility of using this technogenic raw material in the technology of manufacturing ceramic bricks has been proven. The use of burnt rocks and ash and slag waste in the compositions for the manufacture of ceramic bricks can improve its quality, including strength and frost resistance. In all respects, prototypes of ceramic bricks meet the requirements of regulatory documents. The involvement of technogenic raw materials in production allows you to save part of natural raw materials, reduce the cost of products while improving their quality, and help reduce the negative impact of waste on the environment in the areas of their location.The involvement of technogenic raw materials in production allows you to save part of natural raw materials, reduce the cost of products while improving their quality, and help reduce the negative impact of waste on the environment in the areas where they are located.

Manufacture of Sustainable Clay Bricks Using Waste from Secondary Aluminum Recycling as Raw Material.

The aluminum recycling industry produces aluminum filter dust (AFD), a waste byproduct of the aluminum recycling process composed mainly of aluminum oxide in a percentage between 60–70%, 8% calcium oxide, almost 15% sodium chloride, and between 5–10% potassium chloride. Due to its aluminum content, this waste can be used as a raw material in the manufacture of ceramic bricks, at the same time reducing the environmental impact produced in landfill. In this work, the partial substitution of a clay mixture (40% black, 30% red, and 30% yellow clay) by different proportions of AFD in the range 0–25 wt % for the production of fired clay brick was studied. The raw materials, clays, and waste were characterized by XRF and XRD. The brick specimens were fired at 950 °C and their physical and mechanical properties, such as water absorption, water suction, loss of ignition, linear shrinkage, bulk density, and compressive strength, were analyzed. The more relevant results were obtained with the addition of up to 20 wt % AFD, obtaining bricks with physical properties comparable to pure clay-based bricks used as a reference and better compressive strength and thermal conductivity due to the balance between the melting and pore-forming effects of the waste. These sustainable bricks also comply with the regulations of heavy metals leached to the environment, as indicated by the leaching test.

Consumption of energy in the manufacturing of ceramic bricks in the metropolitan area of Cúcuta, Colombia

This research determined the consumption of electrical and thermal energy in the manufacturing of ceramic bricks in the metropolitan area of Cúcuta, city located in Colombia, South America. Three bricks manufacturers were selected using extrusion forming technology, artificial drying and tunnel kiln firing in their production system. An inventory of equipment that consumes electrical energy in industrial facilities was made, quantifying the power consumed and relating it to the monthly work hours. In order to estimate the thermal energy demand generated by the coal supplied in the drying and firing stages, we worked under the regime of stationary operation, measuring the mass of coal dosed in the drying and firing cycle, keeping the pressure variables stable and the temperature. We know that by cogeneration, part of the combustion gases of the furnace, are provided as a flow of hot air to the artificial dryer. The demand for electrical energy in the process was 42000kWh/month; while the thermal energy consumption was 998010kWh/month; and the monthly global energy consumption was 1040010kWh. It was concluded that the distribution of consumption was 96% of thermal energy and only 4% is electrical energy; the stages of firing and drying being those of greater energy expenditure.

Arquitetura, matéria e historiografia: interfaces entre investigação tecnológica e pesquisa histórica, a partir de tijolos cerâmicos em Santa Leopoldina (ES)

Considerando a potencialidade do material construtivo como ferramenta para a historiografia, este artigo consiste em análise de tijolos cerâmicos presentes no sistema construtivo de edificações do Sítio Histórico de Santa Leopoldina, no Estado do Espírito Santo, Brasil, protegido em esfera estadual em 1983. Para além da necessidade de documentação dos sistemas construtivos tradicionais brasileiros e da imprescindibilidade de subsídios técnicos para intervenção no patrimônio edificado, aborda-se a importância da investigação tecnológica para compreensão do processo construtivo da edificação. O critério adotado parte da análise física e mineralógica de um grupo amostral e da interpretação desta análise, admitindo a historicidade da arquitetura como ferramenta de conhecimento da sociedade. Para fundamentação teórica, busca-se o conhecimento da matéria prima do objeto de estudo, bem como os métodos típicos empregados no século XIX, para a produção de tijolos cerâmicos. Metodologicamente, a análise compreende a realização de ensaios laboratoriais para caracterização física e mineralógica dos tijolos, cujos resultados são correlacionados à pesquisa histórica da produção de tijolo cerâmico em Vitória, capital do Estado, entre o século XIX e o início do século XX. O resultado consiste em considerações acerca da fabricação dos tijolos cerâmicos em Santa Leopoldina e contribui para a compreensão dos métodos construtivos utilizados pelos imigrantes europeus não lusitanos que, ao chegarem ao Brasil, a partir da segunda metade do século XIX, colonizam o interior do Espírito Santo.

Comparative Study of the Use of Different Biomass Bottom Ash in the Manufacture of Ceramic Bricks

AbstractThe present study evaluates the suitability of several types of biomass bottom ashes [wood bottom ash (WBA), pine-olive pruning bottom ash (POPBA), olive stone bottom ash (OSBA), and olive ...

Microsilica as a Modifying Component in Fired Ceramics

The principal directions in the development of construction material industry include expansion of raw material sources, quality improvement of raw materials subjected to preliminary treatment, application of modifying components, constructive and technological modernization of manufacturing process. Manufacturing of ceramic bricks is one that dominates this industry. We know that there isn’t enough conditional clay suitable for ceramics production in most East regions of Russia and West Siberia. However, in many regions there are powerful heat power plants and highly-developed metallurgical enterprises, which produce sideline products alongside with basic output. The issue of complex utilization of wastes produced by power engineering and metallurgy has not been successfully resolved yet. Slag and other silica-containing sideline products of main production have not practically been used to the full. Nevertheless, it’s necessary to note, that disperse condition of silica-containing wastes as well as their physical and chemical characteristics predetermine prospective application of silica-containing materials in ceramics.

Использование рисовой соломы в производстве керамического кирпича

Предложены рациональные способы утилизации рисовой соломы и способы улучшения качества керамического кирпича за счет использования рисовой соломы как выгорающей добавки и образующегося в процессе ее сгорания аморфного кремнезема. Представлены характеристики сырьевых материалов, технологические приемы получения изделий и их основные свойства. Определены оптимальные значения содержания добавок соломы и золы в исследуемых композициях.

Uso productivo de lodos de plantas de tratamiento de agua potable en la fabricación de ladrillos cerámicos

Uno de los problemas mas importantes en el tratamiento de agua con coagulacion quimica es la generacion de lodos, cuya disposicion final es predominantemente en cuerpos de agua, afectando su calidad y usos potenciales; el uso productivo de estos puede ayudar en la recuperacion de los recursos naturales y disminuir la contaminacion ambiental. En este estudio se evaluo el uso de lodo aluminoso en la fabricacion de ladrillos ceramicos; los resultados muestran que es viable incorporar estos lodos en reemplazo parcial de uno de los materiales constitutivos del ladrillo, en este caso la arena en un porcentaje del 10%; sin embargo, para evitar comprometer la resistencia a la compresion debe optimizarse la deshidratacion previa del lodo para aumentar el potencial de aprovechamiento. El ladrillo obtenido cumple caracteristicas adecuadas para uso no estructural. Rev. ing. constr. [online]. 2012, vol.27, n.3, pp. 145-154. ISSN 0718-5073. http://dx.doi.org/10.4067/S0718-50732012000300003

Spent Brewery Grains for Improvement of Thermal Insulation of Ceramic Bricks

AbstractOne by-product of the brewing process is a waste containing spent grains (barley malt and maize grits). In the brewing process, this cake is composed mainly of organic matter containing high fiber content, provided by the separation of suspended particles through wort filtration. The study presented here was carried out to assess if the spent brewery grains could be recycled through their incorporation in a paste used in the manufacture of ceramic bricks, and how such incorporation affects some of the physical properties, namely mechanical strength, porosity, and thermal conductivity of the ceramic material. The main objective of the study was to decrease the thermal conductivity of the ceramic paste without significant losses of the mechanical strength of the final product. Spent brewery grains (SBG) characterized by powder X-ray diffraction, X-ray fluorescence spectrometry, scanning electron microscopy, thermogravimetry, differential scanning calorimetry, and heat of combustion were used as an a...

Manufacture of Ceramic Bricks Using Recycled Brewing Spent Kieselguhr

In the brewing process, kieselguhr performs as a filtration medium and one generated by-product is a sludge containing kieselguhr, which is mainly composed of fragmented diatom frustules associated to organic material retained during the clarification process. The physic-mechanic tests were performed on assemblages with brick composition and brewing spent kieselguhr containing 3, 9, and 15 wt% incorporation levels of sludge, being extruded and dried (105°C) before being submitted to slow firing at 900°C, 950°C, and 1000°C. The obtained results showed that, even when at its maximum incorporation level, the spent kieselguhr for all firing temperatures do not cause important losses on the properties exhibited by the clay paste without kieselguhr incorporation and the best incorporation levels are 4.2 wt% when fired at 900°C, 9.8 wt% when fired at 950°C, and 13.4 wt% when fired at 1000°C. When fired at 950°C, 15 wt% addition of spent kieselguhr increased by 27% the open porosity and decreased by 10% the bulk density of the brick paste. Furthermore, physic-mechanic tests and ecotoxicity evaluation on semi-industrial brick manufactured with 9 wt% of brewing spent kieselguhr were accessed. The results do no show any constrain concerning mechanical properties, and the ecotoxicity evaluation shows the safety of the brewing spent kieselguhr incorporation in ceramic products.

Incorporation of Waelz Slag into Commercial Ceramic Bricks: A Practical Example of Industrial Ecology

The recovery of electric arc furnace (EAF) dust generates large amounts of an industrial byproduct called Waelz slag. This residue, consisting primarily of iron oxide contaminated with other metal oxides (including zinc and lead), is usually disposed of in landfill sites at a high economic and environmental cost. This paper investigates an alternative based on industrial ecology principles, which involves the incorporation of Waelz slag into clay ceramic construction bricks. For the purpose of this work, Waelz slag and raw materials employed in the manufacture of ceramic bricks (natural clays, wood pulp) were characterized. Subsequently, a series of brick specimens were manufactured according to commercial mixes and using industrial equipment and procedures. Similar specimens were also produced replacing 20−30 wt % of the clay with Waelz slag. The resulting products were analyzed for their physical (bulk density, water absorption, open porosity), mechanical (modulus of rupture), and chemical properties (soluble salts content) in order to evaluate compliance with quality standards for construction materials. The environmental consequences of incorporating slag into ceramic products were also investigated at three stages of their life cycle: release of potentially toxic species during their use (NEN 7345), leaching of heavy metals after disposal in landfill sites (EN 12457 1 and 2), and emission of atmospheric pollutants during the firing process. The experimental results demonstrate that incorporation of Waelz slag does not deteriorate the physical, mechanical, and chemical properties of the resulting products. The leaching of species during its useful lives show compliance with threshold values established according to the Dutch Building Materials Decree (DBMD), and Waelz slag containing bricks fall into the category of nonhazardous waste landfill, just like conventional bricks used at this work. Emissions of CO2 and NOx were reduced versus the emissions of halogenated gases and SO2, which were favored due to the thermal decomposition of S, Cl, and F contained in the waste material.

The use of different forms of waste in the manufacture of ceramic bricks

In this study, various industrial wastes such as urban sewage sludge, bagasse, and sludge from the brewing industry, olive mill wastewater, and coffee ground residue were blended with clay to produce bricks. The clay and waste were characterized by X-ray diffraction, X-ray fluorescence, and thermogravimetric, differential thermal, and chemical elemental analysis. The bricks were manufactured from clay and the optimal proportion of waste. The influence of the waste addition on the linear shrinkage, bulk density, water absorption, and mechanical and thermal properties was investigated. Water absorption increased to above 35% when urban sewage sludge, brewing industry sludge and bagasse were incorporated into the body, but the compressive strength decreased by a maximum of 19% and the thermal insulation increased by at least 8%. The incorporation of coffee grounds and olive mill wastewater of clay was more beneficial, with compressive strength values similar to bricks without waste and a 19% improvement in thermal conductivity. Water absorption and the SEM micrographs indicated that the changes in the results were due to the type of porosity formed by the quantity and the type of waste.

Environmental Conditions in the Deterioration of Brick Façades

Despite the great progress made in the last few years in the manufacturing of ceramic bricks and their fitting technology, brick facades still suffer from a series of critical problems and in some cases the number of pathologies have even increased. The most common and critical problem of brick facade enclosures is the detachment of pieces from the die, thus the loss of union. This detachment can be associated with three different causes: an inadequate prescription of the griping material, the absence of control joints to make the enclosure compatible, and the incidence of sun and rain on the facades. While the first two factors are directly related to the design process, the fitting techniques, training of the work force, and quality control efficiency, the third factor is related to environmental factors that generate a different microclimate in each facade depending on its orientation. This paper describes some examples of detachments in brick facade enclosures and the main causes that originated from them.

Stabilization/solidification of ashes in clays used in the manufacturing of ceramic bricks

This paper presents the results of the lixiviation of metals from different mixtures of fly and bottom ashes that have been stabilized and solidified in clays used in the manufacture of bricks. The ashes used for this study were obtained from a Hoffmann-type brick furnace adapted for the incineration of municipal solid waste during the manufacturing of ceramic bricks. The ashes were stabilized in clay in different proportions of clay:ash mix (99:1, 95:5, 90:10, 80:20 and 60:40). Such mixes were used to manufacture bricks that were calcined at a temperature ranging from 50 to 1100 degrees C. The clay, ashes and manufactured bricks were characterized using X-ray diffraction, fluorescent X-ray, thermogravimetry, differential thermal analysis, atomic absorption spectroscopy and scanning electronic microscopy. In addition, toxicity characteristic leaching procedure lixiviation tests were performed according to the EPA 1311 method for the determination of heavy metals. The results showed an affinity between clay and ash, and also that the bricks manufactured with these mixtures present low lixiviation levels. The tests also showed the highest decrease in the concentration of arsenic, nickel, chromium, zinc and silver for 99:1 mixtures. The 95:5 mixture was found to be the most favourable for the stabilization (greater concentration decrease) of lead and cadmium. Selenium was the metal with the lowest concentration change whereas arsenic, nickel, chromium, zinc and cadmium showed the greatest concentration change in all mixtures, with the exception of cadmium in the mixture 99:1.

Use of waste from oil shale mining in the Volga basin for the manufacture of ceramic bricks

Use of waste from oil shale mining in the Volga basin for the manufacture of ceramic bricks

Oily Wastes Application in Ceramic Materials Manufacturing

The application of oily residues produced by PETRÓLEO BRASILEIRO S.A. -PETROBRÁS in the manufacturing of ceramic bricks appears as a promising alternative of their reutilization, in comparison with the traditional method of storage in ponds or dikes and to the biodégradation process by landfarming. The application of said residues started experimentally in 1988, in a ceramic bricks factory located in the Paraíba do Sul Valley, State of São Paulo, near the Henrique Lage Refinery (REVAP). In mid-1989, the Presidente Bernardes Refinery (RPBC), the Capuava Refinery (RECAP) and the Petroleum Products Terminals of São Paulo (TEDEP) started sending oily residues to factories participating in the Red Ceramics Association of Itu and its Region (ACERVIR). As an advantage of this process, almost all the costs with disposal of said residues are eliminated for PETROBRÁS; on the other hand, the reduction in maintenance costs, lower energy consumption, and a significant increase in production are advantages for the ceramics factories.