Production Of Ceramic Materials Research Articles

Preparation of Ceramic Press Powder Based on Aluminosilicate Clay Raw Materials and Ash and Slag Waste from Thermal Power Plants Synthesized by Vitreous Microspheres

The possibility of using 3-component charges in the production of wall ceramics by semi-dry pressing from aluminosilicate loams in a composition with ash and slag waste from CHP plants, cullet and silica gel obtained by the sol-gel method is considered. The physicochemical processes and phase formations occurring in the production of ceramic materials using WCO at the firing stage have been studied. It was found that the introduction of fluxes in the form of cullet and silica gel reduces the temperature of heat treatment and are intensifiers of mineral neoplasms that increase mechanical strength compared with samples made from 2-component compositions «loam + ASW».

Kaolin from Poletaevskoye deposit (Chelyabinsk region, Russia) in ceramics production

The paper presents the results of a study of the properties of Poletaevsky kaolin with the aim of using it in the ceramic industry. Based on the results of determining the chemical, mineral and granulometric composition. The mineral composition of Poletaevsky kaolin is kaolinite 80–85 wt %, muscovite and illite 10–15 wt %, quartz up to 10–15 wt %. It has been established that the Hinckley index for Poletaevsky kaolin is 0.68, compared to 1.38 for Glukhovetsky one. The ratio of highly ordered kaolinite to low ordered kaolinite for Poletaevsky kaolin is 22 : 78, for Glukhovetsky kaolin the ratio of highly ordered kaolinite to low-ordered kaolinite is 57 : 43. It was established that Poletaevsky kaolin can be used in the production of ceramic materials by plastic or semi-dry molding. The determined low content of high-ordered kaolinite and the insignificant content of particles less than 2 μm according to the results of laser diffraction analysis can lead to the production of an unstable slip. When firing samples of Poletaevsky kaolin, a minimum water absorption of 5.5 % was achieved at a firing temperature of 1450 °C. In this case, the resulting maximum apparent density was 2.17 g/cm3, the maximum mullite content was 38 %, and the maximum compressive strength was 32 MPa.

Study of Shomishkul kaolin for producing ceramic materials

The article discusses the results of research studies of kaolins from the Shomishkul deposit in Karakalpakstan using chemical-mineralogical and X-ray phase analyses. As a result of the tests, it was established that samples of clay minerals from the studied deposits can be used as the main raw material component for the production of ceramic materials, which helps to expand the raw material base for the production of ceramic materials for construction purposes.

Enhancing the sustainable production of cost-effective ceramics with high strength using kaolin, sewage sludge and blast-furnace slag

Solid waste treatment remains an unavoidable environmental burden for modern cities. Currently, the multipurpose utilization of solid waste in construction and building materials is worth in-depth research as it furnishes high-value commercialization pathways with environmental and economic benefits for managing waste and addressing resource scarcity. This study explored the cost-effective ceramic fabrication from 40 % sewage sludge, 10 % blast-furnace slag and 50 % kaolin through in-situ sintering method, which enhanced the sustainable production of ceramic materials. The influences of firing temperature on the ceramic sintering effects, including mineral composition, micromorphology, pore structure and process performance, were systematically investigated. Results showed that the particle consolidation and sintering degrees of finished ceramics continuously increased as the firing temperature raised, presenting different surface, cross-sectional and pore structure characteristics. This was because increasing the firing temperature changed natures of the formed glass phase, such as content and viscosity. Moreover, variations in the ceramic structure would further affect its process performance. The ceramics prepared at 1250 °C were determined to have best firing effects with the densest structure and excellent performance, and the corresponding water absorption, bulk density, apparent porosity and compressive strength were 0.97 %, 2.32 g/cm3, 2 % and 70 MPa, respectively. Finally, comparisons with other researches confirmed that the developed ceramics possessed strong competitiveness in process performance. The presented study provided data support for the value-added application and sintering optimization of waste slag and sludge in ceramic production.

Discrete element modelling of the size-dependent mechanical behavior of Al2O3 ceramic under quasi-static uniaxial compression

The size-dependent mechanical behavior of Al2O3 ceramic under quasit-static uniaxial compression was simulated via two-dimensional discrete element method. The numerical sample of Al2O3 ceramic was established by adopting the linear parallel bond contact model, and the inherent defects was further generated by randomly removing a subset of elementary discs. The uniaxial compressive strength of Al2O3 ceramic samples with different sizes follows the Weibull distribution. With an increase in sample size, the magnitude of the uniaxial compressive strength decreases, while its variability increases. Additionally, with sample size increases, both the Young's modulus and Poisson's ratio decrease. Meanwhile, the variability in Young's modulus and Poisson's ratio is more pronounced in larger samples than in smaller ones. The progressive fracture process of Al2O3 ceramic sample can be categorized into four typical stages, namely linear-elastic stage, crack initiation stage, crack propagation stage and complete failure stage. The final fragment size distributions of Al2O3 ceramic samples of different sizes can be accurately described by the fractal model. Notably, smaller samples tend to exhibit a greater breakage extent compared to larger samples. Finally, a size-dependent statistical equation of uniaxial compressive strength of Al2O3 ceramic is proposed based on the numerical results and the inverse function of the Weibull distribution, which can provide a theoretical basis for the design and production of ceramic materials.

Reusing Ceramic Waste as a Precursor in Alkali-Activated Cements: A Review

Concrete and ceramic products are among the most widely used materials in the construction sector. The production of ceramic materials has significantly grown in recent years. Concrete is one of the most widely used materials worldwide and most of its carbon dioxide (CO2) emissions are attributed to Portland cement (PC) production. This review analyzed previous research works into the use of ceramic waste (CW) as a precursor in alkali-activated (AA) cements. The physico-chemical properties of different CW materials were analyzed, and the properties and environmental impact of three main categories of AA CW cements were explored: those developed solely with CW; hybrid cements combining CW with traditional binders (PC, calcium hydroxide or calcium aluminate cement); combinations of CW with other precursors (i.e., blast furnace slag, fly ash, fluid catalytic cracking residue, etc.). The results evidenced that CW can be successfully employed as a precursor in AA cements, particularly in the context of prefabricated products where thermal curing is a prevalent procedure. When enhanced mechanical strength is requisite, it is feasible to attain improvements by employing hybrid systems or by combining CW with other precursors, such as blast furnace slag. This new alternative reuse option allows progress to be made toward sustainable development by reducing not only CO2 emissions and embodied energy compared to PC but also PC consumption and CW accumulation in landfills.

Using glass wastes and bentonite to produce a new ceramic tile

Abstract This paper discusses the recycling of glass waste as a compound in the production of ceramic tiles. The present study aims to investigate the effects of glass waste (with two different granulometries) on the physical and mechanical properties of ceramic tiles, in order to demonstrate their suitability for the production of ceramic materials. A series of ceramic tiles was prepared based on bentonite (B) by adding 70, 65, and 60 wt% glass wastes (GW1 and GW2 with two different granulometries) into the batch composition. The ceramic tiles were sintered at a constant temperature of 900 °C following the same production protocol. The physical-mechanical properties and chemical durability of all ceramic tiles produced were evaluated. The results show that ceramic tiles can be produced from a basic mixture of 35% bentonite and 65% glass waste, with good physical, mechanical, and thermal properties (the local Algerian bentonite is considered a clay binder and has excellent plasticity).

Composite Concrete Paving Stones for Road Construction

The society pays attention to the reduction of construction costs and modern technologies and recommends using environmentally friendly and durable road paving materials instead of traditionally used asphalt concrete. Many years of experience accumulated in European countries shows the effectiveness of laying streets with small paving stones. Currently, the paving stones are made of natural stone (paving stones), ceramic stone (clinker) and fine-grained concrete. The most durable paving blocks are paving blocks, but for their production it is necessary to dig quarries and process precious stone, resulting in small waste. One of the main factors hindering their use in the production of ceramic materials is the high sintering temperature (1500°C), which significantly increases energy consumption. Concrete screed is mainly made of fine-grained concrete, but the screed itself is not as strong as blocks and clinker. In this paper, a review of studies on the inclusion of glass in the composite composition of concrete floors is carried out. Discussed of how the physical and mechanical parameters of concrete are subject to changes

Review of modern ceramic cellular materials and composites used in heat engineering

THE PURPOSE. Cellular ceramic materials and composites have found application in many industries: energy, chemical industry, construction, aerospace. Due to their high thermomechanical properties, resistance to high temperatures and low density, cellular ceramic materials are widely used as heat exchangers for heat recovery from exhaust gases of gas turbine engines, combined-cycle plants, industrial furnaces, etc. The purpose of this work is to review modern cellular ceramic materials and composites used in heat engineering and having different structure, properties and chemical composition.METHODS. We have carried out a broad review of the literature on ceramic cellular materials and composites. We studied both domestic and foreign literature.RESULTS. The analysis of cellular ceramic materials with a regular (lattices) and random (foam) structure has been carried out. The main factors influencing the properties of ceramic foams and lattices are analyzed. Also, the main methods for the production of ceramic materials were studied, their advantages and disadvantages were revealed. A review of modern composite materials based on a ceramic matrix reinforced with carbon nanotubes, graphene nanoplates, and carbon fibers has been carried out.CONCLUSION. The properties of ceramic cellular materials, as well as their areas of application, depend on the production methods and the structure of the material. Open-cell foams are used as filters, heat exchangers, while closed-cell foams are used as thermal insulation. Applications for ceramic lattices are limited by the precision, resolution, and size of 3D printing. Thus, the improvement of additive manufacturing technologies will improve the characteristics of ceramic gratings and expand their areas of application.

Low-cost flame synthesized La2/3Cu3Ti4O12 electro-ceramic and extensive investigation on electrical, impedance, modulus, and optical properties

An environmentally-friendly synthesis route and low-cost starting materials are more appropriate for the production of ceramic materials at the industry level. With this concern we prepared the La2/3Cu3Ti4O12(LCTO), which is isostructural of CaCu3Ti4O12 (CCTO), using the low-cost TiO2 instead of a high-cost of titanium source (titanium isopropoxide or titanium chloride) using a low-cost wet-chemical route. Although, there are lots of synthetic methods reported for LCTO fabrication in terms of duration, cheap reagents, energy consumption, feasibility, etc. The present method is far better than the others. The prepared ceramic samples were sintered at 1050 °C/12 h and studied their structural, morphology and impedance, and modulus studies for further confirmation. The prepared LCTO ceramic shows the pure phase with the cubic type of morphology. The homogenous distribution of all the elements was observed through dispersive X-ray analysis. X-ray photoelectron spectroscopy studies revels that La is in +3 oxidation state, Cu is in a +2 oxidation state, and Ti is multiple (+3 and + 4) oxidation state. The LCTO ceramic displayed the very high dielectric constant (∼3852) and dielectric loss (0.322), at 1 kHz and at room temperature. Calculated the activation energy using the impedance and modulus data and it shows the superior to that of CCTO ceramic synthesized by the same method. The prepared samples exhibited Debye-type relaxation, which is evoked from the impedance and modulus studies. The calculated optical energy bandgap of LCTO (2.06 eV) is found to be lesser than that of the well-known structure of perovskites (BaTiO3 (3.28 eV), PbTiO3 (3.18 eV), LiNbO3 (3.78 eV) and BiFeO3 (2.67 eV) as well as structure of spinel CoCr2O4 (3.10 eV) and LuFe2O4 (2.18 eV)) materials.

From high-volume industrial waste to new ceramic material: The case of red gypsum muds in the TiO2 industry

The present study aims to apply the principles of circular economy, using special inorganic waste (in particular, red gypsum muds from a TiO2 plant in Tuscany, Italy) to produce ceramic materials for the construction and building industries. Red gypsum (RG) muds produced during more than 10 years of industrial processing were chemically and mineralogically characterized by X-ray fluorescence spectrometry (XRF), X-ray powder diffraction (XRPD), scanning electron microscopy with energy dispersive X-ray spectrometer (SEM/EDS), and thermal analyses (TA). The analyses testify that RG waste production is chemically and mineralogically constant over time, and therefore suitable to be used as a secondary raw material in industrial ceramic production. Ceramic specimens have been realized using an extremely high amount of the RG waste (up to 70%) and characterized using the same chemical-mineralogical techniques, revealing that anhydrite, pyroxene, and Fe/Ti oxides are the main crystalline phases, embedded in a glassy compact matrix. Overall results indicate that the production of ceramic materials could represent a definitive and sustainable solution for the problematic management of the large volumes of RG waste deriving from TiO2 plants.

GEL CASTING METHOD FOR THE PRODUCTION OF CERAMIC MATERIALS

Gel casting is one of the new and promising methods for producing ceramics. Modern research on the production of ceramic materials by gel casting covers a wide range of materials, including both dense and porous ceramic materials. The advantages of this method, such as ease of processing, the use of technological equipment of traditional methods, increased productivity, the possibility of obtaining products of large shapes and complex geometry, gave impetus to new research and development. This article provides an overview of publications devoted to research in recent decades on the production by gel casting of both dense ceramics for the manufacture of structural elements and porous ceramics for the manufacture of thermal insulation, porous filters and membranes.

Синтез и фазовые превращения двойного фосфата магния — натрия

In this work we found optimal conditions for magnesium — sodium double phosphate MgNaPO4 synthesis, which according to the literature could not be obtained single-phase. Compounds polymorphic transformations have been studied with thermal analysis methods, which is important for further ceramic materials production from the considering compound.

Solar technology possibilities and features in ceramic materials production

The necessity of developing technologies based on the use of solar energy as an energy-saving renewable natural resource is shown. Ceramic materials were obtained in a Large solar furnace (Parkent) with a capacity of 1000 kW: aluminum titanate, corundum, solid solutions based on ZrO2, Bi/Pb-superconducting material and the influence of the conditions for obtaining these materials on the microstructure, unit cell parameters, strength was established. The possibility of the development and practical application of concentrated solar energy for ceramic materials production is shown. Ill. 3. Ref. 25. Tab. 1.

Heat and Mass Transfer in Structural Ceramic Blocks: An Analytical and Phenomenological Approach

The ceramic industry is one of the pillars of the Brazilian economy, characterized by making low-cost products and an obsolete manufacturing process from a technological point of view. Among the various stages of production of ceramic materials, drying is one of the most energy-consuming and, in general, causes structural damage to the product, compromising its mechanical performance and final quality. Despite the relevance, studies on the drying of ceramic materials are mostly conducted at the experimental level and limited to some specific operational conditions. In this scenario, this research aims to theoretically study the heat and mass transfers in industrial ceramic blocks during drying. Based on the lumped analysis method, and considering the dimensional variations of the material, new phenomenological mathematical models and their respective analytical solutions are proposed to describe the kinetics of mass loss and heating of the material. The predicted results referring to the thermal and gravimetric behavior of the block during the oven drying process under different conditions are compared with the experimental data, obtaining excellent agreement between the results. Furthermore, the transport coefficients were estimated, proving the dependence of these parameters on the drying air conditions. The convective mass transfer coefficient ranged from 6.69 × 10–7 to 15.97 × 10–7 m/s on the outer surface of the block and from 0.70 × 10–7 to 1.03 × 10–7 m/s on the inner surface of the material when the drying air temperature ranged from 50 to 100 °C. The convective heat transfer coefficient ranged from 4.79 to 2.04 W/(m2.°C) on the outer surface of the block and from 1.00 to 0.94 W/(m2.°C) on the inner surface of the material when air temperature ranged from 50 to 100 °C.

Effects of plaster to water ratio on physical and mechanical properties of ceramic pieces produced by the slip casting process

In the slip casting process, the relationship between the amount of plaster and water used in the production of molds influences the production of ceramic materials, because the higher the water content in the mixture, the lower the mechanical strength of the mold and higher the water absorption rate. In order to evaluate the influence of the variation in the plaster/water (P/W) ratio in the production of ceramic pieces, plaster molds with P/W ratios of 2.0, 1.67, 1.43, and 1.25 (100 parts of plaster/50, 60, 70, and 80 parts of water by weight) were manufactured and used in the production of ceramic pieces. It was found that the fluidity, density, flexural and compressive strength of the molds decreased with the increase of water content. For pieces sintered at 1050 °C, higher density and lower porosity were observed for ceramic materials obtained with molds with higher plaster/water ratios.

Получение сейсмостойкого кирпича на основе вторичных энергетических ресурсов без применения природного традиционного сырья

Smeared soil from oil production with an increased content of calorific value is advisable to use not only as a thinning agent, but also as burnout additives for the production of ceramic materials. Obtained on the basis of large-tonnage waste: combustible shale – shale clay, oil and gas processing complex – smeared soil and nanotechnogenic waste of petrochemical production — catalyst IM - 2201 without the use of natural traditional materials earthquake-resistant brick with high physical and mechanical properties.

Industrijski otpad kao faktor povećanja hemijske otpornosti keramike

The possibility of the manufacturing of ceramics with equally high indicators of acid and alkali resistance is shown. The effect achieved is associated with the formation of a system of crystalline phases of anortite-hematite-cristobalite during the firing of masses created on the base of compositions of red mud and polymineral clay. Technological schemes of the production of ceramic materials from masses with the total content of 60-80% of red mud, non-ferrous metallurgy waste, which is the factor of increase of decorative and operational characteristics of production are proposed.

Rapid preparation of Bi0.5Na0.5TiO3 ceramics by reactive flash sintering of Bi2O3-NaCO3-TiO2 mixed powders

Lead-free Bi0.5Na0.5TiO3 piezoelectric ceramics were successfully prepared by reactive flash sintering of Bi2O3-NaCO3-TiO2 mixed powders, where phase transformation and densification occurred simultaneously. The influence of electric field strength, current density and holding time at constant current state on the phase transformation and densification were investigated. The current density had a significant influence on the extent of phase transformation and densification. The holding time had no influence on the phase transformation, but had an important effect on crystallinity of sample. The sintered bulks exhibited the maximum polarization Pm of 16.8 μC/cm2, remanent polarization Pr of 9.6 μC/cm2, coercive field Ec of 29 kV/cmm, maximum electric-field-induced strain of 0.053 %, and piezoelectric coefficient d33 of 85 pC/N. The reactive flash sintering can prepare the dense and single-phase ceramics from multiphase precursor powders in one step of flash, providing a new way for rapid production of ceramic materials.

Energy lost in endothermic reactions in the production of clay blocks in a continuous kiln

In Ocaña, Norte de Santander, Colombia, the production of ceramic materials is done in a traditional and empirical manner, generating heat losses, low productivity and product quality, and increased emissions of polluting gases into the environment. A virtual instrument for temperature data acquisition was developed and the firing process was monitored in two loading doors of a Hoffman kiln. 29040 blocks were produced, and 1370.76 kg of pulverized charcoal were consumed. The firing process lasted sixty-two hours and the virtual instrument was programmed to record data every 5 minutes. The energy supplied to the brick kiln was 340.16x106 kJ and the heat due to loading of the products and heat lost in the endothermic reactions of the clay was 107.71x106 kJ and 105.71x106 kJ respectively, representing 31.66% and 31.08% of the energy supplied. The results have made it possible to establish trends in the temperatures and energy consumed in the endothermic reactions in the clay. This will allow the implementation of coal quality and grinding procedures, increasing energy efficiency, and reducing gas emissions into the environment, thus avoiding acute respiratory diseases.