Clay Raw Materials Research Articles

Protection of dumpcar bodies for transportationof clay raw materials of construction enterprises

Protection of dumpcar bodies for transportationof clay raw materials of construction enterprises

Development of lightweight bricks using agricultural and industrial waste

Abstract The construction industry is undergoing a notable shift towards environmental sustainability, driving the innovation of construction materials that are robust, lightweight, and eco-friendly. this study delves into the formation of lightweight bricks, with a focus on their mechanical properties, thermal insulation capabilities, and environment-imperative agricultural and industrial waste material. In response to the environmental imperative to reduce reliance on clay and other raw materials in construction, this study investigates the utilization of flower waste, iron ore, chaff, and wheat husk, in the production of lightweight bricks. This alternative material offers a sustainable solution to mitigate the environmental impact of traditional brick manufacturing processes. Through a systematic evaluation of physical properties, materialistic properties, and thermal performance the study provides insights into the feasibility and efficacy of incorporating chaff and wheat husk into brick production. The findings offer practical recommendations for the development of environment-friendly construction materials contribute to the conservation of natural resources and the promotion of sustainable building practices.

Evaluation of Clayey Raw Materials and Ceramic Masses from Ceramic Building Material Companies Located in Northeastern Brazil

The challenge of improving the quality of ceramic products is faced worldwide, especially in areas where artisanal production is common and the need for in-depth knowledge about raw materials, together with inefficient production processes, limits the advancement of the ceramic industry. Scientifically, detailed investigation of ceramic masses’ physical, chemical and mechanical properties can provide essential insights to optimize production, contribute to developing more advanced and sustainable techniques, and increase competitiveness. This study evaluated raw clay materials and ceramic masses obtained from northeastern Brazilian, focusing on their chemical composition, mineralogical phases, thermal behavior, and particle size distribution. Rectangular samples (80 mm × 20 mm × 7 mm) prepared using uniaxial pressing (25 MPa by 30 s) were fired at different temperatures (950 and 1050 °C) and linear shrinkage, flexural strength, water absorption, and apparent porosity measurements were taken. The results showed that the companies still need to improve the production process to meet the minimum strength requirement of 1.5 MPa according to the Brazilian standard NBR 15270.

Geochemical Characteristics of Clay Deposits, Bussaya Area, Southern Iraq

This study concerned with the geochemical characteristics of clay deposits belong to Nfayilbeds (Middle Miocene) in Al Muthana Governorate southern Iraq, as a new resource of clayraw material. Twenty three samples of clay deposits were analyzed by using X-RayFluorescence technique (XRF) for the major oxides; (SiO2, Al2O3, Fe2O3, MgO, CaO, Na2O,K2O, TiO2, and L.O.I), and trace elements; (V, Cr, Co, Ni, Cu, Zn, As, Sr, Pb, Ga, Rb, Ba, andZr). The chemical results demonstrated due to the relation between Sr and Cu, that thedepositional environment predominated by hot and arid paleoclimate conditions, while from therelation between Al2O3 with (Al2O3, CaO, Na2O, and K2O) reveals a low to relatively moderatechemical weathering. Whereas the ratio of Ni/Co reveals that the deposition was within hypoxicenvironment, while due to the ratio of Al2O3 / TiO2 in which advocated by Ti- Zr relation whichdemonstrates that the intermediate igneous rocks as a provenance of the studied clays.

КЕРАМИКАЛЫҚ ЖОЛ ТӨСЕНІШТЕРДІ ӨНДІРУДЕГІ КЕРАМИКАЛЫҚ МАССА КОМПОЗИЦИЯСЫН ЖЕТІЛДІРУ

The article presents the results of a study of the chemical and mineralogical composition of the raw material components in the ceramic mass and provides techniques for the technology of laying ceramic material by vibropressing using talc rock in the mass and methods for determining the composition of clay raw materials. Formulations for the production of ceramic road surfaces, taking into account the factors of preference for mixtures to improve the properties of the finished product as a molding, drying and ceramic material, have been studied in two different components. It was found that the introduction of talc into the ceramic composition has an effect on the formation of high-temperature augite and amphibole phases and the intensification of the formation of minerals in clay, on the formation of high-temperature phases - sanidine, ackermanite elements. This process leads to an increase in the physical and mechanical properties of the resulting samples.The main patterns of formation of the structure and phase of ceramic compositions by firing in the temperature range 1000оC-1100оC were studied by isothermal control.In this pattern, sintering processes with solid and solid liquid-phase syntheses were carried out to ensure the phase - mineral composition, the study clarified the production of high-strength and frost-resistant ceramic pavement. In order to be used in the improvement of the city territory (sidewalks, alleys, park areas, playgrounds, etc.), the possibility of obtaining ceramic road surfaces that meet environmental and operational requirements has been proven. It has been established that one of the priority properties of ceramic road surfaces is a significant abundance of their porosity (25-30%), which allows you to quickly absorb moisture from precipitation (rain, sleet, etc.) and filter water through the body into the ground.Such properties of ceramic paving stones prevent the accumulation of moisture on the surface of the roadway and create comfortable conditions during pedestrian movement, reducing the likelihood of ice formation on the surface of the paving stones in the cold season.

The influence of addition of fly ash from biomass combustion on selected properties of red building ceramics

The paper characterizes waste in the form of fly ash generated in a power plant during the combustion of biomass in a fluidized bed in terms of its possible use in the ceramic building materials industry. This is important from the point of view of environmental protection. In order to assess the possibility of using ash in the production of red ceramics (e.g. bricks), two different clay raw materials (Clay I and Clay II) were selected to prepare the raw material sets. First of all, the investigated fly ash was subjected to thermogravimetric TG-DTG analysis and its basic chemical composition was determined. Then the specific density was determined for all the raw materials, XRD analysis was also performed and finally characteristic temperatures were determined by means of a high-temperature microscope. The basic raw material sets included clayey raw material and fly ash in various contents: 5 wt%, 10 wt% and 15 wt%. Samples were pressed from the ready sets and fired at the temperature of 1000℃. Afterwards, the obtained samples were subjected to XRD and microstructural tests, then selected physical properties were determined, i.e. water absorption, porosity, apparent density, and compressive strength. Based on the research and analysis of the results, it was found that the introduction of fly ash from biomass combustion into the raw material set in the range of 5–15 wt% has a positive effect on the insulating properties of red ceramics. In addition, the density of the red ceramics decreases with the increase in the addition of fly ash, while its porosity and water absorption increase. Furthermore, the addition of fly ash decreases the compressive strength and visually brightens the microstructure of the products.

Sustainable approach to raw clays for ceramic and refractory applications: insights from updated traditional ternary diagrams

AbstractThe study analysed 93 samples from four Serbian clay deposits to determine their suitability for ceramics production. The samples were mainly composed of illite and kaolinite. Ternary diagrams were used to classify the samples and evaluate their applicability. Winkler's diagrams, ternary graphs and mineralogical compositions were analysed. The results showed a broader area in these graphs than previously determined for structural ceramics, as well as the potential of these clays for ceramic production. The study used dry-milled, hydraulically semi-dry, pressed and fired samples to assess water absorption and flexural strength and statistical analysis to determine the key parameters influencing final product quality, including that of refractory, wall and floor tiles. This paper evaluates the raw clay materials’ applicability in ceramic production, promoting sustainable use through rapid initial tests, energy savings through dry milling and ecologically sound principles through resource-efficient evaluation.

Unveiling the distinctive geochemical signature of fine ware through Sr–Nd–Pb isotopes: A site‐specific perspective from the site of Cales (South Italy)

AbstractThis study explores the use of three isotopic systematics—Sr, Nd, and Pb— combined together for the first time to trace the origins of ancient pottery. This approach strengthens our ability to relate raw materials to the final products. The materials selected for the analysis are from a well‐documented data set, previously subjected to a thorough mineralogical–petrographic and chemical characterization. Seventeen ceramic specimens represented by black‐glazed pottery, Terra sigillata, and fine common ware as well as production indicators such as black‐glazed pottery wasters and spacers were examined via isotope analyses. These samples were discovered in the archaeological site of Cales, presently Calvi Risorta, in South Italy. CaO‐rich clay raw materials from the area of interest were also analyzed as comparative references for the investigated ceramics. The comparison of the archaeometric data of the ceramic samples with the clay raw materials showed an affinity between the ceramics studied and local clay raw materials belonging to Mio‐Pliocene marine sediments from the Campania Apennine Mountain area. This affinity was more accurately defined through the Sr, Nd, and Pb isotopes, which show coinciding signatures among ceramic samples, production indicators, and raw materials. The method yields promising outcomes that reinforce prior experimental investigations and amplify its reliability. The multi‐isotopic methodology highlights the significance of combining geochemical data to pinpoint the origins of raw materials used for ancient ceramic production.

Raw clay material-based modified carbon paste electrodes for sensitive heavy metal detection in drinking water

A new electrode based on carbon paste (CP) modified with natural clay was used for heavy metals detection. The investigation of the raw clay material (X-ray diffraction, infrared spectroscopy, scanning electron microscopy, energy-dispersive X-ray spectroscopy, thermal analysis and particle size distribution) revealed different morpho-structural properties of the natural material. The electrochemical behaviour of the modified carbon paste electrode and its ability to detect heavy metals (Zn2+, Cd2+, and Cu2+) was studied by different electrochemical techniques like cyclic voltammetry (CV), electrochemical impedance spectroscopy (EIS), and square wave anodic stripping voltammetry (SWASV). Both electrochemical and analytical parameters of the investigated modified electrode recommend them as stable, sensitive and reproducible sensors for individual heavy metals detection.

Artificial lightweight aggregate made from alternative and waste raw materials, hardened using the hybrid method

Lightweight aggregates are a material used in many industries. A huge amount of this material is used in construction and architecture. For the most part, lightweight construction aggregates are obtained from natural resources such as clay raw materials that have the ability to swell at high temperatures. Resources of these clays are limited and not available everywhere. Therefore, opportunities are being sought to produce lightweight artificial aggregates that have interesting performance characteristics due to their properties. For example, special preparation techniques can reduce or increase the water absorption of such an aggregate depending on the needs and application. The production of artificial lightweight aggregate using various types of waste materials is environmentally friendly as it reduces the depletion of natural resources. Therefore, this article proposes a method of obtaining artificial lightweight aggregate consolidated using two methods: drum and dynamic granulation. Hardening was achieved using combined methods: sintering and hydration, trying to maintain the highest possible porosity. Waste materials were used, such as dust from construction rubble and residues from the processing of PET bottles, as well as clay from the Bełchatów mine as a raw material accompanying the lignite overburden. High open porosity of the aggregates was achieved, above 30%, low apparent density of 1.23 g/cm3, low leachability of approximately 250 µS. The produced lightweight aggregates could ultimately be used in green roofs.

Revitalization Of Balango: Local Ceramic Art and Products from Galogandang Luhak Nan Tuo, West Sumatra

Balango, a traditional pottery used as a cooking utensil in Minangkabau villages, has been transformed as an interior aesthetic support or aesthetic element, so that balango becomes more dynamic and has prospects as an art commodity. This research aims to examine the revitalization of pottery at Galogandang Pottery Hall in Luhan Nan Tuo, West Sumatra. This research uses a mixed method as a reference strategy for developing the potential of clay for the application of local pottery crafts in a sustainable manner through a creative approach supported by laboratory tests. Balango at Galogandang Pottery Hall, there is a development of local art product designs in the form of flower vases; pendil teapots, and kadhai whose clay raw materials are formulated from three types of soil with a clay fraction of 23% (sandy loam clay); kaolinite (21%), illite (41%), and quartz (38) minerals; oxide composition dominated by SiO2 (37%) and Fe2O3 (35%); burn shrinkage (19%); specific gravity (1.75 g cm-3), porosity (26.60%) and compressive strength (225.48 kg cm-2). This composition can be used to customize new ideas for other products by combining different forms (figurative and abstract), resulting in visually beautiful and functional utilitarian pottery for interiors with artistic quality and local flavor.

Production of effective materials on the basis of sulfuric acid industry wastes

Introduction. Solving the urgent problem of the production of special concretes using certain varieties of substandard natural raw materials and a number of industrial wastes will support introducing the principles of resource saving and improving the technological features of production.Aim. To make a comprehensive assessment of the impact of sulfuric acid production wastes and substandard natural clay raw materials on the production of high-quality and durable concretes for special purposes.Materials and methods. Easily fusible clay rocks serve as a raw material for the production of expanded clay gravel. Organic (solar oil) and ferruginous (pyrite cinders) additives were used. X-ray analysis was carried out to determine the crystalline phases in the clay of the Nikolskoe oil-field, in the resulting expanded clay gravel, as well as to analyze the factory bulk samples of pyrite cinders. A tubular electric furnace was used for firing in a two-stage mode of 700 and 1100 °C to obtain high-strength expanded clay gravel under laboratory conditions. The research involved studying parameters of phosphate binder formation and properties of iron phosphate concrete based on H3PO4 and sulfuric acid industry wastes – pyrite cinders.Results. It was found that Nikolskoye field clay forms a good raw material for the production of high-strength heavy expanded clay gravel with a strength of up to 550 kg/cm2, water absorption of 1.5 % and resistance to aggressive environments, thereby making it suitable for manufacturing special concretes. The results obtained specify the test methods and technical requirements, control methods and product acceptance rules, thus improving the quality and durability of the concretes considered.Conclusions. The investigated non-bloating clay can be used with organic and ferruginous additives to obtain high-strength expanded clay gravel for the manufacture of structural concretes. A mixed iron phosphate binder serves for producing heat-resistant concretes for linings of melting and casting units in non-ferrous metallurgy with high resistance and durability.

Clay influence on lightweight brick’s properties: Investigating the impact of waste’s nature and amount as secondary variables

The present study aims to examine whether incorporating a specific proportion of a particular waste material consistently yields bricks with favorable properties, regardless of the raw clay type utilized. In this context, different mixtures were produced with a clay named AMD2 and 0 wt%, 5 wt% and 10 wt% addition of two wastes named argan nut shell and wheat straw. A first investigation of the used raw clay material revealed the presence of Quartz as a dominant mineral, along with Orthoclase, Illite, and Hematite. Furthermore, the elaborated bricks have been subjected to a physical, mechanical, and structural characterization including loss on ignition (LOI), linear shrinkage (LS), water absorption (WA), apparent porosity (AP), bulk density (BD), and compressive strength (CS). A comparison between the current study and a previous one using the same waste materials and identical proportions of addition but employing a different clay type revealed notable differences in outcomes. In the previous study, bricks fabricated with AMD1 clay and 5 wt% of argan nut shell displayed excellent characteristics. However, in the current investigation using AMD2 clay, bricks with the same waste addition ratio exhibited less favorable properties. Specifically, bricks made with AMD2 clay and 5 wt% argan nut shell showed a loss on ignition of 7.30 %, a linear shrinkage of 3.7 %, a water absorption of 23.3 %, an apparent porosity of 38.20 %, a bulk density of 1.64 g/cm3, and a compressive strength of 9.90 MPa. These outcomes indicated a water absorption above the specified limit and significantly higher apparent porosity compared to bricks produced with AMD1 and 5 wt% argan nut shell, which met standard specifications. This variation highlights how the mineral composition of clay significantly impacts brick properties, even when using the same waste materials and proportions, confirming the importance of considering the raw clay material's nature in bricks’ production, and thus emphasizing the need for a preliminary study before combining clay and wastes in order to achieve excellent results.

Alternative material recommendation for facade cladding: High silica-containing stonepaste ceramics

This study investigated the potential of using stonepaste ceramics, which were widely preferred as a coating and decoration material on the facades of architectural buildings in ancient times and continues to be produced on a workshop scale today as a cladding material on building facades. Stonepaste ceramics, made from a mixture prepared with a high amount of crystalline quartz as well as frit, plastic clay, and bentonite raw materials, were hand-shaped and sintered at 930 °C after glazing. The physico-mechanical properties of stonepaste ceramics, their behaviour under various environmental conditions (resistance to chemicals, frost, and thermal shock), and their microstructures have been characterized. The characterization results were compared with the properties of commonly used facade cladding materials. It was determined that stonepaste ceramics had a very low firing shrinkage value (2.84 %) compared to that of other ceramic cladding materials, a higher water absorption value (11.79 %) than that of porcelain tiles and floor tiles, and close to wall tiles, and a flexural strength value (33.64MPa) higher than wall tiles and close to porcelain tiles despite the high-water absorption value. Ten cycles of thermal shock resistance showed that the body and glaze layer of the stonepaste ceramic material are well bonded to each other, and there is no significant thermal expansion mismatch between them. One hundred cycles of freeze-thaw conditions indicated that the stonepaste ceramic had good adhesion and thermal expansion compatibility between the glaze and the body but only chipping damage under the action of tensile forces caused by the freezing of water entering the pores of the body. In terms of behaviour against various chemicals, stonepaste ceramics were found to be highly resistant to high and low concentrations of household chemicals, swimming pool salts, and alkalis but less resistant to low concentrations of HCl and citric acid and high concentrations of HCl and lactic acid compared to other chemicals. The results show that stonepaste ceramics, despite their high-water absorption potential, have properties close to those of traditional ceramic tiles and, like these materials, can serve for significant periods in various environmental conditions when used as facade cladding. Consequently, it has been revealed that stonepaste ceramics can be used as a facade cladding material in sustainable, long-lasting, contemporary architectural facades thanks to their technical and protective properties.

Technological Properties of Clay Raw Materials of the Northwest Orenburg Region

Technological Properties of Clay Raw Materials of the Northwest Orenburg Region

Experimental Studies of Fluidized Bed Calcination of Granulated Clay Material.

The work presents a detailed analysis of the possibilities of the thermal processing of clay raw material granulates in a fluidized bed reactor powered by coal fuel. Potential customers of calcined granulates include the following: plants producing refractory materials for the steel industry, producers of refractory concrete, sanitaryware plants, tile plants, large-size tile plants, industry abrasives, chemicals, paints, paper, food and medical industries and others. The advantage of the presented fluid bed calcination technology is the possibility of the continuous operation of the reactor and the short time of the material in the bed, compared to the previously used methods of calcination in a shaft and rotary kiln, which lasts less than twenty minutes in the temperature range of 650-850 °C. During the experimental studies of calcination in the fluidized bed layer, the influence of the type of coal, its particle size and the mass share of coal in the feed mixture on the calcination process and the final product obtained was analysed. As a result of the conducted research, it was proven that solid fuels such as anthracite and steam coal type 31.2 (flaming) can be successfully used in the fluidized bed calcination process of clay materials. The key parameter determining the fluidized bed calcination process is the fuel particle distribution.

Advancements in Expanded Clay Manufacturing Using "Clay-Desert Sand-Oil Sludge" Sludge Composite Materials

This study explores the development of resource-saving expanded clay technology utilizing underutilized clay raw materials and oil extraction waste. Traditional expanded clay production is energy-intensive and often employs high-quality clay; however, our research identifies technological modes and parameters for producing expanded clay through plastic molding, incorporating substandard raw materials and oil sludge. This method eliminates the need for costly energy-releasing additives and reduces energy costs associated with drying and firing by 25-30%. The research aims to demonstrate the feasibility of this novel production technique in the Republic of Kazakhstan, considering the local availability of raw materials, energy resources, and regional demand for thermal insulation materials in industrial and civil construction. Our findings suggest that integrating 'Desert Sand-Oil Sludge' into the batch composition can effectively produce granulated porous thermal insulation material, aligning with the region's development strategy and offering significant economic and environmental benefits.
 Highlights:
 
 Resource Utilization: Uses oil waste and substandard clay to produce expanded clay, reducing reliance on high-quality materials.
 Energy Savings: Cuts energy costs for production by 25-30% through innovative processing.
 Regional Benefit: Aligns with Kazakhstan's strategy by utilizing local resources and supporting construction needs.
 
 Keywords: Expanded Clay, Oil Sludge, Desert Sand

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».

Low Capacity Brick Factories

The article outlines the concept of construction of seasonal plants of small and medium capacity with proposals to complete them exclusively with domestic equipment and economic justification of profitability of such enterprises. It should be noted that, contrary to popular opinion, the idea of building small and medium capacity plants, including seasonal operation, has proven to be quite viable and reasonable for a number of southern and central regions of Russia and, in the future, for the new regions of Novorossiya, where agriculture is the main type of activity. This is due to climate, population density, building traditions and many other factors. In the foreign press, small factories are mentioned not only in terms of special products, but also as branches of large enterprises for the development of small deposits of unique clay raw materials, on the basis of which the production of facade building ceramics is organized.

USE of Thermal Power Engineering Waste to Reduce the Average Density of Ceramic Wall Materials with a Matrix Structure

It has been presented the results of studies on reducing the average density of ceramic wall materials through the use of ash granules. The chemical, granulometric, and mineral compositions of clay raw materials and fly ash are given. It has been considered the compositions of ceramic charges with different contents of thermal power waste and sample preparation techniques. In the first case, mechanical mixing of the charge components was used, in the second case, granulation of the components and creation of a shell on the surface of the granules was used. The physical and mechanical properties of ceramic samples produced by both methods are presented. It has been established that an increase in the fly ash content in the charge leads to a decrease in the average density and compressive strength of ceramic samples. The use of the developed method for producing ceramic materials increases the strength characteristics of the samples, which makes it possible to increase the content of the ash component to 70–80 wt. % in the composition of the charge. It has been shown that the content of fly ash in the charge is more than 60 wt. % leads to an increase in water absorption of more than 20%, which practically indicates the absence of sintering processes in ash granules. Prospects and main directions for further research are formulated.