Red Ceramic Industry Research Articles

Industrial Scale Manufacturing of Red Ceramic Sealing Blocks with Ornamental Stone Wastes

Purpose: The objective of this work was to manufacture, on an industrial scale, sealing blocks, made in the red ceramic industry, incorporating ornamental stone wastes in percentages of 0%, 10% and 20% in the ceramic mass. Theoretical framework: Red ceramics has an important paper in the construction industry. The sealing block is one of the most used products due to its thermal and acoustic insulation power. The state of Espírito Santo is one of the largest producers and exporters of ornamental stones in the country. The processing of these stones generate large amounts of fine waste. These wastes are deposited daily in ornamental stone landfills. Brazil generates around 2.5 million tons of fine waste per year, where the state of Espírito Santo is responsible for 2 million tons. Method/design/approach: The sealing blocks were manufactured by extrusion in the size of 90x190x190 mm, without waste and with ornamental stone waste. After extrusion, the artifacts were dried in an oven for 7 days at 40°C. They were subsequently burned for 72 hours at a temperature of 900°C. Results and conclusion: The results showed that the specimens manufactured with waste showed lower water absorption, which is a positive factor, they also met the geometric characteristics tests determined by the Brazilian standard for ceramic materials. Research implications: Use ornamental stone waste that is deposited in millions of tons in landfills to manufacture red ceramic artifacts and thus contribute to reducing environmental impact. Originality/value: Produce sealing blocks with ten holes in the red clay ceramic industry and certify their technological feasibility through tests established by Brazilian standards.

Evaluation of the physical properties of composite panels with eucalyptus sawdust waste and castor oil-based polyurethane

Natural fibers have several advantages over synthetic fibers, and due to this, they are being increasingly used in various applications. Industrial waste generated during the production chain of different types of sectors is becoming a major environmental problem. The objective of this work was to produce and evaluate the physical properties of composite panels produced with waste from the wood industry, eucalyptus sawdust, and also with another waste, this time from the red ceramic industry, chamotte, and matrix polyurethane resin based on of castor oil. The composite panels were produced in volumetric fractions of 70, 75, 80, 85 and 90% of eucalyptus sawdust, and a variation of 0, 5 and 10% of chamotte. The tests to evaluate the physical properties were: Density, Moisture Content, Water Absorption and Thickness Swelling. The results showed that as the volumetric fraction of chamotte was incorporated into the composite, the higher the density value was obtained, and that this value decreased as the eucalyptus fiber fraction increased in the formulation. The SEM images revealed that chamotte provided a reduction in the amount of bubbles present in the resin. The moisture content, water absorption and swelling increased as the volumetric fraction of fiber increased, and decreased as the volumetric fraction of chamotte incorporation increased. It is concluded that there is technical feasibility for the use of eucalyptus residue, together with chamotte and castor oil-based polyurethane resin for the manufacture of composites. The perspective after this research is make a partner with a wood panels industry and create a new line of green composites panels made by recycled waste from industry.

Technological and microstructural perspective of the use of ceramic waste in cement-based mortars

The construction sector is constantly growing and, consequently, the increase in the use of building materials. In view of this, the red ceramic industry is responsible for a large amount of waste, through failures in its process and thus generating defective parts. Therefore, this work aims to reuse these wastes generated by the red ceramic industry in mortars, as a partial substitute for natural sand. The ceramic waste was ground in a crusher mill-type crusher for one hour. Mortars were made, in the mix proportion 1:6 (cement: sand) in mass, replacing the sand with ceramic waste in replacing of 10, 20 and 30% and the mixture reference (0%), using the ordinary portland cement. The mortars were subjected to tests of workability, water retention, density, incorporated air content, density in the hardened state, water absorption, flexural strength in bending and compressive strength. Soon after, microstructural characterization techniques were performed in mixtures, such as isothermal calorimetry, mercury intrusion porosimetry and X-ray diffraction. The results show that the mixture with 10% improved the flexural strength in bending and compressive strength, indicating a lower coefficient of capillarity, as they have fewer pores and a greater amorphous halo. The ceramic waste caused an increase in density in the fresh and hardened state and a decrease in the content of incorporated air. In the mixtures with 20% and 30% of ceramic waste, there was a loss in the properties, mainly in the strength. Therefore, the most satisfactory mixtures were with 10% ceramic waste.

BALANCE BETWEEN BIOMASS SUPPLY AND DEMAND IN THE RED CERAMICS SECTOR OF RIO GRANDE DO NORTE, BRAZIL

Illegal deforestation in Caatinga sometimes corresponds to supplying the local energy demand, even though legalized firewood options are available on the market. Studies show that the red ceramic industry is the largest consumer of firewood in Rio Grande do Norte (RN), Brazil. Considering the firewood from the Sustainable Forest Management Plans as a viable alternative to supplying this sector, the objective was to analyze the current offer of forest biomass in RN, in line with the demand for this resource in the industry of red ceramics. The number, area and volume of the current management plans were obtained by the agency responsible for state forest management. The Annual Operational Plans were analyzed to acquire the amount of wood available in one year. The survey found 22 sustainable management plans with authorization for exploration valid for the year of 2019, distributed in 20 cities in the state, adding up to an area of 988.99 hectares. A current supply of available firewood for the energy of 26,223.13 tMS.year -1 was calculated. It is noticed that the supply of firewood from the management plans meets only 5.5% of the energy demand in the state ceramics sector. In contrast, the potential supply of firewood available in Caatinga remnants of the state exceeds the sector's demand by more than six times. It is concluded that there is a need for reinforcement in the governmental sphere, to propose measures that stimulate the use of the forest resource in a legalized manner in proportion to the current consumption.

Evaluation of the potential use of granite waste in products of the red ceramic industry in the state of Amazonas

The increase in the exploitation of raw materials in the civil construction sector has led to an increase in damage to the environment, mainly due to the improper disposal of granitic waste. However, this fact has caused damage to the environment. Therefore, this research aims to analyze the influence of the introduction of granite waste in a clay matrix aiming its use in the red ceramic industry. For this, the clay from the ceramic pole in the city of Iranduba - AM and granite waste from a company located in the municipality of Presidente Figueiredo - AM were collected. Formulations were made containing three levels of waste (0, 10 and 20% mass) and three firing temperatures (1173, 1273 and 1373K). The materials were characterized by X-ray fluorescence spectroscopy, X-ray diffraction, scanning electron microscopy and the following technological properties were determined: water absorption; linear retraction; apparent porosity; specific mass; and 3-point flexural rupture module. The results showed that the glassy phases generated provide a better densification of the formulations with 20% of waste, sintered at 1373K, as they presented favorable mechanical properties for the manufacture of red ceramic products, providing a correct destination of the waste and providing alternatives for the social, economic context and environmental impact of the Amazon region.

Perspective of the application of ash from the ceramic industry in the development of alkali-activated roof tiles

The construction industry is always in need of new technologies and products that improve technological characteristics. Alkali-activated materials appear as an alternative to reduce energy costs, improve technological properties and still present themselves as materials with the potential for incorporating industrial waste. The objective of this research was the development of roof tiles through the process of alkaline activation using ash from the kilns of burning of a red ceramic industry. After the process of processing the materials and their characterizations, prismatic specimens (115 × 30 × 20 mm) were made with the replacement of 0, 6.25, 12.5, 25 and 50% ash by metakaolin and subsequently separated into two groups, (i) subjected to curing at room temperature and (ii) subjected to curing at a temperature of 80 °C, in both cases with a curing time of 7, 14 and 28 days. After each curing period and group, the specimens were subjected to technological evaluation of water absorption, porosity, flexural strength and scanning electron microscopy. The results obtained demonstrate that the use of ash from ceramic waste, mainly replacing 12.5% of the metakaolin, promotes a reduction in water absorption and porosity, and an increase in flexural strength. The results obtained at 28 days in thermal curing are 44.05 MPa for 12.5% ash, much higher than the reference composition (16.02 MPa). The increase in strength happens due to the formation of tobermorite, due to the calcium present in the ash, and due to the formation of phases rich in potassium from the ash, such as kalsilite. Thus, it is concluded that the use of ash from ceramic waste is possible in the alkaline activation of roof tiles due to the occurrence of additional mechanisms of alkaline activation.

Durability of Sustainable Ceramics Produced by Alkaline Activation of Clay Brick Residue

Alkali-activated materials (AAMs) were produced using residues from the red ceramic industry as a precursor, and sodium hydroxide (NaOH), potassium hydroxide (KOH), and sodium silicate (Na2SiO3) as alkaline activators. The effect of activators and curing conditions on physical-mechanical properties and durability were evaluated. The processing parameters (amount of water and consistency index) and the activation conditions (the activator contents and curing temperature) were defined based on an experimental design getting the flexural rupture module as the response. The durability behavior was evaluated by natural aging, accelerated aging (simulated rain test), exposure to the marine environment (salt fog), and acidic environments (HCl and H2SO4). The results showed that the NaOH- and KOH-activated samples exhibited inferior mechanical behavior than those activated with Na2SiO3. In the durability studies, due to leaching, there was a decrease in mechanical strength when samples are subjected to aggressive exposure conditions. However, the strength values are still higher than the minimum indicated for traditional ceramic applications.

INCORPORAÇÃO DO RESÍDUO DE VIDRO PLANO EM CERÂMICA VERMELHA

The present work aims to evaluate the influence of different residue incorporations on the physical and mechanical properties of a typical red ceramic composition, replacing the sand, by using the residue from the first stage of tempered glass manufacturing. Ceramic specimens were prepared with incorporations of 0 and 20% of flat glass waste. The samples were obtained by extrusion, dried and fired at 800, 900, 1000 ° C in a laboratory oven. Analyzes of the raw materials were performed, among which the thermal, morphological, physical and chemical can be highlighted. Tests on the fired ceramic specimens were also performed. The firing properties obtained were the dry bulk density, relative density, water absorption, dry linear shrinkage, linear firing shrinkage and flexural strength. The results showed that both the increase of the glass content and the increase of temperature had a positive influence on the studied properties. Furthermore, it confirmed that the glass waste acted in order to lower the proper firing temperature. Flat glass waste is therefore a highly recommended fluxing element for the red ceramic industry, as it can be incorporated in quantities as significant as 20% without major negative effects on the properties, therefore optimizing the amount of waste used and acting positively on the properties studied, reducing energy and raw material costs.

Temporal dynamics of soil susceptibility to erosion in semiarid watersheds

The intensification of anthropogenic activities on soils contributes to soil loss through erosion. Moreover, the pattern of soil loss in the Cobra River watershed, located in the semiarid region of Rio Grande do Norte, is related to the history of land use and occupation, mainly from agriculture and the red ceramic industry, as well as the climatic seasonality of the region. Thus, the objective of this work was to identify the pattern of soil loss from the Cobra River microbasin in the state of Rio Grande do Norte. For this, the following analyses were performed: a survey of land use class areas for the years 1987, 1997, 2007 and 2017 as part of the Mapbiomas project; estimation of basin soil loss for these years; and quantification of areas of erosion vulnerability classes for this period. QGIS software was used to treat georeferenced data. According to the results, the land cover classes in the rich Cobra River microbasin fluctuated over time. Potential soil loss from the watershed increased from 1987 to 2017, with an increase of approximately 20 million megagrams of potentially erodible soil. The study of soil loss in a microbasin located in the Brazilian semiarid region should consider the variation in land cover over time, climatic seasonality and anthropic activity. To this end, it is important to use geotechnology and geoprocessing techniques to conduct a more robust spatiotemporal analysis.

ENVIRONMENTAL DEGRADATION ON THE CURU RIVER BANKS IN THE STATE OF CEARÁ

The coarse sand works as aggregate in the making of concrete and mortars used asmaterials in the construction industry, and the clay serves as raw material for making bricks, andtiles, among other products. The following paper analyzes the environmental impact caused bythe removal of coarse sand from the Curu River bed and banks and the clay used as raw materialin the red ceramic industry. When the Curu River is dry or even when it still has little water in itsbed, they remove the coarse sand, which is known as washed sand. The same happens on the riverbanks, showing that sand extraction, which is nothing more than a mining process, generates asignificant environmental impact on the local flora and fauna. It was also possible to concludethat the extraction of clay on the banks of the Curu River to supply two red ceramic industriesgenerated environmental impact, degrading the riparian forest.

Red ceramic industry residues: Used to produce Portland cement

The objective of this study was to investigate the feasibility of using waste from the production process of the ceramic industry as feedstock for the manufacture of Portland cement. Analysis was performed in a cement industry quality control laboratory, performing chemical, physical, and mechanical tests. The results met specifications for cement production. The cement color was a limiting factor, since the consumer tends to reject cements with a slightly reddish hue. Of the tested compositions, the Red Ceramic Residue (RCR) percentage achieving favorable results for cement manufacturing without compromising color, was the 4% addition. In terms of economic and environmental viability (in Paraíba, Brazil), using this percentage to manufacture cement could represent consumption of about 48,000 tons/year of RCR, generating cost savings, and lower CO2 emissions, being an alternative for large-scale use.

Sustainable practices of the red ceramic industry and its influence on local communities

The purpose of the study presented in this article was to identify and summarize the sustainable practices adopted by producers of the red ceramic in a process of extraction and transportation of clay in a specific region. Initially designed as descriptive, the research combines bibliographic review with data collection, followed by qualitative and quantitative methods. The study sample was collected by interviewing the traditional producers located around Brazilian town of Prudentópolis in the state of Paraná, Brazil. The article reveals the factors of economic, environmental and social impact of the industry as well as emphasizes the problematic aspects of relationships between production companies and local communities. The red ceramic industry is a significant part of the economic landscape in several a small municipality in the state of Paraná. Even though the activities of clay extraction and transportation are inherently harmful for environment, local producers’ practices include recuperation techniques that somewhat allows to mitigate the consequences of the landscape degradation in a long run. The study revealed an environmental concern among companies’ managers and their conscious incentives to apply those recuperation measures. At the same time, we had to observe that a whole complex of the necessary activities was not implemented by any of the observed companies. The social impact of the industry is emphasized by its noise and pollution that causes tensions between companies and affected communities. Shortage of manual labour in the region can also be included into the list of socially determined challenges of the industrial actors.

Potential use of ceramic waste as precursor in the geopolymerization reaction for the production of ceramic roof tiles

The red ceramic industry is responsible for generating high amounts of solid wastes around the world from manufacture process failures, such as ineffective firing and issues related to the products transportation. Besides the necessity of clean alternatives to discard the solid wastes, the civil construction industry has been demanding the development of better technological properties new materials. One an example of those new materials is the geopolymeric materials, characterized by the gain of mechanical strength at early ages, high fire resistance, low water absorption and refractoriness. All these characteristics imply that geopolymers are suitable for civil construction applications. The characterization of clay bricks waste, named chamotte, and its use as an alternative precursor to produce geopolymeric materials, such as roof tiles for buildings are the aims of this present work. The chemical characterization, particle size distribution, X-ray diffraction, specific mass, pozzolanic activity index (PAI) and scanning electron microscopy (SEM) were performed, in addition to the technological tests carried out on the geopolymer specimens, such as flexural strength, water absorption, linear shrinkage and apparent porosity. The chemical and mineralogical analysis proved that the waste is rich in silica and alumina, which are fundamental compounds for the geopolymers synthesis. The chamotte also has fine particles and high pozzolanic reactivity. Thus, this waste has great potential to be used as a raw material for obtaining of ceramic roof tiles by means of geopolymeric reactions.

Use of Red Ceramic Industry Residue for Structural Masonry Blocks Production in Amazon

Use of Red Ceramic Industry Residue for Structural Masonry Blocks Production in Amazon

Evaluation of kaolin and bauxite from the Amazonian region addition on mechanical-, physical-, chemical properties and microstructural characterization of red ceramic industry clay of Manaus metropolitan region

The present work investigated properties of red ceramic from the Amazonian region after the addition of kaolin and bauxite mixture with 0, 10, 20 and 30%wt. in red ceramic industry clay. Assessed mechanical properties were flexural strength and Young's modulus. The assessed physical properties were density and porosity. The microstructural images were assessed with SEM and OM microscopies. The fired samples XRD, the raw materials XRF and the XRD were made for chemical composition and present phases assessments. Samples were manufactured by uniaxial compaction and fired at 1200°C and 1250°C. Samples without the mixture of kaolin/bauxite presented higher assessed properties, with approximately 32 MPa of flexural strength and 12% of porosity with 2.3 g/cm3 density. Although the initial idea of this work was to add the mixture of kaolin/bauxite in the red ceramic industry clay for improving assessed properties of red ceramic fired parts, the red ceramic industry clay without addition presented better properties. Such properties were attributed to the high aluminous materials content in the raw material. This behaviour is correlated to the fact that bauxite from this region presents 55%wt. of iron oxide content with aluminium oxide content lower than 25%wt. Additionally, the assessed properties of the ceramic industry parts fired at 1250°C presented this material as promising material for ceramic products with a better added value.

Characterization and Evaluation of Ceramic Properties with Spherical and Prismatic Samples of Clay Used in Red Ceramics

The Brazilian red ceramic industry monthly consumes about 10.3 million tons of clay, its main raw material. In most potteries, characterization of the clay is made empirically, which can result in roof tiles and blocks not according to standards. In this sense, this paper aims to characterize clays used in the manufacturing of red ceramic products in a factory located in Colatina-ES, which appears as a ceramic pole with about twenty small and midsize industries. The clays were characterized by: X-ray fluorescence, X-ray diffraction, thermal analysis (DSC/TG), granulometry, Atterberg limits and content of organic matter. Specimens of clay and mixture containing four clays were shaped. Specimens were shaped, dried at 110°C, and burned at 850oC in an industrial furnace-type tunnel for 24 hours. The ceramics and mechanical properties evaluated were: mechanic strength, water absorption, apparent porosity, apparent specific mass and shrinkage by drying and firing. The characterization showed that kaolinitic clay presents high plasticity, but high porosity. The mixture formed by the four clays does not meet the requirements of the Brazilian standard clays for red ceramic. It is possible to confirm the use of the methodology of the spheres in potteries for analysis of ceramics raw materials.

Chamotte clay as potential low cost adsorbent to be used in the palm kernel biodiesel purification

Solid waste from the red ceramic industry (chamotte clay) was assessed as glycerol adsorbent for biodiesel purification by dry washing. Its structure and composition was analyzed by several techniques, such as X-ray diffraction, FT-IR, scanning electron microscopy and particle size. By using a simulated medium (5w/v% glycerol in an ethanol solution), a face centered composite design was used to analyze the combined effect of chamotte concentration and temperature on glycerol removal. Chamotte levels of 2.5w/v% at 45°C maximized glycerol removal (1282mgglycerolg−1) with minimum loss of adsorbate. Kinetic data on glycerol adsorption by chamotte clay could be adjusted using the pseudo-second order model, which indicates that the rate-limiting step may be chemisorption. Moreover, chamotte clay was used for purifying ethyl biodiesel samples from palm kernel oil by chemical and biochemical catalysis. In the presence of chamotte clay, low glycerol levels (<0.02wt%) were found in comparison with crude biodiesel (0.29±0.03wt%). Chamotte clay was also able to remove residual levels of monoacylglycerols and diacylglycerols and provided samples with properties that are similar to those attained by traditional wet washing.

Evaluation of toxic and genotoxic potential of a wet gas scrubber effluent obtained from wooden-based biomass furnaces: A case study in the red ceramic industry in southern Brazil

Red ceramic industry in southern Brazil commonly uses wood biomass as furnace fuel generating great amounts of gas emissions and ash. To avoid their impact on atmospheric environment, wet scrubbing is currently being applied in several plants. However, the water leachate formed could be potentially toxic and not managed as a common water-based effluent, since the resulting wastewater could carry many toxic compounds derived from wood pyrolysis. There is a lack of studies regarding this kind of effluent obtained specifically and strictly from wooden-based biomass furnaces. Therefore, we conducted an evaluation of toxic and genotoxic potentials of this particular type of wet gas scrubber effluent. Physical-chemical analysis showed high contents of several contaminants, including phenols, sulphates and ammoniacal nitrogen, as well as the total and suspended solids. The effluent cause significant toxicity towards microcrustacean Artemia sp. (LC50 = 34.4%) and Daphnia magna (Toxicity Factor = 6 on average) and to higher plants (Lactuca sativa L. and Allium cepa L.) with acute and sub-acute effects in several parameters. Besides, using plasmid DNA, significant damage was observed in concentrations 12.5% and higher. In cellular DNA, concentrations starting from 12.5% and 6.25% showed significant increase in Damage Index (DI) and Damage Frequency (DF), respectively. The results altogether suggest that the effluent components, such phenols, produced by wood combustion can be volatilized, water scrubbed, resulting in a toxic and genotoxic effluent which could contaminate the environment.

ESTUDO DO PERFIL TÉRMICO DE FORNOS DO TIPO "CAIPIRA" UTILIZADOS PELO SETOR DE CERÂMICA VERMELHA EM PARELHAS NA REGIÃO DO SERIDÓ, RN1

RESUMO Este trabalho teve como objetivo caracterizar o perfil térmico de fornos tipo "caipira" utilizados pelo setor de cerâmica vermelha em Parelhas, na região do Seridó, RN, visando propor intervenções estruturais que possam colaborar para aumentar a produtividade e qualidade dos produtos, otimizar o consumo de madeira e mitigar as perdas durante o processo de queima. O trabalho foi desenvolvido na Cerâmica Esperança, na cidade de Parelhas, RN. Foram realizados quatro tratamentos com três repetições, sendo a argila o parâmetro utilizado como referência para distinguir os tratamentos. Foram monitorados a quantidade da lenha, a qualidade da telha e o tempo de cada queima. Foram aferidas temperaturas em 15 pontos marcados na superfície da carga enfornada, em intervalos de 30 min a partir do pré-aquecimento até o final da queima, utilizando um pirômetro de mira a laser. Os resultados indicaram que a madeira utilizada como lenha apresentou densidade sem diferença significativa entre os tratamentos, umidade dentro dos padrões permitidos e consumo heterogêneo, enquanto a argila teve pouca retração linear quando submetida ao fogo e o forno, perfil térmico heterogêneo. O parâmetro do fio, que é utilizado como referência para o controle da queima, foi significativo, embora com oscilações diferenciadas, razão por que não deve ser o único critério para finalização do processo de queimas. A parte central do forno foi a área que atingiu maiores temperaturas de maneira homogênea, com maior concentração de produtos de primeira qualidade; a curva de temperatura ideal foi do tratamento 1, com uma média de 18,66% de produto de primeira qualidade, com temperatura de 100 °C a 400 °C.

Preparação e caracterização de sistemas chamote/argila visando o reaproveitamento de descartes industriais

&lt;p&gt;A contribuição do setor ceramista relativa aos bens produzidos nacionalmente reflete a informalidade vigente nas olarias associada ao desconhecimento, em sua maioria, daqueles que manufaturam os produtos. Na região do nordeste, mais especificamente na Paraíba, a indústria de cerâmica vermelha também vivencia tal problemática associada à falta de um protocolo mais efetivo. Desse modo, este projeto foi desenvolvido visando contribuir para reduzir os impactos ambientais originados pela olaria Santa Cecília Ltda., PB, Brasil avaliando-se nova formulação com reaproveitamento do descarte, chamote. A caracterização dos materiais foi realizada por difração de raios X, por fluorescência de raios X por energia dispersiva, por microscopias, óptica e eletrônica de varredura. Os sistemas, chamote/amostras, queimados a 800, 900 e 1000 ºC foram também avaliados quanto às características cerâmicas.&lt;/p&gt;