One-time firing ceramic mix using manufacturing waste products as fluxes

Abstract

Compositions of one-time firing ceramic tile have been developed and tested, using as fluxes phosphogypsum and wastes (LiCl) from the production of acetate fiber. The methods of mathematical planning of experiments were used to obtain a system of mathematical equations that describes the dependence of the ceramic tile properties on the content of different components. The computational results are checked.A ceramic tile for interior facing is used in construction and remodeling. The main items in the production of such tiles are raw materials and electricity costs. It is generally acknowledged that the largest decrease of energy consumption for production can be attained by adopting a technology which permits one-time firing.Ceramic tiles for interior facing are used in construction and remodeling. The main expense items in the manufacturing of such tiles are the materials and fuel costs. Everyone recognizes that the greatest reduction of energy intensiveness can be achieved by adopting a one-time firing technology.At the present time domestic enterprises use predominately a production cycle with fast two-time firing. Objective difficulties arise in switching to the one-time firing technology, the main one being the lack of mixes developed taking account of the possibilities of the nearest raw materials base. In addition, the deposits of the conventional materials which intensify the sintering process are exhausted or located at considerable distances, as a result of which the raw materials costs are continually increasing. Consequently, the development of a ceramic mix based on local raw materials for onetime firing using fluxes consisting of various manufacturing wastes is a topical problem.One accessible clayey material for which adequate supplies are available is alkaline nonenriched kaolin from the Ekaterinburg deposit. The uniformity of the composition, high whiteness, and high mechanical properties of the finished product make this material very promising. The mineral composition of alkaline kaolin is as follows (% 3 ): 36.1 potassium feldspar, 26.7 kaolinite, 35.1 quartz, and 2.1 other.However, the elevated content of refractory components makes it necessary to use highly efficient fluxes. The conventional component that intensifies the sintering process is chalk, but when chalk is added, especially with one-time firing, the particulars of its dissociation process must be taken into account [1]. In this connection, priority is given to developing a composition for facing tile, i.e., searching for a flux that intensifies the sintering process with one-time firing.We have investigated the use of phosphogypsum -a waste from mineral fertilizer production by "EvroKhimBelorechenskie Minudobreniya" JSC -as a mineralizer. This component is characterized by the following composition: the main substance CaSO 4 × 2H 2 O 92% in terms of dry dihydrate, general phosphates 0.9% in terms of P 2 O 5 , water soluble phosphates 0.2% in terms of P 2 O 5 , and water soluble fluorine compounds 0.1% in terms of fluorine.The deg...

Properties and microstructure of porous ceramic bodies containing fly ash

“…The main items in the production of ceramic tiles are raw materials and electricity and fuel costs. It is generally acknowledged that the largest decrease of energy consumption for production can be attained by adopting a technology that permits one-time firing (Zubekhin et al, 2009).…”