Wherllyson Patrício Gonçalves

Statistical design for recycling kaolin processing waste in the manufacturing of mullite-based ceramics

Mineral extraction and processing industries have been cited as sources of environmental contamination and pollution. However, waste recycling represents an alternative recovery option, which is interesting from an environmental and economic standpoint. In this work, recycling of kaolin processing waste in the manufacture of mullite-based ceramics was investigated based on the statistical design of mixture experiments methodology. Ten formulations using kaolin processing waste, alumina and ball clay were used in the experiment design. Test specimens were fired and characterized to determine their water absorption and modulus of rupture. Regression models were calculated, relating the properties with the composition. The significance and validity of the models were confirmed through statistical analysis and verification experiments. The regression models were used to analyze the influence of waste content on the properties of the fired bodies. The results indicated that the statistical design of mixture experiments methodology can be successfully used to optimize formulations containing large amount of wastes.

Influence of Firing Conditions on Properties of Red Ceramic

In the ceramic industry, the firing is one of the main stages of the production process. There are two heating rates prevailing at this stage: low heating rate (long residence time) and high heating rate (fast residence time), the low rate is more used in traditional ceramics. This study aims to evaluate the influence of firing conditions on technological properties of three compositions of clay, used in the manufacture of red ceramic products. Initially, the mixtures were characterized subsequently were extruded, dried and submitted to firing at temperatures at 900 and 1000 °C with heating rates of 1, 2, 5, 15, 20 and 30 °C/min. The crystalline evolution of the different samples was analyzed using X-ray diffraction and the technological properties were determined. For the mechanical resistance, it was not observed significant change with the increase of the temperature and heat rate

Influence of Power and Synthesis Time in the Formation of Mullite Obtained by Microwave Heating

Front of the large number of applications of the mullite mineral, many researchers seek to synthesize it from the mixture of Al2O3 and SiO2 powders, or from aluminossilicates, such as smectite. The synthesis of mullite from clays via rapid heating by microwaves emerges as an alternative process. This process accelerates the kinetics of nucleation and the development of mullite phase. Thus, the aim of this work is to study the effect of power and timeon synthesis of mullite from clay, via rapid heating in microwave. The synthesis times were 15 and 20 minutes, with powers of 1.26 and 1.44kW. The obtained powderswere characterized by X-ray diffraction and scanning electron microscopy. The best results were obtained with a power of 1.44kW for 20 minutes.

Avaliação da influência de diferentes tratamentos térmicos sobre as transformações de fases esmectitas

Smectite clays have been used in various technical applications, particularly in traditional ceramic material, for ensuring the plasticity required for the forming green and simultaneously promote the development of mullite crystals during the firing phase, which confers mechanical strength to the final product. an important innovation over the past decades in the ceramic sector is the use of fast firing, which can induce changes during thermal processing of raw materials and mixtures. to implement changes in firing parameters it is crucial the knowledge of phase transformations of clays, being necessary in some situations the formulation of new compositions. the aim of this work is to analyze the influence of different heat treatments on the mineralogical and microstructural changes of smectites, emphasizing the presence of mullite. two samples of natural bentonite and one imported commercial were used. the natural samples were initially subjected to a milling process. subsequently, they were submitted to chemical analysis by x-ray fluorescence, thermogravimetric and differential thermal analyses. the clays were treated in the 800-1250 °c range with a heating rate 30 °c/min and kept at the maximum temperature for 10 min. the results showed that the clay composition and the temperature have influence on the amount of mullite formed.

Influência do uso de resíduo de quartzito na expansão por umidade de massas de revestimentos cerâmicos planos

The moisture expansion (ME) is characterized as an increase in physical dimensions of ceramic body when in contact with water (liquid or vapor). The ME phenomenon may contribute to the appearance of serious pathology in ceramic tiles such as cracks, detachment or more severe damages. This work aimed to study the problem of ME in ceramic masses added with quartzite waste for use in tiles using the dilatometry and three-point flexural strength methods. The raw materials were processed and characterized by laser diffraction particle size analysis, plasticity, chemical analysis, thermogravimetric and differential thermal analysis, and X-ray diffraction. The results showed that the addition of quartzite waste generally elevated ME values for bodies fired at temperatures below 1100 °C. For bodies fired at 1200 °C the results indicated high mechanical performance and ME decrease, and the best results for additive formulations was 15% of quartzite.

Influence of the Heating Rate on the Phase and Microstructural Transformations of Smectite Clays

Clays are very important raw materials in the manufacturing of traditional ceramic products. The present study was intended to study the phase transformations of smectites submitted to thermal treatment in conventional stove, applying slow and fast cycles. We used three clays, two national and one imported, which were beneficiated and characterized by mineralogical analysis. Later, they were submitted to a thermal treatment at 1100, 1200 and 1250°C, with heating rate of 5 and 30°C/min, remaining under the maximum temperature for 60 minutes. We observed the presence of mullite peaks starting at 1100°C for all samples. It was verified that the sample with the highest alumina/silica ratio presented more intense mullite peaks, and the sample with the high MgO content, besides the mullite phase, also formed cordierite.

Production of Mullite from Bentonite Clays and Alumina Residue

Among the ceramic raw materials, mullite is highlighted for presenting features which are of great interest for industry. However, the process through which this material is obtained requires pure reagents, raising the production costs. Therefore, this work is intended to obtain mullite from bentonite clays (source of silicon and aluminum oxides) and alumina residue, resulting from the Bayer process, thus becoming an interesting process from the economic and environmental standpoint. For this purpose, we made use of the thermal treatment in conventional furnace, temperature of 1500°C, heating rate of 5°C/min and dwell time of 60 min at maximum temperature. The synthesized samples were characterized by X-ray fluorescence (EDX), X-ray diffraction (XRD) and scanning electron microscopy (SEM) coupled to an EDS, besides the quantification of the phases present in the samples. The results revealed that mullite was the major phase produced, but corundum appeared as secondary phase.

Sinthesys of Mullite Using Microwave Furnace from Kaolin and Alumina Residue

Heating with microwave power is a process in which the materials take up electromagnetic energy volumetrically and turn it into heat inside a piece. This is the great difference from the conventional method, where the heat flows between objects by means of conduction, radiation and convection, in which the surface of the materials is heated first, and then the heat is transferred to the interior of the piece, thus forming a temperature gradient. On the other hand, microwave heating generates heat first inside the piece, heating the whole volume later. [1]

Use of Microwave Energy for Obtaining the Mullite

The kaolin beneficiation industries produce waste that is rich in Al2O3 and SiO2, oxides that when sintered at high temperatures react to form mullite. Due to the rare occurrence of the mullite mineral in nature, the number of studies in order to obtain it has been growing in recent years due to its properties excellent. This study aims to examine the feasibility of the use of microwave energy as an alternative to synthesize mullite from kaolin residue, since the use of microwave energy in the synthesis of materials has gained importance for the speed and economy when compared to conventional methods. The compositions studied (residual kaolin + alumina) were established according to the stoichiometry of mullite. The samples were sintered in a microwave oven home changed, varying power and time. It was observed that with the increase of these variables the intensity of the peaks of the mullite phase increased.