Uso de resíduo e de minerais de pegmatito da região do seridó RN e de argilas portuguesas em formulações de grês porcelanato

In the State Rio Grande do Norte, Brazil, the most significant deposits of minerals in the production of granite and pegmatite are Seridó region. Municipalities of Parelhas and Equador are the main responsible for the production of feldspar, quartz, kaolin and granite. The ceramic industries are always in search of competitiveness by investing in new products or improving existing techniques. The stoneware is a type of pottery that stands in the market because it presents technical and aesthetic characteristics superior to other existing products. Characteristics of the raw materials initially obtained with chemical analysis and mineralogical analysis are crucial in getting a product that satisfies the conditions in a manufacturing process and is, in principle, directly related to the firing cycle. This research aimed at developing new formulations for the mass production of ceramic stoneware. The raw materials initially characterized were feldspar, quartz, kaolin and granite. As part of the research was developed at the University of Aveiro, in Portugal, we used two clays used in the production of Portuguese ceramics. The raw material Brazilian and Portuguese and the final product, both in Portugal and Brazil, were analyzed for X-ray fluorescence, X-ray diffraction, granulometric analysis, dilatometric analysis, thermal analysis and analysis of scanning electron microscopy (MEV). The specimens prepared at the University of Aveiro (DECV) were sintered at 10000C and 12000C and the specimens prepared in UFRN were sintered at 10000C, 10500C, 11000C, 11500C, 12000C, 12500C and 13000C, but the best results and demonstrating the presence of the mineral mullite were at temperatures of 12000C, 12500C and 13000C. The results showed that the granite waste used may be considered raw material of excellent quality for use in the ceramic industry and coating floors and more accurately by the industry of stoneware. Physical and mechanical tests conducted on samples of the formulations F01 and F02 developed in UFRN showed a water absorption and mechanical strength suitable for the stoneware

Efeito das variáveis laboratoriais protéticas na adesão da porcelana com ligas de níquel-cromo

The metalceramic crowns are usually used in dentistry because they provide a resistant structure due to its metallic base and its aesthetics from the porcelain that recovers this structure. To manufacture these crowns, a series of stages should be accomplished in the prosthetic laboratories, and many variables can influence its success. Changes in these variables cause alterations in the metallic alloy and in the porcelain, so, as consequence, in the adhesion between them. The composition of the metal alloy can be modified by recasting alloys, a common practice in some prosthetic laboratories. The aim of this paper is to make a systematic study investigating metalceramic crowns as well as analyzing the effect of recasting Ni-Cr alloys. Another variable which can influence the mechanism of metalceramic union is the temperature used in firing porcelain procedure. Each porcelain has to be fired in a fixed temperature which is determined by the manufacturer and its change can cause serious damages. This research simulate situations that may occur on laboratory procedures and observe their consequences in the quality of the metalceramic union. A scanning eletron microscopy and an optic microscopy were accomplish to analyse the metal-ceramic interface. No differences have been found when remelting alloys were used. The microhardness were similar in Ni-Cr alloys casted once, twice and three times. A wettability test was accomplished using a software developed at the Laboratório de Processamento de Materiais por Plasma, on the Universidade Federal do Rio Grande do Norte. No differences were found in the contact angle between the solid surface (metallic substratum) and the tangencial plane to the liquid surface (opaque). To analyse if the temperature of porcelain firing procedure could influence the contact area between metal and porcelain, a variation in its final temperature was achieve from 980° to 955°C. Once more, no differences have been found

Estudo de massa cerâmica triaxial visando à otimização do ciclo de queima da indústria de cerâmica estrutural

Over recent years the structural ceramics industry in Brazil has found a very favorable market for growth. However, difficulties related to productivity and product quality are partially inhibiting this possible growth. An alternative for trying to solve these problems and, thus, provide the pottery industry the feasibility of full development, is the substitution of firewood used in the burning process by natural gas. In order to contribute to this process of technological innovation, this paper studies the effect of co-use of ceramic phyllite and kaolin waste on the properties of a clay matrix, verifying the possible benefits that these raw materials can give to the final product, as well as the possibility of such materials to reduce the heat load necessary to obtain products with equal or superior quality. The study was divided into two steps: characterization of materials and study of formulations. Two clays, a phyllite and a residue of kaolin were characterized by the following techniques: laser granulometry, plasticity index by Atterberg limits, X-ray fluorescence, X-ray diffraction, mineralogical composition by Rietveld, thermogravimetric and differential thermal analysis. To study the formulations, specifically for evaluation of technological properties of the parts, was performed an experimental model that combined planning involving a mixture of three components (standard mass x phyllite x kaolin waste) and a 23 factorial design with central point associated with thermal processing parameters. The experiment was performed with restricted strip-plot randomization. In total, 13 compositional points were investigated within the following constraints: phyllite ≤ 20% by weight, kaolin waste ≤ 40% by weight, and standard mass ≥ 60% by weight. The thermal parameters were used at the following levels: 750 and 950 °C to the firing temperature, 5 and 15 °C/min at the heating rate, 15 and 45min to the baseline. The results showed that the introduction of phyllite and/or kaolin waste in ceramic body produced a number of benefits in properties of the final product, such as: decreased absorption of water, apparent porosity and linear retraction at burn; besides the increase in apparent specific mass and mechanical properties of parts. The best results were obtained in the compositional points where the sum of the levels of kaolin waste and phyllite was maximal (40% by weight), as well as conditions which were used in firing temperatures of 950 °C. Regarding the prospect of savings in heat energy required to form the desired microstructure, the phyllite and the residue of kaolin, for having small particle sizes and constitutions mineralogical phases with the presence of fluxes, contributed to the optimization of the firing cycle.

Efeito da Gália como aditivo de sinterização em eletrólitos cerâmicos à base de céria sintetizados pelo método de complexação de cátions

Fuel cells are considered one of the most promising ways of converting electrical energy due to its high yield and by using hydrogen (as fuel) which is considered one of the most important source of clean energy for the future. Rare earths doped ceria has been widely investigated as an alternative material for the electrolyte of solid oxide fuel cells (SOFCs) due to its high ionic conductivity at low operating temperatures compared with the traditional electrolytes based on stabilized zirconia. This work investigates the effect of gallium oxide (Gallia) as a sintering aid in Eu doped ceria ceramic electrolytes since this effect has already been investigated for Gd, Sm and Y doped ceria electrolytes. The desired goal with the use of a sintering aid is to reduce the sintering temperature aiming to produce dense ceramics. In this study we investigated the effects on densification, microstructure and ionic conduction caused by different molar fraction of the dopants europium (10, 15 and 20%) and gallium oxide (0.3, 0.6 and 0.9%) in samples sintered at 1300, 1350 and 1450 0 C. Samaria (10 and 20%) doped ceria samples sintered between 1350 and 1450 °C were used as reference. Samples were synthesized using the cation complexation method. The ceramics powders were characterized by XRF, XRD and SEM, while the sintered samples were investigated by its relative density, SEM and impedance spectroscopy. It was showed that gallia contents up to 0.6% act as excellent sintering aids in Eu doped ceria. Above this aid content, gallia addition does not promote significant increase in density of the ceramics. In Ga free samples the larger densification were accomplished with Eu 15% molar, effect expressed in the microstructure with higher grain growth although reduced and surrounded by many open pores. Relative densities greater than 95 % were obtained by sintering between 1300 and 1350 °C against the usual range 1500 - 1600 0 C. Samples containing 10% of Sm and 0.9% of Ga reached 96% of theoretical density by sintering at 1350 0 C for 3h, a gain compared to 97% achieved with 20% of Sm and 1% of Ga co-doped cerias sintered at 1450 0 C for 24 h as described in the literature. It is found that the addition of gallia in the Eu doped ceria has a positive effect on the grain conductivity and a negative one in the grain boundary conductivity resulting in a small decrease in the total conductivity which will not compromise its application as sintering aids in ceria based electrolytes. Typical total conductivity values at 600 and 700 °C, around 10 and 30 mS.cm -1 respectively were reached in this study. Samples with 15% of Eu and 0.9 % of Ga sintered at 1300 and 1350 °C showed relative densities greater than 96% and total conductivity (measured at 700 °C) between 20 and 33 mS.cm -1 . The simultaneous sintering of the electrolyte with the anode is one of the goals of research in materials for SOFCs. The results obtained in this study suggest that dense Eu and Ga co-doped ceria electrolytes with good ionic conductivity can be sintered simultaneously with the anode at temperatures below 1350 °C, the usual temperature for firing porous anode materials

Aplicação da metodologia de planejamento de experimentos para formulação de massas cerâmicas para telhas

Rio Grande do Norte State stands out as one great producer of structural clay of the brazilian northeastern. The Valley Assu ceramic tiles production stands out obtained from ilitics ball clays that abound in the region under study. Ceramics formulation and the design of experiments with mixture approach, has been applied for researchers, come as an important aid to decrease the number of experiments necessary to the optimization. In this context, the objective of this work is to evaluate the effects of the formulation, temperature and heating rate in the physical-mechanical properties of the red ceramic body used for roofing tile fabrication of the Valley Assu, using design of mixture experiments. Four clays samples used in two ceramics industry of the region were use as raw material and characterized by X-ray diffraction, chemical composition, differential thermal analysis (DTA), thermogravimetric analysis (TGA), particle size distribution analysis and plasticity techniques. Afterwards, they were defined initial molded bodies and made specimens were then prepared by uniaxial pressing at 25 MPa before firing at 850, 950 and 1050 ºC in a laboratory furnace, with heating rate in the proportions of 5, 10 e 15 ºC/min. The following tecnologicals properties were evaluated: linear firing shrinkage, water absorption and flexural strength. Results show that the temperature 1050 ºC and heating rate of 5 ºC/min was the best condition, therefore presented significance in all physical-mechanical properties. The model was accepted as valid based of the production of three new formulations with fractions mass diferents of the initial molded bodies and heated with temperature at 1050 ºC and heating rate of 5 ºC/min. Considering the formulation, temperature and heating rate as variables of the equations, another model was suggested, where from the aplication of design of experiments with mixtures was possible to get a best formulation, whose experimental error is the minor in relation to the too much formulations

Análise da Conformidade e Caracterização da Matéria- Prima Empregada na Fabricação de Blocos Cerâmicos na Região Metropolitana de Salvador

The potential market of the metropolitan area of Salvador accounts for the estimated consumption of roughly 800 million horizontally perforated extruded clay bricks a year. The growing demand of consumers along with the competitiveness of the structural ceramic sector has driven forward a number of recent efforts and investments towards improving the quality of structural ceramics. In this scenario, the present study focused on sampling and evaluating the conformity of 8-hole horizontally perforated extruded clay bricks manufactured by different plants (A, B and C) in the metropolitan area of Salvador. In addition, representative clay and sandy-clay materials were collected from each plant and characterized by conventional physical, chemical and mineralogical techniques. Finally, experimental compositions designated as A, B and C, according to the source, were prepared by mixing different contents of the raw materials collected in the plants, fired at different temperatures and characterized. The results revealed a series of non conformities regarding ABNT guidelines. The characterization of raw materials revealed the presence of kaolinite and ilite in concentrations ranging from 64 to 90 wt.% along with free quartz (10 - 25%). The sandy-clay samples consisted basically of kaolinite. All raw materials depicted low contents of organics, amorphous constituents, alkaline oxides and feldspar. An analysis of the firing behavior of all different ceramic compositions revealed that the linear contraction of composition A was rather significant considering the temperature range evaluated, and it justifies the significant dimensional non conformity that was shown by bricks made with the ceramic A

Avaliação da potencialidade de argilas de queima clara como matérias-primas para o desenvolvimento de novos produtos cerâmicos

The industries of structural ceramics are among the most important production chains in the state of Rio Grande do Norte. The industry and other interest groups to target the replacement of firewood by natural gas. Studies accordingly concluded that simple change does not guarantee products of superior quality, and that the increase in spending on fuel can economically cripple the use of gas for burning the majority of products manufactured by that action. However some proposals of innovations in terms of process and product are being studied in an attempt to justify the use of natural gas in industry, structural ceramics. One of the aspects investigated is the development of ceramic products differentiated, with new designs and greater value added. Inserted in that context, this paper aims to investigate the potential use of clay-firing clear fabrication of the "bricks of apparent joins drought", a new ceramic product with an innovative way. The development of the work was done in three stages. In the initial stage was held the characterization of raw materials, sought information on physical, chemical, mineralogical and mechanical samples. In the second stage five bodies were made using two of the nine ceramic clay characterized the first step. The masses were analyzed and compared with respect to the size distribution, plasticity and technological properties. In the last part of this work was carried out tests on massive bricks manufactured on an industrial scale. The results show that the nine clays can be used in the manufacture of new ceramic products, is the only constituent of mass ceramic or by mixing with other(s) clay(s

Estudo da formulação de massas cerâmicas provenientes da região do Seridó-RN para fabricação de telhas

This work has for objective study compared the characteristics and technological properties of ceramic bodies from the region of Seridó-RN. The region under study has identified 23 cities where they were 80 ceramics industries. To define the universe of search, there was a survey of pottery that are part of APL Seridó next to the IEL. The characteristics and operating conditions of ceramics industries of the region were identified through a socio-economic questionnaire applied locally, which addressed issues such as: profiles of companies, production process etc. The analysis of information collected from 24 companies identified in seven cities shows that the vast majority of industries is small, with family structure, obsolete equipment and labo, little qualified. Most of the pottery works with low technical knowledge, poor control of the production process and product technology. The raw collected were submitted to analysis of X ray diffraction, chemical composition, termical analysis, particle size distribution and plasticity. Then were produced five formulations and made by uniaxial pressure at 25 MPa for firing in temperatures varying from 850 to 1050 °C. The firing technological properties evaluated were: mass loss to fire, lineal shrinkage, apparent density, apparent porosity, water absorption and flexural strength (3 points). The results indicated that the raw materials from the region have significant similarities in the composition chemical and mineralogical. Furthermore, it indicates the possibility of the use of cycles of firing faster and efficient than the current, limited to some clay mass burning of certain conditions

Produção de grês porcelanato a partir de matérias-primas do Rio Grande do Norte e queima a gás natural

The State of Rio Grande do Norte, Brazil, possess major deposits of feldspar, clay, kaolin and talc, all raw materials used in the production of porcelainized stoneware tiles. Conversely, state industries manufacture only low added value red ceramics. Porcelainized stoneware tiles is one of the noblest ceramics, depicting low water absorption (typically below of 0,5%), in addition to excellent staining resistance and mechanical strength. The present work aims at investigating the potential of local raw materials for the production of porcelainized stoneware tiles. To that end, these materials were characterized by X-ray fluorescence, X-ray diffraction, particle size analysis, thermal gravimetric analysis and thermal differential analysis. Admixtures containing different compositions were prepared and fired at three temperatures, 1150, 1200 and 1250°C for 30 min. After firing, tests samples were characterized by water absorption tests, linear retraction, dilatometric analysis, apparent porosity, apparent specific mass, flexural strength, and microstructural analysis by XRD and SEM. The results revealed that ceramics with porcelainized stoneware tiles characteristics could be produced from raw materials originated in the State of Rio Grande do Norte

Produção de grês porcelanato a partir de matérias-primas do estado da Bahia

The State Bahia, Brazil, presents different geological sites it with a very expressive variety minerals. It is situated among the very important States which produces minerals for industries, such as pointed aggregate, ornamentals stones and ceramics raw materials. Nowadays only four companies producting ceramics tiles. Porcelainized stoneware tiles is one of the noblest ceramics, depicting low water absorption (typically below of 0,5%), in addition to excellent staining resistance and mechanical strength. The present work aims at investigating the potential of local raw materials for the production of porcelainized stoneware tiles. For this purpose, these materials were characterized by X-ray fluorescence, X-ray diffraction, particle size analysis, thermal gravimetric analysis, thermal differential analysis and dilatometric analysis. Admixtures containing different compositions were prepared and fired at four temperatures, 1100 ºC, 1150 ºC, 1200 ºC and 1250 ºC with isotherm for 60 minute and heathing rate of 5 oC/min. After firing the samples, they were characterized by water absorption tests, linear retraction, analysis, apparent porosity, apparent specific mass, flexural strength, and microstructural analysis by X-ray diffraction and scanning electron microscopy . The results revealed three ceramics with porcelainized stoneware tiles characteristics and porcelain tile will be produce from raw materials originated in the State of Bahia

Propriedades cerâmicas e imobilização do manganês em cerâmica estrutural

In this work is the addition of a metallic ion, of the metal Manganese, in a clay of Rio Grande do Norte state for structural ceramics use, the objective this study was to assess the evolution of ceramic properties. The clay was characterized by Chemical and Thermal analysis and Xray difraction. The metallic ion was added in the clay as aqueous solutions at concentrations of 100, 150 and 200 mg / L. The molded by extrusion and the burned were temperatures at 850, 950, 1050 and 1150 º C. Was made Chemical Analysis and investigated the following parameters environmental and ceramic: Solubility, Colour, Linear Retraction (%), Water Absorption (%), Gresification Curves, Apparent Porosity (%), Apparent Specific Mass (g/cm3) and Flexion Rupture Module (kgf/cm2). The results showed that increasing the concentration of metallic ion, properties such as Apparent Porosity (%), Water Absorption (%) decreases and the Flexion Rupture Module (kgf/cm2) increases with increasing temperature independent of the concentration of the ion. The gresification curves showed that the optimum firing temperatures were in the range between 950 and 1050 ° C. The evaluation of the properties showed that the ceramic material can be studied its use in solid brick and ceramic materials with structural function of filling. The results of solubility showed that the addition of ion offers no risk to the environment

Influência do teor e granulometria da calcita e da temperatura de sinterização no desenvolvimento de massas cerâmicas para revestimento poroso(BIII)

This work aims at studying the influence of the concentration of calcite, its grain size and sintering temperature to obtain porous coating formulations that meet the design specifications. The experiments involved the physical-chemical and mineralogical caracterization of the raw materials, and mechanical tests on specimens dried and sintered, performing a planning mixture and factorial experiment, using the response surface methodology. The ceramic bodies studied were prepared by dry process, characterized, placed in conformity by uniaxial pressing and sintered at temperatures of 940 º C, 1000ºC, 1060ºC, 1120°C and 1180°C using a fast-firing cycle. The crystalline phases formed during sintering at temperatures under study, revealed the presence of anorthite and wolastonite, and quartz-phase remaining. These phases were mainly responsible for the physical and mechanical properties of the sintered especimens. The results shown that as increases the participation of carbonate in the composition of ceramic bodies there is an increase of water absorption and a slight reduction in linear shrinkage for all sintering temperatures. As for the mechanical strength it was observed that it tended to decrease for sintering at temperatures between 940 ° C and 1060 ° C and to increase for sintering at temperatures above 1060 ° C occurring with greater intensity for compositions with higher content of calcite. The resistence decreased with increasing participation of quartz in all sintering temperatures. The decrease in grain size of calcite caused a slight increase in water absorption for formulation with the same concentration of carbonate, remaining virtually unchanged the results of linear shrinkage and mechanical strength. In conclusion, porous ceramic coating (BIII) can be obtained using high concentrations of calcite and keeping the properties required in technical standards and that the particle size of calcite can be used as tuning parameter for the properties of ceramic products.

Incorporação de resíduo de perfuração em matriz cerâmica: estabilização por solidificação

One of the waste generated during the drilling of oil wells are gravel which are impregnated of drilling fluid. This residue consists of highly toxic chemicals, including toxic metals. This study suggests an alternative process to the treatment of this waste, by incorporating it the form of raw material in the ceramic matrix , and by solidification and stabilize the metals present, Aluminum (Al), Iron (Fe), Manganese (Mn) and Zinc (Zn). The raw materials were characterized by the techniques of X ray fluorescence (FRX), X ray diffraction (DRX), laser granulometry (GL), thermogravimetry (TG) and differential thermal analysis (ADT). To evaluate the percentage of gravel effect the environmental and technological properties were obtained from formulations containing 0, 10 and 20 % by weight of gravel in the ceramic matrix. After sintering at temperatures 1080, 1120 and 1160 °C, the samples were tested for water absorption, the linear shrinkage firing, voltage of rupture and solubility. The results obtained showed that the stabilization by solidification, is a viable alternative to safe disposal of waste drilling. Ceramics products can be used in the manufacture of solid bricks

Uso da cinza do bagaço da cana-de-açúcar como matéria-prima na substituição dos fundentes para aplicações em porcelanato

The present study aims to evaluate the potential use of bagasse ash from sugar cane (CBC) as a flux, replacing phyllite and/or feldspar in standard industrial mass production of enameled porcelain, verifying the possibility of the CBC contribute to the overall reduction of the coefficient of thermal expansion of the ceramic mass. To this end, as a result of the research, we characterized the raw material components of the standard mass (clay, phyllite, kaolin, feldspar, quartz and talc) and the residue of BCC, by testing by XRF, XRD, AG, DTA and ATG. Specimens (CDP) were manufactured in the dimensions of 100 mm x 50 mm x 8 mm in uniaxial matrix under compaction pressure of 33 MPa, assembled in batches of 3 units subsequently sintered at temperatures of 1150°C to 1210°C by varying the Rating Scale at 10°C, heating and cooling ramp of 50°C/min and 25°C/min, with levels of 1 min, 3 min, 5 min, 8 min, 10 min, 15 min, 30 min and 60 min. analyzing the results of the physical properties of water absorption (WA), linear firing shrinkage (LFS), dilatometric analysis (DTA), flexural strain (SFT) and SEM of the sintered bodies in order to verify the adequacy of CDP to ISO 13006, ISO 10545, NBR 13816 standards; NBR 13817 and NBR 13818. The study showed that the formulations that best suit the requirements of the standards are:. G4 - which was applied in 10% of replacing the CBC phyllite, sintering temperature 1210 ° C for 10 min and porch, and F3 - with application of 7.5% of CBC to replace the feldspar in the sintering temperatures of 1190°C, 1200°C and 1210°C for 10 min and porch. These formulations showed better performance regarding the formation of primary and secondary mullite, with considerable reduction of cracks and pores, meeting the prerequisites of standards for glazed porcelain. The results shows that the use of the CBC as a flux in the preparation of porcelain mass meets standard parameters for the manufacture of the product, and thereby can reduce environmental impact and the cost of production. Therefore, it is recommended to use this residue in the ceramics industry, due to its industrial, commercial and collaborative viability for sustainability.

Estudo da incorporação de cinza e chamote gerado pela cerâmica vermelha ao próprio processo industrial

The ceramics industry generates waste at various stages of that process, defective products, waste from burning solid fuels, among others. This waste is dumped in landfills, garbage dumps or directly on roads, which has a negative environmental impact. This paper presents a study to incorporate the waste of algaroba wood and chamote (scrap pieces of ceramic already sintered), in to the ceramic material for making sealing blocks. The methodological procedures consist in the characterization of chemical and mineralogical residues, raw materials, and physical-mechanical of the formulations of mixes with clay, silt and waste. By pressing test pieces were produced using a pressure of 200 kgf/cm², varying compositions in the range of 0%, 5%, 10% and 15% by weight of residue. The sintering was performed in a muffle furnace, with the temperature levels of 850 ° C, 900 ° C, 950 ° C, 1000 ° C and 1050 ° C. The evaluated physical and mechanical properties were: Water Absorption, Linear Shrinkage Burning, Apparent Porosity, Apparent Density and Mechanical Resistance to Flexion. Analysis was carried out by Scanning Electron Microscopy on fracture surfaces of the specimens. Evaluation of linear shrinkage property drying and firing , water absorption and mechanical resistance to compression of the sealing blocks 5% wood ash residue, sintered at 900 °C hold temperature in the laboratory the products manufactured on an industrial scale. The main results, it was found on the viability of using the residues of algaroba wood and to confer refractory properties of the ceramic product. The main results, it was concluded feasibility of using the ash residues algaroba wood to impart refractory properties to the ceramic product and the residue of chamote, being derived from the own ceramic product not interfere with the properties, when used in a percentage of up to 5%.Since the residue of chamote being derived from the ceramic product itself had no effect on the properties. Studies in the laboratory have shown that the incorporation of up to 5% of these residues may be adopted as an alternative technology to reduce the environmental impact caused by the industrial sector, without compromising the final properties of the material, since the results on an industrial scale showed absorption values 11.66 and 11.74 of water and waste products respectively, within the parameters of NBR - 15,270, since the mechanical strength was 1.25 MPa and 0.94 MPa respectively for products with and without residue, lower than the minimum required by the technical standard that is 1.5 MPa.