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 tecnologia de microondas nas propriedades tecnológicas dos componentes de cerâmica estrutural

O processamento térmico de materiais cerâmicos via energia de microondas, no estágio atual, vem ganhando cada dia mais importância, tendo em vista suas inúmeras aplicações, como por exemplo: aplicação de microondas na área de processamento mineral (aquecimento de minérios antes da moagem, secagem, redução carbotérmica de óxidos minerais, lixiviação, fusão, pré-tratamento de minérios e concentrados de ouro refratário, regeneração de carvão, etc. de acordo com Kigman & Rowson, 1998). Em virtude de uma série de vantagens em potencial, frente aos métodos convencionais de aquecimento, como redução no tempo de processamento; economia de energia; diminuição do diâmetro médio das partículas e melhoramento nas propriedades tecnológicas em geral, esta tecnologia vem se destacando. Neste contexto, o objetivo geral deste trabalho, é desenvolver uma pesquisa visando identificar e caracterizar novas opções de matérias-primas cerâmicas como argilas, feldspatos e caulins que sejam eficazes para definir a formulação de uma ou mais massas para produção de componentes de cerâmica estrutural com propriedades físicas, mecânicas e estéticas adequadas após passarem por sinterização convencional e por energia de microondas destacando as vantagens desta última. Além dos requisitos técnicos e de processo, as formulações apresentadas deverão atender às expectativas de preço e de logística de fornecimento. No estudo foram conformados corpos-de-prova por extrusão e prensagem, sinterizados em fornos microondas e convencional, sob ciclos de queima mais rápidos que os atualmente praticados. As matérias-primas foram caracterizadas e analisadas, utilizando as técnicas de fluorescência por raios X (FRX), difração por raios X (DRX), análise térmica diferencial (DTA), análise térmica gravimétrica (DTG), análise granulométrica (AG), microscopia eletrônica de varredura (MEV), absorção d agua (AA), massa especifica aparente (MEA), porosidade aparente (PA), retração linear (RL) e tensão de ruptura e flexão (TRF). Os resultados obtidos indicaram que as propriedades tecnológicas de Absorção de água (AA) e Tensão de Ruptura e flexão (TRF), proposto no trabalho foram adquiridos com sucesso e estão bem além do limite exigido pelas especificações das normas da ABNT NBR 15.270/05 e 15.310/09

Efeito da velocidade de aquecimento nas propriedades de produtos da cerâmica estrutural

Heating rate is one of the main variables that determine a fire cycle. In industrial processes that use high temperatures, greater fire great can reduce the cost of production and increase productivity. The use of faster and more efficient fire cycles has been little investigated by the structural ceramic industry in Brazil. However, one of the possibilities that aims at modernizing the sector is the use of roller kilns and the inclusion of natural gas as fuel. Thus, the purpose of this study is to investigate the effect of heating rate on the technological properties of structural ceramic products. Clay raw materials from the main ceramic industries in the state of Rio Grande do Norte were characterized. Some of the raw materials characterized were formulated to obtain the best physical and mechanical properties. Next, raw materials and formulations were selected to study the influence of heating rate on the final properties of the ceramic materials. The samples were shaped by pressing and extrusion and submitted to rates of 1 °C/min, 10 °C/min and 20 °C/min, with final temperatures of 850 °C, 950 °C and 1050 °C. Discontinuous cycles with rates of 10 °C/min or 15 °C/min up to 600 °C and a rate of 20 °C/min up to final temperature were also investigated. Technological properties were determined for all the samples and microstructural analysis was carried out under a number of fire conditions. Results indicate that faster and more efficient fire cycles than those currently in practice could be used, limiting only some clay doughs to certain fire conditions. The best results were obtained for the samples submitted to slow cycles up to 600 °C and fast fire sinterization up to 950 °C. This paper presents for the first time the use of a fast fire rate for raw materials and clay formulations and seeks to determine ideal dough and processing conditions for using shorter fire times, thus enabling the use of roller kilns and natural gas in structural ceramic industries

Efeito da introdução de resíduo de cinza de forno cerâmico em massa para cerâmica estrutural

The red ceramics and structural ceramics, as they are known, include ceramic materials made by blocks of seals and structures, bricks, tiles, smail flagstones manacles, rustic floors and ornamental materials. Their fabrication uses raw material such as clay and clay sites, with some content of impurity. It has good durability and mechanical strength to compression, low cost, making it one of the mainly used materials in civil engineering. The incorporation of many industrial activities residue to ceramic products is a technological alternative for reducing the environmental impact caused by its carefree disposal. This incorporation can promote chemical change and inertness of metals from residue, by fixation in the glassy phase of ceramic during the burning stage. The main aim of this project is to study the technical feasibility of the addition of ceramic oven ash into formulations of mass for structural ceramics. In this project two kinds of clay (plastic and non-plastic) were used, as well as the ash from firewood used in the process of burning of structural ceramics. A group of experiments was outlined, which permitted the evaluation of the influence of the burning cycle in different temperatures of the ash content in formulations for ceramic blocks through technological properties, mechanical behavior and microstructure. Five samples were processed of each one of the masses of plastic and non-plastic clay without addition of ash and with addition of ash on the percentages of 10 % and 20 %, for temperatures of 850 °C, 950 °C, 1050 °C and 1150 °C, obtained through sinterization process. Among the studied compositions, the one which presented best performance was the mass of clay with 10 % of ash, at temperature of 1150 °C, with the smallest absorption of water, the smallest apparent porosity, specific apparent mass a bit over the others and greatest mechanical resistance to flexion. The composition made confirmed the technical feasibility of the use of ash in the mass for structural ceramics with maintenance of its necessary characteristics for its purposes

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

Balanço energético de um forno túnel de cerâmica estrutural convertido de lenha para gás natural

In energy systems, the balance of entrances, exits and losses are fundamental to rationalize the energy consumption, independently of the source (sun, natural gas, wind, water, firewood or oil). This estimate is important so much in the phase of project of the facilities, as in the exploration or operation. In the project phase it indicates the energy needs of the process and the contribution of the energy in the cost of the product and the capacity of storage of the fuel and in the operation phase it allows to evaluate the use of the energy in the process of it burns, showing the weak points that should suffer intervention to improve the efficiency. With this tool, it can be implemented routines of calculation of thermal balances in ovens of it burns of structural ceramic, in way to generate an optimized mathematical model for application in the current and promising structural ceramic brazilian industry. The ceramic oven in study is located in the metropolitan area of Natal (Rio Grande do Norte) and it is a continuous oven of the type wagons tunnel, converted of firewood for natural gas and it produces blocks of red ceramic. The energy balance was applied in the oven tunnel before and after the conversion and made the comparisons of the energy efficiencies (it burns to the firewood and it burns to natural gas), what showed that the gaseous fuel is more efficient when we burn structural ceramic in ovens tunnels. When we burn natural gas, the requested energy is smaller and better used. Tests were accomplished in the burned product that showed the best quality of the burned brick with natural gas. That quality improvement makes possible to accomplish new interventions for the most rational use of the energy in the oven tunnel of the Ceramic in study and in the industries of structural ceramic of the whole Brazil, that need control tools of burning and of quality

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 tecnologia de microondas nas propriedades tecnológicas dos componentes de cerâmica estrutural

O processamento térmico de materiais cerâmicos via energia de microondas, no estágio atual, vem ganhando cada dia mais importância, tendo em vista suas inúmeras aplicações, como por exemplo: aplicação de microondas na área de processamento mineral (aquecimento de minérios antes da moagem, secagem, redução carbotérmica de óxidos minerais, lixiviação, fusão, pré-tratamento de minérios e concentrados de ouro refratário, regeneração de carvão, etc. de acordo com Kigman & Rowson, 1998). Em virtude de uma série de vantagens em potencial, frente aos métodos convencionais de aquecimento, como redução no tempo de processamento; economia de energia; diminuição do diâmetro médio das partículas e melhoramento nas propriedades tecnológicas em geral, esta tecnologia vem se destacando. Neste contexto, o objetivo geral deste trabalho, é desenvolver uma pesquisa visando identificar e caracterizar novas opções de matérias-primas cerâmicas como argilas, feldspatos e caulins que sejam eficazes para definir a formulação de uma ou mais massas para produção de componentes de cerâmica estrutural com propriedades físicas, mecânicas e estéticas adequadas após passarem por sinterização convencional e por energia de microondas destacando as vantagens desta última. Além dos requisitos técnicos e de processo, as formulações apresentadas deverão atender às expectativas de preço e de logística de fornecimento. No estudo foram conformados corpos-de-prova por extrusão e prensagem, sinterizados em fornos microondas e convencional, sob ciclos de queima mais rápidos que os atualmente praticados. As matérias-primas foram caracterizadas e analisadas, utilizando as técnicas de fluorescência por raios X (FRX), difração por raios X (DRX), análise térmica diferencial (DTA), análise térmica gravimétrica (DTG), análise granulométrica (AG), microscopia eletrônica de varredura (MEV), absorção d agua (AA), massa especifica aparente (MEA), porosidade aparente (PA), retração linear (RL) e tensão de ruptura e flexão (TRF). Os resultados obtidos indicaram que as propriedades tecnológicas de Absorção de água (AA) e Tensão de Ruptura e flexão (TRF), proposto no trabalho foram adquiridos com sucesso e estão bem além do limite exigido pelas especificações das normas da ABNT NBR 15.270/05 e 15.310/09

Efeito da velocidade de aquecimento nas propriedades de produtos da cerâmica estrutural

Heating rate is one of the main variables that determine a fire cycle. In industrial processes that use high temperatures, greater fire great can reduce the cost of production and increase productivity. The use of faster and more efficient fire cycles has been little investigated by the structural ceramic industry in Brazil. However, one of the possibilities that aims at modernizing the sector is the use of roller kilns and the inclusion of natural gas as fuel. Thus, the purpose of this study is to investigate the effect of heating rate on the technological properties of structural ceramic products. Clay raw materials from the main ceramic industries in the state of Rio Grande do Norte were characterized. Some of the raw materials characterized were formulated to obtain the best physical and mechanical properties. Next, raw materials and formulations were selected to study the influence of heating rate on the final properties of the ceramic materials. The samples were shaped by pressing and extrusion and submitted to rates of 1 °C/min, 10 °C/min and 20 °C/min, with final temperatures of 850 °C, 950 °C and 1050 °C. Discontinuous cycles with rates of 10 °C/min or 15 °C/min up to 600 °C and a rate of 20 °C/min up to final temperature were also investigated. Technological properties were determined for all the samples and microstructural analysis was carried out under a number of fire conditions. Results indicate that faster and more efficient fire cycles than those currently in practice could be used, limiting only some clay doughs to certain fire conditions. The best results were obtained for the samples submitted to slow cycles up to 600 °C and fast fire sinterization up to 950 °C. This paper presents for the first time the use of a fast fire rate for raw materials and clay formulations and seeks to determine ideal dough and processing conditions for using shorter fire times, thus enabling the use of roller kilns and natural gas in structural ceramic industries

Estudo comparativo da queima rápida com a queima tradicional nas propriedades de materiais cerâmicos de base argilos

Dutra, R. P. S.; Varela,M. L.; Nascimento, R. M. ; Gomes, U. U. ; Martinelli1, A. E. ; Paskocimas, C. A. Estudo comparativo da queima rápida com a queima tradicional nas propriedades de materiais cerâmicos de base argilosa. Cerâmica [online]. 2009, vol.55, n.333, pp. 100-105. ISSN 0366-6913. doi:Disponivem em: . Acesso em: 04 out. 2010.

Influência do teor de calcário no comportamento físico, mecânico e microestrutural de cerâmicas estruturais

There are ores of clay in Piauí State that are used for red structural ceramics, which are naturally contaminated with calcareous vein. This is one thing that impedes its exploration in an adequate way, especially for tile production. The present work aims at verifying the influence of the calcareous contents in the technological structural ceramics area, seeking to determine a maximum permissible calcareous proportion/contents in the ceramic mass using the patterns of the local industry production. For the consecution of this paper, it was characterized the clay and calcareous material by FRX, DRX, TGA and DTA. It was also configurated by extrusion and burnt in the temperatures of 850°C, 900°C, 950°C and 1000°C pieces of the corpus with 0, 5, 10, 15 e 20% of calcareous proportion. After that, it was carried out technological samples of linear retraction, water absortion, apparent porosity, specific apparent mass and mechanic resistance. The results showed the possibility of using calcareous in the ceramic mass and in some cases the technological properties got better

Avaliação da conformidade de blocos cerâmicos para alvenaria de vedação produzidas na Região Integrada de Desenvolvimento da Grande Teresina

This research presents an outlook of the industries of red ceramic in the region next to the city of Teresina and an analysis of the ceramic products producted in this pole. The microregion investigated possesses 13 boroughs where were identified 32 ceramic in operation, being that 24 are located in Teresina, the ceramic region more important of Piauí, 1 is located in the city of Miguel Leão and 7 is located in Timon city that belongs to the state of Maranhão. The majority of ceramics are pulverized in these two cities, Teresina and Timon , responsible by a largely production independent of distance between fabric and consumer market. Furthermore, there is an artisanal production realized in other boroughs, mainly manual conformation bricks, where are producted diverse types of handicraft and ceramics utilitarian. The objective of this research is to evalue the conformity of ceramic blocks for brick of obstruction made by red ceramic industry of microregion at studying, verifying their pontentialities and adequacy in terms of production. In this research universe made a search of ceramic industries related to the Foundation CEPRO (Foundation Center of Research Social and Economic of Piauí). For the analysis of the ceramic products , were colected 60 crude bricks sample in three industries for their characterization, and 39 burned bricks sample for the Evaluation of Conformity. The results of the characterization made reached a accetptable standard in all formulations and temperature studied. The burned samples were applied to the geometric, physical and mechanical assays according to the ABNT standards (Brazilian Association of Technical Standards). The results of the physical assays showed that all the samples are at the same band recommended by standard. However, through the geometric assays just two industries did not present results according to the standard, due to lack of control in their process such as in their equipments. Taking into account the mechanical properties, only one industry investigated was not according to the standard

Estudo do efeito da adição da escória de aciaria no processamento e propriedades finais de telhas cerâmicas

This research presents an overview of the addition steelwork dust of ceramic shingles in order to contribute to the utilization use of such residue. The ceramic industry perspective in the Brazilian State of Piauí is quite promising. Unlike other productive sectors, the ceramic industry uses basically natural raw materials. Its final products are, in short, the result of transforming clay compounds. These raw materials are composed primarily of aluminum oxide, silicon, iron, sodium, magnesium, end calcium, among others. It was verified that steelwork dust is composed primarily of these same oxides, so that its incorporation in to structural ceramics is a very reasonable idea. Both clay and steelwork powder were characterized by AG, XRF, XRD, TGA and DTA. In addition, steelwork dust samples containing (0%, 5%, 10%, 15%, 20% and 25%) were extruded and burned at 800°C, 850°C, 900°C and 950°C. Then t echnological tests of linear shrinkage, water uptake, apparent porosity, apparent density and flexural strengthwere carried at. The results showed the possibility of using steelwork powder in ceramic shingles until 15% significant improvement in physical and mechanical properties. This behavior shows the possibility of burning at temperatures lower than 850ºC, thus promoting a product final cost reduction

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