Avaliação da incorporação combinada dos resíduos de cascalho de perfuração de poço de petróleo e de polimento do porcelanato em cerâmica vermelha

Among the industries, those that produce ceramic porcelain for use in construction industry and oil, during the exploration and production period, play an important role in the production of waste. Much research has been carried out both by academia and the productive sector, sometimes reintroducing them in the same production line that generated them, sometimes in areas unrelated to their generation, as in the production of concrete and mortar for the construction, for example, but each one in an isolated way. In this research, the aim is to study the combined incorporation of the waste drill cuttings of oil well and the residue of the polishing of porcelain, generated in the final stage of finishing of this product in a clay matrix, for the production of red pottery, specifically bricks, ceramic blocks and tiles. The clay comes from the municipality of São Gonçalo, RN, the drilling waste is from the Natal basin, in Rio Grande do Norte, and the residue of the polishing proceeds from a ceramic porcelain of the State of Paraíba. For this purpose, we used a mixture of a plastic clay with a non-plastic, in a ratio of 50% each, settling formulations with the addition of these two residues in this clay matrix. In the formulations, both residues were incorporated with a minimum percentage of 2.5% and maximum of 12.5%, varying from 2.5% each, in each formulation, which the sum of the waste be no more than 15%. It should be noted that the residue of the polishing of ceramic porcelain is a IIa class (not inert). The materials were characterized by XRF, XRD, TG, DTA, laser granulometry and the plasticity index. The technological properties of water absorption, apparent porosity, linear shrinkage of burning, flexural tensile strength and bulk density were evaluated after the sintering of the pieces to 850 °C, 950 °C and 1050 °C, with a burning time of 3 hr, 3 hr and 30 minutes, and 3 hr and 50 minutes, respectively, with a heating rate of 10 °C/minute, for all formulations and landing of 30 minutes. To better understand the influence of each residue and temperature on the evaluated properties, we used the factorial planning and its surfaces of response for the interpretation of the results. It was found that the temperature has no statistical significance at a 95% of reliability level in flexural tensile strength and that it decreases the water absorption and the porosity, but increases the shrinkage and the bulk density. The results showed the feasibility of the desired incorporation, but adjusting the temperature to each product and formulation, and that the temperatures of 850 °C and 950 °C were the one that responded to the largest number of formulations

Aproveitamento de resíduo de beneficiamento do caulim na produção de porcelanato cerâmico

Nowadays, industries from all sectors have great concerns over the disposition of the residues generated along the productive process. This is not different in the mineral sector, as this generates great volumes of residues. It was verified that the kaolin improvement industry generates great volumes of residue basically constituted of kaolinite, muscovite mica and quartz, which are basic constitution elements to formularisations of ceramics masses to the production of covering of stoneware tiles type. This happens because the methodology applied to the improvement process is still very rudimentary, what causes a very low yield, only ¼ from all the material volume that enters the improvement process, in the end, is marketable. The disposal of this residue, in a general way, causes a very big negative environmental impact, what has justified the researches efforts aiming to find a rational solution to this problem. In this way, the intention of this present work is the utilization of this residue in the manufacture of products to high quality ceramics covering, stoneware tiles in an industrial scale. For this purpose, the influence of the addition of the residue to a standard ceramics mass used by a ceramics sector company, already established in the market, with the intention of verifying the possibility of use of this residue as the mass complementary raw material and even the possible partial or total substitution of one of the components of the mass for the raw material in evidence will be studied. To the accomplishment of this work, the kaolin improvement residue generated by an industry of exploitation and improvement of kaolin, located in the region of Equador-RN, in the levels 1,2,4,8, 16 and 32% will be added to the standard mass already used for the production of stoneware tiles. The raw materials used, kaolin residue and the standard mass, were characterized through DRX, FRX, DTA, TGA and dilatometry. After the sintering of the bodies of test, tests of water absorption, apparent porosity, post burning linear retraction, apparent specific mass and flexural strength (3 point bending) were realized to determinate the technological properties of these materials. The results show the studied residue can be considered raw material of great potential to the industry of floor and ceramics covering of the stoneware tiles type

Influência da adição de gres porcelanato no comportamento mecânico e microestrutural em pastas de cimento portland para cimentação de poços de petróleo

Cementation operation consists in an extremely important work for the phases of perforation and completion of oil wells, causing a great impact on the well productivity. Several problems can occur with the cement during the primary cementation, as well as throughout the productive period. The corrective operations are frequent, but they are expensive and demands production time. Besides the direct cost, prejudices from the interruption of oil and gas production till the implementation of a corrective operation must be also taken into account. The purpose of this work is the development of an alternative cement paste constituted of Portland cement and porcelainized stoneware residue produced by ceramic industry in order to achieve characteristics as low permeability, high tenacity, and high mechanical resistance, capable of supporting various operations as production or oil wells recuperation. Four different concentration measures of hydrated paste were evaluated: a reference paste, and three additional ones with ceramic residue in concentrations of the order of 10%, 20% and 30% in relation to cement dough. High resistance and low permeability were found in high concentration of residues, as well as it was proved the pozolanic reactivity of the residue in relation to Portland cement, which was characterized through x-ray and thermogravimetry assays. It was evident the decrease of calcium hydroxide content, once it was substituted by formation of new hydrated products as it was added ceramic residue

Prevalencia de dolor lumbar en los trabajadores de una planta de fabricación de productos de cerámica de Madrid, Cundinamarca, en el turno de 6 am a 2pm, año 2014.

Objetivo: Establecer la prevalencia, incapacidad y discapacidad de dolor lumbar en los trabajadores de la planta de fabricación de productos de cerámica, de Madrid Cundinamarca, del turno de 6 am a 2 pm año 2014. Metodología: Se realizó un estudio de corte transversal para determinar la prevalencia, incapacidad y discapacidad de dolor lumbar en un grupo de trabajadores que asisten en el turno de 6 am a 2 pm, en una empresa fabricante de productos de cerámica en el municipio de Madrid, departamento de Cundinamarca, Colombia. Se tuvieron en cuenta variables como edad, puesto de trabajo, antigüedad en cargo actual, consumo de cigarrillo, actividad física, presencia o ausencia de dolor lumbar e intensidad del dolor lumbar. Se aplicaron dos escalas para determinar el nivel de incapacidad y discapacidad para el dolor lumbar. Se empleó la escala de Owestry (ODI, OswestryDisabilityIndex) para evaluar la incapacidad de dolor lumbar y la escala de Roland-Morris para discapacidad física. Para le análisis de las variables continuas se determinó el supuesto de normalidad utilizando la prueba de ShapiroWilks.Para determinar la presencia de asociaciones se utilizó la prueba de Ji cuadrado de Pearson o el test exacto de Fischer si el valor esperado es menor a cinco. Para el análisis de la información se utilizó el software EpiInfo versión 7.1.3 (CDC, Atlanta, EE.UU.) Resultados: Se incluyeron 99 trabajadores, rango de edad entre 32 y 46 años y una mediana de 37 años. Más de la mitad de los trabajadores evaluados reportaron un dolor moderado (n=57), tan solo un 10% reportó máximo dolor, la escala de incapacidad de Oswestry78 trabajadores se ubicaron entre 0 y 40% reflejando esto ausencia de incapacidad, y solo 4 pacientes presentaron valores entre 40 y 60% incapacidad moderada. La escala de discapacidad de Roland-Morris mostró que la mayoría de los trabajadores presentan una discapacidad leve (n=97) y tan solo 2 trabajadores presentaron discapacidad moderada.La única asociación positiva encontrada se dio entre la presencia de dolor lumbar y la ejecución de actividad física una vez a la semana (p 0,005). Conclusiones: el dolor lumbar está presente en más del 50% de los trabajadores encuestados; sin embargo solo 4 de los trabajadores encuestados, presenta incapacidad por este dolor. En cuanto a la discapacidad pudimos determinar que solo 2 de los trabajadores la manifiesta.

Utilização de resíduos industriais de baixa granulometria em massas cerâmicas de argila vermelha : aspectos tecnológicos e ambientais

Este trabalho avalia o efeito da adição de diferentes resíduos, todos de baixa granulometria e gerados não muito distantes de empresas fabricantes de produtos de cerâmica vermelha, quando incorporados a argilas para processamento cerâmico tradicional. Foram utilizadas argilas da região de Sangão e Forquilhinha (Santa Catarina), bem como os seguintes resíduos: resíduo siderúrgico da produção de aço em forno elétrico (pó de aciaria), resíduo de atomizador de uma indústria de revestimentos cerâmicos e resíduo do polimento de grês porcelanato. Após a caracterização das matérias-primas, foram formuladas massas cerâmicas na relação argila/resíduo de 5:1 para cada resíduo. E, como padrão de comparação, utilizou-se a formulação apenas com argilas. As massas cerâmicas foram conformadas por prensagem e submetidas à queima em forno elétrico tipo mufla nas seguintes temperaturas 800, 900, 950, 1000 e 1100oC. Os corpos cerâmicos assim obtidos foram caracterizados segundo suas propriedades físicas (retração linear e absorção de água – curva de gresificação) e mecânicas (resistência mecânica à flexão a quatro pontos). Além disso, os corpos cerâmicos fabricados, utilizando pó de aciaria (resíduo perigoso segundo a ABNT), foram avaliados segundo as normas NBR 10005 e NBR 10006, quanto ao seu aspecto ambiental. Os resultados mostraram a viabilidade do uso destes resíduos na fabricação de produtos cerâmicos. As propriedades finais e a cor de queima (entre marrom claro e marrom escuro) variaram de acordo com a natureza do resíduo e temperatura de queima. A formulação testada com pó de atomizador de industria cerâmica apresentou em todas as temperaturas ensaiadas os maiores incrementos de resistência mecânica em relação às formulações testadas, sendo que à temperatura de 1100oC, a formulação com pó de aciaria apresentou desempenho similar, porém com menor absorção de água e maior retração linear. Nestas condições, os corpos cerâmicos com pó de aciaria mostraram-se inertes quanto ao aspecto ambiental de acordo com as normas Brasileiras.

Aproveitamento de resíduos minerais na formulação de argamassas para a construção civil

Current environmental concerns include the excessive consumption and inefficient use of non-renewable natural resources. The construction industry is considered one of the largest consumers of natural raw materials, significantly contributing to the environmental degradation of the planet. The use of calcareous quarry (RPPC) and porcelain tile polishing residues (RPP) as partial replacements of the cement in mortars is an interesting alternative to minimize the exploration of considerably large amounts of natural resources. The present study aimed at investigating the properties of fresh and hardened mortars produced using residues to replace cement. The residues used were fully characterized to determine their specific mass, unitary mass, particle size distribution and morphology, and composition. The performance of the mortars was compared to that of reference compositions, prepared without residues. A total of 18 compositions were prepared, 16 using residues and 2 reference ones. The mortars were prepared using Portland CP II F 32 cement, CH I hydrated lime, river sand and tap water. The compositions of the mortars were 1:1:6 and 1:0.5:4.5 (vol%), and water to cement ratios of 1.87 and 1.45 were used, respectively. The mortars in the fresh state were evaluated by consistency index, water retention, density of mass and incorporated air content tests. In their hardened state, the mortars were evaluated by apparent mass density, modulus of elasticity, flexural tensile strength, compressive strength and water absorption by capillarity. The mortars were also analyzed by scanning electron microscopy, energy dispersive spectroscopy, X-ray diffraction and fluorescence. Finally, they were classified according to NBR 13281 standards. The mortars prepared using residues partially replacing the cement exhibited lower modulus of elasticity compared to the reference compositions, thus improving the performance in their intended use. On the downside, the water absorption by capillarity was affected by the presence of residues and both the tensile and compressive strength were reduced. However, from the overall standpoint, the replacement of cement by calcareous quarry or porcelain tile polishing residues did not result in significant changes in the properties of the mortars. Therefore, compositions containing these residues can be used in the construction industry

Efeito da adição de cargas minerais leves na resistência mecânica de grautes para cimentação de poços offshore

The preparation of cement slurries for offshore well cementing involves mixing all solid components to be added to the mixing water on the platform. The aim of this work was to study the formulation of pre-prepared dry mixtures, or grouts, for offshore oilwell cementing. The addition of mineral fillers in the strength of lightweight grouts applied for depths down to 400 m under water depths of 500 m was investigated. Lightweight materials and fine aggregates were selected. For the choice of starting materials, a study of the pozzolanic activity of low-cost fillers such as porcelain tile residue, microsilica and diatomaceous earth was carried out by X-ray diffraction and mechanical strength tests. Hardened grouts containing porcelain tile residue and microsilica depicted high strength at early ages. Based on such preliminary investigation, a study of the mechanical strength of grouts with density 1.74 g/cm3 (14.5 lb/gal) cured initially at 27 °C was performed using cement, microsilica, porcelain tile residue and an anti-foaming agent. The results showed that the mixture containing 7% of porcelain tile residue and 7% of microsilica was the one with the highest compressive strength after curing for 24 hours. This composition was chosen to be studied and adapted for offshore conditions based on testes performed at 4 °C. The grout containing cement, 7% of porcelain tile residue, 7% of active silica and admixtures (CaCl2), anti-foaming and dispersant resulted satisfactory rheology and mechanical strength after curing for 24 hours of curing

Utilização de resíduos de rochas ornamentais na produção de cerâmica branca

The marble and granite waste come from the process of mining of those ornamental rocks for use in the building industry. Brazil is one of the largest producers of blocks or finished products of ornamental rocks, extracting about 5.2 tons / year. The largest national producers are the states of Espírito Santo, Minas Gerais and Bahia which account for 80% of the Brazilian production. However, the waste total amount during processing of these blocks reaches 40% of the total. The use of the waste produced by this industry in white ceramics could be a form of disposition, because these materials, are thrownasa mud directly at decantation ponds, wastelands or in rivers, without any treatment. The present work has as main purpose to study the influence that reject of the ornamental rocks on the physical and mechanical properties of white ceramics. X-Ray characterizations of raw materials by were performed X-Ray fluorescence, X-Ray diffraction, granulometric, thermogravimetric and thermodiferencial analysis, five formulations were made (0, 10, 20, 30, 40% in granite weight) wich were burned at three temperatures: 1100°C, 1150°C and 1200ºC with 60 minutes of sorling time. After sintering, the samples were submitted to different analyser absorption of water, linear retraction, apparent porosity, apparent specific mass, flexival stronght, and scanning were obtained microscopy. Compatible technological properties within the limits demanded for the production of porcelainized stoneware

Aproveitamento de resíduos de cinza da cana de açúcar em massas cerâmicas

This study aimed to investigate the use of cane sugar ashes from small-scale stills of Eunápolis region, state of Bahia, in pottery mass that can be developed as porcelain stoneware. Bahia is the second largest producer of rum distillery in Brazil. In the production of rum is produced residue called bagasse, which is used to generate electricity in Power plants and in the distillery itself, generating ashes as residue, which is played in nature, causing environmental damage. We studied 5 (five) formulations of 0% 10% 20%, 30% and 40% by weight of the ash, without ignition and 3 (three) formulations of 10%, 20% and 30% with gray ash temperature of 1250ºC. The formulation at 0% by weight of ash was used for a comparison between the traditional mass of porcelain stoneware and the masses with the addition of ash calcined, replacing feldspar. The percentage by weight of kaolin and of Clay was kept the same, 30%, and all raw materials were derived from the state of Bahia. The samples were made in uniaxial array with dimensions of (60 x 20 x 5) mm and compressed to a pressure of 45 MPa. Assays were performed to characterize the raw by X-ray fluorescence, X-ray diffraction, ATD and ATG and Dilatometric analysis. The samples were sintered at temperatures of 1100°C, 1150°C, 1200°C and 1250°C, for the specimens with the ashes without ash and 1150° C and 1200° C for specimens with the gray level of calcined 60 minutes. and then we made a cooling ramp with the same rate of warming until reach ambient temperature. The sintered bodies were characterized by water absorption, porosity, linear shrinkage, bending strength and XRD of the fracture surface and the results analyzed. It was proven, after results of tests performed, that it is possible to use the ash residue of sugar cane bagasse on ceramic coating with the addition of up to 10% wt of the residue ash

Incorporação de cinzas da casca de café na produção de placas cerâmicas para revestimento

Brazil is the world s leading coffee producer. In 2008, 45.99 million of 60 kg bags of benefited coffee were produced. In the process of improvement 50% is grain and 50% is husk, thus, 1.38 million tons of coffee husk are produced annually. The husk is used as combustible in the drying and improvement ovens in the coffee farms, generating ash as residue. These ashes contain a high concentration of alkaline metals and earth metals, mainly K2O and CaO. This work studies the use of this residue in the ceramic tiles industry, as fluxing agents in substitution to the feldspar. Ten mixtures with equal ratios of clay and kaolin, proceeding from Bahia and the residue (varying from 30 to 5%) were defined and produced in uniaxial tool die of 60x20mm with approximately 5 mm of thickness and 45MPa compacting pressure. The samples were fired in four different temperatures: 1100 °C, 1150 °C, 1185 °C and 1200 °C during 60 minutes and characterized by means of X-ray fluorescence, X-ray diffraction, gravimetric thermal analysis and differential thermal analysis. The results of water absorption, apparent porosity, linear shrinkage, XRD, dilatometry, flexural strength and SEM were also analysed. The test specimen with addition of 10% of ash fired in 1200 °C resulted in 0.18% water absorption and 40.77 MPa flexural strength, being classified as porcelain stoneware tiles according to ABNT, UNI and ISO norms

Redução da susceptibilidade à deformação piroplástica das argilas do Pólo Cerâmico de Santa Gertrudes através da adição de matérias-primas

Fundação de Amparo à Pesquisa do Estado de São Paulo (FAPESP)

Placas cerâmicas para revestimento de baixa absorção de água e estabilidade dimensional confeccionadas por moagem a seco usando o material da formação Corumbataí

Conselho Nacional de Desenvolvimento Científico e Tecnológico (CNPq)

Aproveitamento de resíduos minerais na formulação de argamassas para a construção civil

Current environmental concerns include the excessive consumption and inefficient use of non-renewable natural resources. The construction industry is considered one of the largest consumers of natural raw materials, significantly contributing to the environmental degradation of the planet. The use of calcareous quarry (RPPC) and porcelain tile polishing residues (RPP) as partial replacements of the cement in mortars is an interesting alternative to minimize the exploration of considerably large amounts of natural resources. The present study aimed at investigating the properties of fresh and hardened mortars produced using residues to replace cement. The residues used were fully characterized to determine their specific mass, unitary mass, particle size distribution and morphology, and composition. The performance of the mortars was compared to that of reference compositions, prepared without residues. A total of 18 compositions were prepared, 16 using residues and 2 reference ones. The mortars were prepared using Portland CP II F 32 cement, CH I hydrated lime, river sand and tap water. The compositions of the mortars were 1:1:6 and 1:0.5:4.5 (vol%), and water to cement ratios of 1.87 and 1.45 were used, respectively. The mortars in the fresh state were evaluated by consistency index, water retention, density of mass and incorporated air content tests. In their hardened state, the mortars were evaluated by apparent mass density, modulus of elasticity, flexural tensile strength, compressive strength and water absorption by capillarity. The mortars were also analyzed by scanning electron microscopy, energy dispersive spectroscopy, X-ray diffraction and fluorescence. Finally, they were classified according to NBR 13281 standards. The mortars prepared using residues partially replacing the cement exhibited lower modulus of elasticity compared to the reference compositions, thus improving the performance in their intended use. On the downside, the water absorption by capillarity was affected by the presence of residues and both the tensile and compressive strength were reduced. However, from the overall standpoint, the replacement of cement by calcareous quarry or porcelain tile polishing residues did not result in significant changes in the properties of the mortars. Therefore, compositions containing these residues can be used in the construction industry

Efeito da adição de cargas minerais leves na resistência mecânica de grautes para cimentação de poços offshore

The preparation of cement slurries for offshore well cementing involves mixing all solid components to be added to the mixing water on the platform. The aim of this work was to study the formulation of pre-prepared dry mixtures, or grouts, for offshore oilwell cementing. The addition of mineral fillers in the strength of lightweight grouts applied for depths down to 400 m under water depths of 500 m was investigated. Lightweight materials and fine aggregates were selected. For the choice of starting materials, a study of the pozzolanic activity of low-cost fillers such as porcelain tile residue, microsilica and diatomaceous earth was carried out by X-ray diffraction and mechanical strength tests. Hardened grouts containing porcelain tile residue and microsilica depicted high strength at early ages. Based on such preliminary investigation, a study of the mechanical strength of grouts with density 1.74 g/cm3 (14.5 lb/gal) cured initially at 27 °C was performed using cement, microsilica, porcelain tile residue and an anti-foaming agent. The results showed that the mixture containing 7% of porcelain tile residue and 7% of microsilica was the one with the highest compressive strength after curing for 24 hours. This composition was chosen to be studied and adapted for offshore conditions based on testes performed at 4 °C. The grout containing cement, 7% of porcelain tile residue, 7% of active silica and admixtures (CaCl2), anti-foaming and dispersant resulted satisfactory rheology and mechanical strength after curing for 24 hours of curing