Desenvolvimento de cerâmica vermelha utilizando rejeitos da construção civil

The Industry of the Civil Construction has been one of the sectors that most contribute to the pollution of the environment, due to the great amount of residues generated by the construction, demolition and the extraction of raw material. As a way of minimizing the environmental impacts generated by this industry, some governmental organizations have elaborated laws and measures about the disposal of residues from the building construction (CONAMA - resolution 307). This work has as objective the reutilization of residues compound of sand, concrete, cement, red bricks and blocks of cement and mortar for the production of red ceramic, with the objective of minimizing costs and environmental impacts. The investigated samples contained 0% to 50% of residues in weight, and they were sintered at temperatures of 950°C, 1000°C, 1050°C, 1100°C and 1150°C. After the sinterization, the samples were submitted to tests of absorption of water, linear retraction, resistance to bending, apparent porosity, specific density, XRD and SEM. Satisfactory results were obtained in all studied compositions, with the possible incorporation of up to 50% of residues in ceramic mass without great losses in the mechanical strength, giving better results to the incorporation of 30% of residues in the fabrication of ceramic parts, such as roofing tiles, bricks masonry and pierced bricks

Efeito da adição de carbonatos em formulação de massa para revestimento cerâmico utilizando matérias-primas do Piauí

Piauí state is a major producer of traditional red ceramic burning as bricks, tiles and ceramic tiles, with its main production center located in the city of Teresina. The state has large reserves of raw materials that can be used in the ceramic coating as clays, quartz, talc and carbonates. However, in the preparation of ceramic bodies using only a mixture of clays with different characteristics. The study aims to evaluate the effect of adding two types of carbonates in the ceramic semiporous mass coating produced in Piauí and then to verify the potential use of these carbonates as supplementary raw material product manufactured or the feasibility of obtaining a ceramic plate that meets the specifications for the porous coating. For this, were characterized the ceramic Piauí coating mass, a calcitic carbonate and a dolomitic, were made in the levels of 2, 4, 8, 16, and 32%. The masses were formed by pressing and burneds in two environments: a laboratory furnace (1080°C, 1120°C, 1140°C, and 1160°C) and an industrial furnace (1140°C). Then, following tests of linear shrinkage water absorption, apparent porosity, bulk density and flexural strength. Furthermore, the fired specimens were tested for their macrostructure and microstructure. The results showed the possibility of using the carbonate in ceramic mass flooring produced in Piauí, as added in small proportions improved dimensional stability and increased mechanical strength of ceramics pieces. It also proved itself possible to produce porous coating when added in higher levels

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

Desenvolvimento de membranas porosas de alumina para fins de tratamento de efluente industrial têxtil

Textile production has been considered as an activity of high environmental impact due to the generation of large volumes of waste water with high load of organic compounds and strongly colored effluents, toxic and difficult biodegradability. This thesis deals with obtaining porous alumina ceramic membranes for filtration of textile effluent in the removal of contaminants, mainly color and turbidity. Two types of alumina with different particle sizes as a basis for the preparation of formulation for mass production of ceramic samples and membranes. The technological properties of the samples were evaluated after using sintering conditions: 1,350ºC-2H, 1,450ºC-30M, 1,450ºC-2H, 1,475ºC-30M and 1,475ºC-2H. The sintered samples were characterized by XRD, XRF, AG, TG, DSC, DL, AA, MEA, RL, MRF-3P, SEM and Intrusion Porosimetry by Mercury. After the characterization, a standard membrane was selected with their respective sintering condition for the filterability tests. The effluent was provided by a local Textile Industry and characterized at the entry and exit of the treatment plant. A statistical analysis was used to study the effluent using the following parameters: pH, temperature, EC, SS, SD, oil and grease, turbidity, COD, DO, total phosphorus, chlorides, phenols, metals and fecal coliform. The filtered effluent was evaluated by using the same parameters. These results demonstrate that the feasibility of the use of porous alumina ceramic membranes for removing contaminants from textile effluent with improved average pore size of 0.4 micrometre (distribution range varying from 0,025 to 2.0 micrometre), with total porosity of 29.66%, and average percentages of color removal efficiency of 89.02%, 92.49% of SS, turbidity of 94.55%, metals 2.70% (manganese) to 71.52% (iron) according to each metal and COD removal of 72.80%

Estudo de Matérias-Primas do Rio Grande do Norte para Uso em Revestimento Poroso: Influência do teor de dolomita e temperatura de calcinação nas propriedades físico-mecânicas

The state of Rio Grande do Norte presents a great potentiality for the production of ceramic tiles because of having natural raw material in quantity and quality making its economical exploration possible, beyond the great energetic differential of the state, the natural gás. This works aims to study the influence of the dolomite and granulometry concentration and calcinations temperature in the obtaining of formulations for porous coverings which have to be coherent to the project,s specifications. The experiments have involved the physical-chemical and mineralogical characterizations of raw materials and mechanical tests in the dry and burnt proof bodies preceding a mixture experiment planning with the use of the response surface methodology, in order to get the best raw materials combinations to produce a ceramic mass with specific properties. The twelve ceramic masses studied in this work were prepared by the via dry process, characterized, shaped by uniaxial pressing and sinterized in the temperatures of 940ºC, 1000ºC, 1060ºC, 1120ºC and 1180ºC, using a fast burning cycle. The crystalline phases formed during the sintering in the temperatures in study have revealed the presence of anorthite and diopside beyond quartz with a remaining phase. These phases were the main responsible ones by the physical- mechanical properties of the sinterized proof bodies. The proof bodies after the sintering stage have presented water absorption higher than 10% and a good dimensional stability in all studied temperatures. However, the flexural breaking strength results in the temperatures of 940ºC, 1000ºC and 1060ºC, under the temperature zone of the vitrification of ceramic whiteware do not reach the flexural breaking strength specific for the porous wall tile (15 MPa), but in the temperature of 1120ºC next to the vitrification temperature zone, some whiteware ceramic (formulations) has reached the specified value for the porous wall tile. The results of this work have showed that the studied raw materials have great importance for used in the production of porous wall tiles (BIII)

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

Obtenção de placas cerâmico a partir de formulações de massas triaxiais de resíduos de caulim, chamote de telha e cinza vegetal

The production of red ceramic is an industrial activity that causes an intense impact. The manufacture of its products considerably increases the demand for natural resources, mainly with the extraction of raw material. The ceramic material produced generates waste, such as ash firewood and chamote. The residue from the beneficiation of kaolin is deposited in a poor, degrades the environment and contaminate water sources and soil, constituting in this manner, ecological disasters. The main objective of this work is to develop the formulation of a ceramic product consisting solely of industrial solid wastes, from ceramic tiles, (chamote) residue of kaolin and ash firewood. It is assumed that this product made in the laboratory can be used in coatings, wall and floor. The aim is to facilitate the replacement of the raw material of original composition of a ceramic body, for waste, while the process of production equal to the conventionally used, so that the properties of the product are reproduced. This work is characterized waste as its chemical composition, analysis of particle size, X-ray diffraction and thermal behavior. Several formulations were studied. The mass of waste was prepared by dry process, pressed to 25 MPa, and then burned in muffle type oven to 850, 950, 1050 and 1150 °C. The results showed that it is technically possible to produce porous tiles only with waste. It was found that the formulations of bodies play a key role in the properties of the final product, as well as the sintering temperature and heating rates. RN in the waste of kaolin is estimated at 15,000 t/month, about 3,000 gray t/month and chamote with 10 million pieces/month damaged. The presence of carbonates of calcium and magnesium at 1050 ° C results in an appropriate porosity and mechanical strength. The formulation M3JE, composed of 69% waste of kaolin, 7.7% and 23.3% of chamote of gray, became suitable for porous materials with the strength and absorption within the level of national and international standards

Formulação e caracterização de massas de grês porcelanato preparadas a partir de matérias-primas naturais do Rio Grande do norte e com adição de chamote de telhas

Traditional ceramics have an important role in the economy of Rio Grande do Norte. The local industries manufacture over 50 million shingles a month, corresponding to 60% of their overall production. As a result of processing flaws, roughly 20% of the production must be discarded, since little or no use has been envisaged for such fired components. Therefore, the use of this kind of residue, especially in the composition of other ceramic materials, comes as an interesting option from the economical and environmental point of view. In this scenario, the objective of the present study was to assess the effect of the addition of fired shingle waste in the composition of porcelainized stoneware tiles. To that end, two porcelainized stoneware tiles compositions were initially prepared. Subsequently, contents from 10 to 30% of roofing tiles chamote were added to each one of them. All raw materials and grog were characterized by FRX, XRD, and thermal analysis. The ceramics were fired using natural gas for 30 min at different temperatures, i.e. 1150, 1200 and 1250ºC, and fully characterized. The addition of roofing tiles chamote resulted in composition with superior properties compared to additive-free compositions. Porcelainized stoneware tiles products that fulfill required standards for practical applications were achieved

Efeitos da composição mineralógica e distribuição de partículas na formulação de massas: pólo cerâmico de Santa Gertrudes

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

Influência da distribuição granulométrica na estabilidade dimensional de placas cerâmicas de base vermelha

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

Estudo de formulação de massas através do controle da mistura: argilas aluvionares do pólo cerâmico de Russas-Ceará

Conselho Nacional de Desenvolvimento Científico e Tecnológico (CNPq)

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)

Efeito do selamento dentinário imediato na resistência de união de restaurações cerâmicas

O objetivo deste trabalho foi avaliar o efeito do selamento dentinário imediato na cimentação definitiva de restaurações cerâmicas (Empress2Ivoclar Vivadent), levando em consideração a influência de diferentes métodos de remoção dos restos de cimento provisório da superfície dentinária previamente selada. Para isso foram utilizados 72 molares, hígidos, conseguidos no banco de dentes da Universidade do Estado do Rio de Janeiro. Os dentes foram divididos em nove grupos, os três primeiros serviram como grupo controle, onde não houve contaminação com nenhum cimento provisório, sendo eles: G1, onde o selamento e a cimentação definitiva foram feitas 15 dias após a confecção dos preparos cavitários; G2, onde o selamento dentinário foi feito imediatamente após o preparo e a cimentação definitiva após 15 dias; G3, onde o preparo, selamento e cimentação definitiva foram feitos no mesmo momento. Os próximos grupos foram os do selamento tardio, onde o sistema adesivo foi aplicado somente no momento da cimentação. Nestes grupos, após o preparo foram cimentadas restaurações provisórias com um cimento livre de eugenol (Temp BondNE) e após 15 dias as restaurações provisórias foram removidas e os restos de cimento limpos com diferentes métodos: G4: remoção com instrumento manual; G5: remoção com jato de bicarbonato; G6: remoção com pontas de ultra-som; após esta limpeza o sistema adesivo foi aplicado e as restaurações cerâmicas cimentadas. Por último foram os grupos do selamento dentinário imediato, onde o sistema adesivo foi aplicado imediatamente após a confecção dos preparos cavitários e em seguida foi feita a cimentação das restaurações provisórias. Após 15 dias as restaurações provisórias foram removidas, os restos de cimento foram limpos com os diferentes métodos: G7: remoção com instrumento manual; G8: remoção com jato de bicarbonato; G9: remoção com pontas de ultra-som. Após a limpeza as restaurações cerâmicas foram cimentadas. Para todos os grupos o sistema adesivo utilizado foi o Optibond FL Kerr e o cimento resinoso foi o Rely X ARC3M/ESPE. Vinte e quatro horas após as cimentações cerâmicas os corpos de prova foram submetidos ao ensaio mecânico de push out em uma máquina de ensaios universais EMIC DL. Os valores de resistência de união foram obtidos em KgF, convertidos em MPa e analisados estatisticamente. O teste de ANOVA mostrou que houve diferença estatisticamente significante entre os grupos (p≤0,05) e em seguida o t-teste mostrou que a técnica do selamento imediato resultou nos melhores valores de resistência de união. Por último, o teste de comparações múltiplas Student-Newman-Keuls (Teste SNK) mostrou que o método de limpeza dos restos de cimento provisório da superfície dentinária apresenta influência na resistência de união das restaurações cerâmicas. Com base nos resultados pôde-se concluir que a técnica do selamento imediato promoveu maior resistência adesiva para as restaurações cerâmicas e quanto ao método de limpeza, o melhor resultado, independente da técnica adesiva utilizada, foi a remoção com as pontas de ultrasson.

Resistência à flexão e microestrutura de vidro-cerâmicas feldspáticas processadas por injeção em moldes à alta temperatura

Enquanto os métodos tradicionais de processamento de restaurações cerâmicas tornaram-se notórios por sua complexidade, as técnicas mais modernas vêm privilegiando a simplicidade de execução e a automação. Dentre estas, destaca-se a injeção em moldes, que recentemente, foi associada a métodos CAD-CAM. Estudos anteriores demonstraram a viabilidade de utilização de um vidro feldspático de baixa expansão térmica, Alpha (Vita Zahnfabrik), para injeção, porém, faltam informações quanto às propriedades mecânicas e a microestrutura deste material quando submetido à injeção. Os objetivos deste estudo são: produzir pastilhas vidrocerâmicas para injeção a quente a partir de Alpha e da mistura deste vidro com partículas de alumina e zircônia; avaliar a resistência à flexão dos materiais processados, e compará-la a um material compatível existente no mercado (PM9 - Vita Zahnfabrik); estudar a estrutura microscópica dos materiais e correlacioná-la com suas propriedades mecânicas; identificar por meio de difração de raios X a formação de fases cristalinas durante as diferentes etapas de processamento. A injeção aumentou a resistência do vidro Alpha devido à redução na quantidade e tamanho dos defeitos internos, principalmente porosidades. Apesar de ter sido observada nucleação de cristais nos dois materiais, durante o processamento, não foi possível determinar de que forma este fenômeno afetou as propriedades mecânicas dos materiais. Não foi detectada alteração no padrão de distribuição das fases cristalinas observadas em microscópio eletrônico de varredura antes e depois da injeção. Não foi verificada diferença estatística significante entre a resistência à flexão de Alpha injetado e PM9. A adição de partículas de alumina e zirconia ao vidro Alpha provocou redução da resistência, devido à formação de aglomerados durante a confecção das pastilhas e a incapacidade da injeção em dispersá-los. Tais aglomerados funcionaram como concentradores de tensões, enfraquecendo o material.

Resistência de união entre cimentos resinosos autoadesivos e cerâmicas de zircônia policristalina

O objetivo deste estudo foi avaliar a resistência de união a microtração de cimentos resinosos autoadesivos a cerâmicas de zircônia policristalina. Dezoito blocos cerâmicos de zircônia 3Y-TZP (9 LAVA e 9 LAVA Plus) foram jateados com partículas de 50 m de Al2O3por 20 s com pressão de 28 psi a uma distância de 10 mm. Os blocos cerâmicos foram duplicados em resina composta (Point 4, Kerr) por moldagem com silicone. Os blocos de resina composta foram cimentados à superfície jateada da zircônia usando três diferentes cimentos resinosos autoadesivos: (1) RelyX Unicem 2 (3M ESPE); (2) SmartCem 2 (Dentsply); (3) Speedcem (Ivoclar Vivadent). Após 24 h imersos em água destilada a 37oC, os blocos cimentados foram cortados em palitos para testes de microtração,com área da interface adesiva de 1 mm2 0,2 mm, e tensionados até a fratura. Os resultados foram analisados pelo teste de análise de variância de dois fatores e pelo teste de comparações múltiplas LSD (α=0.05). As amostras fraturadas foram analisadas com microscopia eletrônica de varredura (MEV) e o modo de falha foi registrado. A topografia das superfícies cerâmicas antes e após o jateamento foi comparada por microscopia de força atômica (AFM). A resistência de união do cimento Speedcem à zircônia foi estatisticamente superior àquela reportada pelos cimentos RelyX Unicem 2 e SmartCem 2, independentemente da cerâmica usada (p<0,05). O fator cerâmica não teve influência estatística na resistência de união. A interação entre os dois fatores se mostrou significativa (p<0,05). O modo de fratura associado ao SmartCem 2 foi quase exclusivamente adesiva, enquanto oRelyX Unicem 2e o Speedcem exibiram um maior percentual de falhas mistas. Não foram observadas falhas coesivas. O AFM não revelou diferença no padrão de topografia de superfície entre as duas cerâmicas antes ou após o jateamento. Concluiu-se que o cimento Speedcem foi superior na adesão a cerâmicas de zircônia policristalina.