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Proceedings of the

1st International Conference on Engineering Materials and Metallurgical Engineering

22- 24 December, 2016 Bangladesh Council of Scientific and Industrial Research (BCSIR)

Dhaka, Bangladesh

* Corresponding author. Tel.:01712481118; fax: 88-0571- 62911. E-mail address:shammiswe@yahoo.com.

PHYSICAL AND MICRO STRUCTURAL PROPERTIES OF CERAMIC MATERIALS MANUFACTURING FROM WASTE MATERIAL

Mst. Shanjida Sultanaa, Aninda Nafis Ahmedb, Mohammad Nazim Zamana, Md. Aminur Rahmana a Institute of Mining, Mineralogy and Metallurgy, Bangladesh Council of Scientific and Industrial Research,, Joypurhat, Bangladesh-5900

bPilot Plant & Process Development Centre,, Bangladesh Council of Scientific and Industrial Research ,Dhaka-1205

Abstract In Bangladesh adequate amounts of agricultural waste and industrial waste produces from different source and illegal disposal of these wastes cause enormous environmental problems. This research carried out incorporation of those wastes for producing ceramic materials. Different percentages wastes (Rock Dust, Bagasse Ash, Fly Ash) were thoroughly mixed with clay to analysis various physical and micro structural properties of ceramic samples followed by firing different temperature (800 to 1150°C). The samples were tested for different properties such as water absorption, porosity, mechanical strength. Water absorption and porosity decreased with increasing firing temperature. The percentage of water absorption was within 1.0 to 12.00 % for different amounts of waste which may be suitable for ceramic and tiles purposes. The range of strength were within 22-59 MPa by incorporating bagasse ash whereas mechanical strength of the samples were within the range of 31-53 MPa by incorporating various percentages of rock dust for different temperature. The possibility of producing high strength ceramic product incorporating up to 30% of rock dust having better properties fired at different temperature. Up to 10% bagasse ash and 15% fly ash could be used to produce ceramic materials. Microstructures of sintered samples incorporating with rock dust and bagasse ash were observed by SEM (scanning electron microscopy) and confirmed the vitrification of the ceramic sample. The results confirmed that moderate percentages of waste material could be favorable in the production of red ceramic. Thus red clay reinforced with different appropriate quantities waste material could be used as raw material in ceramic industry purposes and solve waste disposal problem. Keywords: Waste material, strength, ceramic, microstructure

1. INTRODUCTION

The technological development and the increasing rate at which raw materials are continuously transformed into industrial products result in environmental aggressions and waste generation, which affect public health. Recycling waste as useful raw material in ceramic industry is a very important environmental management tool for achieving sustainable development. Natural materials used in the manufacture of clay-based ceramic products exhibit a wide range of product which are very heterogeneous with compositional variation. Such ceramic products can allow raw material variation and the ceramic industry is very capable of using variety of waste materials[1-6] .Raw materials for the ceramic industry use as alternative raw materials, wastes have been classed [2] as fuel wastes, which contain high level of organic substances; fluxing wastes, which promote better sinterability of the ceramic body (glassy phase former); and plasticity-controlling wastes, which affect mostly green body preparation (shrinkage controller, both during drying and firing). The chemistry of fly ash enables its use as raw material for ceramic industry as a part replacement of traditional clay. The potential of fly ash as a raw material for ceramic applications was reviewed by Sen et al [7]. Several authors have studied the effect of fly ash addition on the conventional tile properties and reported its suitability [8,9] Utilization of bagasse ash as an adsorbent as well as mineral admixture in cement and concrete has been examined [10].The SCBA waste and rock dust is mainly composed of silicon oxide (SiO2), with other minor components such as aluminum, iron, calcium, and potassium oxides. The use of wastes from the beneficiation of rocks has been investigated, usually up to 50% of waste are incorporated into clay products [11]. The wastes may be used to replace conventional fluxing materials, with the advantage of controlling the plasticity and shrinkage of the ceramic body . The objective of the study is the characterization of physical, micro structural properties of ceramic sample manufacturing from waste materials thus determining the applicability of these wastes in appropriate ceramic industry.

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2. MATERIALS

The clay samples were collected from four stations of the Northern region of Bangladesh. Clay samples were taken from 0 to 30 feet depth by drilling in four stations and collected 24 samples from different depth.

Rock dust collected from Maddhapara Hard Rock Mine, Bangladesh. Maddhapara is situated at the northwestern part of Bangladesh. Sugarcane bagasse ash (SCBA) was collected from Joypurhat Sugar Mill, Joypurhat, Bangladesh. Fly ash was collected from thermal power plant of Boropukuria, Dinajpur district of Bangladesh.

3. METHODS

3.1 ANALYSIS OF RAW MATERIALS

Clay samples and waste materials (rock dust, bagasse ash and fly ash) were ground in powder form, dried in air dry and sieving at 250µm and samples were used for geochemical study (Major element like SiO2, Al2O3, TiO2, CaO, MgO, Na2O, K2O, Fe2O3 etc.) by using Rigaku ZSX Primus XRF machine equipped with an end window 4.kW RH-anode X-ray tube.

3.2 PREPARATION AND ANALYSIS OF CERAMIC SAMPLE

Waste materials (rock dust, fly ash and fly ash) and clay sample were ground in powder form, dried in air. Different percentages of waste material were thoroughly mixed with clay and granulated for better compaction using 5% moisture. Table 1.represents the batch compositions of ceramic tiles body using different waste material.

The test specimens were rectangular (50 mm×50 mm× ~15 mm) in size. The specimens were air dried at room temperature for 24hr and then oven dried at 110oC for another 24 hr to remove moisture content. All the specimens were fired at different (800°C to 1150°C) temperature in a muffle furnace for 1hr under heating rate of 10oC /min. Then various physical properties of prepared samples were analyzed.

Table 1: Compositions of various ceramic samples with different waste material

3.3 PHYSICAL AND MICRO STRUCTURAL ANALYSIS OF CERAMIC SAMPLES

The fired specimens were subjected to various physical analyses. Bulk density, water absorption and apparent porosity were determined by Archimedes’s immersion technique on keeping the sample in boiling water. The mechanical strength of the samples was studied by Universal Testing Machine (UTM Testometric Model FS-300KN). Microstructures of the ceramic bodies were examined by scanning electron microscopy (FESEM-JEOL JSM-7600F).

4. RESULTS AND DISCUSSION 4.1CHARACTERIZATION OF WASTE MATERIALS

Results of chemical analyses of the raw materials are presented in Table 2. From the table, the result shows high silica content of all raw materials. It has also observed relatively large percentages of alkali and alkaline earth oxides (Na2O, MgO, K2O) in wastes (fly ash, bagasse ash and rock dust) composition which act as fluxing agents helping the sintering process of the ceramic materials [9].

Table 2 : Chemical compositions of raw materials

Oxides/wt% Clay Fly ash Bagasse ash Rock dust SiO2 65.3 53.77 60.75 53.57

Al2O3 20.2 29.69 4.14 16.51 Na2O 0.31 0.09 0.77 3.01

Sample name Red clay % Waste material %

Sample-clay 100 0 Sample-B2 90 10 Sample-F3 85 15 Sample-R3 70 30

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MgO 1.1 0.58 2.39 4.48 K2O 3.55 1.78 14.63 3.15 CaO 0.27 3.09 4.48 0.76

Fe2O3 7.53 6.33 5.27 9.07

4.2 PHYSICAL PROPERTIES OF PREPARED CERAMIC SAMPLES

It can be observed from fig 1 and fig 2 a decreased in water absorption and porosity for all samples with increasing temperature. It is natural behavior of ceramic body. With increase in firing temperature, values for water absorption tend to decrease since a greater densification of the sample occurred. The water absorption of sample-B2 and sample-R3 were better (<10%) compare with Sample-F3. The behavior of water absorption as firing temperature was better for sample –R3 than other samples which formulated with 30% rock dust. The apparent porosity versus temperature curves shows a similar trend to that of water absorption.

Fig 1.variation of water absorption with different compositions of ceramic sample

Fig 2.variation of water absorption with different compositions of ceramic sample

There are various parameters that affect the mechanical strength of ceramic materials. As better physical properties like water absorption and porosity were found for sample-B2 and sample-R3, compressive strength

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for those samples were analyzed. From fig 3, maximum strength (53 MPa) was observed for sample-R3 fired at 1100°C. Mechanical strength increased with increasing temperature. The range of strength were within 22-53Mpa for temperature ranging from 900°C to 1100°C.

Fig 3.variation of water absorption with different compositions of ceramic sample

. 4.3 MICRO STRUCTURAL ANALYSIS OF CERAMIC SAMPLES

The micro structural characterization of ceramic sample was performed by scanning electron microscopy. Micrographs of the surface of two samples (Sample-B2 and Sample-R3) fired at 1100◦C temperature are shown in Figure 4. In Figure 4-a and 4-b different sizes of pores and formation of glassy phase are evident. For sample B2, it was developed some large amount of porosity and glassy phase compare to sample R3, which affected its mechanical properties.

(a) (b)

Fig 4. SEM photographs for Sample-B2 (a) and Sample-R3 (b) firing at 1100◦C

5. CONCLUSION

The results confirmed that waste material e.g., rock dust, fly ash and bagasse ash are attractive alternative and renewable raw material for ceramic material. Physical and micro structural analyses of ceramic sample lead to following conclusions:

The percentage of water absorption was within 1 to 12 % for different amounts of wastes which may be suitable for ceramic and tiles purposes.

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Up to 30% waste material could be used to produce ceramic materials. However, moderate percentage of waste could be favorable in the production of red ceramic.

Samples with 30% rock dust obtained the highest mechanical strength. These waste materials could be used to produce a wide range of ceramic and industrial product by

taking advantages of low cost and environmental protection.

6. ACKNOWLEDGEMENT

The authors would like to thank Ministry of Science and Technology, Government of Bangladesh for funding this research under special R&D allocation project.

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