Investigation of Used Water Sediments from Ceramic Tile Fabrication

Used water treatment is one of the most important aspects of environmental protection regarding industrial processes. Particulate matter dispersions affect water parameters; for example, increased pH values such as 10.21 are found for used floor tile water, and values of 10.84 are found for used wall tile water. However, pH decreases to about 9.42 after the sediment filtration process. This influences water turbidity, which is higher for used wall tile water due to its finer suspensions, and it is considerably decreased after the filtration process. Thus, the main aim of the present research is to investigate particulate matter dispersion into the water flows that are involved in ceramic tile technological processes before and after treatment at used water treatment facilities. X-ray diffraction (XRD) coupled with mineralogical optical microscopy (MOM) reveals that waters from wall tiles and floor tiles have similar mineral dispersions, containing mineral particles of quartz (5–50 μm), kaolinite (1–30 μm), and mullite (5–125 μm). Glass particles (having a dark appearance at MOM investigation) were also found in both samples in a size range of 20–55 μm. High-resolution SEM imaging coupled with the EDS elemental analysis confirms the XRD and MOM observations. Water samples collected after treatment at the treatment facility reveal a significant reduction in the particulate matter MOM, evidencing only small traces of quartz, kaolinite, and mullite in a size range of 1–15 μm, with most of the particles being attached to the filters, as confirmed by XRD. Atomic force microscopy (AFM) effectuated on this sample reveals the presence of kaolinite nanoparticles with a tabular–lamellar aspect and sizes ranging from 40 to 90 nm. The obtained results prove the efficacy of the filtering system regarding targeted particulate matters, ensuring water recirculation into the technological processes. The sludge resulting from the filtration process presents with a dense grainy structure of sediment particles containing quartz, mullite, and kaolinite, along with traces of iron hydroxide crystallized as goethite. Therefore, it cannot be reused in the technological flux, as the iron causes glaze staining; but the observed microstructure, along with the mineralogical composition, indicates that it could be used for other applications, such as ecological bricks or plasters, which will be further investigated

Conditioning Influence of Kaolinite Matrices on Flexural Strength of Raw Pressed Slurry Collected from Ceramic Tile Production Wastewater

Kaolinite is able to assure the high binding affinity of the filler particles of raw ceramic bodies. It acts as a matrix that strongly holds the other constituents’ particles in a compact structure. The slurry samples were characterized by XRD, mineralogical microscopy and SEM coupled with an EDX elemental analysis. The slurry collected from the ceramic tile production wastewaters had a significant amount of kaolinite (36%), mostly fine particles of 3 µm, less surrounding quartz (37%) and mullite (19%) particles of 5–100 µm in diameter and traces of lepidocrocite (8%). It is a dense paste with a relative moisture of 25%. The square bar of the slurry as received, pressed at a load of 350 N, had a flexural strength of 0.61 MPa. Increasing the moisture to 33% using regular water, followed by mechanical attrition at 2000 rpm for 5 min, resulted in a porous bar with a flexural strength of 0.09 MPa; by increasing the attrition speed to 6000 rpm, the microstructural homogenization was improved and the flexural strength was about 0.68 MPa. It seems that regular water does not assure an optimal moisture for the kaolinite matrix conditioning. Therefore, we used technological water at pH = 10, a moisture of 33% and attrition at 6000 rpm for 5 min, and the bar pressed at a load of 350 N had a flexural strength of 1.17 MPa. The results demonstrate that the bar moistened with technological water and an attrition regime assured a proper conditioning for the kaolinite matrix, achieving the optimal binding of the quartz and mullite particles under the pressing load. Bars with the optimal mixture were pressed at several loads, including 70, 140, 210 and 350 N, and the flexural strength was progressively increased from 0.56 MPa to 1.17 MPa. SEM fractography coupled with atomic force microscopy (AFM) revealed that the optimal moisture facilitated a proper kaolinite particle disposal regarding the quartz and mullite filler particles, and the progressive load assured the strong binding of the finest kaolinite platelets onto their surface