Bochkarihinskoe clay as raw material to building ceramics production

The possibility of using clay from Bochkarikhinskoe deposit (Sverdlovskaya oblast, Russia) in the ceramic building production has been considered. The chemical, mineral and granulometric composition of clay was determined. The basic technological properties of clay were studied: plasticity, sensitivity to drying, sintering. The frost resistance and mechanical properties of ceramic brick samples were determined. The clay studied with introduction of organic additives also may be used in ceramic production. © Published under licence by IOP Publishing Ltd

Lightening of ceramic bricks based on red-burning clay

To determine the possibility of using a mineral pigment based on the rutile form of titanium dioxide in the production of volume-colored ceramic brick in order to obtain lighter brick tones the studies are conducted. The previously studied low-melting clay of the Tyumen deposit was used as a basis. It was established that significant lightening of the brick does not occur even with the introduction of 8% of the specified pigment, although some lightening is appeared. In addition, with the pigment introduction, an increase in water absorption of bricks is observed, which leads to a decrease in the sample strength. Increasing the firing temperature to 950°C does not lead to an improvement in the quality characteristics of the samples, and even vice versa makes them worse. Thus, the use of a white pigment under investigation does not give a significant effect of lightening of ceramic red-burning clay. © 2019 IOP Publishing Ltd. All rights reserved

Technogenic Raw Materials in High-Alumina Chamotte Production

The paper presents studies on the production of a high-alumina aggregate with an Al2O3 content of 75% based on fine-grained corundum dust generated by grinding fused corundum. Finely dispersed corundum powder is a by-product and due to the low Al2O3 content (93 - 95%) is not used in further production. It is proposed to obtain high-alumina aggregate without joint grinding of the components. Aggregate was obtained by pressing through a "false grain"from a mixture of kaolin and corundum dust in a certain ratio. The samples firing was carried out at a temperature of 1700 C. The phase composition of the obtained aggregate is represented by 46 - 51% corundum, 45 - 49% mullite. The water absorption of such chamotte is 14 - 16%, open porosity is 33 - 35%, apparent density is 2230 - 2290 kg•m-3. Now, it was not possible to obtain a high-density filler grade ZML and ZMK that meets the requirements of GOST 23037 - 78. The production flow chart of high-alumina chamotte based on kaolin and corundum dust should include a joint fine grinding of the components, or a separate grinding of corundum dust until it passes completely through the 0.063 mm mesh. © Published under licence by IOP Publishing Ltd

The use of technogenic raw materials to produce a high-alumina chamotte

When fused corundum is crushed, a finely dispersed powder is formed with an Al2O3 content of 93-95%, in the form of substandard material. It is advantageous to utilize this powder to obtain high-alumina chamotte with Al2O3 content of more than 62%. High-alumina aggregate (chamotte) was obtained by semi-dry technology with intermediate briquette molding from a mixture of corundum dispersed powder and enriched kaolin. Based on a final Al2O3 content of 65 wt. % the batch composition of the mass to produce a high alumina aggregate (chamotte) was calculated. From a mixture of dispersed corundum powder and kaolin moistened with a 5-7% technical lignosulfonate solution with a density of 1050 kg•m-3, a briquette was formed at a specific pressing pressure of 15-20 MPa. The briquette was fired at a temperature of 1700 C. The fired briquette had a strength of 164 to 193 MPa. The water absorption of briquettes was 11-12%. The phase composition of the briquette is represented mainly by corundum and mullite. The enriched kaolin did not show sintering effect on fine corundum. © Published under licence by IOP Publishing Ltd

The effect of enrichment on quartz sand properties

The technological properties of quartz sand (without and after enrichment) by methods of emission spectral analysis, petrography, and X-ray phase analysis are investigated. The studied sand is a waste after extraction of titanium-containing components from raw materials. It is shown that the enrichment of quartz sand expands the field of its application. It has been established that quartz sand can be used as a filler of heavy, light, fine-grained, cellular and silicate concrete, mortar, and the preparation of dry construction mixtures. Also, sand can be claimed as a raw material component to produce ceramic tiles, porcelain stoneware, glazed ceramic products, wall ceramics, as well as proppants. Hydraulic enrichment leads to a decrease in the content of clay particles in the sand, which allows it to be used also for the construction of bases and coatings of roads and airfields. The integrated use of raw materials and waste allows solving the problem of creating non-waste and environmentally friendly technologies, which ensures the saving of natural raw materials, and on the other hand, allows it to be disposed of, improving the environmental situation. © Published under licence by IOP Publishing Ltd

The Possibility of Using Tyumen Keramzite Clay in the Production of Ceramic Materials

The properties of red low-melting clay with the aim of its use in the production of building ceramics are investigated. The presented sample of clay raw materials by mineral composition refers to kaolinite clays with mixed-layer formations in the form of illite and ferruginous montmorillonite with Na-, Ca- and Mg-interlayer hydrated exchange cations. It is characterized by an average content of free SiO2 (10 - 25%). The clay is medium plastic with a low content of coarse inclusions, it refers to medium raw materials. Clay is medium-drying, medium-sensitive to drying, non-sintering. Mechanical strength during firing at a temperature of 900 C is 27.5 MPa. When firing samples in the temperature range 900 - 1050 C, a significant black core is formed. At a firing temperature of 1050 C, swelling of the samples occurs. Considering the properties of this clay, it cannot be recommended to produce face and ordinary building bricks. However, the studied clay can be used to produce expanded clay. The introduction of 0.5% of spent technical oil allows to get the expansion coefficient of 3.83. The temperature range of expansion is 1050 - 1170 C. The density of expanded clay granules in this case is 560 kg•m-3. © Published under licence by IOP Publishing Ltd

Production technology of ceramic roof tiles based on raw materials of Ural region

The technology of production of ceramic roof tiles on the basis of low-melting red-burning clay, namely on the basis of clay from the Sadovoye deposit of the Sverdlovsk region, is proposed. The samples of ceramic roof tiles, molded by plastic and semi-dry way, were obtained with the properties that meet the requirements of Russian standards and correspond to the quality of the Röben ceramic roof tiles. The water absorption of such products is 6.2-6.9%, the apparent density is 2.19-2.31 g/cm3, the products are waterproof for more than 4 hours, and withstand frost resistance for more than 150 cycles. The production technology involves the use of high-speed firing way in the temperature range of 1150-1200°C. The production technology provides for grinding the clay to a grain size of less than 0.3 mm. Molding of products can be done both in a plastic or semi-dry way. The use of high-speed firing is allowed. There is no destruction of products made on the basis of Sadovoye deposit clay. © 2019 IOP Publishing Ltd. All rights reserved

UTILIZATION OF BY-PRODUCTS OF CERAMIC TILE PRODUCTION

The properties of finely dispersed by-products arising in the production of ceramic tiles are investigated, and an overview of the methods of their use is given. The properties of the formed by-products, the so-called polishing cakes, have been investigated. The polishing cake is mainly a glassy phase of 80 %, quartz — 14 %, mullite — 5 %. The particle size of the polishing cake is less than 0.2 mm. The results of studying the products properties lead to the following disposal ways: as a filler in the silicate production, polymer-cement, water-dispersion and oil paints, as a filler in production of roofing materials, as bituminous roofing mastics based on organic binders, as raw materials in foam glass production.В работе исследованы свойства побочных тонкодисперсных продуктов, возникающих при производстве керамической плитки, и приведен обзор способов их использования. Исследованы свойства образующихся побочных продуктов, так называемых кеков полировки. Кек полировки представляет собой преимущественно стеклообразную фазу порядка 80 %, кварц — 14 %, муллит — 5 %. Размер частиц кека полировки составляет менее 0,2 мм. По результатам исследования свойств продуктов можно определить следующие пути утилизации: в качестве наполнителя для производства силикатных, полимерцементных, водно-дисперсионных, масляных красок, наполнителя для производства кровельных материалов, битумных кровельных мастик на основе органических вяжущих материалов, сырьевых компонентов для изготовления материалов и изделий из пеностекла

HIGH-ALUMINA CHAMOTTE BASED ON TECHNOGENIC RAW MATERIALS

The paper presents both the results of the mass composition development and the technology to produce the high-alumina chamotte with an Al2O3 content of 65–85 % based on technogenic raw materials — fine corundum dust formed during grinding of fused corundum. Finely dispersed corundum powder contains 93–95 % Al2O3, which is a by-product and can be used to produce high-alumina chamotte. The phase composition of chamotte with Al2O3 content is as follows: 65 % — corundum (35–38 %), mullite (46–50 %), thialite (up to 4 %), cristobalite (6–8 %); 75 % corundum (43–50 %), mullite (45–47 %), thialite (up to 4 %); 85 % — corundum (68–71 %), mullite (24–27 %).В работе представлены результаты разработки составов масс и технологии получения высокоглиноземистого шамота с содержанием Al2O3 65–85 % на основе техногенного сырья — тонкодисперсной корундовой пыли, образующейся при помоле плавленого корунда. Тонкодисперсный корундовый порошок содержит 93–95 % Al2O3, является побочным продуктом и может быть востребован для получения высокоглиноземистого шамота. Фазовый состав полученного шамота с содержанием Al2O3: 65 % — корунд (35–38 %), муллит (46–50 %), тиалит (до 4 %), кристобалит (6–8 %); 75 % — корунд (43–50 %), муллит (45–47 %), тиалит (до 4 %); 85 % — корунд (68–71 %), муллит (24–27 %)

Il'insky diatomite in building ceramics production

The possibility of using diatomite rocks of the Il'insky deposit in the ceramic brick production has been considered. The chemical and mineral composition of diatomite was determined, and its molding properties were studied. The effect of temperature on the degree of sintering of diatomite was established. The technology of brick production was developed. The main stages of brick production by the method of semi-dry molding are determined. The recommended molding parameters (moisture content and specific pressure of pressing) are proposed. The diatomite properties have been studied and the technology of producing bricks by the method of semi-dry forming has been developed. The samples of ceramic bricks of the grade M100 up to M400 with the medium density class - 1.2 have thermal characteristics, relating to the group of effective products with the coefficient of thermal conductivity of the masonry in the dry state in the range of 0.24 to 0.36 W/(m•°C). © Published under licence by IOP Publishing Ltd