Effect of calcium phosphate addition on sintering of El-Oued sand quartz raw materials

This work addresses the development of an eventual low cost ceramic insulating or microfiltration membrane supports from inexpensive raw materials such Eloued quartz sand (EQS) and calcium phosphate (CP) using uniaxially dry compaction method. The prepared samples were sintered at different temperatures ranging between 1200 and 1550 ºC. Subsequently, the effects of sintering temperature and amount of CP on samples proprieties were investigated. It is observed that X-ray diffracion measurements confirmed that EQS was transformed into cristobalite and tridymite phases when both sintering temperature and holding time were increased. This transformation is favored with increasing amount of CP, it is observed also formation of CaSiO3 and Ca(Fe)(Al)PO4. The SEM images of the samples sintered at different temperatures illustrate that silica grains, CP grains, intergranular phase contents (Si, Ca, P, and O) and an important open porosity depend on the sintering temperature. The porosity ratio changes in the range between 37% and 34% according to sintering temperature and to CP content; these values are in good agreement with SEM images. The thermal expansion behavior shows a weak expansion in the range of temperature between 600 and 1000 ºC which is situated between 1.27% and 1.33% (variation of 0.05% at 400 ºC)

Grain Growth in Sintered Natural Hydroxyapatite

Hydroxyapatite (HA: Ca10(PO4)6(OH)2) can be synthesized using several methods or manufactured from natural materials such as coral or bone after removal of the organic matter by heating (denoted as NHA). The in vitro and in vivo studies showed that the natural apatite was well tolerated and has better osteoconductive properties than synthetic HA. In addition, the exploitation of natural source represents an economical way of synthesizing NHA by means of sintering, rather than by sol-gel techniques. For these reasons, the NHA was manufactured from cortical bovine bones in all our studies. Moreover, there has been much effort to improve the mechanical properties of HA by introducing foreign oxides or finding out other alternative processes such as grain growth control. Indeed, encouraging lower AGS instead of exaggerated grain growth may be jugged useful for many applications. Since the works carried out on the correlation between AGS and physico-chemical properties of NHA were very limited, the present study was mainly focused on its grain growth. A carful combination between the main parameters controlling NHA production such as milling techniques, compacting pressure, sintering temperature and holding time may lead to an interesting NHA based bio-ceramics. In this way, a simple and energetically vibratory multidirectional milling system using bimodal distribution of highly resistant ceramics has been used for obtaining sub-micron sized NHA powders. For example, the AGS was ranged between 0.75 and 1.40 µm (using intercept method) when NHA samples were sintered at 1250 C for 15 and 480 min, respectively

Grain Growth in Sintered Natural Hydroxyapatite

Hydroxyapatite $(HA: Ca_{10}(PO_4)_6(OH)_2)$ can be synthesized using several methods or manufactured from natural materials such as coral or bone after removal of the organic matter by heating (denoted as NHA). The "in vitro" and "in vivo" studies showed that the natural apatite was well tolerated and has better osteoconductive properties than synthetic HA. In addition, the exploitation of natural source represents an economical way of synthesizing NHA by means of sintering, rather than by sol-gel techniques. For these reasons, the NHA was manufactured from cortical bovine bones in all our studies. Moreover, there has been much effort to improve the mechanical properties of HA by introducing foreign oxides or finding out other alternative processes such as grain growth control. Indeed, encouraging lower AGS instead of exaggerated grain growth may be jugged useful for many applications. Since the works carried out on the correlation between AGS and physico-chemical properties of NHA were very limited, the present study was mainly focused on its grain growth. A carful combination between the main parameters controlling NHA production such as milling techniques, compacting pressure, sintering temperature and holding time may lead to an interesting NHA based bio-ceramics. In this way, a simple and energetically vibratory multidirectional milling system using bimodal distribution of highly resistant ceramics has been used for obtaining sub-micron sized NHA powders. For example, the AGS was ranged between 0.75 and 1.40 μm (using intercept method) when NHA samples were sintered at 1250°C for 15 and 480 min, respectively

Porous Ceramic Supports for Membranes Prepared from Kaolin (DD3) and Calcite Mixtures

The supports for microfiltration (MF) and ultrafiltration (UF) were prepared with local kaolin (Djebel Debagh: type 3: DD3) and calcium carbonate (CaCO₃) mixtures. The choice of these materials is based on their natural abundance (low price). In this work, the tubular ceramic supports were prepared by the extrusion method. The sintering was carried out for 2 hours, at temperatures laying between 1150 and 1300°C. They are then characterized by various techniques: mercury porosimetry, scanning electron microscopy and x-ray diffraction. The obtained results revealed that the main phase formed during the sintering step was anorthite with a minor phase of mullite. Moreover, it has been found that supports sintered at temperatures less than 1300°C had interesting characteristics; an average pore size ranged between 3.91-8.56 μm, a porosity ratio of 42.0-50.4%, a flexural strength ≈67-77 MPa and the pore size distribution is bimodal type. According to their average pore sizes, they may be used either as supports for MF or UF membranes

Preparation and characterization of ZnO microfiltration membrane and its support using kaolin (DD3) and CaCO3

Abstract The objective of the present paper was to prepare a ceramic support with membrane. Tubular ceramic supports prepared from kaolin (DD3) and calcium carbonate with 6 and 10 mm inner and outer diameters, respectively, were extruded and sintered at 1200 °C. It has been found that sintered supports had interesting characteristics: average pore size of about 5µm, porosity of about 50%, and monomodal pore size distribution. This support was used to be substrate for a membrane layer of microfiltration. This membrane layer was elaborated from zinc oxide, using slip casting technique. The specimens were subsequently sintered at 1000 °C. The microstructure and porosity as well as the permeability have also been studied. It has been found that the average pore size was about 1.2µm, the layer thickness was ~33µm, and the water permeability measured was about 880 L.h-1.m-2.bar-1

Sintering and dielectric properties of a technical porcelain prepared from economical natural raw materials

Abstract In this study, the production of a technical porcelain, for the ceramic dielectric applications by using economical natural raw materials, was investigated. The basic porcelain composition was selected consisting of 30 wt% kaolin, 45 wt% potash-feldspar and 25 wt% quartz. The obtained phases in the sintered samples were investigated by X-ray diffraction, Fourier transform infrared spectroscopy analysis, and scanning electron microscopy images. It has been confirmed by these techniques that the main crystalline phases were quartz and mullite. Dielectric measurements of technical porcelains have been carried out at 1 kHz from room temperature to 200 °C. The dielectric constant, loss factor, dielectric loss tangent, and resistivity of the porcelain sample sintered at 1160 °C were 22-25, 0.32-1.80, 0.006-0.07, and 0.2-9 x 1013 Ω.cm, respectively. The value of dielectric constant was significantly high when compared to that of conventional porcelains which did not exceed generally 9

Elaboration of porous gehlenite and anorthite based ceramics using low price raw materials

Abstract Porous ceramics of good quality cost a lot in the world market, which has limited their use in developing countries. This is why this work was mainly devoted to prepare low-cost and good quality ceramics, using kaolin (DD2 type) and calcite (CaCO3) available in abundance in Algeria. Based on previous results, 28 wt% CaCO3 ceramic was selected. The presence of CaCO3 favors to achieve porous samples characterized by a high percentage of porosity due to the CO2 release and CaO formation during its calcination at about 700 °C. The choice of these raw materials is based on their natural abundance (low price). It has been found that the samples had interesting characteristics: average pore size between 2.87 and 6.50 μm and porosity between 53 and 57%. It has also been found that the manufactured membrane supports are mainly constituted of gehlenite and anorthite phases. Moreover, the pore size distribution was mono-modal type. The surface and cross-section morphologies observed through a scanning electron microscope were also homogeneous and do not present any possible macro-defects (cracks, etc.)