Sinterability study of ceramic bodies made from a mixture of mineral coal bottom ash and soda-lime glass cullet.

The aim of this study was to investigate the sinterability to improve the technical properties of ceramic bodies made from coal bottom ash and soda-lime glass cullet. Different mixtures of bottom ash and glass cullet were formulated. The amount of bottom ash was 100, 70, 50 and 30 wt.%. The particle size distribution was the same for all formulations. The mixture containing 50 wt.% bottom ash also had its particle size distribution changed. Samples were formed by dry pressing and then fired at 950, 1050 and 1150 degrees C. Samples were evaluated for linear shrinkage, water absorption, flexural mechanical resistance, scanning electronic microscopy, pyroplastic deformation and thermodilatometric analysis. The higher firing temperature led to a decrease in water absorption and increased linear shrinkage, mechanical resistance and pyroplastic deformation. This effect was also observed for addition of glass up to 50 wt.%. The effect of smaller particles of bottom ash was more significant for linear shrinkage and mechanical resistance of ceramic bodies fired at 1150 degrees C. The use of a finer powder contributed to increase these properties. The influence of finer particles on water absorption and mechanical resistance of ceramic bodies fired at 950 and 1050 degrees C was not significant.     

Production and characterization of glazed tiles containing incinerated sewage sludge

In this article, glaze with different colorants was applied to tile specimens manufactured by incinerated sewage sludge ash (ISSA) and clay. Improvements using different amounts of colorants, and glaze components and concentrations on tile bodies were investigated. Four different proportions of clay (by weight ratio) were replaced by ISSA. Tiles of size 12 cm x 6 cm x 1 cm were made and left in an electric furnace to make biscuit tiles at 800 degrees C. Afterwards, four colorants, Fe2O3 (red), V2O5 (yellow), CoCO3 (blue), and MnO2 (purple), and four different glaze concentrations were applied on biscuit tile specimens. These specimens were later sintered into glazed tiles at 1050 degrees C. The study shows that replacement of clay by sludge ash had adverse effects on properties of tiles. Water absorption increased and bending strength reduced with increased amounts of ash. However, both water absorption and bending strength improved for glazed ash tiles. Abrasion of grazed tiles reduced noticeably from 0.001 to 0.002 g. This implies glaze can enhance abrasion resistance of tiles. Effects like lightfastness and acid-alkali resistance improved as different glazes were applied on tiles. In general, red glazed tiles showed the most stable performance, followed by blue, yellow, and purple.     

Bioabsorbable soy protein plastic composites: Effect of polyphosphate fillers on water absorption and mechanical properties

The use of synthetic and natural bioabsorbable plastics has been severely limited due to their low stiffness and strength properties as well as their strong tendency to absorb moisture. This research focused on the development of bioabsorbable polyphosphate filler/soy protein plastic composites with enhanced stiffness, strength, and water resistance. Bioabsorbable polyphosphate fillers, biodegradable soy protein isolate, plasticizer, and adhesion promoter were homogenized and compression-molded. Physical, mechanical, and water absorption testing was performed on the molded specimens. Results showed improvements in stiffness, strength, and water resistance with increasing polyphosphate filler content up to 20% by weight. Application of a coupling agent produced further mechanical property enhancements and a dramatic improvement in water resistance, interpreted by an interfacial chemical bonding model. Examination of the fracture surfaces of the materials revealed that the addition of the polyphosphate fillers changed the failure mode from brittle to pseudo-ductile. These results suggest that these materials are suitable for many load-bearing applications in both humid and dry environments where current soy protein plastics are not usable.     

Effects of recycled glass substitution on the physical and mechanical properties of clay bricks

In this study, wasted glasses from structural glass walls up to 45 wt.% were added into clay mixtures in brick manufacturing process. Physical and mechanical properties of clay bricks were investigated as functions of the wasted glass content and the firing temperature. The results indicated that with proper amount of wasted glasses and firing temperature, clay bricks with suitable physical and mechanical properties could be obtained. The compressive strength as high as 26–41 MPa and water absorption as low as 2–3% were achieved for bricks containing 15–30 wt.% of glass content and fired at 1100 °C. When the glass waste content was 45 wt.%, apparent porosity and water absorption was rapidly increased.     

Management of agricultural biomass wastes: Preliminary study on characterization and valorisation in clay matrix bricks

In this work the feasibility of using woody agricultural biomass wastes as grapes and cherries seeds, sawdust, as pore forming agent, and sugar cane ash, as silica precursor, in bricks, were reported.Sawdust and grapes and cherries seeds, thanks to their organic substances content, during their combustion, bring an energetic support in the bricks firing phase and act as pore forming agent. Usually the addition of this kind of waste is limited to 10 wt.% in order to reach an equilibrium between positive (weight and shrinkage decrease and porosity increase) and negative (increase of water absorption and mechanical resistance decrease) effects. The results show that grapes and cherries seeds, added in a percentage of 5 wt.% to a brick formulation, have better influence with respect to the sawdust, maintaining the mechanical properties of the fired brick (950 °C), showing modulus of rupture around 21–23 MPa with a weight reduction of 3–10% (respect to the standard one). Regarding the sugar cane ash, the addition of 5 wt.% improves the mechanical properties (modulus of rupture around 27 MPa) and no weight decrease is observed. These results confirmed the role played by this kind of agricultural waste, which thanks to its high silica content (61 wt.%) is capable to demonstrate a filler and plasticity reducing effect on the brick bodies. Tests carried out highlighted that the addition of these by-products (5 wt.%) do not change negatively the main technological properties measured (water absorption, linear shrinkage, flexural resistance, etc.) and permit to hypothesize their use to obtain bricks with both insulating and higher mechanical properties using a pore agent forming or silica carrier alternative raw materials, respectively.     

Recycling of iron foundry sand and glass waste as raw material for production of whiteware.

The purpose of this study was to evaluate the production feasibility of triaxial whiteware using sand from cast iron moulds as a raw material instead of silica, and recycled glass in place of feldspar. Formulations were prepared using sand, glass waste, and white-firing clay such that only 50% of the composition was virgin material (clay). The ceramic bodies were formed by pressing and fired at different temperatures (between 1100 and 1300 degrees C). Specimens were characterized in terms of green density prior to firing; and their flexural strength, linear shrinkage, and water absorption were measured after firing. The microstructure was determined by scanning electron microscopy. Possible environmental impacts of this recycling process were also evaluated, through solubility and leaching tests, according to Brazilian standards. Gaseous emissions during the firing process were also analysed. The results showed that it is possible to produce triaxial ceramics by using such alternative raw materials.     

Effect of Surface Treatment on Betel Nut (Areca catechu) Fiber in Polypropylene Composite

Betel nut fiber (Bn)/polypropylene (PP) composites were prepared in the different ratio of 10:90, 20:80, 30:70, 40:60 (Bn wt%:PP wt%) using extruding and hot press moulding technique. From the results, it can be inferred that Bn30:PP70 mixture composite (BnPP) showed better performance among the composites prepared. For further improvement, betel nut fiber was subjected to detergent wash as well as alkali treatment for composite preparation. This work investigated the tensile strength, bending strength, tensile modulus, bending modulus, elongation at break and impact strength of the composites. Fracture morphology of the composite as well as the water absorption capacity has been monitored.     

The applicability of different waste materials for the production of lightweight aggregates

The applicability of different waste materials for the production of lightweight aggregates has been studied. The following waste materials were investigated: silica sludge, superfluous clay in the quarry, waste glass, and residue from the polishing process of different types of stone. SiC and MnO₂ were selected as foaming agents. Feldspar containing minerals and scrap glass were added in order to lower the softening point of the waste materials. The granules were prepared by mixing together finely ground waste with one or both of the selected foaming agents. The granules were then fired at different temperatures above the softening point of the glassy phase within the temperature range from 1150 to 1220 °C, where the foaming agent degasses, and the resulting gasses remain trapped in the glassy structure. The foaming process was observed by hot-stage microscopy. The properties of the so-obtained granules, such as their apparent density and compressive strength, were determined, and their microstructures were evaluating using SEM and polarizing microscopy.With the addition to clay of polishing residue from granite-like rocks, after firing at 1220 °C homogeneously porous granules with a density down to 0.42 g/cm³ were obtained, whereas with the addition to waste silica sludge of polishing residue from granite-like rocks and waste glass with a foaming agent, after firing at 1220 °C densities from 0.57 to 0.82 g/cm³ were obtained.     

Utilization of kaolin processing waste for the production of porous ceramic bodies

The kaolin processing industry generates large amounts of waste in producing countries such as Brazil. The aim of this study was to characterize kaolin processing waste and evaluate its suitability as an alternative ceramic raw material for the production of porous technical ceramic bodies. The waste material was physically and chemically characterized and its thermal behaviour is described. Several formulations were prepared and sintered at different temperatures. The sintered samples were characterized to determine their porosity, water absorption, firing shrinkage and mechanical strength. Fired samples were microstructurally analysed by X-ray diffraction and scanning electron microscopy. The results indicated that the waste consisted of quartz, kaolinite, and mica, and that ceramic formulations containing up to 66% of waste can be used for the production of ceramics with porosities higher than 40% and strength of about 70 MPa.     

Investigation of the usage of centrifuging waste of mineral wool melt (CMWW), contaminated with phenol and formaldehyde,in manufacturing of ceramic products

Large amounts of centrifuging waste of mineral wool melt (CMWW) are created during the production of mineral wool. CMWW is technogenic aluminum silicate raw material, formed from the particles of undefibred melt (60–70%) and mineral wool fibers (30–40%). 0.3–0.6% of organic binder with phenol and formaldehyde in its composition exists in this material. Objective of the research is to investigate the possibility to use CMWW as an additive for the production of ceramic products, by neutralising phenol and formaldehyde existing in CMWW. Formation masses were prepared by incorporating 10%, 20% and 30% of CMWW additive and burned at various temperatures. It was identified that the amount of 10–30% of CMWW additive influences the following physical and mechanical properties of the ceramic body: lowers drying and firing shrinkage, density, increases compressive strength and water absorption. Investigations carried out show that CMWW waste can be used for the production of ceramic products of various purposes.     

Biodegradable plastic made from soybean products. II. Effects of cross-linking and cellulose incorporation on mechanical properties and water absorption

Soy isolate was treated with formaldehyde and glyoxal at 1.0, 2.5, and 5.0% (w/w isolate) and with adipic and acetic anhydrides. The materials were then compression-molded into plastic tensile bars and tested for tensile and yield strength, percentage elongation, Young's modulus, and water absorption. Treatment with 5% formaldehyde increased the tensile strength significantly, to 4.9 kg/mm², compared with the untreated sample (3.7 kg/mm²). The yield strength increased slightly, to 0.68 kg/mm². Elongation was significantly less after treatment with formaldehyde. Young's modulus increased after treatment and leveled off at 174 kg/mm². Water absorption decreased as the formaldehyde concentration increased. Treatment with either glyoxal or adipic/acetic anhydride had a detrimental effect on the mechanical properties of the plastic specimens. Water absorption was decreased by glyoxal treatment but was not affected by adipic/acetic anhydride treatment. Long-fiber (lf), short-fiber (sf), and microcrystalline (mc) cellulose were incorporated into soy isolate at various levels. Cellulose addition decreased the percentage elongation and increased the rigidity of the plastic. All three cellulose additions increased Young's modulus. The tensile strength increased with the addition of sf-cellulose to soy isolate; lf-cellulose decreased the tensile strength, whereas the incorporation of mc-cellulose did not have a significant effect. The yield strength increased slightly with the addition of sf-cellulose and was less affected by the addition of lf- or mc-cellulose. All three types of cellulose slightly decreased water absorption at ca. 15% content.Journal Paper No. J-15563 of the Iowa Agriculture and Home Economics Experiment Station, Ames; Project No. 2863.     

Evaluation of concrete incorporating bottom ash as a natural aggregates replacement

A study on the incorporation of coal bottom ash from thermoelectric power stations as a substitute material for natural sand in the production of concrete is here presented. The normally coarse, fused, glassy texture of bottom ash makes it an ideal substitute for natural aggregates. The use of bottom ash in concrete presents several technical challenges: the physical and mineralogical characteristics of the bottom ash; the effect on water demand and the participation on cements hydratation. In the production of the concrete, substitutions in volume were used. Two different ways to employ bottom ash were used to make up the mix proportions: one considering the natural humidity present in the porous particles and the other not considering it, seeking to maintain the same strength. These considerations are fundamental given that the process of bottom ash extraction is carried out through moisture. Mechanical tests by compressive strength were performed and the elastic modulus was determined. An analysis of the influence of bottom ash in the formation of pores was carried out through tests for the water loss by air drying and water uptake by capillary absorption. The results show that the higher the bottom ash contents in the concrete, the worse the performance regarding moisture transport. However, for one bottom ash concrete type, the mechanical properties were maintained.     

UTILIZING THE USED CATALYST FROM REFINERY FCC UNITS AS A SUBSTITUTE FOR KAOLIN IN FORMULATING CERAMIC FRITS

Frits are materials of a vitreous nature which are used for obtaining the glaze used to coat glazed ceramic tiles. One of the raw materials usually employed in preparing frits is kaolin, which provides the aluminium and part of the silicon they contain.This study investigates the possibility of utilizing the used catalyst from the FCC (fluidized catalyst cracking) units involved in petroleum refining, to substitute for kaolin as a raw material in the preparation of ceramic frits. On assessing the aesthetic and technical characteristics (whiteness, gloss, microhardness, etc.) of the glazes obtained from two frits that were prepared by substituting kaolin with the industrial waste mentioned above, no important differences were observed relative to the characteristics of the glazes obtained from the standard frits.     

Development of rice husks-plastics composites for building materials

In this paper, a new effective recycling method for rice husks and waste expanded polystyrene is developed by using a combination of both wastes. A styrene solution of waste expanded polystyrene is used as a binder for rice husks-plastics composites. The composites are prepared with various mix proportions by a hot press molding method, and tested for apparent density, water absorption, expansion in thickness, and dry and wet flexural strengths. From the test results, the apparent density of the composites is increased with increasing binder content and filler-binder ratio. Their flexural strength and wet flexural strengths reach maximums at a binder content of 30.0% and a filler-binder ratio of 1.0. Their water absorption and expansion in thickness are decreased with increasing binder content and filler-binder ratio. Since the composites have a high flexural strength and water resistance, their uses as building materials are expected.     

Biodegradable Polyester-Based Blend Reinforced with Curauá Fiber: Thermal,Mechanical and Biodegradation Behaviour

Biodegradable composites can be produced by the combination of biodegradable polymers (BP) as matrix and vegetal fibers as reinforcement. Composites of a commercial biodegradable polymer blend and curauá fibers (loaded at 5, 15 and 20 wt%) were prepared by melt mixing in a twin-screw extruder. Chemical treatments such as alkali treatment of the fiber and addition of maleic anhydride grafted polypropylene (MA-g-PP) as coupling agent were performed to promote polymer/fiber interfacial adhesion so that mechanical performance can be improved. The resulting composites were evaluated through hardness, melt flow index and tensile, flexural and impact strengths as well as water absorption. Thermal analysis and Fourier transform infrared spectroscopy were also employed to characterize the composites. The polymer/fiber interface was investigated through scanning electron microscopy analysis. The biodegradability of composites was evaluated by compost-soil burial test. The addition of curauá fiber promoted an increase in the mechanical strengths and composites treated with 2 wt% MA-g-PP with 20 wt% curauá fiber showed an increase of nearly 75% in tensile and 56% in flexural strengths besides an improvement in impact strength with respect to neat polymer blend. Nevertheless, treated composites showed an increase in water absorption and biodegradation tests showed that the addition of fiber retards degradation time. The retained mass of BP/20 wt% fiber composite with MA-g-PP and neat BP was 68 and 26%, respectively, after 210 days of degradation test.     

Natural Fiber Reinforced Poly(vinyl chloride) Composites: Effect of Fiber Type and Impact Modifier

Poly(vinyl chloride) (PVC) and natural fiber composites were prepared by melt compounding and compression molding. The influence of fiber type (i.e., bagasse, rice straw, rice husk, and pine fiber) and loading level of styrene-ethylene-butylene-styrene (SEBS) block copolymer on composite properties was investigated. Mechanical analysis showed that storage modulus and tensile strength increased with fiber loading at the 30% level for all composites, but there was little difference in both properties among the composites from various fiber types. The use of SEBS decreased storage moduli, but enhanced tensile strength of the composites. The addition of fiber impaired impact strength of the composites, and the use of SEBS led to little change of the property for most of the composites. The addition of fiber to PVC matrix increased glass transition temperature (T_g), but lowered degradation temperature (T_d) and thermal activation energy (E_a). After being immersed in water for four weeks, PVC/rice husk composites presented relatively smaller water absorption (WA) and thickness swelling (TS) rate compared with other composites. The results of the study demonstrate that PVC composites filled with agricultural fibers had properties comparable with those of PVC/wood composite.     

Influence of Fibers on the Mechanical Properties of Cassava Starch Foams

The utilization of renewable resources in packaging can provide solutions to ecological problems such as waste quantity. Agricultural resources are alternative raw materials, among which there is starch, a natural polysaccharide that can be used to form resistant foam under wet and warm conditions. The starch foam is obtained by thermo pressing process where cassava starch, water and additives are processed to form a rigid structure by swelling, gelatinization and network formation. Natural fibers can be used to improve the mechanical properties of starch foams. In this project was investigated the influence of the addition of fibers in the levels of 1, 2 and 3% of cassava (short fiber) and 1, 2 and 3% of wheat fiber (powered fiber) in the starch dough. The foams were characterized by physical methods of strength, flexibility, density and by Scanning Electron Microscopy (SEM). The increase in fibers quantity has resulted in foams with higher density and less flexibility, whatever the fiber type. Most fibers quantity did not improve the foam strength. Foam made with 1% of cassava fiber showed higher compression strength; by increasing the percentage quantity there was a decrease on the compression resistance. Foam made with wheat fiber presented a lower result in 2%. The fiber type had no statistical significance in strength, flexibility and density foam. Only the fiber quantity was significant. The results showed that both fibers presented limited dimensions to improve the reinforcement of the starch foams up to 1%.     

Effect of Nano-SiO<Subscript>2</Subscript> and Bark Flour Content on the Physical and Mechanical Properties of Wood–Plastic Composites

The aim of this study is to evaluate the impact of nano-SiO₂ and bark flour (BF) on the natural fiber–plastic composites engineering properties made from high density polyethylene (HDPE) and beech wood flour (WF). For this purpose, WF and BF in 60 mesh size and weight ratio of (50, 0 %), (30, 20 %), (10, 40 %) and (0, 50 %) respectively were mixed with HDPE. In order to increase the interfacial adhesion between the filler and the matrix, the maleic anhydride grafted polyethylene was constantly used at 3 wt% for all formulations as a coupling agent. The nano-SiO₂ particles with weight ratio of 0, 1, 2, and 4 % were also utilized to enhance the composites properties. The materials were mixed in an internal mixer (HAAKE) and then the bark and/or wood–plastic composite samples were made utilizing an injection molding machine. The physical tests including water absorption and thickness swelling, and mechanical tests including bending characteristics and un-notched impact strength were carried out on the samples based on ASTM standard. The results indicated that as the BF content increased in the composite, mechanical and physical properties were reduced, but the given properties were increased with the addition of nano-SiO₂. The addition of nano-SiO₂ had a negative impact on the physical properties, but when it was up to 2 %, it increased the impact strength.     

Starch- polyvinyl alcohol crosslinked film— performance and biodegradation

Starch-PVOH cast films were prepared with and without crosslinking agent (hexamethoxymethylmelamine) in the absence of plasticizer. Moisture absorption in films without crosslinking agent at a low relative humidity was similar to that of PVOH and increased as the relative humidity increased. Films with crosslinking agent showed moisture absorption linearly proportional to the relative humidity. Significant improvement in resistance to water disintegration for crosslinked starch-PVOH films was observed. While the tensile strength decreased with increased relative humidity, crosslinking significantly improved the tensile strength. Increased PVOH content improved elongation of films even when the relative humidity was 80% or higher. Biodegradation studies revealed that the degradation rate was negatively correlated with the PVOH content in films and crosslinking generated more converged degradation curves. Names are necessary to report factually on available data; however, the USDA neither guarantees nor warrants the standard of the product, and the use of the name by USDA implies no approval of the product to the exclusion of others that may also be suitable.     

Utilization of textile effluent wastewater treatment plant sludge as brick material

In the present work, the feasibility of using sludge generated in wastewater treatment plants of textile industry as a partial replacement for clay in the conventional brick manufacturing process is examined. Physico-chemical properties of the sludge and clay were studied. The characteristics of bricks with replacement of sludge (0–50 %) with an increment of 3 % were determined. All the brick samples satisfied the requirements of Indian Standards norms in terms of weight loss on ignition. The bricks with sludge up to 15 % satisfied the prescribed norms for compressive strength and water absorption. Results also showed that the brick weight loss on ignition was mainly attributed to the organic matter content in the sludge being burnt off during the firing process. The characteristics of bricks such as efflorescence, density and weight loss on ignition for bricks with replacement of clayey soil with textile sludge up to 15 % also satisfied the requirements of the Indian Standard. Thus, textile sludge up to 15 % can be effectively added to make brick material.