Study of a Waste Kaolin as Raw Material for Mullite Ceramics and Mullite Refractories by Reaction Sintering

A deposit of raw kaolin, located in West Andalusia (Spain), was studied in this work using a representative sample. The methods of characterization were X-ray diffraction (XRD), X-ray fluorescence (XRF), particle size analysis by sieving and sedimentation, and thermal analysis. The ceramic properties were determined. A sample of commercial kaolin from Burela (Lugo, Spain), with applications in the ceramic industry, was used in some determinations for comparison purposes. The kaolin deposit has been produced by alteration of feldspar-rich rocks. This raw kaolin was applied as an additive in local manufactures of ceramics and refractories. However, there is not previous studies concerning its characteristics and firing properties. Thus, the meaning of this investigation was to conduct a scientific study on this subject and to evaluate the possibilities of application. The raw kaolin was washed for the beneficiation of the rock using water to increase the kaolinite content of the resultant material. The results indicated that the kaolinite content of the raw material was 20 wt % as determined by XRD, showing ~23 wt % of particles lower than 63 µm. The kaolinite content of the fraction lower than 63 µm was 50 wt %. Thus, an improvement of the kaolinite content of this raw kaolin was produced by wet separation. However, the kaolin was considered as a waste kaolin, with microcline, muscovite and quartz identified by XRD. Thermal analyses by Thermo-Dilatometry (TD), Differential Thermal Analysis (DTA) and Thermo-Gravimetry (TG) allowed observe kaolinite thermal decomposition, quartz phase transition and sintering effects. Pressed samples of this raw kaolin, the fraction lower than 63 µm obtained by water washing and the raw kaolin ground using a hammer mill were fired at several temperatures in the range 1000–1500 °C for 2 h. The ceramic properties of all these samples were determined and compared. The results showed the progressive linear firing shrinkage by sintering in these samples, with a maximum value of ~9% in the fraction lower than 63 µm. In general, water absorption capacity of the fired samples showed a decrease from ~18–20% at 1050 °C up to almost zero after firing at 1300 °C, followed by an increase of the experimental values. The open porosity was almost zero after firing at 1350 °C for 2 h and the bulk density reached a maximum value of 2.40 g/cm3 as observed in the ground raw kaolin sample. The XRD examination of fired samples indicated that they are composed by mullite, from kaolinite thermal decomposition, and quartz, present in the raw sample, as main crystalline phases besides a vitreous phase. Fully-densified or vitrified materials were obtained by firing at 1300–1350 °C for 2 h. In a second step of this research, it was examined the promising application of the previous study to increase the amount of mullite by incorporation of alumina (α-alumina) to this kaolin sample. Firing of mixtures, prepared using this kaolin and α-alumina under wet processing conditions, produced the increase of mullite in relative proportion by reaction sintering at temperatures higher than 1500 °C for 2 h. Consequently, a mullite refractory can be prepared using this kaolin. This processing of high-alumina refractories is favoured by a previous size separation, which increases the kaolinite content, or better a grinding treatment of the raw kaolin.

Mild Hydrothermal Synthesis of 11Å-TA from Alumina Extracted Coal Fly Ash and Its Application in Water Adsorption of Heavy Metal Ions (Cu(II) and Pb(II))

Non-biodegradable copper (Cu) and lead (Pb) contaminants in water are highly toxic and have series adverse effects. Therefore, it is very important to extract heavy metals from wastewater before it is discharged into the environment. Adsorption is a cost-effective alternative method for wastewater treatment. Choosing a low-cost adsorbent can help reduce the cost of adsorption. In this study, conversion of reside after extracting aluminum (REA) produced by sub-molten salt method transform high-alumina coal fly ash (CFA) into 11Å-tobermorite to adsorb Cu(II) and Pb(II) from aqueous solutions at room temperature. The synthesis of the adsorbent was confirmed using scanning electron microscope (SEM), X-ray diffractometer (XRD) and Brunauer–Emmett–Teller (BET) method surface analysis. To study the adsorption characteristics, factors such as initial Cu(II) and Pb(II) concentration, pH, contact time, adsorption characteristics and temperature were investigated in batch mode. The maximum adsorption capacity of Cu(II) and Pb(II) was 177.1 mg·g−1 and 176.2 mg·g−1, respectively. The Langmuir adsorption model was employed to better describe the isothermal adsorption behavior and confirm the monolayer adsorption phenomenon. The pseudo-second-order kinetic model was used to highlight Cu(II) and Pb(II) adsorption kinetics. Thermodynamic analysis indicated the removal Cu(II) and Pb(II) by TA-adsorbent was a nonspontaneous and exothermic reaction. The obtained results are of great significance to the conversion of industrial waste to low-cost adsorbent for Cu(II) and Pb(II) removal from water.

Paleoenvironmental Conditions during the Paleocene–Eocene Transition Imprinted within the Glauconitic Giral Member of the Barmer Basin, India

The roughly 6 m thick limestone–green shale alternation within the lignite-bearing Giral Member of the Barmer Basin corresponds to a marine flooding event immediately after the Paleocene–Eocene transition. A detailed characterization of the glauconite using Electron Probe Micro Analyzer (EPMA), X-Ray Diffraction (XRD), Mössbauer and Field Emission Gun-Scanning Electron Microscope (FEG-SEM) reveals its origin in the backdrop of prevailing warm climatic conditions. The glauconite pellets vary from fine silt-sized to coarse sand-sized pellets, often reaching ~60% of the rock by volume. Mineralogical investigation reveals a ‘nascent’ to ‘slightly evolved’ character of the marginal marine-originated glauconite showing considerable interstratification. The chemical composition of the glauconite is unusual with a high Al2O3 (>10 wt%) and moderately high Fe2O3(total) contents (>15 wt%). While the K2O content of these glauconites is low, the interlayer sites are atypically rich in Na2O, frequently occupying ~33% of the total interlayer sites. The Mössbauer spectrum indicates 10% of the total iron is in ferrous form. High tetrahedral Al3+ of these glauconites suggests a high-alumina substrate that transformed to glauconite by octahedral Al-for-Fe substitution followed by the addition of K into the interlayer structure. The unusually high Na2O suggests the possibility of a soda-rich pore water formed by the dissolution of alkaline volcanic minerals. The Giral glauconite formation could have been a part of the major contributors in the Fe-sequestration cycle in the Early Eocene shelves. Warm climate during the Early Eocene time favored the glauconitization because of the enhanced supply of Fe, Al, and Si and proliferation of an oxygen-depleted depositional environment.

PERICLASE-SPINEL REFRACTORY MODIFIED ТІО2

Over the past decades, the development and improvement of refractory materials for lining high-temperature zones of rotary kilns continues. The main requirements for refractory products for lining rotary kilns for cement clinker roasting are: high density and ultimate compressive strength, low porosity and gas permeability, increased abrasion resistance, low thermal conductivity, high corrosion resistance and the ability to form a protective layer.Today, the main goal of modern researchers is to create a heat-resistant refractory with a flexible structure that ensures its integrity at high temperatures and mechanical loads, which have the ability to form a protective coating layer. In this work, a technological approach has been tested for introducing a vibro-milled modifier (briquette based on a high-alumina component and a titanium-containing additive) into the composition of the raw charge for periclase-spinel refractory in the form of a pre-synthesized product containing crystalline phases of the Al2O3 – TiO2 – FeO system. The basis for the production of periclase-spinel refractories modified with TiO2 is the four-component system MgO – Al2O3 – FeO – TiO2, on the basis of thermodynamic calculations of which the content of individual components of the charge was selected and the operational characteristics were predicted. The interrelation of physical and mechanical properties with the content of individual components in the initial charge warehouses is shown, and the directions of solid-phase processes with their participation are noted. The features of the microstructure of the sample material are noted in relation to the formation of an optimal set of properties. It is shown that the nature of the organization of micropores is favorable for increasing the thermal stability of the material, which complements the phase adaptation mechanism also with the structural effect of damping mechanical stresses during thermal cycling.

SELECTION AND ANALYSIS OF RAW MATERIALS FOR A PROTECTIVE AND DECORATIVE LAYER OF COMPOSITE MATERIAL

With modern housing construction, the cost of finishing work has increased significantly. The development of protective and decorative coatings is necessary, with architectural and artistic advantages and high performance properties with a slight increase in cost. It is necessary to develop a high-quality multilayer monolithic composite with a high degree of adhesion of functional layers to each other. Glass industry waste of various fractions and coloring salts of metals are proposed to be used for a decorative layer, which allows to obtain an almost unlimited color gamut of the coating during plasma chemical modification. The choice of application of high-alumina refractory and alumina cement in the protective layer is justified due to their high thermal resistance to sudden temperature changes. Compositions of a protective layer based on binders and a decorative layer using crushed colored container glass and coloring metal salts moistened with a 5% aqueous solution of liquid glass have been proposed, which makes it possible to significantly expand the raw material base for obtaining functional coatings on concrete. The melt heating temperature and the kinetics of its cooling are determined in order to identify rational rates and duration of high-temperature treatment for further coating creation. Rational rates of plasma processing of composite material for the formation of coatings of various textures are revealed

Teardrops at the Lake: Chemistry of New Kingdom to Makuria Glass Beads and Pendants Between the First and Second Nile Cataracts

International expeditions extensively excavated Lower Nubia (between the First and Second Nile Cataracts) before it was submerged under the waters of Lake Nasser and Lake Nubia. The expeditions concentrated on monumental architecture and cemeteries, including sites at Qustul and Serra East, where the New Kingdom, and Napatan, Meroitic, Nobadian, and Makurian-period elites and common people were buried, ca. 1400 BC–AD 1400. Although the finds abound in adornments, including bead imports from Egypt and South India/Sri Lanka, only a few traces of local glass bead-making have been recorded in Nubia so far. Based on results of laser ablation–inductively coupled plasma–mass spectrometry (LA-ICP-MS) analysis of 76 glass beads, pendants, and chunks from Qustul and Serra East contexts, dated between the New Kingdom and the Makuria Kingdom periods, this paper discusses the composition and provenance of two types of plant-ash soda-lime (v-Na-Ca) glass, two types of mineral soda-lime glass (m-Na-Ca), and two types of mineral-soda-high alumina (m-Na-Al) glass. It also presents the remains of a probable local glass bead-making workshop dated to the period of intensive long-distance bead trade in Northeast Africa, AD 400–600.