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7ASTE 'LASS IN 0ORCELAIN
3AULO 2OCA "RAGAN½A
#ARLOS 0£REZ "ERGMANN
,ABORATRIO DE #ERºMICOS
!V /SVALDO !RANHA S
0ORTO !LEGRE
23 "RAZIL
)NTRODUCTION
4HE CHOICE OF RECYCLABLE MATERIALS TO REPLACE CONVENTIONAL RAW WAS COMPOSED OF WT QUARTZ WT KAOLIN AND
MATERIALS MUST BE MADE CAREFULLY 4HE lRST STEP IS TO ANALYZE THE WT FELDSPAR TRADITIONAL PORCELAIN
40 AND THE OTHER ONE WAS
DECOMPOSITION OF THE MATERIALS DURING THE lRING PROCESS DUE TO THE COMPOSED OF WT OF KAOLIN WT QUARTZ AND
POSSIBLE RELEASE OF POISONOUS GASES 4HIS WILL PROBABLY ELIMINATE WT POWDERED SODA
LIME GLASS GLASS POWDER PORCELAIN
'0
THE USE OF POLYMERIC WASTES SUCH AS TIRES PLASTIC BOTTLES ETC )N
'LASS POWDER WAS USED IN THE SECOND BATCH REPLACING FELDSPAR WHICH
ORGANIC MATERIALS MAY RELEASE HEAVY METALS mUORINE AND SULPHUR IS NORMALLY USED IN TRADITIONAL COMPOSITIONS 4HE MAIN OBSERVATIONS
WHICH ARE VERY HARMFUL TO HUMAN HEALTH !N EXPENSIVE ALTERNATIVE SHOWED THE ROLE OF THE GLASS POWDER AS A mUXING AGENT WHICH COULD
WOULD BE THE TREATMENT OF THE mUE GAS HOWEVER THESE EMISSIONS BE EASILY COMPARED TO 40 4ABLE SHOWS THE CHEMICAL ANALYSES OF
CAN ALSO CAUSE SERIOUS DAMAGES ON KILN REFRACTORY BRICKS 4HE GAS THE RAW MATERIALS
EMISSION LEVELS WHICH WILL PROBABLY BE EVEN MORE RESTRICTED IN THE 4HE GLASS POWDER WAS OBTAINED FROM HIGH TRANSPARENCY SODA
LIME
FUTURE SINCE THEY ARE CONTROLLED BY ENVIRONMENTAL STANDARDS MUST GLASS POTS AND BOTTLES WITHOUT COLOURING OXIDES 4HE GLASS WAS BALL
BE CONSIDERED TOO 4HE SECOND STEP IS TO MAKE SURE THAT THE CERAMIC MILLED AND SIEVED TO MESH MM 4HE CRYSTALLINE PHASES IN
PRODUCT IS INERT DURING USAGE 4HIS IS ESPECIALLY IMPORTANT IN THE CASE RAW MATERIALS WERE DETERMINED BY 82$ &OR KAOLIN THE RESULTS SHOWED
OF DINNERWARE SANITARY WARE AND SO ON ,EACHING CAN BE A SERIOUS THE PRESENCE OF KAOLINITE !L 3I / /( AS THE MAIN CRYSTALLINE
PROBLEM FOR mOOR TILES AND ROOF TILES AND ALSO LIMITS THE CHOICE OF PHASE AND MUSCOVITE + !L !L 3I / /( PLUS ILLITE + !L 3I
MATERIALS THAT CAN BE USED IN BODY COMPOSITION 4HUS THE USE OF / /( AS SECONDARY CRYSTALLINE PHASES +AOLIN WAS SIEVED TO PASS
RECYCLED COLORLESS GLASS IN THE SUBSTITUTION OF FELDSPAR IN THE PORCELAIN MESH MM &OR FELDSPAR WHICH WAS SIEVED TO PASS MESH
PRODUCTION AS PROPOSED IN THIS WORK SEEMS TO BE VERY SUITABLE AND MM MAIN CRYSTALLINE PHASES WERE MICROCLINE +!L3I/ AND
ENVIRONMENTALLY SAFE ALBITE .A!L3I/ 1UARTZ WAS SIEVED TO MESH MM WHICH
!S AN INITIAL CRITERION AND PRIOR TO MAKE ANY EXPERIMENTAL TESTS IS THE PARTICLE SIZE USED IN MOST "RAZILIAN INDUSTRIES
THE AVAILABILITY OF RECYCLED GLASS POWDER TO THE INDUSTRY WAS CHECKED
)N "RAZIL TONS OF GLASS PER YEAR ARE PRODUCED SO THERE IS A
4ABLE #HEMICAL COMPOSITION OF THE RAW MATERIALS WEIGHT
HUGE POTENTIAL OF RECYCLED GLASS POWDER AVAILABILITY 4HE TOTAL AMOUNT
OF GLASS COLLECTED IN THE CITIES FOR RECYCLING EXCEEDS TONS &ELDSPAR 'LASS 1UARTZ
+AOLIN
4HIS COULD BE SIGNIlCANTLY INCREASED BY GOVERNMENTAL INCENTIVES 4HE 0OWDER
QUANTITY OF GLASS ON THE URBAN WASTE IN THE 5NITED 3TATES IS OF 3I/
THE TOTAL WEIGHT AND IS EQUIVALENT TO MILLION TONS OF GLASS !L/
4HE AIM OF THIS WORK WAS TO EVALUATE THE QUALITY OF THE PORCELAIN &E/
THAT CAN BE MADE USING GLASS POWDER 3AMPLES WERE PRODUCED AND lRED
-N/
IN LABORATORY SCALE 4ECHNICAL PARAMETERS SUCH AS WATER ABSORPTION
SHRINKAGE MODULUS OF RUPTURE APPARENT POROSITY DENSITY WEIGHT LOSS #A/
AND FRACTURE TOUGHNESS WERE DETERMINED 4HE PHASES PRESENT IN THE .A/
MICROSTRUCTURE WERE EVALUATED USING 3CANNING %LECTRON -ICROSCOPY +/
AND 8
RAY DIFFRACTOMETRY 4I/
0/
%XPERIMENTAL ,/)
4WO BATCH COMPOSITIONS WERE TESTED IN THIS WORK /NE BATCH 4OTAL
40 BUT WITHIN A SHORTER TEMPERATURE RANGE TO lRE '0 4ABLE SHOWS
3HRINKAGE
THAT OF WATER ABSORPTION AND OF LINEAR SHRINKAGE OCCURRED
FOR THE # '0 SAMPLES WHILE THE # 40 SAMPLES ATTAINED
VALUES OF WATER ABSORPTION AND OF LINEAR SHRINKAGE 4HE
LOWER lRING TEMPERATURE IS AN ADVANTAGE FOR '0 AND CONlRMS THAT
THE GLASS POWDER IS A STRONG mUX "UT THE SHORT TEMPERATURE RANGE FOR
lRING '0 INDICATES THAT MORE ACCURATE TEMPERATURE CONTROL IS REQUIRED
DURING THE lRING PROCESS OF THIS PORCELAIN
-ICROSTRUCTURAL ANALYSIS REVEALED WHICH FACTORS WERE MORE
4EMPERATURE #
IMPORTANT TO GOVERN THE lNAL SHRINKAGE AND DENSITY OF THE PIECES
&IGURE 4HE PRESENCE OF A LARGER QUANTITY OF GAS BUBBLES TRAPPED &IGURE 7ATER ABSORPTION AND SHRINKAGE AS A FUNCTION OF PEAK TEMPERATURE
IN GLASSY PHASE COMPARED WITH PREVIOUS TEMPERATURE HAD A STRONGER SHOWING THE DIFFERENCE IN OPTIMUM lRING TEMPERATURE BETWEEN GLASS PORCELAIN
INmUENCE 40 SAMPLES HAD THE SAME BEHAVIOUR &IGURE BUT IN THIS '0 AND TRADITIONAL PORCELAIN 40
&IGURE 3%- PHOTOMICROGRAPH OF GLASS PORCELAIN lRED AT # AND # "LOATING AS A CONSEQUENCE OF TEMPERATURE INCREASING