FABRICATION OF CERAMIC FLOOR TILES FROM INDUSTRIAL WASTES
Keywords:
Industrial waste, ceramic floor tile, furnace slag, recycled glass, red clayAbstract
The present study focuses on the recycling of red mud waste (RM) from zinc hydrometallurgy, furnace slag (FS), and recycled cullet (RC) for manufacturing vitrified floor tile products. Incorporation was attempted aiming at designing new formulations intended to be less costly and possessing low water absorption and high flexural strength. The floor tiles containing RM 60-70 wt%, FS 10-20 wt%, and RC 10-20 wt% were uniaxially pressed. The green tiles were vitrified at 900-1050oC in an oxidizing atmosphere in a gas furnace with a firing rate of 5oC/min for 30 min. The fabricated floor tiles were tested for linear shrinkage, water absorption, apparent density, and flexural strength. The chemical and mineralogical analyses by X-ray fluorescence and X-ray diffraction (XRF and XRD) were also investigated. Microstructural evolution was carried out by scanning electron microscopy (SEM). The floor tiles fired at 1050oC showed linear shrinkage at 11 + 0.45% approximately, a density of 2.4 + 0.09 g/cm3, and low water absorption at 2.6 + 0.36%. The flexural strength was achieved at 26.31 + 0.46 MPa due to the formation of needle-like crystals of mullite, wollastonite, and the flake crystals of anorthite. The dominant compositions were SiO2, Al2O3, CaO, Fe2O3, Na2O, and ZnO. The results indicated that all the industrial wastes (RM, FS, and RC) could be used for floor tile production. The new products, composed (in wt%) of 70RM, 15FS, and 15RC and fired at 1050oC, fulfilled the requirements of the Thailand industrial standard 2398-2551.
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