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Wastes:
Excellent raw
materials 12/12/12
Teresa Vieira
Introduction
Recycling → Raw material
Environment
protection
Social
development
Economic
growth
2
Inorganic industrial wastes
Ceramic
1. Slate wastes such as for flooring (award of Innovation – Tecktonica 2001);
2. Slate wastes as additive
3. Sludge from aluminium surface treatment
a. explosive compaction such as
b. Extrusion as additive
Metallic
4. Metallic chip from machining processes
Introduction 3
1. Slate
Industry of extraction of natural resources (Portugal)
Thousands of tons of clay are
extracted per day The inefficient use leads to the depletion
Extraction of slate generated
about nine tons of powder per day In the most cases there are deposited in
landfills
Recycling slate wastes through the incorporation in clay
Technical behavior
Technical performance
Economic sustainability
Impact on the environment
4
1. Slate
Aim
To understand the role of the slate wastes in the
properties of the final product
To obtain a new product with better properties than
those resulting from traditional raw materials
Study the effect of slate wastes by incorporation in two different
types of clay
using two different particle sizes of slate
5
1. Slate
Density (kg/m3) d50 (µm) Phases
Clay
Unusable 2.74 7.6
Q – Quartz
M – Muscovite
K - Kaolinite
Conventional 2.60 25.5
Q – Quartz
M – Muscovite
C - Chlorite
Slate
A
2.88
7.4 Q – Quartz
M – Muscovite
K – Kaolinite
S - Smectites
B 65.0
6
1. Slate
Mixing and
homogenization
Extrusion
Drying
Sintering
7
C
C
C
C
C
1. Slate
Processing properties
Parameters Material Unusual Clay Conventional Clay
Additive Slate A* Slate B* Slate A Slate B
% 0 5 10 5 10 0 5 10 5 10
Shrinkage % 4.4 4.3 4.4 4.2 3.7 7.6 7.1 6.8 6.8 6.5
Total water % 27.1 26.8 27.8 27.8 24.3 23.5 23.1 23.7 22.8 23.6
Weigth loss % 4.5 4.5 4.5 4.6 4.8 6.3 5.6 5.3 4.7 4.5
conventional clay presents the highest values of shrinkage
unusable clay needs more water content to be processed than
the traditional one
weight loss remains almost constant to the unusable clay;
when slate is incorporated conventional clay has a slight
decrease of weight
*Slate A – low size distribution
*Slate B – high size distribution
8
C
C C
C C
Physical properties
1. Slate
Parameters Material Unusable Clay Conventional Clay
Additive Slate A Slate B Slate A Slate B
% 0 5 10 5 10 0 5 10 5 10
Bulk
density g/cm3 1.7 1.7 1.6 1.7 7 1.9 1.9 1.9 1.9 1.9
Total
porosity % 39.6 39.0 40.7 39.0 38.9 27.7 26.9 28.5 27.8 27.5
Water
absorption % 20.1 20.0 20.8 19.9 19.0 14.1 13.3 13.9 13.6 13.7
the addition of slate not change the bulk density
the unusable clay has higher porosity than the conventional
clay
insignificant variations of water absorption was observed by
the presence of slate waste
C
9
C C
Thermal conductivity
Parameters Material Unusable Clay Conventional Clay
Additive Slate A Slate B Slate A Slate B
% 0 5 10 5 10 0 5 10 5 10
Thermal
Conductivity W/(m2.˚C) 0.31 0.32 0.32 0.31 0.36 0.61 0.63 0.62 0.61 0.63
Unusable clay shows much thermal resistance than
conventional clay
In both type of clays the thermal resistance is not affected by
the incorporation of slate, whatever the content
10 1. Slate
C C
1. Slate
Compressive strength
Parameters Material Unusable Clay Conventional Clay
Additive Slate A Slate B Slate A Slate B
% 0 5 10 5 10 0 5 10 5 10
Compressive
Strength MPa 11.7 14.2 12.5 14.9 13.8 28.9 33.7 35.4 31.2 31.8
Standard
desviation 0,84 1,02 1,11 0,98 1,14 0,81 0,82 1,07 1,09 1,04
After consolidation as expected the unusable clay has lower
mechanical strength than conventional clay submitted to the
same firing cycle
In unusual clay 5 % of slate addition improves slightly the
mechanical strength
In conventional clay the addition of slate also induces an
improvement of mechanical strength
11
The incorporation of slate wastes in clays can
improve the mechanical resistance without
affecting negatively the thermal conductivity…
… but, it will be possible to improve
these to parameters simultaneously???
1. Slate
Sludge from anodizing and lacquering industry
12
1. Slate
Incorporation of slate + anodizing sludge
Total
shrinkage Plasticity
Mass
loss
Bulk
density
Total
porosity
Water
absorption
Thermal
Conductivity
Compressive
Strength
% % % g/cm3 % % W/m2.˚C MPa
Clay 7.6 23.5 6.3 1.9 27.7 14.1 0.61 28.9
Clay bi-added
(slate and sludge) 6.5 26.2 7.5 1.7 33.6 19.3 0.50 34.6
This new formulation shows that the addition of sludge
slightly increases the porosity and water absorption, but yet
lower than the values of standards for clay products
The values of the thermal conductivity are improved (18 %)
The presence of slate continues to contribute to an increase
of mechanical strength (20 %)
13
1. Slate
It is possible to produce a new “composite” for efficient
building (matrice = clay; a mechanical reinforcement = micro slate and a
thermal reinforcement = nanocrystalline aluminium sludge), with high
mechanical performance and thermal resistance, allowing
the recycling of two industrial by-product
The use of smaller particle size, without any
previous treatment, leads to the best properties
The addition of anodizing sludge into the
mixture improves the thermal conductivity
without affecting the former enhanced
mechanical resistance
14
Production of -alumina (1650 ºC)
Induces an agglomeration of the particles and reduction of specific
surface area
Reduction their sinterability.
Explosive compaction: distort the crystal lattice, activate the particle
surface, particle fragmentation
Promoting the sintering process
After explosive compaction and sintering: density and hardness similar
to commercial -alumina
These results make this strategy to recover aluminium sludge
impossible due to high energy costs
2b. Sludge - explosion
15
Decrease the environmental impact of the heat treatments
(calcination and sintering)
Study the explosive compaction of sludge calcinated at low
temperature (800 ºC) and subsequent sintering
2b. Sludge - explosion
16
The sludge as-received had aluminium hydroxide and water
After heating at 800ºC the main phase was -alumina
Density: 2850 kg/m3
Mean size of particles: 31 m
In both cases the nanometric character of the crystallite size is evident.
20 40 60 80 100
o
T=800oC
As received
Inte
nsity [
u.a
.]
2 [o]
2b. Sludge - explosion
17
2b. Sludge - explosion
18
2b. Sludge - explosion
19
2 mm 2 mm
1 cm
Before explosion
After explosion
2b. Sludge - explosion
20
Sulphur quantity
4.5% (w/w)
0.04% (w/w)
20 40 60 80 100
Before explosion
After explosion
Inte
nsity [
u.a
.]
2 [o]
Phase Density
-alumina 2850 kg/m3
-alumina 3930 kg/m3
Explosion
Patm →T>1200 ºC Patm →T>800 ºC
Explosion
2b. Sludge - explosion
21
Process Explosion
Explosion and sintering
1 h at 1200 ºC 1 h at 1650 ºC
Hardness [GPa] 4.91.0 8.61.4 15.60.8
Process of Compaction
Hardness *[GPa]
1h at 1650ºC 4h at 1650ºC
Sludge at 160ºC
Explosive 7,9±1,3 8,5±1.4
Explosive 12,0±1,5 15,0±1.6
CommerciaAlumina
Uniaxial 11,2±1,3 13,0±0.9
Explosive 17,4±1,3 20,2±2.1
Explosive 17,9±1,5 17,9±0.8
*A.R. Farinha, J.B., Ribeiro, R. Mendes, M.T. Vieira, Sock activation of α-alumina from calcinated Al-rich
sludge, Ceram. Int., 35 (2009) 1897-1904.
2b. Sludge - explosion
22
From sludge calcinated at 800 °C (-alumina and sulphates), by
explosive compaction it is possible to produce -alumina with low
sulphur content.
The sintering after explosive compaction leads to parts with
hardness values close to those of alumina produced by conventional
techniques.
Possibility of recovering this type of sludge to produce parts of -
alumina
Future work
Optimization of sintering at low temperatures and the possibility of
using sludge calcinated at temperatures below 800 °C to minimize
the environmental impact.
2b. Sludge - explosion
23
ANODIZING AND LACQUERING
INDUSTRY
Officially recognized as a highly polluting industry: 1000 tons of residual sludge each year ;
Cost of sludge management:55€/ton;
Location:
Viana do Castelo, Portugal
Sludge characteristics
Nano cristallyne
Non toxic (List of waste 19 02 06)
Inert
Odorless
Water content (77%)
Is this a waste… or a raw
material?
2a. Sludge - extrusion
24
AIM
To develop a thermal resistant brick by adding aluminium sludge in bricks
production (recycling):
using all the sludge;
avoiding the landfill disposal
developing one product (brick) without significant costs
2a. Sludge - extrusion
25
KEY-POINTS OF THE RECYCLING
PROCESS
Cost of the sludge transport: 15€/ton;
Previous treatments required;
Use of the real parameters of the plants operations;
Recycling the waste to produce a product with added-value.
Transport provided by transporting lines of the bricks that already exists;
Disagglomeration of the sludge
Clay and production cycle of Preceram;
Addition of sludge to produce a brick with thermal comfort properties.
2a. Sludge - extrusion
26
STAGES OF THE RECYCLING PROJECT
1. Laboratory tests and Pilot line: feasability assessment
2. Full scale test: industrial viability assessment
Preparation Shaping Drying Firing New product
Characterization
2a. Sludge - extrusion
27
1. Laboratory tests and Pilot line: feasability assessment
Characterization of raw materials;
Technological behavior of the mixtures;
Technical properties of the ceramic material;
Nano crystalline character of sludge: using synthetic gamma alumina
nanoparticles (nano crystalline)
d50 wt. % additive
Clay m 15.56 0
Synthetic γ-alumina
nanoparticles nm 50 5
Agglomerated sludge m 4.87 5
2a. Sludge - extrusion
28
NEW CERAMIC
TECHNOLOGICAL BEHAVIOR
Physical properties of new ceramic material
Formulation Clay Clay +
5% γ-alumina
Clay +
5% Sludge
Total water* (%) 18,4 29,7 24,8
Total shrinkage (%) 5,0 9,3 5,8
Weight loss (%) 3,1 6,7 5,3
The presence of additives increases the needs of water, which is
responsible for the less technological behavior;
Range values of water content for extrusion: 15-25%;
*To be extruded
2a. Sludge - extrusion
29
Pore diameter distribution
Formulation Clay Clay +
5% γ-alumina
Clay +
5% Sludge
Bulk density (g/cm3) 2,0 1,8 1,7
Real density (g/cm3) 2,5 2,7 2,6
Total porosity (%) 28,0 33,6 35,9
Water absorption (%) 13,7 18,6 18,9
NEW CERAMIC
PROPERTIES OF THE MATERIAL AFTER FIRING
The presence of additives increases the
porosity;
Nanoalumina produces a bimodal curve:
submicrometer and nanometer porosity;
Maximum value of water absorption: 20 wt.%.
2a. Sludge - extrusion
30
NEW CERAMIC
TECHNICAL BEHAVIOR OF THE MATERIAL
Formulation Clay Clay +
5% γ-alumina
Clay +
5% Sludge
Compressive strength (MPa) 22,0 14,3 13
Thermal conductivity coefficient
K ( W/mºC) 0,70 0,42 0,52
Mechanical test and fracture observed
in the samples
Decrease of mechanical strength, according
to the tipical value of tradicional bricks;
Decreasing of Thermal conductivity : 25%
2a. Sludge - extrusion
31
I. Laboratory tests and Pilot line: feasibility assessment
Remarks
Content of water to extrude and its effects
Water absorption and mechanical strength: technical standards and market
requirements
The nanometric character is important: the presence of nanoparticles induces
better values of thermal isolation; BUT the cost of disagglomeration is too
hight to this particular case
The addition of agglomerated sludge (without significant cost of
disagglomation) produce similar effects, due to the nanocrystalline character
of the agglomerates
It seems to be feasible to recycle the aluminium sludge in bricks production
2a. Sludge - extrusion
32
1. Full scale test
Technological behavior of the mixtures;
Technical behavior of the new brick: in agreement to technical
standards and market requirements.
2a. Sludge - extrusion
33
TECHNOLOGICAL BEHAVIOR
Formulation Clay Sludge
Total water (%) 16-18 19,7
Industrial trial observations:
The extrusion occured without significant variations in the production parameters, but is
was needed a slight increase of water content
Good homogenization of the mixture
No visible defects during extrusion, drying or after the firing
2a. Sludge - extrusion
34
TECHNICAL PROPERTIES OF THE NEW BRICK
Brick New brick
Net dry density (kg/m3) 2030 1920
Water absorption (%) 9,5 12,5
Porosity (%) 56 60
2a. Sludge - extrusion
35
TECHNICAL PROPERTIES OF THE NEW BRICK
Brick New brick
Compressive strength (MPa) 7,3 6,3
Thermal conductivity coefficient
k ( W/mºC) 0,53 0,34
Transmission coefficient
U numerical method (W/m2ºC) 0,82 0,65
36%
21%
2a. Sludge - extrusion
36
Aluminium sludge can be recycled as an additive for clay bricks:
enhancing the thermal behavior of bricks up to 36%, without increasing the
brick production cost;
the physical-mechanical properties still are in according to the standards
(water absorption and compression strength);
Finally, it can be stated that the sludge nanoparticles should lead to better
properties, but it is too expensive to disagglomerate for applications like bricks.
CONCLUSIONS
A new thermal brick is coming soon, in a
wall close to you!
2a. Sludge - extrusion
37
High speed
machining
Chip Plastic deformation
Micrometric or nanometric
grain size
Processing
Improve of mechanic properties
3. Metallic Chips
38
Conventional chips
RECYCLING
Chips of High speed
machining
Dyn
am
ic C
on
solid
ati
on
Product with high value
3. Metallic Chips
39
Explosive: ANFO
Detonation velocity: 2.7 mm/µs
Al_5_3A >1mm
Al_5_3B <1mm • Without defects;
• Some porosity;
• Deformation;
• Grain not well defined.
3. Metallic Chips
Aluminium alloy 5083
40
FWHM Integral breadth
Crystallite size(nm)
Sherrer Equation
Chip <1mm 32 29
Al_5_2B 39 30
Al_5_3B 40 31
Chip >1mm 37 28
Al_5_3A 39 30
Pressed chip :
Crystallite nanometric
After dynamic consolidation:
Crystallite nanometric
Sherrer equation
3. Metallic Chips
41
Al alloy 5083
00
00
00
01
01
01
01
01
02
02
02
0 2000 4000 6000 8000
H (
GPa
)
Distance to periphery (µm)
Al_5_2B
Periphery Centre .00
.200
.400
.600
.800
1.00
1.200
1.400
1.600
1.800
2.00
0 2000 4000 6000 8000
H (
GPa
)
Distance to periphery (µm)
Al_5_3A
Al_5_3B
Periphery Centre
Macrohardness commercial: 0.91-1.4 GPa
“in accordance”
3. Metallic Chips
42
Explosive emulsion 15 & 5% MEOV
Detonation velocity: 3.7 & 4.8 mm/µs
Al_6_4B < 1mm
Al_6_6B >1mm Grain size
micrometric
• Without defects;
• Low porosity;
• Grain not well defined in some regions.
3. Metallic Chips
Aluminium alloy 6061
43
Al_6_5B
Al_6_5B
Al_6_6B
Consolidation
3. Metallic Chips
44
.00
.200
.400
.600
.800
1.00
1.200
1.400
1.600
1.800
2.00
0 2000 4000 6000 8000 10000 12000
H (
GPa
)
Distance to periphery (µm)
Al_6_5C
Al_6_5B
Periphery Periphery
Central region
00
00
00
01
01
01
01
01
02
02
02
0 2000 4000 6000 8000 10000 12000
H (
GPa
)
Distance to periphery (µm)
Al_6_6B
Periphery Periphery Central region
3. Metallic Chips
45
Al alloy 6061
Macrohardness commercial: 0.751-1.39 GPa
“in accordance”
Al_7_9B >1mm Al_7_9B >1mm
Centr
al r
egi
on
Peri
phery
3. Metallic Chips
Aluminium alloy 7022
46
Explosive emulsion 5% MEOV
Detonation velocity: 5 mm/µs
• Insignificant defects;
• Low porosity;
• Grain with elongated shape.
Al_7_9B Al_7_9B
Consolidation between two chips
3. Metallic Chips
47
00
00
00
01
01
01
01
01
02
02
02
0 2000 4000 6000 8000 10000 12000
H (
GPa
)
Distance to periphery (µm)
Al_7_9B
Perifphery Periferia Central region
Different behavior in
the periphery
3. Metallic Chips
48
Al alloy 7022
Macrohardness commercial: 1.27 GPa
“in accordance”
Grain size
micrometric
Cu_8B <1mm
Cu_8B <1mm
3. Metallic Chips
Copper
49
Explosive emulsion 5% MEOV
Detonation velocity: 5 mm/µs
Centr
al r
egi
on
Peri
phery
• Without defects;
• Low porosity;
• Possibility of nanometric
grain in the periphery.
dendritic
structure
Example bond between
3 chips
Cu_8B Cu_8B
3. Metallic Chips
50
Copper
00
00
00
01
01
01
01
01
02
02
02
0 2000 4000 6000 8000 10000 12000
H (
GPa
)
Distance to periphery (µm)
Cu_8B
Periphery Central region Periphery
Centre
Less hardness
Higher grain size
Periphery
High hardness
Possibility of
nanometric
grain in the
periphery
3. Metallic Chips
51
Macrohardness commercial: 0.6 GPa
“Hardening”
Emulsão explosiva - 5% MEOV
Velocidade de detonação: 5,0 mm/µs
H13_7B < 1mm
H13_7B <1mm
3. Metallic Chips
Steel H13
52
Grain size
micrometric
• Low porosity
Centr
al r
egi
on
Peri
phery
C
entr
al r
egi
on
H13_7B H13_7B
EDS
Z1-vanadium carbide
Z2-molybdenum carbide
Z3-chromium carbide
Consolidation very
efficient
3. Metallic Chips
53
02
03
04
05
06
07
08
09
0 2000 4000 6000 8000 10000 12000
H (
GPa
)
Distance to periphery (µm)
H13_7B
Periphery Periphery Central region
Dissolution
of primary
carbides
Martensite
3. Metallic Chips
Steel H13
54
Macrohardness commercial: 2.9 GPa
“Hardening”
Al alloy 5083 • ANFO (2.7 mm / ms) efficient in compaction but not in the consolidation;
• Without macrodefeitos, porosity;
• Grain size submicrometric or nanometric;
• Hardness low for the grain size.
Al alloy 6061 • Emulsion + 15% or 5% hollow glass microspheres Consolidation
• Without macrodefeitos, low porosity;
• Grain size micrometer;
• Regions with efficient bond between chips;
• Hardness in accordance with the commercial values .
Al alloy 7022
• Defects in the central;
• Consolidation between efficient chips;
• Some non-symmetrical hardening.
3. Metallic Chips
55
Copper
• Without macrodefects;
• Low porosity;
• Central zone with grain size of micrometer;
• Dendritic structures (melting);
• Different states consolidation;
• Hardening symmetrical in the periphery.
Steel H13
• Overheating in the central zone;
• Central zone with micrometric grain size but high hardness (enriched in carbon
martensite);
• Efficient consolidation.
Promising technique for the production of nanocrystalline metallic
materials and sub micrometer, but needs optimization in particular the
shock wave
3. Metallic Chips
56
•Challenge of minimizing weight and costs is increasingly assertive and requires the use of
new materials and new manufacturing solutions.
• Among the many advantages of starting with powders, the excellence of the resulting
properties should be highlighted. Indeed, it has been widely demonstrated that metallic
materials with grain size below 100 nm.
• Task has not proved easy to perform, especially when applied to nanosized metallic powders,
not only due to handling difficulties, but mainly due to their high chemical reactivity and high
grain growth kinetic.
Innovation Industrial Project
• Tool steels chips
• Bimodal grain size (micro and nanocrystalline)
• Hybrid materials
Future work
57
Teresa Vieira (teresa.vieira@dem.uc.pt)
Ana Rita Farinha
Cecília Lavrador
Ivânia Marques
Sílvia Godinho
Vanessa Neto
58
Thank you
59
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