You are on page 1of 6

Extended abstract for the Regional Invention Contests and Exhibits 2011 (RICE 2011)

International Quality Ceramic Wares Made From Locally Available Materials: A Discovery of a Novel Alternative Ceramic Flux for Conservation of Energy and Lowering of Processing Time in the Production Process
Jewel Anne G. Salvador , Anthon Mark Jay A. Rivas and Engr. Ryan D. Corpuz
1
2 3

Main Reseacher, New Era University, No. 9 Central Avenue, New Era, Quezon City, 1107, Philippines,

Co-researcher, University of San Carlos, P. Del Rosario St., Cebu City, Cebu, 6000, Philippines Adviser, Mindanao State University Iligan Institute of Technology, Bonifacio Ave., Tibanga, Iligan City, Lanao Del Norte, 9200, Philippines

Incorporating fluxes in the body composition of a ceramic ware allows its formation at attainable temperature. The temperature is attainable but it is still above 1000C. This means: consuming more energy and requiring longer processing time. Furthermore, the fluxes used in the industry at present are being mined and the clay is being imported. This study uncovers a ceramic body formation through soft-mud process at only 850C using the locally available clay and brown seaweed as flux. The resulting ceramics was classified using an international standard: ASTM C67-87 (1998). This shows that importation can be avoided by utilizing locally available materials in producing ceramic wares. Moreover, brown seaweed was utilized as a flux which lowered the vitrification temperature to 850C, thereby reducing processing time and conserving energy.

1. Introduction Problem Description Pottery is an important discovery in human civilization. It serves as one of the earliest arts in human history. It has been studied intensively and its development advanced human society to new technology levels. Clay, the main raw material in the traditional ceramic production process, is usually imported. Importation costs (costs of buying materials from outside sources, including material handling cost, storage cost and freight) should be minimized or eliminated. Meanwhile, ceramic flux is added to the body of either functional or decorative ceramic wares. The incorporation of which in the body is an effective method in regulating the properties of ceramic bodies. Without fluxes, pottery fabrication would have been beyond the reach of prehistoric people. This substance serves as impurity, enabling the production of ceramic wares to be attainable at a considerable temperature of above 1000C. This basic manufacturing process requiring high energy consumption remained unchanged. The discovery of a flux, that will change the basic ceramic firing process commonly employed at temperatures above 1000C and will produce ceramic wares at 850C, will be of great help in fuel consumption reduction. Meaning: energy conservation and processing time reduction.

Ceramic fluxes commonly used today are being mined. The discovery of alternative fluxes is needed for more efficient production. The utilization of unused red clays is to be explored, especially now that the world is recovering from a global financial crisis, to make way for developments, sustain (or even continuously improve) those advancements and eventually survive. Impact on Humanity The present work successfully created functional and decorative ceramic wares from locally available materials; the mass production of which will warrant livelihood projects, thereby benefiting the local people and dwellers, their community and ultimately, the economy. Furthermore, this project found an alternative, cheap, renewable and environment-friendly ceramic flux which lowered the vitrification temperature of a ceramic body. This discovery is advantageous to the ceramic industry for several reasons. First, fuel consumption is reduced. Instead of processing above 1000C which requires higher amount of energy and longer processing time, manufacturing can be done at a lower temperature and shorter time. Second, since the raw materials used (brown seaweed and clay) are available locally, importation costs (costs of buying materials from outside sources or other places, including

Extended abstract for the Regional Invention Contests and Exhibits 2011 (RICE 2011)

material handling cost, storage cost and freight) are minimized or eliminated. This efficient production technique will lead to a decrease in ceramic ware price. Meanwhile, creativity is enhanced in the creation of decorative wares. Artists will have a new vehicle to communicate their ideas and messages. Indirectly, this project will reduce flux mining and its effects in the environment. Thus, stripping of large areas of flora and fauna area will be minimized. Since mining uses a lot of energy, its reduction means energy conservation. With all these positive contributions to humanity, the researchers were enthusiastically motivated pursuing the study that possesses a great promise for commercial implementation with tremendous intimacy.

3. Results and Discussion A. Test Results Mean Test bars fired at 850C yielded the mean results presented below.

2. Experimental Details Ceramic test bars were made using the locally available clay with the brown seaweed, Sargassum sp. as the ceramic flux. Soft-Mud Process, a standard procedure in making bricks was used in the production of test bars. The physical properties were then evaluated after firing. Total shrinkage was determined using the appropriate formula and presented in percentage shrinkage. Modulus of Rupture (MOR) was a measure of the flexural breaking load (bending strength) of sample ceramic bars. Compressive strengths were also determined. A relationship between water absorption and porosity was previously reported and studied (Salmang, 1961; Pocelanosa, 2005). The more porous an article, the greater will be its water absorption. Hence, porosity was measured through water absorption. The obtained results were expressed in percentage water absorbed with respect to the mass of the test specimen. The analyses of result differences were tested in order to infer whether the increase of brown seaweed content was really significant or if it was due instead to random chance.

B. Total Shrinkage Figure 3.1 showed the reference mark that was put before firing and the re-measured mark results from Formula A and Formula B. At 850C, all the test bars of the two formulations exhibited shrinkage. Notice further that all the measurement for the test bars of Formula A were lesser than that of Fomula B. This indicated that Formula Bs shrinkage is lesser than that of Formula A. This phenomenon can be clearly seen in Figure 3.2.

From the data above, t=-13.488 which was less than the critical value of -t23 with =0.01 level of significance which was -2.500. The null hypothesis was rejected. There was sufficient evidence to reject it. Obtained measurement results from the test bars of Formula A was different from the test bars of Formula B (H1). Based on this result, the increase in brown seaweed content in the body composition significantly decreased the total shrinkage. Table 3.2 summarizes the result of the t test.

Extended abstract for the Regional Invention Contests and Exhibits 2011 (RICE 2011)

Table 3.2: Separate -Variance t Test for Total Shrinkage, =0.01 Fomula A Mean Variance Number of Test Bars 45.565 0.005 20 Formula B 45.800 0.001 20

Given the results acquired, brown seaweed presented an attribute that only nonplastic materials and fillers can demonstrate. This phenomenon showed that brown seaweed behaved like other fluxes for it exhibited non-plastic characteristic.

df t Stat t Critical one-tail

23 -13.488 -2.500

Decision: Reject H0 (t=-13.488<-t23=-2.500)

Figure 3.2 explicitly displayed that total shrinkage decreased when increasing the brown seaweed content. Furthermore, the increase of brown seaweed content in the formulation yielded a significant decrease of total shrinkage based on the t test result with a confidence level of 99%.

C. Modulus of Rupture (MOR) The MOR of the test bars of the two formulations were shown in Figure 3.4. Formula As test bars had lower MOR compared to test bars of formula B. This meant that the increase of brown seaweed content in the ceramic body caused the strength to increase. Moreover, this increased strength of red ceramic bodies was significant. Table 3.3 summarized the t test.

The mean of formula A and Formula B were graphed in Figure 3.3. Mean shrinkage obtained from Formula A was 8.87%. On the other hand, Formula B had a mean shrinkage of 8.40%. The increase in brown seaweed content in the ceramic body resulted to a decrease of about 0.47%. This difference was proven to be statistically significant. The shrinkage was associated with the clay content only (Salmang, 1961). Meaning, any addition of non-plastic material will not increase shrinkage as water vaporizes but instead, led to diminution of contraction. Nonclay materials restrain shrinkage by not reacting or not allowing water to pass through its matrix. Moreover, only materials that were considered fillers can possibly reduce shrinkage. Such materials include quartz and alumina.

The t of the above data is 20.810. This was more than the critical value of t31 with =0.01 level of significance which was 2.453. The null hypothesis was rejected. There was sufficient evidence to reject it. Strength of Formula As test bars was different from the strength of Formula Bs test bars (H1). Based on this result, the increase in brown seaweed content in the body composition significantly decreased the total shrinkage. Table 3.3 summarizes the result of the t test.

Extended abstract for the Regional Invention Contests and Exhibits 2011 (RICE 2011)

Table 3.3: Separate-Variance t Test for Modulus of Rupture, =0.01 Fomula A Mean Variance Number of Test Bars 14.74 0.131 20 Formula B 18.09 0.387 20

Df t Stat t Critical one-tail

31 -20.810 -2.453

Decision: Reject H0 (t=-20.810<-t31=-2.453)

MOR of Formula A was 14.74 kg/cm. Increased in MOR was observed when brown seaweed content was increased to 5%. From 14.74 kg/cm, it became 18.09 kg/cm. Note that an increase of 2% brown seaweed in the formulation increased the strength of the ceramic article by 18.5%. The increased strength was significant. The presence of alkali ions in a flux produced more melt which was the reason for the increased in strength (Steinzor 1986). The melt filled up the gaps between unreacted particles. Upon cooling, the article became denser and stronger. In this present study, potassium (potash probably) might be the reason for the increased strength. Previous study of one of the species of brown seaweed (Sargassum thunbergii) reported that potassium existed in its body (Yan et al., 1996). It further reported the high absorbance of potassium. Then perhaps, the incorporation of brown seaweed introduced more potassium ions in the clay. Thus, upon firing, potassium ions reacted with other impurity ions such as iron, calcium and sodium that might be present in the fired article. The reaction formed a melt. This melt filled the gaps between unreacted particles resulting to a denser mass and an increased in strength.

D. Water Absorption The weight of Formula As test bars were shown in Figure 3.6. As expected, test bars fired weight (weight after firing) was lower compared to the weight when wet. The same observation can be said with the test bars of Formula B as shown in Figure 3.7. All the test bars absorbed water in their body. The increased weight was the evidence for these. The mass of water absorbed was no longer presented but can be observed clearly in the displayed graphs. In order to examine more closely the water absorbed, Figure 3.8 graphically showed the percentage water absorbed of the test bars of Formula A and Formula B.

Figure 3.8 below showed the percetage of water absorbed by the test bars of the two formulations. All the test bars of Formula A absorbed more water than the test bars of Formula B. This signified increasing the brown seaweed in the ceramic body composition will yield a decrease of absorbed water. Decreased water absorbed meant lesser porosity of the ceramic body.

Extended abstract for the Regional Invention Contests and Exhibits 2011 (RICE 2011)

The t of the data above was 12.549 which was greater than the critical value of t27 with =0.01 level of significance which was 2.437. The null hypothesis was rejected. There was sufficient evidence to reject it. Water absorption percentages of the test bars of Formula A were different from the test bars of Formula B (H1). Based on this result, the increase in brown seaweed content in the body composition significantly decreased the water absorption percentage, hence, the porosity. Table 3.4 summarized the t test.
Table 3.4: Separate -Variance t Test for Water Absorption %, =0.01 Fomula A Mean Variance Number of Test Bars 22.880 0.054 20 Formula B 22.160 0.012 20

other impurity ion such as calcium, sodium and iron forming a melt. The melt produced filled the voids between unreacted particles and likely reacted with the articles surface, binded them together forming a less porous ceramic body ware upon cooling.

E. Results Obtained and the Ideal Range


Table 3.5: Ideal Range of Acceptability for Functional Wares Physical Properties Ideal Range 0 to 13 3.52 to 105.63 0 to 23 Formula A: 8.87 14.74 22.88 Formula B: 8.40 18.09 22.16

df t Stat t Critical one-tail

27 12.549 2.473

Total Shrinkage (%) Modulus of Rupture (kg/cm) Water Absorption (%)

Decision: Reject H0 (t=12.549>t23=2.473)

Since water absorption was related to the porosity (Salmang 1961), an article which was more porous will absorbed water more than the less porous one. Formula A yielded a mean of 22.88% water absorption while Formula Bs water absorption mean was 22.16%. The decrease of water absorption was 3.15%. This incident can be attributed to the reduction of pores during vitrification by the addition of brown seaweed in the ceramic body wares. The incorporation of brown seaweed into the clay probably introduced potassium ions (previous study by Yan et al. in 1996 revealed presence of potassium in the body of Sargassum thunbergii) which reacted with

The obtained values for the physical properties fell within the ideal range of acceptability as a functional ware. F. ASTM Classification Note that the brown seaweed was only 5% in the formulation. Fluxes were usually added up to 30% of the body content. By the observed trend from the results obtained, it can be inferred that increasing the seaweed content in the ceramic body will yield increased strength and decreased water absorption and shrinkage. Note: P=Passed

Extended abstract for the Regional Invention Contests and Exhibits 2011 (RICE 2011)

G. Energy Conserved A unique value of amount of heat will be required for each substance to change the temperature of its one kg by one degree Celsius. This value required was referred to as the specific heat of substance. Let Q be the heat transferred to m grams of a substance, thereby changing its temperature by dT. The specific heat of substance was:
c Q m dt

REFERENCES Budnikov, P. D., The Technology of Ceramics and Refractories. Translations by Scripts Technia. Massachussettes: The MIT Press. 1964. Downie. N. M and R.W. Heath., Basic Statistical Methods. New York: Harper and Row Publisher. (2nd Edition), 1965. INASEITO Co. Ltd., Ceramic Tile Extraction Handbook of Ceramic Wall Tile. Lamar, R.S., A Review of Methods for determining Particle Size Distribution. Ceramic Bulletin, 3[8] 1952. Montgomery, D.C., Design and Analysis of Experimental. New York: John Wiley and Sons. (2nd edition), 19. Mostrales, D., A. G. Trinidad, V. E. Empig and M.S. Dimamay. The Introduction of Micro-concrete Roofing Technology in Mindanao (Philippines). Iligan City: MSU-IIT, 1991. Liwanag et al., Stoneware Formulation Using Slip Casting Method. Iligan City: MSU-IIT, 1991. Bullard E. C. Maxwell, A. E. and Revelle R. "Heat Flow Through the Deep Sea Floor". Advances in geophysics, Volume 3. Academic Press: 1956. MSRI Handouts on Physical Testing of Ceramic Materials. Norton, F.A. Fine Ceramics: Technology and Applications.USA: McGraw Hill, 1974. Norton, F.H. and S. Speil. The Measurement of Particle Sizes in Clays. Journal of American Ceramic Society. 21[3] 1983, 89-97. Ryan, W. and C. Radford. Whiteware Production, Testing and Quality Control. England: The Institute of Ceramics, Pergamon Press.1987. Salmang, H. Ceramic Physical and Chemical Fundamental. Translated by Marcus Francis. London: Buttersworth and Co. Ltd. 1961.

Rearranging the equation, the heat transferred from a body to its surrounding or the other way around can be computed.
Q c m dt

The specific heat of clay was 0.181 cal g C (Bullard, Maxwell & Revelle, 1956). The energy used in the study:

QTotal
QTotal QTotal

Q Formula A
413,874.6cal 835,785.6cal

Q Formula B
421,911cal

Usually, clay was fired above 1000C. The energy used in this usual process was:

QTotal
Q Total Q Total

Q Formula A
1,005,201.6cal

Q Formula B

497,768.1 cal 504,733.5 cal

The energy conserved:

QTotal
QConserved QConserved

Q Formula A
1,005,201.6cal 169,416cal

Q Formula B
835,785.6cal

Shreves Chemical Process Industries. New York: Mc-Graw Hill. 1974. Steinzor, Benjamin., Basic Ceramics, Prentice-Hall, Incorporated, USA, 1986. Stulz, R and K. Mujerki. Appropriate Building Material. St. Gallen, Switzerland: SKAT- GATE-ITDG.1988. Yan, X., Hou X., Sun, B., Fan, X., Han, L. Element Composition of Sargassum thunbergii. Chinese Journal of Oceanlogy and Limnology, Vol 16. China: 1998 Watson, D. Construction Materials and Processes. USA. McGraw Hill (2nd ed.). 1978. Whittaker, E. Effect of Particle Size on Plasticity of Kaolinite Journal of American Ceramic Society. 2[1] 1939.16-23. Worrall, W.E. Clays and Ceramic Raw Materials. London: Elvisier Science Publishing Co. Inc. 1986.

This was only an estimate. Other factors such as efficiency of the machines used influence the energy used. Notwithstanding, the firing temperature was lowered down. Thereby, conserving energy and shortening processing time.

4. Summary The present study discovered that the production of international quality ceramic wares using locally available materials at 850C only is attainable with the integration of brown seaweed as fluxing agent.

You might also like