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Ceramics International
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A R T I C L E I N F O A BS T RAC T
Keywords: Rice husk has been used as a thermal energy source for electricity generation, resulting in the formation of silica
Refractory ceramic from rice husk as a by-product. This research aims to develop refractory ceramic materials by replacing kaolin
Kaolin clay clay with rice husk silica at 5%, 10% and 20% volume percentages. The samples were investigated in terms of
Silica from rice husk their density, apparent porosity, tensile strength in three-point bending test, compressive strength, thermal
Sustainable development
shock and mineralogical composition. The use of 20% silica resulted in an increase in the formation of
Renewable energy sources
cristobalite, higher packing of granular mixtures, and consequently, an improvement in the tensile strength and
compression strength of the samples. However, the material that was most successful in increasing the
mechanical strength without decreasing the thermal shock strength was the sample processed with 10% clay
replacement by silica from rice husk.
⁎
Corresponding author.
E-mail address: marcotier@unipampa.edu.br (M.D. Tier).
http://dx.doi.org/10.1016/j.ceramint.2017.02.147
Received 19 September 2016; Received in revised form 22 February 2017; Accepted 27 February 2017
0272-8842/ © 2017 Elsevier Ltd and Techna Group S.r.l. All rights reserved.
Please cite this article as: Sobrosa, F.Z., Ceramics International (2017), http://dx.doi.org/10.1016/j.ceramint.2017.02.147
F.Z. Sobrosa et al. Ceramics International xxx (xxxx) xxx–xxx
Table 1 Table 3
Chemical composition of KC and RHS. Nomenclature used for mixes.
Source: Helager Industria e Comércio Ltda/Sílica Verde do Arroz Ltda
Mixes Abbreviation
Element KC RHS
KC KC
Percentage (%) Percentage (%) KC with 5% of RHS KS5
KC with 10% of RHS KS10
SiO2 57.83 91.48 KC with 20% of RHS KS20
CaO 0.13 0.36
MgO 0.36 0.32
Fe2O3 2.25 0.05 initial drying, the CPs were placed in a kiln at a temperature of 105 ±
Al2O3 27.52 ND
Na2O < 0.001 0.04
10 °C for 24 h.
K2O 1.87 1.40 Subsequently, all samples were sintered at 1300 °C in a muffle-type
TiO2 0.38 0.003 furnace. Cooling was performed naturally in the oven after shutdown.
MnO < 0.01 0.32
SO3 – 0.15
P2O5 – 0.45 2.3. Testing and analysis
Loss to fire 8.63 3.50
To evaluate the physical properties of the samples, porosity and
apparent mass density tests were performed by employing a water bath
2. Materials and methods
with a digital thermostat and a hydrostatic balance, in accordance with
the ISO 5017:2015 standard (NBR [20]).
2.1. Raw materials
The mechanical properties were investigated through tensile
strength using three-point bending and compressive strength testing.
The raw materials used for manufacturing the refractory ceramics
The thermomechanical properties were evaluated by thermal shock
were kaolin clay (KC) and rice husk silica (RHS). KC was chosen due to
testing.
low availability of iron oxide, which favours refractivity.
Flexural strength was assessed using three-point bending tests in a
RHS was produced using a rice husk combustion process in a
Shimadzu universal testing machine with a 5-kN load capacity,
fluidized bed with controlled temperature (below 650 °C), resulting in
following the ISO 5014: 2012 standard guidelines (NBR [21]).
silica extraction with an amorphous structure (Yalçin [16]; Pandolfelli
The compressive strength test was performed according to ISO
[17]; Nair [18]). Table 1 shows the chemical composition of KC and
standards 201410059-2:2014 (NBR [22]) in an EMIC brand universal
RHS.
testing machine with a 200-KN load capacity. The samples were
previously capped with Sikadur 32 epoxy glue on both sides to level
2.2. Test parts manufacturing the surface. This prevents sample rupture through shearing caused by
eventual irregularities on the surface.
Initially, the effects of RHS on the plasticity limit and the liquidity The thermal shock resistance test was performed following [23]
limit of ceramic mass were evaluated by testing in accordance with ISO specifications. For each cycle, samples remained at 1200 °C for 10 min
17892-12: 2004 [19]. Table 2 shows the plasticity index values, and were immediately removed and added into a tank of water, where
indicating that replacement of silica led to a decrease in clay plasticity. they remained for 5 min. The samples were removed from the tank and
The calculated kaolin clay plasticity index indicated a plasticity after 5 min at room temperature were placed back in the furnace for a
suitable for shaping until the 20% threshold of KC substitution by RHS. new cycle. This procedure was performed until the CPs ruptured.
Four formulations were used to manufacture the test parts (CPs) RHS mineralogical analysis by XRD were performed using an R θ2θ
with up to 20% clay replacement with silica. The first composition Ultima IV diffractometer with Bragg Brentano geometry.
consisted of 100% kaolin clay, and the second, third and fourth
formulations were carried out with replacements of 5%, 10% and 3. Results
20% of KC with RHS. Table 3 presents the nomenclature used to
identify CPs. 3.1. X-ray diffraction
The refractory ceramics were processed by extrusion under 28 kg/
cm³ operating pressure; 35% moisture content was defined by pre- According to Fig. 1, RHS is predominantly amorphous since it
testing aimed towards adequate plasticity. Below this value, it was presents a wide and diffuse peak between 20° and 30° as reported by
difficult to shape parts. During extrusion, the material was subjected to
manual cutting. The dimensions of the test parts were
10 cm×3.13 cm×2.14 cm.
After the cutting procedure, the CPs were wrapped in damp cloths
and covered to prevent accelerated moisture loss, which could cause
defects and imperfections such as curling of the parts. This natural
drying was performed at room temperature for 20 days. After this
Table 2
Plasticity index.
Mixes PL LL PI Variation PI %
2
F.Z. Sobrosa et al. Ceramics International xxx (xxxx) xxx–xxx
Table 4
Fig. 3. XRD after burning: KC, KS5, KS10 and KS20. Results of resistance to thermal shock.
3
F.Z. Sobrosa et al. Ceramics International xxx (xxxx) xxx–xxx
obtained with refractory clay. Thus, it is believed that the use of silica
resulted in improved packing of mixture grains.
Fig. 8. Fracture forms from the thermal shock test: (a) KC; (B) KS5; (C) KS10; (D) KS20.
4
F.Z. Sobrosa et al. Ceramics International xxx (xxxx) xxx–xxx
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[20] NBR ISO 5017:2015 (A). Dense Shaped Refractory Products - Determination of
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Acknowledgments [21] NBR ISO 5014:2012. Dense and Insulating Shaped Refractory Products -
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