Utilization of discarded foundry sand (DFS) and inorganic waste from cellulose and paper industry for the manufacture of glass-ceramic materials

Silva, L. M. S. e; Magalhães, R. S.; Macedo, W. C.; Santos, G. T. A.; Albas, A. E. S.; Teixeira, S. R.

doi:10.1590/0366-69132020663802899

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Articles • Cerâmica 66 (380) • Oct-Dec 2020 • https://doi.org/10.1590/0366-69132020663802899 copy

Utilization of discarded foundry sand (DFS) and inorganic waste from cellulose and paper industry for the manufacture of glass-ceramic materials

Utilização de areia descartada de fundição (ADF) e resíduos inorgânicos da indústria de papel e celulose para a produção de materiais vitrocerâmicos

Authorship SCIMAGO INSTITUTIONS RANKINGS

Abstract

Recycling has been pointed out as an alternative to the disposal of waste materials in industrial landfills. In the present study, the transformation of residues (discarded foundry sand - DFS, grits, and lime mud) in glass-ceramic materials is shown. The glasses were obtained by the melting/cooling method. The precursor materials, glasses, and glass-ceramics were characterized by X-ray diffraction (XRD), X-ray fluorescence (XRF), and differential scanning calorimetry/thermal gravimetric analysis (DSC/TGA). The glassy materials were milled, pelleted, and thermally treated at the crystallization temperatures given by DSC data to obtain the glass-ceramics (885, 961, and 1090 ºC). The main formed phases were cristobalite, α-wollastonite (parawollastonite), and β-wollastonite (pseudowollastonite). The glass-ceramics showed very low water absorption and apparent porosity (0.26 to 0.88 wt% and 0.66 to 1.77 vol%, respectively). The results confirmed that the studied residues can be used as raw materials for the manufacture of vitreous and glass-ceramic materials.

Keywords:
DFS; grits; lime mud; glass; glass-ceramic

Table I Compositions of the two mixtures to prepare the frits.

Glass	Composition (wt%)
A	70% DFS-20% grits-5% Na₂O-5% Al₂O₃
B	70% DFS-20% lime mud-5% Na₂O-5% Al₂O₃

Table II Results of particle size analysis (retained fraction) of precursor wastes.

Sieve (mesh)	Opening (mm)	DFS (wt%)	Grits (wt%)	Lime mud (wt%)
4	4.760	9.42	0.00	0.06
8	2.380	4.91	2.10	0.66
16	1.190	1.34	25.30	0.64
30	0.590	0.62	37.90	0.53
50	0.297	24.90	11.90	0.98
100	0.149	53.70	9.07	10.90
200	0.074	2.54	8.89	46.10
<200	<0.074	2.57	4.83	40.20

Table III Results of semi-quantitative chemical analysis (wt%) of precursor wastes by XRF spectrometry.

Oxide	DFS	Grits	Lime mud
CaO	0.20	55.80	55.00
SiO₂	95.40	0.90	0.20
Al₂O₃	0.60	0.70	0.10
P₂O₅	<0.10	0.60	0.50
Na₂O	0.10	0.60	0.50
MgO	0.10	0.30	0.30
SrO	-	0.30	0.30
SO₃	<0.10	0.20	0.10
Fe₂O₃	1.00	0.10	0.10
K₂O	0.10	<0.10	<0.10
TiO₂	<0.10	-	-
ZrO₂	<0.10	-	-
LOI	2.50	40.40	43.10

Table IV Results of semi-quantitative chemical analysis (wt%) of glasses A and B by XRF spectroscopy.

Oxide	Glass A	Glass B
SiO₂	69.40	70.10
CaO	18.30	17.60
Al₂O₃	5.41	5.43
Na₂O	5.02	5.21
Fe₂O₃	0.65	0.68
SO₃	0.62	0.59
SrO	0.39	0.13
TiO₂	0.06	0.07
MnO	0.04	0.04
K₂O	0.03	0.06
PdO	0.02	0.03
ZrO2	0.02	0.02
CuO	0.01	0.02
Ag₂O	0.01	0.01
ZnO	0.01	0.01

Table V Water absorption, apparent porosity, and apparent specific gravity for glass-ceramics A and B.

Glass-ceramic	Water absorption (wt%)		Apparent porosity (vol%)		Apparent specific gravity(g/cm³)
Glass-ceramic	Minimum value	Maximum value	Minimum value	Maximum value	Minimum value	Maximum value
A	0.26	0.88	0.66	1.77	2.00	2.50
B	0.33	0.40	0.71	0.97	2.08	2.49

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