Study the feasibility of using natural stone polishing residue in porcelain

ABSTRACT

Porcelains are multiphase ceramics produced from natural raw materials and used in manufacturing a wide variety of products. This study aimed to verify the feasibility of the total and partial replacement of feldspar present in the formulation of porcelain by ornamental stones residue coming from the polishing process of a medium-sized company. The materials selected were comminuted in the wet ball mill and subsequently sieved through 80 mesh Fluorescence X-ray analysis, scanning electron microscopy and also particle size distribution were made. They were formulated four compositions by varying the amount of residue replacing feldspar. In these samples the particle size distribution analyzes were performed and subsequently the samples were pressed and sintered at temperatures ranging from 1100 to 1250°C in resistive electric oven for 2 hours. The porcelains characterizations were made by apparent porosity, water absorption and apparent density by the Archimedes method; mechanical resistance measurements were also performed made by bending at three points; X-ray diffraction for the analysis of the phases, and scanning electron microscopy for microstructural analysis. The results showed that it is feasible to replace the feldspar for ornamental rocks polishing residue, since the physical properties of the porcelain as water absorption and mechanical strength and are slightly changed. Furthermore, the addition of residue reduces the sintering temperature, however, it is necessary to have greater control of this temperature in the production process due to the lower firing range.

Keywords:
porcelain; ornamental stones residue; feldspar