Aluminum Rich Sludge as Raw Material for the Ceramic Industry A.P. Novaes de Oliveira, V. Gomes, D. Hotza, O.R.K. Montedo, R. Piccoli, F. R. Perei Temenos, A ti Pte Noes de Ot vs cine dapcin Aly fa TT viel ini Susan he ara wok ot the Fede Un very ofS Corn n FlovonolisSC. oth ane ie fe fal Egosing bet isemogel upton Du ing hispid iid «dag in echnical Engin (1990) ada Nase Mech Eo inn (193) fam te Sone insta Fam Sage 191 ol 199 heated spe clan couse ented Aplin eink ih emperor er tes edb he pan Ineo ation Agency (IA) in Nogoy (apn) in 198, hes eis PhD. fom te Un ves na a). Sine Nach 2001 he os been raft ente cof fates Technology (SENAI/TCnat in Ce ci zl isu Press oth Fels Unites of Sarat ‘in Voted Gomssis Ph.D. stuleat and Dochamir Homi sac Profesor Sania Caine Fea niesy Bail Oscar Ruben Hlgurs ante is Senin R= seater Sc} od PhD. stent Resa ial Reseach Engines ond Se set nana Rug eins esc (Scand PhD. se cn SENA-IGt, Bi 44 ae The manufacturing and material tronsformation industries ‘generate, to a greeter or lesser degree, amounts of wastes ‘which are not always re-used or even hove a correc! eco logical destination. In many cases, these secondary products ‘can be direcly re-used or exploited as a basic raw material in other industrial processes. In this context, this work briefly presents aspecs related to choracterisics and applications 6f wastes [aluminum-rich sludge} resulting from the alu- ‘minum anodizing processing. in parlicular, # emphasizes the potenticl and evan the possibilty of applying this woste ‘sa raw material for the ceramic industry to produce ceramic components. KEYWORDS: ceramic, clumino, waste, aluminum sludge, recycling 1 Introduction Due to the necessity of stiking a balance between consuming ‘ond conserving energy and environmental resources, the re-use of materials ploys relevant len both reducing the consumption of natural raw materials and in diminishing indiscriminate pollution. e-using makes bosic raw material production match the rate of consumption of products ond services with society. In the industrialized world, the devel- ‘opment of new technologies, processes and producs is constant. In recent years, processes that are related to both the necessity of production end the search for preserving the environment have been emphasized [1-2]. Nowadays, the market in general is based on principles strongly related to competitiveness. In the field of ceramic production, competitiveness is a worldwide reality that involves technical aspects, i.e. to optimize production pro- ‘cesses ond io rafionaiize aspects regarding work ond human behaviour Inthis case, wastes from material processing hos been the focus of many researchers since is use as ¢ row moterial can enhance ceramic manufacturers’ competi- tiveness on the market. In fac, Fone considers the products ‘onthe market, cll of them, to 0 greater or lower degree, show losses associated fo their production. Therefore, final prices have a tendency to increase since these associated losses are proportionally divided into the product final prices (2) In this context, itis very important fo pursue the development ‘of research works that observe the use of wastes, faking under consideration thet these pollutants os important raw materials for noble applications with higher aggregated value csiming at their transformation for the benefit of society 0s wall as environment protection, The objective of his work is mainly to present the state-of the-ort on using wastes (aluminum-rich sludge) from alu- minum enodizing a: raw material o produce ceramic com- ponenis, through dota evcilable in literature, aswell as to ‘accomplish its preliminary characierizotion, Aluminum anodizing is an electrochemical method of con- ‘ering luminum nto oluminum oxide (AsO) al he surface ofthe component being cooted. This processes iso commonly used technique fo provide the surface with high corrosion cand abrasion resistance. Ii also allows achieving some ‘esthetic effects such as colouring, yet maintaining the standards set in the original design [3-4]. This process generates large amounts of sludge, consisting mainly of aluminum hydroxide (up to 87 %), sodium or calcium (from neutralization solutions) and aluminum sulfate {used as floccvating agent} as minor consituents and water itis classified as « non-toxic waste but, duet the quantities produced and the dificuly in reducing is volume, this sludge requires high csi for ronsporing and disposing itn andl Onthe other hand, he high alumina contents present in this calcined waste andthe constancy in ts composition mokes this waste very attracive for recycling processes, for example, the processing of materials based on clumina or its in- corporation in other products. In his last case, many materials have been investigated with respect fo inertization in the cement matrix, glass and ceramic [5-6} Iris known that aluminas an important raw material forthe ceramic industry, used for the production of glasses, re- fractories, crucibles, etc, When alumina is added to glass, it ‘enhances both mechenical srengih and refractoriness ofthe resulting material [7]. 2 Using Wastes in the Ceramic Industry The necessity of he market to achieve new ceramic products with beter functional properties has remarkably simuloted research into the use of low-cost materials. In recent years, there have been mary studies which enalyse the possibil of recycling © variely of industrial wastes. Mony of these demonstra the importance of recycling for environmental protecion and technological development Using wastes in ceramic industries can be made possible by the subsitufion of one or more row materials from the origi- ‘nal composition, thus maintaining the same processes which are used for conventional production in order to reproduce the original properties (1-2, 8] Different kinds of industrial wastes such as blast furnace, chamotte, steelwork slag and fly ash have been used, ac- cording to recent research works [9-14], o produce gloss and glass-ceramic materials. 2.1 Using Aluminum-Rich Sludge for the Production of Ceramic Components ‘There are few studies about aluminum rich sludge, parti- cularly in Brozil, due to its treatment operations and to difculiesin developing a suitable processing technology. Interceram + Vol. 52+ No. 1, 2009‘Many research works have shown the efficiency of using this waste os raw moterial, lone or combined with traditional cones, fo produce ceramic components, presenting technol- ogical properties of great interest with electrical and me- chonical resisiance and refractoriness. Production dota were obtained initially from two industries locoied in Sonia Catarina state (Broz). The production of cluminurich dudge rom heseindusies are3 and 150t/month of waste, respectively. thas been verified thot, currently the final destination of hese wostesis their deposiioninindusriol landfills, resulting in costs for transportation and neuirelizing this woste ‘The preliminary analyses of the residues (aluminum-rich sludge) were performed by X-ray diffraction (XRD) using Ni- filtered CuKo radiation in the 5-B5° 2q angle range, wave- length-dispersve fluorescence spectrometry (XRF), diferen- fil hermol analysis (OTA), thermal gravimetric analysis TGA} nnd laser light scatering analyser for paricke size distribution ‘measurements in previously dried samples at 120°C for 24h}. ‘The moisture content determined on drying samples ct 120°C. for 24 h varied in the range 72-80 mass-%. The average chemical composition ofthe cluminum rich sludges shown in Table 1. From Table 1 it can be seen thot wastes are composed basicaly of clurnina. XRD analysis reveals the single presence of aluminum hydroxide, according o Fig. 1 DIA/TGA curves are shown in Fig. 2. According to Fig. 2, removal of moisture and decomposition reacions are denoted by the lowerweight changes up to cbout 600°C and between 600 and 1100 °C on TGAcurve, DTA curve shows a strong endothermic peak thot occurs up to about 200°C that may correspond the decomposition of aluminum hydroxide. As referred to in the literature, the aluminum hydroxide is decomposed in alumina between 200-250°C. Particle size distriaution, showing he data in the usual forms ofthe cumulative curve and the distributive histograms [Fig 3}, indicates that waste I shows 6 parce size distribution behveen 0.5 ond 50 mm while wast between 0.5 and 30 mm, This portcle size distribution is of fundamental importance in increasing the green material density ond consequently in improving the reactvily of particles. 3 Final Considerations Using waste from aluminum anodizing processes asthe min ‘component in formulating ceramic bodies can be cn im- portant alternative of recycling. The alumina content and compositional constancy makes waste a row material source in many applications in the treditional ceramic industries such as ceremic products shaped by pressing, slip casting or extrusion, Upto now, few research works hove been corried oul using this wasie 0s raw material. is necessary o develop oppro- 1] V. Gomes: Obtengao de material vtrocerémico wll aando escéria da aciaria. Master Thesis, Universidade Federal de Sonta Caterina, Florianépolis/SC- Brazil, 1999 [2] AP Novoes de Oliveira, ©. Estevan Alarcon: Vitracerémicos: Caracterisiicas, propriedades @ opi cages industricis, Cerdmica Informacdo (1998) [1] 35-92 Interceram + Vol. 52+ No, 1, 2008 Xctay difeation of aluminum anodizing wastes: Fig. 2 Simultaneous DTA/TGA curves for: a} waste sample; 6) waste sample i setae Fig.3 Price size disribuion of 0) waste somple :b) waste sample oe Chemical analysis of the aluminum anodizing ‘Waste sample | ‘Censlivente priate processing technology for its transformation o available raw moterial for use. [3] Olga Color SPA: Anodizagdo de luminio, ‘worw.olgaclorspa.com.br [4] PF Silva: Introdugéo @ corraséo € protecéo dos superficies metélicas, Belo Herizorte, imprensa uni- versitéria UFMG, 1981 [5] MJ. Ribeiro, D.'U. Gonoy J. M. Ferreira, J. A. Lo brincha: Recycling of Al-Rich Industrial Sludge in Refractory Ceramie Pressed Bodies, Ceramics Inter- 4546 nnofionel 28 (2002) 319-226 [6] LM. Ferreiro, S. M. Olhero: OF Al-Rich Sludge Treatments towards Recycling. J. ECerS; ariicle in press, ww.elzevier.com/locete/jeurceramsoc [7] 1S. Reed: Introduetion te Principles of Ceramic Processing. New York: John Wiley, 1988 [8] G. Scarinci, G. Brusantin, et ol: Vilfication of Industrial and Natural Wastes with Production of Glass Fibers, J. ECerS, 20 (2000) 2485-2490 [9] FG.daRose, M. Folgueras,A.L. Longo, A. Cechenel, ‘A.B Novaes de Oliveira, D. Hotza, O. £. Alarcon: Caracterizactio de Residuas Industrials pora Uso nc Composigio de Massas Cerdmicas, 43 Congresso Brasileiro de Cerémica, Florianépolis-SC, Brezil, 1999 [10] MV Folgueras, J.P Marana Faijdo, A. P Novoes de Oliveira, O. E. Alarcon: Obtengéo de Motericis Vitrocerémicos « Parr de Escérias de Alio Forno Ginzos Volontes. 43 Congresso Brasileiro de Ceramica, Floriandpolis-SC, Bro2il, 1999 [11] M.C. Casagrande, A. P Novaes de Oliveira, D. Hotza, LR, Alexandre: Recycling of Solid Wastes in the Production of Ceramic Floor Tiles. Proc. of the Vil World Congress on Ceramic Tile Quality QUALICER 2002, Casellén (Spain) Vol. Il, pp. 39-46 [12] M.¥. Folgueras, J.B Marana Feijao, A. P Novaes de Oliveira, O. E. Alarcon: Obtencéo de Vidros e Vitro- Cerémicos « Partir de Residuos de Silicatos. Parte | Comportomento Durante a Cristalizacao. Cerém. Inf (1999) [2/3] 51-55 113] FG. da Roso, M. V. Folgueras, A. L. Longo, A. Chachenel, A. B Novaes de Oliveira, D. Hotza, O. E Alaccon: Caracterizagae de Residues Industrials para Uso na Compasicao de Massas Cerémicas. Cerdm, Inf, (2000) (8} 30-34 [14] FG. da Rose, M, V, Folgueras, AL. Longo, A. Chechenel, A. & Novoes de Oliveira, D. Holza, O. €. Alarcon. Caracterizagéo de Resfduos Industriais para Uso na Composigéo de Mossos Cerdmicas. Tile & Brick 18 (2002} [1] 20-23 Received: 21.10.2002 Antonio Pedro Novaes de Oliveira, Oscar Rubem Klegues Montedo, Rosaura Piccoli, Fabiano Raupp Pereira SENAI/CTCmat, Centro de Tecnologia em Materiais, Cricidma/SC, Brazil e-mail: pedronovaes@ctc.org.br Vaneide Gomes Departamento de Engenharia Mecénica, Programa de Pés-Graduacéo em Ciéncia © Engenharia de Materiois, Universidade Federal de Santa Catarina, Florianépolis/SC, Brazil Aluminiumreicher Schlamm als Rohstoff far die ke- ramische Industrie Die herstellenden und Moteriol verarbeitenden Industrien erzeugen im gr®Beren oder kleineren Umfang Mengen an Abiallen, die nicht immer wieder verwendet werden oder sogar eine korrekie Skologische Bestimmung haben. In vie~ len Fallen kannen diese Sekundéirprodukte direkt wieder verwendet oder als Basisrohstoff in anderen industriellen Dachamir Hotza Departamento de Engenharia Quimica e Programa de Pés-Graduagéo em Ciéncia e Engenharia de Moteriais, Universidade Federal de Santa Catarina, Florianépolis/SC, Brazil hotza@engq.ufsc.br Verfahren genuiz! werden. In diesem Zusammmenhang wer- den in dieser Arbeit die Aspokie kurz vorgestll, welche die Eigenschatten und Anwendungen von bei der anodischen (Oxidation von Aluminium anfallenden Abféllen (climiniur- reicher Schlomm) betreffen. Besonders hervorgehoben wer- den das Potenzial und sogar die Méglichkeit der Anwen- cdung dieser Abflle ols Rohstoftfir die keramische Industrie, um Keramikteile 2u produzieren. Boues riches en aluminium comme matigres premigres pour I"industrie eéramique Les industries d’éloboration et de transformation des matériaux produisent,& des degrés divers, des déchets qui ne sont pos toujours ré-employés ou recyclés de facon écologiquementcorrecte, Dans denombreuxcos, ces prods secondaires peuvent ire directement ré-employés ou uflisés comme mative premires de bose pour d'autres processus industrels. Dans ce contexte, oricle présente briévement les coractéristiques et les applications de déchets (boues riches en_oluminivm) en provenance diinstolletions donodisation daluminiur. Il souligne en particulier le potentel, et méme la possibilié d'emploi, de ces déchets ‘comme matires premieres de industrie céramique pour la production de composants céramiques. Residuos ricos en cluminio como materias primes para la industria cerémica Lo industria de lo monufactura yla transformacién de mate- fioles produce en mayor o menor grado materiales de residuo {que no siempre son revilizados o tienen una destinacién final compatible con la ecologia. En muchos casos, estos materiales secundarios se pueden reuilizar 0 emplear como ‘materia prima bésica en otros procesos industriales. En este mbito, el articulo presenta brevemente los aspectos relacionados con las caracieristicas y las aplicaciones de meteriales de desecho (suspensiones ricas en aluminio) provenientes del proceso de onodizacion del oluminio. En porticular, se pone énfosis sobre el potencial de oplicacién, de este material como materia prime para producir ‘componentes cerémices. Interceram + Vol. 82+ No. 1, 2003,