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Article history: In order to enhance the use of environment-friendly materials and to stimulate waste recycling, this work
Received 20 January 2011 has developed brown-maroon inorganic pigments belonging to rutile (TiO2 ) and perovskite (CaTiO3 )
Received in revised form 13 April 2011 structures. They were obtained by solid state reaction of industrial residues mixtures: tionite (i.e. insol-
Accepted 9 May 2011
uble residue of titania slag processing), Cr/Ni plating sludge and marble cutting/sawing sludge, for sake
of comparison, analogous formulations were prepared by using reagent-grade precursors. Chromium-
Keywords:
doped (0.04 mole of Cr2 O3 ) perovskite and rutile pigments were obtained at 1200 ◦ C and their phase
Sludges
composition, microstructure, optical properties and technological behaviour were characterized by XRD,
Pigments
Chromium doping
SEM, DRS and application in glazes, respectively. The presence of impurities (e.g. Fe, Ni, Al, Si) in the wastes
Perovskite induced the crystallization of secondary phases, like wollastonite (CaSiO3 ) and titanite (CaTiSiO5 ), whose
Rutile occurrence slightly shaded off the final colouration of the waste-based pigments; a further addition of
chromium is required to improve their colouring power in transparent glazes. The diffuse reflectance
spectroscopy shows that the colour development, in both structures, is due to the partial substitution of
titanium by chromium in octahedral coordination.
© 2011 Elsevier B.V. All rights reserved.
1. Introduction can be utilized. Among Ti-bearing phases, rutile, TiO2 , and per-
ovskite, CaTiO3 , are promising structures which exhibit a brownish
Incorporated in glazes for wall and floor tiles or in unglazed colouration by doping with chromium, that can be tuned by further
porcelain stoneware, the ceramic pigments market is growing with addition of a counterion (W, Mo, Sb, Nb) to maintain the electrical
the huge production of ceramic products. As brown pigments, charge balance [19].
the most used are based on hematite (DCMA 3-06-7) manganese The perovskite structure, with the general formula ABO3 , is
chrome antimony rutile (DCMA 11-46-7) and spinels (DCMA 13- built by a network of corner-linked BO6 octahedra and encloses
33-7, DCMA 13-37-7, DCMA 13-38-9, DCMA N. 13-48-7, DCMA large cavities that accommodate the A-cations [20,21]. For tita-
N. 13-51-7) [1,2]. The last two incorporate some toxic elements nium dioxide, different polymorphs are found in nature: brookite
(Co, Ni, Cr, Nb, . . .) that could be minimized or simply avoided by (orthorhombic symmetry), rutile and anatase (tetragonal symme-
investigation of new formulations, involving also technological and try) [22,23]. The rutile structure is based on six oxygen atoms
economic concerns. surrounding each Ti ion, then forming tetragonally distorted TiO6
The use of industrial wastes as raw materials for the formula- octahedra [23,24]. In this work, both perovskite and rutile struc-
tion of brownish ceramic pigments based on titania is assessed with tures are explored as inorganic pigments, using industrial wastes
the aim to improve the environmental sustainability of pigment as raw materials (or reagent-grade precursors as control), by inves-
production by recycling hazardous residues. Such investigation is tigating their structural and chromatic development as well as their
within a research programme on waste-based ceramic colourants colouring behaviour in ceramic glazes.
[3] that already concerned the following structures: spinel [4,5],
malayaite-titanite [6,7], and hibonite [8,9]. It follows a general
2. Experimental procedure
interest in the literature on the valorization of heavy-metal bearing
residues into high added value products [10–14].
Calcite (Calcitec), chromium (III) oxide (Riedel-de Haën), and
In the ceramic industry, brown pigments are mainly spinels
titanium dioxide (Kronos) were the reagent-grade precursors used
[15], but also rutile [16], perovskite [17], and pseudobrookite [18]
to prepare Cr-doped perovskite (PP) and rutile (PR) pigments. The
Cr2 O3 /TiO2 molar ratio was fixed equal to 0.04 (Table 1). The
pigments synthesis followed a conventional ceramic route. The
∗ Corresponding author. Tel.: +351 234370250; fax: +351 234370204. mixture of precursors was homogenized by ball milling (60 min),
E-mail address: w.hajjaji@ua.pt (W. Hajjaji). dried at 100 ◦ C (24 h) then calcined in an electric kiln (Termolab) at
1385-8947/$ – see front matter © 2011 Elsevier B.V. All rights reserved.
doi:10.1016/j.cej.2011.05.021
W. Hajjaji et al. / Chemical Engineering Journal 171 (2011) 1178–1184 1179
Table 1
Chemical composition of precursors and batch formulations of pigments.
the maximum temperature of 1200 ◦ C (5 ◦ C/min heating rate and interval 2 nm), using BaSO4 white as standard. These methods were
3 h dwell time). The fired powders were manually ground and their also applied to a lead-free transparent bright glaze (SiO2 , Al2 O3 ,
particle size distribution was determined by a Laser Coulter LS230 B2 O3 , CaO as main constituents >8%, 2–8% Na2 O, and <2% K2 O)
granulometer. Analogous formulations (SP and SR) were replicated coloured with the perovskite or rutile pigment, which was added
by using industrial wastes: (i) marble sawing sludge, (ii) Cr/Ni gal- to the glaze (1/20 weight ratio), homogenized and pelletized, then
vanizing sludge and (iii) tionite, whose compositions are reported fired at 1050 ◦ C (5 ◦ C/min heating and cooling rate and 30 min dwell
in Table 1. In favour of comparison, the last sludge (tionite), under time).
the code T1200, was also calcined separately following the same
cycle. 3. Results and discussion
The pigments were characterized by quantitative phase anal-
ysis (XRPD, D8 ADVANCE, fast detector LynkEye Bruker AXS, 3.1. Pigment synthesis
Germany) under the following conditions: CuK␣ radiation in the
10–80◦ 2 range, scan rate 0.02◦ 2, 185 s equivalent per step. Differences in the thermal behaviour between PP and SP are
The quantitative phase analysis was performed using GSAS-EXPGUI detected at low-grade temperatures (<400 ◦ C). TG curves illustrate
software following RIR (Reference Intensity Ratio) and Rietveld a mass loss reaching 15% in waste based mixture related to dehy-
refinement techniques [25–27]. Each X-ray powder diffraction dration reactions. PP and SP show a large endothermic peak (Fig. 1),
pattern consists of approximately 5500 data points and 400 at about 850 ◦ C, due to decarbonation of calcite in both the pure
reflections. Up to 40 independent variables were refined: phase reagent and the marble sawing sludge (25% weight loss in the TG
fractions, zero point, 15–20 coefficients of the shifted Chebyschev curves). Minor effects on the DTA curve are observed at temper-
function to fit the background, unit cell parameters, profile coef- atures higher than 1000 ◦ C, but no mass changes on the TG curve
ficients (one Gaussian, Gw, and one Lorentzian term, Lx). The were registered; they probably stem from the reaction of rutile with
agreement patterns, as defined in GSAS, were found in the fol- calcium oxide to form perovskite [28]. These effects are less visible
lowing ranges: 9.0% < Rp < 13.0%, 13.0% < Rwp < 16.5%, 6.0 < 2 < 11.0, in the SP formulation (Fig. 1). In the waste-based compositions, the
and 11.0% < R(F2) < 15.0%. The experimental uncertainty of phase SO2 evolution was expected due to incomplete decomposition of
amount quantification is 5%. sulphates above 1200 ◦ C, as suggested by the weight loss registered
A scanning electron microscope (SEM, Hitachi, SU 70) equipped on TG. This reaction may be partially hidden by the exothermic
with XRF-EDS microprobe (Bruker AXS, software: Quantax) was peak related to the perovskite formation (on DTA). The volatiliza-
used to assess the microstructure and composition of pigment tion of some sulphur oxide is not novel in the industrial practice,
particles. Inductively coupled plasma emission spectrophotome- because the pigment synthesis is usually promoted by mineralizers,
try (ICP) was carried out by a Horiba Jobin Yvon (Activa M model) i.e. mostly alkaline and alkaline-earth halogenides and sulphates
equipment to verify the chemical composition of pure obtained [2,15], so that flue gas scrubbers are already in operation on kilns.
pigments. The analytical solutions were obtained by microwave In the PR mixture, the total weight loss is less than 2% and it is
assisted acid digestion. Their thermal behaviour was investigated basically due to the release of physically adsorbed water. On the
by DTA and TG simultaneous analyses (in air, 10 ◦ C min−1 heating DTA curve, the peaks occurring above 900 ◦ C are probably related
rate) performed on a Setaram apparatus. to the anatase-to-rutile transition, which allows the chromium
The L*a*b* [L*: 0 = black/100 = white, green (−a*) to red (+a*) insertion into the lattice [29]. In contrast, the SR mixture under-
and blue (−b*) to yellow (+b*)] chromatic parameters, measured went to significant transformations upon heating, mostly caused
by a Konica-Minolta Chroma Meter CR-400 (D65 illuminant and by decomposition of hydroxides (around 300 ◦ C) and sulphates
10◦ standard observer), were used to quantify the colour charac- (around 1100 ◦ C) contained in the tionite sludge. The respective
teristics of the pigments. The colouring mechanisms were studied weight loss measured up to 500 ◦ C reached about 15%; and is close
by UV–Vis–NIR absorption spectroscopy (Shimadzu UV-3100, step to 7% between 1000 and 1200 ◦ C.
1180 W. Hajjaji et al. / Chemical Engineering Journal 171 (2011) 1178–1184
Fig. 2. XRD results observed (+), calculated (line) and difference (below) for pigments.
chromium-doped rutile pigments denote lower brightness (L*) and characteristic of Cr-doped rutile [19]. The first two bands are
red component (+a*), when compared with perovskite, even if the due to the sixfold coordinated Cr3+ transitions 4 A2g → 4 T2g (F) and
resultant colour for both PR and SR pigments is a dark brown. The 4 A → 4 T (F) [7], leading to crystal field strength and a Racah
2g 1g
brightness (L*) and yellow component (+b*) of the SR pigment are B parameter values that are slightly lower than in Cr-doped per-
approximately twice of the PR ones and a green component (−a*) ovskite (around 16,900 cm−1 and 460 cm−1 , respectively). As in the
arises. In SR, the titanite, being present as the second major phase case of perovskite, the occurrence of Cr3+ in substitution of Ti4+
(29 wt.%), is responsible for the strong deviation from the PR col- implies a mismatch of the electrical charge of the rutile structure,
orimetric values. In fact, chromium bearing titanite also develops that is thought to be balanced through oxygen vacancies, already
a brown colour, but its hue is less intense than that obtained now known in the literature for doped rutile [42,43]. The UV–Vis–NIR
for Cr-doped rutile [7]. spectra denote relevant discrepancies between PR and SR pigments,
The optical spectra of rutile-based formulations (Fig. 7) exhibit, concerning the absorbance level, in the red region of the visible
in the visible region, three bands at about 460 nm (∼21,700 cm−1 ), range, as already observed and discussed for L*a*b* parameters.
590 nm (∼16,900 cm−1 ) and 680 nm (∼14,700 cm−1 ) which are The optical spectrum of the SR pigment is analogous to that of tion-
ite calcined at 1200 ◦ C (Fig. 7 and colour coordinates in Table 3);
this is not surprising since the tionite sludge represents ∼98 wt.%
of the SR pigment composition. Impurities, such as iron (∼3 wt.% in
the sludge), may justify the colour deviation, as the Fe-doped rutile
also develops a similar brown colouration [17].
When used to colour the transparent glaze, pink-brown or
orange-brown shades are obtained with perovskite and rutile,
respectively (Fig. 8). The mentioned colorimetric differences
Table 3
L*, a* and b* colorimetric values of pigments and transparent glazes.
L* a* b* L* a* b*
Fig. 4. SEM micrographs and EDS, ICP quantitative analyses of pigments prepared from pure-grade reagents (PP and PR).
between G-PP and G-PR are also easily noticed, especially in terms
of brown shade. The brightness shown by the glaze is rather stable
and close to that developed by the pigments, but red and yellow
components tend to increase in the coloured glaze. This improve-
ment is more significant when PR is used (see Table 3).
The use of waste-based pigments to colour of the transpar-
ent glaze results in distinct features. SP is stable in the glaze and
the changes on L*a*b* coordinates between the pigment and the
coloured glaze are small. However, the use of SR tends to increase
considerably the yellow component (+b*), as shown in Fig. 8 and
Table 3. This tendency is similar to that obtained with T1200. This
change is caused by both the presence of secondary phases in the SR
pigment, such as titanite and wollastonite, and the impurities pro-
vided by residues, especially Ni and Fe. At this stage, the secondary
phases present in SP and SR pigments apparently did not react with
Fig. 5. Particle size distribution of the pigments after calcination. the glaze, as suggested by the diffraction patterns of glazes (Fig. 9).
Similarities in the pattern’s framework of pure (GPP and GPR) and
waste based (GSP and GSR) products are noted. This is a good point
Fig. 6. Optical spectra of Cr-doped perovskite pigments. Fig. 7. Optical spectra of Cr-doped rutile pigments and of calcined tionite.
W. Hajjaji et al. / Chemical Engineering Journal 171 (2011) 1178–1184 1183
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