Recycling and Utilization of some Waste Clays for Production of Sintered Ceramic Bodies

The recycling of industrial waste clays for production of an interesting ceramic product is the main goal of the present research work. Ceramic bodies were prepared using Feeders or Cyclons waste clays, sand and feldspar. 0.0, 15, 20, and 25 wt.% of sand were added at the expanse of kaolin (75-50 wt.%). Constant mass percent (25 wt.%) of feldspar was added for all ceramic compositions. The designed batches were sintered at 1200-1400 degrees C. Physical properties were determined by water displacement method. Phase composition and microstructure were investigated by x-ray diffraction and scanning electron microscope, respectively. The compressive strength was also determined. The results indicated that the ceramic bodies prepared from Cyclons' waste clay exhibited higher physical and mechanical properties than that prepared from Feeders' clay after sintering at 1400 degrees C. The addition of sand enhances the porosity, water absorption, bulk density and mechanical strength after sintering at 1400 degrees C due to the formation of mullite network and glassy phases.