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Presented by Dr. T. K. Bhattacharya & S. K. Chakraborty. Govt. College of Engg. & Ceramic Technology 73 A. C. Banerjee Lane, Kolkata-10 INVESTIGATION ON.

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Presentation on theme: "Presented by Dr. T. K. Bhattacharya & S. K. Chakraborty. Govt. College of Engg. & Ceramic Technology 73 A. C. Banerjee Lane, Kolkata-10 INVESTIGATION ON."— Presentation transcript:

1 Presented by Dr. T. K. Bhattacharya & S. K. Chakraborty. Govt. College of Engg. & Ceramic Technology 73 A. C. Banerjee Lane, Kolkata-10 INVESTIGATION ON THE UTILIZATION OF FLY ASH FOR THE DEVELOPMENT OF PORCELAIN CERAMICS.

2 FLY ASH IN 20 TH CENTURY / 21 ST CENTURY Fly ash is an industrial waste material as a by product of thermal power station (annual production 110 million Ton / Annum, Country rank next to China ) The present scenario in 21 st century is that Fly ash is not an industrial waste material but an alternative source of ceramic raw material which can be used to produce value-added ceramic products. Fly ash is an alumino-silicate type of material with an considerable amount of Fe 2 O 3, CaO, Na 2 O, K 2 O as a fluxing materials.

3 FLY ASH BASED PORCELAIN CERAMICS Fly ash is a prefired material containing mullite, Quartz and Glass. The substitution of quartz as well as clay by fly ash due to the composition similarities. The utilization of fly ash is not only solve the hazardous environmental problem but also maintain the proper reserve of conventional ceramic raw materials like clay, quartz etc.

4 APPLICATION OF FLY ASH IN INDIAN SCENARIO

5 APPLICATION OF FLY ASH IN CERAMIC INDUSTRY Whiteware industry Refractory industry Glass industry Glass Ceramics Composite Others

6 TABLE- 1 (CHEMICAL COMPOSITION OF RAW MATERIALS) Compositi on Oxide based (Wt. % ) Rajmahal China Clay Bikaner Ball Clay QuartzFeldspar Sagardighi Plant Fly ash SiO 2 46.3254.3598.4371.6562.82 Al 2 O 3 33.5628.750.6312.8928.64 Fe 2 O 3 1.980.820.111.766.20 TiO 2 0.991.23 — — — CaO0.340.65 —0.581.31 MgO0.48 —0.060.42 — Na 2 O0.480.11 3.19 — K2OK2O0.230.750.129.23 — LOI15.4513.10.480.261.03 % particle pass through 45 micron 100 788253.75

7 XRD OF FLY ASH

8 BATCH COMPOSITION : TABLE-2 (QUARTZ SUBSTITUTED FLY ASH BASED PORCELAIN) Batch No. Wt.% Clay ( Equal proportion of China and Ball Clay) Wt.% Quartz Wt.% Feldspar Wt.% Fly Ash PF0 50 302000 QF05 50 252005 QF10 50 20 10 QF15 50 152015 QF20 50 1020 QF25 50 052025 QF30 50 002030

9 TABLE-3 (CLAY SUBSTITUTED FLY ASH BASED PORCELAIN ) Batch No. Wt.% Clay ( Equal proportion of China and Ball Clay) Wt.% Quartz Wt.% Feldspar Wt.% Fly Ash PF0 50 302000 CF05 45 302005 CF10 40 302010 CF15 35 302015 CF20 30 20 CF25 25 302025 CF30 20 302030 CF40 10 302040

10 MATERIALS PROCESSING (LAB SCALE & TINY SECTOR INDUSTRIAL DEVELOPMENT). Raw Materials : (China Clay, Ball Clay, Fly Ash & Feldspar with proportionate Amount) ↓↓↓↓ Mixing / Wet Grinding in Ball Mill for 10 Hrs. ↓↓↓↓ Slurry ↓↓↓ Drying of the slurry at 110 0 C ↓↓↓↓ Powder ↓↓↓↓ Fabrication Extrusion ( Lab Scale ) Throwing By Potter Wheel( Pilot Plant) ↓↓↓↓ Drying ( at 110 0 C) ↓↓↓↓ Firing ( 1110 0 C, 1150 0 C, 1200 0 C) ↓↓↓↓ Fired Product

11 CHARACTERIZATION OF FIRED BODY B. D A.P Flexural Strength Phase Analysis by XRD Microstructure by SEM

12 BULK DENSITY & APPARENT POROSITY OF FIRED PRODUCT.

13 FLEXURAL STRENGTH OF FIRED PRODUCT

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17 ARTISAN AT WORK ON POTTER’S WHEEL

18 GLAZING

19 LOADING AND GLOST FIRING

20 PRODUCT READY FOR GLOST FIRING

21 FINISHED PRODUCT 1

22 FINISHED PRODUCT 2

23 FINISHED PRODUCT 3

24 CONCLUSION Incorporation of fly ash in porcelain composition is either by partial or full replacement of quartz or by clay. The bulk density and apparent porosity is the function of Fly ash weight percent as well as firing temperature from 1100 0 C to 1200 0 C The optimized percent of fly ash addition in quartz substituted fly ash based porcelain (QP) is 25 weight percent which gives maximum B.D =, A. P = and flexural strength = 52 MPa The optimized percent of fly ash addition in clay substituted fly ash based porcelain (CP) is 20 weight percent which gives maximum B.D =, A. P = and flexural strength = 45 MPa

25 The bisque fired body developed by throwing method ( Potter wheel ) shows almost white vitreous luster and the glost fired body shows fine and polished surface finished with a colour glaze. The main crystalline phases of fired body is mullite together with unconverted quartz detected by XRD analysis The microstructure of the fired sample is the presence of scaly type primary mullite aggregate together with needle shape secondary mullite crystal embedded in glass and few unconverted quartz rim is detected by SEM analysis.

26 ACKNOWLEDGEMENT Principal, Faculties and staffs of Govt College of Engg. & Ceramic Technology, 73 A. C. Banerjee Lane. Mr. Moloy Dutta – proprietor of Terra Art Centre, Dakshin Para More, Harinath Sen Road, Barasat, 24-Prg. (N).

27 THANK YOU…..


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