Ceramic mass for majolica article production

IPC classes for russian patent Ceramic mass for majolica article production (RU 2278088):

C04B33/24 - Manufacture of porcelain or white ware

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Ceramic mixture comprises 70-=90% clay and 10-30% cobalt concentration tails characterized by bulk density 900 kg/m³, density 2700 kg/m³, fire resistance 1200°C, mineralogic composition including orthoclase, quartz, carbonates, clay minerals, and ferrous compounds, and following chemical analysis, wt %: SiO₂ 32.72, Al₂O₃ 9.33, Fe₂O₃ 10.00, CaO 15.47, MgO 12.01, R₂O 2.30, and calcination loss 17.80.

FIELD: ceramic article production, compositions for majolica article production.

SUBSTANCE: claimed mass contains (mass %): waste from recovery of cobalt concentrate 20-30; tile 5-10; clay 60-70. Reject materials from recovery of cobalt concentrate has bulk mass of 900 kg/m³, density of 2700 kg/m³, and refractoriness of 1180°C.

EFFECT: majolica articles of decreased water adsorption and increased heat stability.

4 tbl

The invention relates to the production technology of ceramics, and in particular to compositions for the manufacture of majolica ware, decorative, domestic and household purposes.

Lime ceramic material for the manufacture of majolica products (A.S. No. 893956), including clay (wt.%) - 30-33, quartz sand - 5-15, nepheline-syenite - 20-25, kaolin - 6-8, skull - 1-10, fireclay - 10-25 and cullet - 7-10. The disadvantage of this mass is that products on its basis have insufficient heat resistance (total of 4 cycles). Great content marshes (contents of broken glass, nepheline-syenite 27-35%) is the tendency of the mass to the strain.

Other ceramic mass (A.S. No. 1196358)containing (in wt.%) 74-82 - clay, 8-10 - chamotte, 1,5-4 - skull, 1-3 quartz sand, 1-2 - broken glass, 2-4 - nepheline-syenite, 2-5 - dolomite, not possible to get the majolica ware high temperature resistance (6 cycles). In addition, the weight has a high firing temperature (980° (C) and contains expensive raw materials such as clay, quartz sand and dolomite, which increases the cost of production.

The closest analogue to the present invention is the weight for the manufacture of majolica products, including clay (wt.%) - 50-70, quartz sand - 10-20, fireclay - 10-20, limestone - 3-15, waste titanium enamel - 5-25% (A.S. No. 1021674). The disadvantage of this mass is that of the product after firing at the high temperatures (T=980-1000° C) they have high water absorption of 13-14%. When the temperature of the products of 6-8 cycles. The high content of quartz sand causes a crash cooling.

The problem to which the invention is directed, is the reduction of water absorption and increase thermal stability majolica products.

The essence of the invention lies in the fact that the ceramic material for the manufacture of majolica products, including clay, skull and tailings, characterized in that as tailing it contains the tails of the extraction of cobalt concentrate in the following ratio of components mass (wt.%): clay - 60-70, skull - 5-10, tails extraction of cobalt concentrate 20-30.

By-products of the extraction of cobalt concentrate are it is a gray powder. Volume weight - 900 kg/m³the density is 2700 kg/m³. The temperature of the fire 1180°C. In the mineralogical composition consists of orthoclase, quartz, carbonates, clay minerals and ferrous compounds. The chemical composition of the tailings extraction of cobalt concentrate is given in table 1.

Table 1
Oxide content (wt.%)
SiO₂	Al₂O₃	Fe_{2 O₃}	CaO	MgO	To₂About	n.n.n.
32,72	was 9.33	10,02	15,47	12,01	4,50	15,60

The chemical composition of the tailings extraction of cobalt concentrate is presented as a natural mixture of marshes known as the nepheline-syenite, broken glass and dolomite.

Introduction to the composition of the paste tailings extraction of cobalt concentrate will reduce water absorption and to increase thermal stability of the products, as well as to reduce the temperature of firing.

As the clay component adopted the fusible szeminska clay (Republic of Tuva) with temperature fire resistance 1210°C. mineralogical basis, this clay is hydrologist-kaolinites. Table 2 shows the chemical composition of Seminskiy clay.

Table 2
Oxide content (wt.%)
SiO₂	Al₂O₃	TiO₂	Fe₂O₃	CaO	MgO	To₂O	Na₂O	n.n.n.
61,22	18,24	0,98	7,68	0,60	2,58	2,16/td>	1,55	4,92

Crock presents substandard products brick on the basis of Seminskiy clay.

The invention is carried out as follows.

Mass (slurry) was prepared by a joint grinding dosed components of the mixture and water in a ball mill until the residue on sieve No. 0063 1%. The moisture content of the finished slip 41-42%. The fluidity of the slip 5. The product was cast in plaster molds. After drying, the product was annealed in an electric furnace. Temperature specific firing 920°and the temperature watered firing 940°C. Items were covered fitovinany glazes irrigation practices and comminution. The glaze had the following chemical composition, wt.%: SiO₂- 64,8;₂On - 18,4; Al₂About₃- 4,9; ZnO₂- 1,2; BaO - 0,7; CaO - 1,4;₂On - 3,9; Na₂O - 4,7.

Table 3 presents the charge composition of the masses. In compounds 2-4 are given the optimum ratio of components in compositions 1 and 5 are given their exorbitant value.

Table 3
Components	Non compositions and Content, wt.%
1	2	3	4	5
Clay	75	70	65	60	60
Chere is n	10	10	7	5	5
Waste extraction of cobalt concentrate	15	20	25	30	35

Table 4 shows the properties of the obtained products.

Optimal formulations 2-4 accepted on the basis of the following positions. With the addition of 15% of the proposed waste received majolica products have high water absorption (13.4 per cent) and insufficient thermal stability (8 cycles)as equivalent. With the increasing content entered additives more than 30% (composition 5) crock with specific firing heavily baked and becomes more dense. As a result, when applying the glaze last poorly absorbed in the body.

The test results showed the effectiveness of the introduction of the proposed additions in the amount of 20-30%. Exactly at the specified content of the waste extract cobalt concentrate composition weight, achieved by reducing water absorption and increase thermal stability of the products. Reduced water absorption is ensured due to the formation of a certain quantity of liquid glass rim in the reaction between the components of the clay and the proposed additions during heat treatment. Steklovata more refractory cement particle mass and correspondingly reduces the internal volume of micropores.

High thermal stability of the obtained products is ensured by the formation of a dense and optimal structure, in which participated magnesium, calcium and iron spinels crystallized during sintering of the ceramic material. Spinel-based selectionne oxides (RO) always have a low coefficient of linear thermal expansion.

Compared with analogue, the proposed lot cheaper, as it doesn't contain expensive components such as clay, silica sand and limestone.

The application of the proposed ceramic material allows you to:

- get majolica products with low water absorption and high heat resistance;

to reduce production costs through the use of waste products, which do not require further technological processing;

- dispose of waste production;

to prevent environmental pollution.

Ceramic material for the manufacture of majolica products, including clay, skull and tailings, characterized in that as tailing it contains the tails of the extraction of cobalt concentrate, characterized by a bulk density of 900 kg/m³density of 2700 kg/m³, refractory 1180°, mineralogical composition, including orthoclase, quartz, carbonates, clay miner is s and ferrous compounds, chemical composition, comprising (in wt.%): SiO₂- 32,72; Al₂O₃was 9.33; CaO - 15,47; MgO - 12,01; R₂O - 4,50; PPP - 15,60 in the following ratio of components, weight, wt.%:

Clay	60-70
Skull	5-10
Tails extraction of cobalt concentrate	20-30