Skip to main content
SpringerLink
Log in

Raw kaolinitic–illitic clays as high-mechanical-performance hydraulically pressed refractories

  • Published:
Journal of Thermal Analysis and Calorimetry Aims and scope Submit manuscript

Abstract

The usage possibility of 19 composites of raw refractory clays from Serbia containing approximately 53.29% of SiO2 and 26.73% of Al2O3 is presented. The sum of fluxing oxides was 57.74%, while these materials contained 32% of quartz, 29% of kaolinite and 26% of illite–mica. Dilatometry tests revealed a sudden shrinkage with the peak at approximately 1115 °C, owing to the formation of mullite. The refractoriness was in the range of 1581–1718 °C, which classifies the composites from low- to high-duty refractories. Based on correlation analysis, the refractoriness mostly depended on the content of alumina. The lightness of the fired test pieces was lower after firing when compared to the dry samples, and it decreased with the firing temperature from reddish to grayish. The study presents a novel attempt to define all the necessary properties of raw refractory clays and products fired at the 1100–1300 °C range on a laboratory level. Most of these clays can be used as natural refractory materials for ceramic and glass furnace lining. The organic matter in some of the samples influences negatively the fast-firing process.

Graphical Abstract

This is a preview of subscription content, log in via an institution to check access.

Access this article

Log in via an institution

Price excludes VAT (USA)
Tax calculation will be finalised during checkout.

Instant access to the full article PDF.

Institutional subscriptions

Fig. 1
Fig. 2
Fig. 3
Fig. 4
Fig. 5
Fig. 6
Fig. 7
Fig. 8
Fig. 9
Fig. 10
Fig. 11

Similar content being viewed by others

References

  1. Pountouenchi A, Njoya D, Njoya A, Rabibisao D, Mache JR, Yongue RF, Njopwouo D, Fagel N, Pilate P, Van Parys L. Characterization of Foumban (West Cameroon) region’s clays and suitability evaluation for refractory bricks manufacturing. Clay Miner. 2018. https://doi.org/10.1180/clm.2018.32.

    Article  Google Scholar 

  2. Patterson SH, Hosterman JW, Huddle JW. Geology and refractory clay deposits of the Haldeman and Wrigley Quadrangles. Kentucky Geol Surv Bull. 1962. https://doi.org/10.3133/b1122F.

    Article  Google Scholar 

  3. Vasić MV, Pezo LL, Zdravković JD, Vrebalov M, Radojević Z. Thermal, ceramic and technological properties of clays used in production of roofing tiles—principal component analysis. Sci Sinter. 2018. https://doi.org/10.2298/SOS1804487V.

    Article  Google Scholar 

  4. Vasić MR, Vasić MV. Optimize, upgrade or invest in a novel dryer?—A brick factory case study. Int J Manuf Econ Manag. 2021. https://doi.org/10.54684/ijmem.2021.1.2.62.

  5. Schacht CA. Refractories handbook. Pennsylvania: Schacht Consulting Services Pittsburgh; 2004.

    Book  Google Scholar 

  6. SRPS U.B1.018. Testing of soils—determination of particle size distribution. Serbia: Institute for Standardization of Serbia; 2005.

  7. Vasić MV, Pezo L, Vasić MR, Mijatović N, Mitrić M, Radojević Z. What is the most relevant method for water absorption determination in ceramic tiles produced by illitic-kaolinitic clays? The mystery behind the gresification diagram. Bol Soc Esp Ceram. 2022. https://doi.org/10.1016/j.bsecv.2020.11.006.

    Article  Google Scholar 

  8. Hillier S. Accurate quantitative analysis of clay and other minerals in sandstones by XRD: Comparison of a Rietveld and reference intensity ratio (RIR) method and the importance of sample preparation. Clay Miner. 2000. https://doi.org/10.1180/000985500546666.

    Article  Google Scholar 

  9. EN 993-12. Methods of test for dense shaped refractory products—part 12: determination of pyrometric cone equivalent (refractoriness). Serbia: Institute for Standardization of Serbia; 1997.

  10. EN 993-13. Methods of test for dense shaped refractory products—part 13: specification for pyrometric reference cones for laboratory use. Serbia: Institute for Standardization of Serbia; 1995.

  11. ASTM C24-09. Standard test method for pyrometric cone equivalent (PCE) of fireclay and high-alumina refractory materials. West Conshohocken: ASTM International; 2018.

  12. Arsenović M, Pezo L, Mančić L, Radojević Z. Thermal and mineralogical characterization of loess heavy clays for potential use in brick industry. Thermochim Acta. 2014. https://doi.org/10.1016/j.tca.2014.01.026.

    Article  Google Scholar 

  13. de la Casa JA, Lorite M, Jiméndez J, Castro E. Valorisation of wastewater from two-phase olive oil extraction in fired clay brick production. J Haz Mater. 2009. https://doi.org/10.1016/j.jhazmat.2009.03.095.

    Article  Google Scholar 

  14. Pfefferkorn KK. Ein beitrag zur bestimmung der plastizität in tonen und kaolinen. Sprechsaal. 1924;57(25):297–9.

    Google Scholar 

  15. ASTM C20-00. Standard test methods for apparent porosity, water absorption, apparent specific gravity, and bulk density of burned refractory brick and shapes by boiling water. West Conshohocken: ASTM International; 2015.

  16. SRPS EN ISO 10545-3. Ceramic tiles—part 3: determination of water absorption, apparent porosity apparent relative density and bulk density. Serbia: Institute for Standardization of Serbia; 2018.

  17. McGuire RG. Reporting of objective color measurements. HortScience. 1992;27:1254–5.

    Article  Google Scholar 

  18. Pavlova IA, Getman AA, Farafontova EP. Technogenic raw materials in high-alumina chamotte production. IOP Conf Ser: Mater Sci Eng. 2020. https://doi.org/10.1088/1757-899X/969/1/012031.

    Article  Google Scholar 

  19. Haddar AE, Manni A, Azdimousa A, El Hassani I-EEA, Bellil A, Sadik C, Fagel N, El Ouahabi M. Elaboration of a high mechanical performance refractory from halloysite and recycled alumina. Bol Soc Esp Ceram V. 2020; https://doi.org/10.1016/j.bsecv.2019.08.002

  20. ISO 10081-1:2003(E). Classification of dense shaped refractory products—part 1: alumina-silica. International Organization for Standardization; 2003.

  21. Wilder DR, Dodd CM. Some effects of titania on refractory clays. In: 55th annual meeting. New York: The American Ceramic Society; 1953.

  22. Garcia-Valles M, Alfonso P, Martínez S, Roca N. Mineralogical and thermal characterization of kaolinitic clays from Terra Alta (Catalonia, Spain). Miner. 2020. https://doi.org/10.3390/min10020142.

    Article  Google Scholar 

  23. Fischer P. Some comments on the color of fired clays. ZI. 1984;37:475–83.

    CAS  Google Scholar 

  24. Dondi M, Raimondo M, Zanelli C. Clays and bodies for ceramic tiles: reappraisal and technological classification. Appl Clay Sci. 2014. https://doi.org/10.1016/j.clay.2014.01.013.

    Article  Google Scholar 

  25. Pruett RJ. Kaolin deposits and their uses: Northern Brazil and Georgia, USA. Appl Clay Sci. 2015. https://doi.org/10.1016/j.clay.2016.01.048.

    Article  Google Scholar 

  26. Chesters JH. Refractories: production and properties. In: The Iron and Steel Institute, 5th edn. House Press, London; 1973. p. 166–207.

  27. SRPS B.F1.010. Refractory materials—refractory clays and kaolins—classification—technical requirements, Institute for Standardization of Serbia, Serbia; 1984.

  28. Ramachandran VS, Paroli RM, Beaudoin JJ, Delgado AH. Handbook of thermal analysis of construction materials. New York: Noyes Publications/William Andrew Publishing, Norwich; 2002.

    Google Scholar 

  29. Ivanova VP, Kasatov BK, Krasavina TN, Rozinova EL. Tepмичecкий aнaлиз минepaлoв и гopныx пopoд, Mиниcтepcтвo гeoлoгии CCCP, издaтeльcтвo „Heдpa“, Лeнингpaд (Thermal analysis of minerals and rocks. Ministry of Geology of the USSR, Nedra Publishing House, Leningrad). In: Russian; 1974.

  30. Murray HH. Developments in clay science 2. Applied clay mineralogy. Occurrences, processing and application of kaolins, bentonites, palygorskite-sepiolite, and common clays. Elsevier; 2007.

  31. Rekik SB, Bouaziz J, Deratana A, Beklouti S. Study of ceramic membrane from naturally occurring-kaolin clays for microfiltration applications. Period Polytech Chem Eng. 2017. https://doi.org/10.3311/PPch.9679.

    Article  Google Scholar 

  32. Papadopoulou ND, Lalia-Kantouri M, Kantiranis N, Stratis AJ. Thermal and mineralogical contribution to the ancient ceramics and natural clays characterization. J Therm Anal Calorim. 2006. https://doi.org/10.1007/s10973-005-7173-y.

    Article  Google Scholar 

  33. China CL, Ahmada ZA, Sow SS. Relationship between the thermal behaviour of the clays and their mineralogical and chemical composition: example of Ipoh, Kuala Rompin and Mersing (Malaysia). Appl Clay Sci. 2017. https://doi.org/10.1016/j.clay.2017.03.037.

    Article  Google Scholar 

  34. Garcia-Valles M, Cuevas D, Alfonso P, Martínez S. Thermal behaviour of ceramics obtained from the kaolinitic clays of Terra Alta, Catalonia, Spain. J Therm Anal Calorim. 2021. https://doi.org/10.1007/s10973-021-11075-9.

    Article  Google Scholar 

  35. Ondro T, Húlan T, Al-Shantir O, Csáki Š, Václavů T, Trník A. Kinetic analysis of the formation of high-temperature phases in an illite-based ceramic body using thermodilatometry. J Therm Anal Calorim. 2019. https://doi.org/10.1007/s10973-019-08781-w.

    Article  Google Scholar 

  36. Walker RF, Zerfoss S, Holley SF, Gross LJ. Temperature of the inversion in cristobalite. J Res Natl Bur Stand. 1958;61(4):251–61.

    Article  CAS  Google Scholar 

  37. Plevova E, Vaculikova L, Valovicova V. Thermal analysis and FT-IR spectroscopy of synthetic clay mineral mixtures. J Therm Anal Calorim. 2020. https://doi.org/10.1007/s10973-020-09527-9.

    Article  Google Scholar 

  38. Karklit AK, Kaplan FS. On loosening of refractory clays in roasting. Refract Ind Ceram. 2000;41(3–4):96–103.

    Article  CAS  Google Scholar 

  39. Cheng H, Yang J, Liu Q, He J, Frost RL. Thermogravimetric analysis–mass spectrometry (TG–MS) of selected Chinese kaolinites. Thermochim Acta. 2010. https://doi.org/10.1016/j.tca.2010.05.007.

    Article  Google Scholar 

  40. Ligas P, Uras I, Dondi M, Marsigli M. Kaolinitic materials from Romana (north-west Sardinia, Italy) and their ceramic properties. Appl Clay Sci. 1997. https://doi.org/10.1016/S0169-1317(97)00004-5.

    Article  Google Scholar 

  41. de Gennaro R, Dondi M, Cappelletti P, Cerri G, de’ Gennaro M, Guarini G, Langella A, Parlato L, Zanelli C. Zeolite–feldspar epiclastic rocks as flux in ceramic tile manufacturing. Micropor Mesopor Mater. 2007; https://doi.org/10.1016/j.micromeso.2007.04.023

  42. Mokwa JB, Lawal SA, Abolarin MS, Bala KC. Characterization and evaluation of selected kaolin clay deposits in Nigeria for furnace lining application. NIJOTECH. 2019. https://doi.org/10.4314/njt.v38i4.17.

    Article  Google Scholar 

  43. Karklit AK, Kakhmurov AV. Burning of briquette to chamotte in a tunnel furnace. Refract. 1994. https://doi.org/10.1007/bf02227385.

    Article  Google Scholar 

  44. Bomeni IY, Njoya A, Ngapgue F, Wouatong ASL, Fouateu RY, Kabeyene VK, Fagel N. Ceramic with potential application of ngwenfon alluvial clays (Noun, West Cameroon) in building construction: Mineralogy, physicochemical composition and thermal behaviour. Constr Build Mater. 2018. https://doi.org/10.1016/j.conbuildmat.2018.06.135.

    Article  Google Scholar 

  45. Kirabira JB, Wijk G, Jonsson S, Byaruhanga JK. Fireclay refractories from Ugandan kaolinitic minerals. Steel Res Int. 2006. https://doi.org/10.1002/srin.200606426.

    Article  Google Scholar 

  46. GOST 3226-93. Meжгocyдapcтвeнный cтaндapт. Глинны фopмoвoчныe oгнeyпopныe. Oбщиe тexничecкиe ycлoвия. (Moulded refractory clays. General specifications), The Russian government Federal Agency on Technical Regulating and Metrology; 1994. In: Russian. https://docs.cntd.ru/document/1200024902. Accessed 02 Sept 2022

  47. Balabanits DA. Refractory clays of the Toretskoe deposit. Glass Ceram. 2003. https://doi.org/10.1023/A:1025777404762.

    Article  Google Scholar 

  48. Lee S, Kim YJ, Moon H-S. Phase transformation sequence from kaolinite to mullite investigated by an energy-filtering transmission electron microscope. J Am Ceram Soc. 1999;82(10):2841–8.

    Article  CAS  Google Scholar 

  49. Koleda VV, Mikhailyuta ES, Alekseev EV, Tsybul`ko ÉS. Technological particularities of clinker brick production. Glass Ceram. 2009; https://doi.org/10.1007/s10717-009-9129-3

  50. Mokrzycki WS, Tatol M. Colour difference ∆E—a survey. Mach Graph Vis. 2011;20(4):383–411.

    Google Scholar 

Download references

Acknowledgements

The presented work is supported by the Ministry of Education, Science and Technological Development of the Republic of Serbia (Contract No. 451-03-68/2022-14/200012 and Contract No. 451-03-68/2022-14/200287), and forms part of a collaboration between the Institute for Testing of Materials IMS and Innovation Centre of the Faculty of Technology and Metallurgy, University of Belgrade.

Author information

Authors and Affiliations

  1. Institute for Testing of Materials IMS, Bulevar Vojvode Mišića 43, 11000, Belgrade, Serbia

    Milica Vidak Vasić & Zagorka Radojević

  2. Innovation Centre of the Faculty of Technology and Metallurgy, University of Belgrade, Karnegijeva 4, 11000, Belgrade, Serbia

    Lidija Radovanović

  3. Institute of General and Physical Chemistry, University of Belgrade, Studentski Trg 12/V, 11000, Belgrade, Serbia

    Lato Pezo

Authors
  1. Milica Vidak Vasić
    View author publications

    You can also search for this author in PubMed Google Scholar

  2. Lidija Radovanović
    View author publications

    You can also search for this author in PubMed Google Scholar

  3. Lato Pezo
    View author publications

    You can also search for this author in PubMed Google Scholar

  4. Zagorka Radojević
    View author publications

    You can also search for this author in PubMed Google Scholar

Contributions

The study conception, methodology, design and writing the first draft of the manuscript were performed by Milica V. Vasić. Material preparation, data collection, visualization, analysis and discussion were also done by Milica V. Vasić. Visualization and discussion are done by Lidija Radovanović. Statistical analysis was performed by Lato Pezo. Conceptualization, methodology and supervision were the tasks done by Zagorka Radojević. The first draft of the manuscript was written by Milica V. Vasić and all authors commented on previous versions of the manuscript. All authors read and approved the final manuscript.

Corresponding author

Correspondence to Milica Vidak Vasić.

Ethics declarations

Conflict of interest

The authors declare that they have no known competing financial interests or personal relationships that could have appeared to influence the work reported in this paper.

Additional information

Publisher's Note

Springer Nature remains neutral with regard to jurisdictional claims in published maps and institutional affiliations.

Electronic supplementary material

Below is the link to the electronic supplementary material.

Supplementary file1 (JPG 256 kb)

Appendix

Appendix

See Appendix Tables

Table 6 Correlation coefficients between oxide content in refractory raw materials with statistical significance
Full size table

6,

Table 7 Correlation coefficients between the contents of minerals in refractory raw materials with statistical significance
Full size table

7,

Table 8 Properties during drying of manually and hydraulically formed samples
Full size table

8,

Table 9 Correlations of mineralogy and shaping moisture to some properties of the fired refractories
Full size table

9 and

Table 10 Correlations of L*a*b* and properties of the fired products
Full size table

10 and Figs. 10 and 11.

Rights and permissions

Springer Nature or its licensor (e.g. a society or other partner) holds exclusive rights to this article under a publishing agreement with the author(s) or other rightsholder(s); author self-archiving of the accepted manuscript version of this article is solely governed by the terms of such publishing agreement and applicable law.

Reprints and permissions

About this article

Check for updates. Verify currency and authenticity via CrossMark

Cite this article

Vasić, M.V., Radovanović, L., Pezo, L. et al. Raw kaolinitic–illitic clays as high-mechanical-performance hydraulically pressed refractories. J Therm Anal Calorim 148, 1783–1803 (2023). https://doi.org/10.1007/s10973-022-11848-w

Download citation

  • Received:

  • Accepted:

  • Published:

  • Issue Date:

  • DOI: https://doi.org/10.1007/s10973-022-11848-w

Keywords

Search

Navigation