X-ray fluorescence of the commercial clay
The XRF results provided by the supplier enterprise J. L. Vicentiz, S. L. (Table 1), were verified and completed. The data obtained shown high similarity, as the main components and quantities agreed. However, a semiquantitative analysis was conducted and its trace elements were identified. Table 4 shows the results obtained both of the major and minor components and trace elements.
Table 4 XRF results expressed in oxides and ppm of the red commercial clay used for the elaboration of the ceramic specimens X-ray powder diffraction
The XRPD pattern of the clay used for the ceramic specimens is shown in Fig. 5. Significant amount of quartz, (SiO2) [JCPDS 01-086-1629] has been identified, together with phyllosilicates (muscovite (KAl3Si3O10(OH)2) [JCPDS 01-076-0929] and/or illite KAl2(Si3Al)O10 (OH)2 [JCPDS 00-043-0685] and clinochlore ((Mg,Fe)6(Si,Al)4O10(OH)8) [JCPDS 00-029-0701]), feldspar (albite Na(AlSi3O8) [JCPDS 01-071-1150] and orthoclase (K(AlSi3O8)) [JCPDS 01-076-0749]), and other minerals as hematite, (Fe2O3) [JCPDS 01-085-0599] (Fig. 5). Some amount of calcite (CaCO3) [JCPDS 01-072-1651]) and dolomite (CaMg(CO3)2) [JCPDS 01-073-2361], were also detected. Among phyllosilicates, the main components were determined by oriented aggregates patterns (OA). According to the results, mica-illite (60%) and smectite (25%) were the main phases, along with chlorite (8%) and kaolinite (7%) in minor concentration.
Besides, the XRPD patterns of the ceramic specimens fired at different temperatures are also included in Fig. 5. The peaks corresponding to phylosillicates (muscovite and/or illite) decreased with the rise in temperature and disappear at 1000 °C. Orthoclase main peak (26.9°) reduces its intensity and disappears at temperatures above 800 °C. Clinochlore disappears before reaching 650 °C. Anorthite is detected at 1000 °C and increases its diffraction peaks at higher temperatures [27, 28]. In the same way, the maximum peaks of hematite became more intense and narrow as the firing temperature increased, probably due to a crystalline growth [7]. The decomposition of calcite begins above 650 °C and disappears above 800 °C. Quartz remains the most abundant phase at all temperatures. The existence of an amorphous phase is evidenced by the increased background noise at temperatures above 800 °C, which suggests that samples are undergoing vitrification.
Besides, the mineralogical composition of the soil from Guarrazar used for the growth of the artificial deposits was analysed. In the XRPD patterns, quartz [JCPDS 01-089-1961], calcite [JCPDS 01-081-2027], phyllosilicates as dickite [JCPDS 01-074-1758] and clinochlore [JCPDS 01-079-1270] were identified. Also plagioclases as anorthite [JCPDS 01-086-1707] and albite [JCPDS 01-076-0898] were detected. The analysis of oriented aggregates of the phyllosilicates (OA) determined its composition by: mica-illite (78%), smectite (12%), chlorite (5%) and kaolinite (5%).
All the clay specimens were studied again after the cleaning treatments, showing no differences in any of the mineralogical phases detected (Fig. 6). Indeed, calcite peaks are detected, in both C650 and C800 specimens, which suggest that the acid treatments did not dissolve the carbonates from the ceramic. However, the semi-quantification of calcium carbonate content was made by the thermogravimetric analysis.
Thermogravimetric analysis
TG–DSC curves were evaluated considering both the mass loss expressed as percentage and the heat flow of samples as a function of temperature.
In all the thermograms, there was an endothermic peak at 573 °C, which did not imply a weight loss, related to the polymorphic inversion of α quartz [29].
Another endothermic peak raised at ~ 400 °C, both in pattern (Fig. 7a) and carbonated specimens (Fig. 7b). This peak is ascribed to the loss of structurally bound water [30,31,32]. In the pattern samples, this peak is observed only in samples fired at low temperature (C650 and C800) and is linked to a small weight loss. Together with the results of XRPD data, this peak is ascribed to dehydroxylation of muscovite [33]. On the other hand, at this temperature range (380–430 °C), another endothermic peak is observed in all the carbonated samples, no matter the firing temperature (Fig. 7b). From the derivative curve, within this temperature range, it is possible to observe two overlapped peaks in the samples fired at low temperature (C650 and C800), and only one in the samples fired at high temperature (C1000 and C1100), both linked to a weight loss. The first one can be ascribed to the dehydroxylation of calcium hydroxide [34], present in all samples, whereas the second one, to the dehydroxylation of muscovite [33], as determined in pattern samples and according to XRPD data. This would mean that during the carbonation process, not all of the calcium hydroxide (Ca(OH)2) applied was transformed into calcium carbonate (CaCO3). The endothermic peak at ~ 400 °C in the treated samples was only present in the specimens fired at low temperature (Fig. 8a, b) as happened in the pattern samples (Fig. 7), so that peak can be ascribed to the dehydroxylation of muscovite alone, meaning that the cleaning treatments were effective in the removal of the Ca(OH)2 present in the carbonated specimens. In DSC curves of pattern specimens C650 and C800 (Fig. 7a), an important endothermic peak appeared ~ 655 °C together with a weight loss around 500–750 °C, related to the decarbonation of calcium carbonate [30, 32], which was in agreement with the XRPD results. On the other hand, pattern specimens fired at 1000 and 1100 °C, did not show any transformation within this temperature range (Fig. 7a), confirming the absence of calcium carbonate in these samples, in consonance with XRPD results. Besides, all the carbonated specimens showed such peaks due to decomposition of calcium carbonate from the carbonation process (Fig. 7b). However, the weight losses linked to this peak were higher for C650 and C800 than those detected in C1000 and C1100 (Fig. 7b).
On the other hand, in thermograms of cleaned specimens (Fig. 8), features related to the decomposition of calcium carbonate were detected in all of them, but with lower magnitude as the firing temperature increases, with the exception of the highest firing temperature (C1100). In the specimen C650 AA a weight loss of 3.9% between 532.6 and 738.4 °C was detected. In a similar way, another weight loss of 4.0% between 515.1 and 723.6 °C was also detected in the specimen C650 NA (Fig. 8a). These weight losses detected at the temperature range 500–740 ºC are higher than the weight loss detected in the pattern sample C650 PAT at the same temperature range (2.7 %) (Fig. 7a). The same occurs for C800 treated samples, as after both treatments (AA and NA), a weight loss of 1.3% is detected between 502.4 and 675.2 °C for C800 AA and 525.9–677.8 °C for C800 NA (Fig. 8b). Also, for the specimens C1000 AA and 283 NA, a small weight loss of 0.3% is detected between 522.5 and 650.3 °C for AA, and between 517.1 and 640.9 °C for NA. However, the weight loss due to the decarbonation process is not detected in C1100 AA and NA specimens after the cleaning treatments (Fig. 8c, d), meaning that, for lower firing temperatures specimens (C650 and C800), the treatments were effective as they removed the artificial deposits, although there were still remains. Whereas for the highest firing temperature specimen (C1100), the cleaning treatments have been more effective, as no remains of calcium carbonate were detected. On the other hand, the endothermic peaks related both to the dehydroxylation of muscovite and calcium hydroxide were noticeable after both acid treatments for the specimens fired at lower temperatures (Fig. 8a, b). However, it was not found in the thermograms of specimens fired at higher temperatures (Fig. 8c, d). So then, the cleaning treatments were effective in the removal of calcium hydroxide, and the peak found in specimens fired at lower temperatures was linked to the muscovite [32].
In addition, according to the results obtained from the thermogravimetric analysis, the approximate calcium carbonate content was calculated regarding the weight loss and the following reaction:
$$\text{CaCO}_{3}\left(100.01 \,\text{g}\right)+\text{Q} \left(\text{J}\right)\to \text{CaO} \left(56.07 \,\text{g}\right)+\text{CO}_{2}(44.01 \,\text{g})$$
The results gathered in Table 5 determined that the calcium carbonate content in pattern specimens was higher for the lower firing temperatures, in agreement with XRPD data. Besides, the carbonation process was effective in the specimens fired at the four temperatures as the calcium carbonate content increased in all of them. However, this content decreased as long as the firing temperature increased. Besides, the calcium carbonate content did not decrease after the cleaning treatments in comparison with the pattern specimens. Indeed, there was a small increase in all cases with the exception in the specimen C1100. This increase might be due to the remains of the calcareous deposits generated after the carbonation process that were not completely removed by the cleaning treatments. However, they were not noticeable to human eye and do not interfere with the aesthetical values of the specimens.
Table 5 Weight loss and content of calcium carbonate in specimens at the four firing temperatures, pattern (PAT), carbonated (CAR) and after the treatments (AA, acetic acid; NA, nitric acid) From the data obtained, the remains of the calcareous deposits were established, calculated as the difference between the calcium carbonate content in carbonated and treated specimens. These contents were attached to the firing temperatures, as for both the acetic and the nitric acid treatments, the values were higher for C650 specimens and decreased along with the specimens fired at higher temperatures (Table 6). Besides, the efficacy of the treatments was calculated taking into account the removal of the artificial calcareous deposits after the acid treatments. For the sample fired at the lowest temperature, the largest deposit was observed (4.1% CaCO3), and the efficacy resulted the lowest (33.3% with AA and 27.8% with NA). As long as the deposit decreased, the efficacy of the treatments increased, reaching 100% efficacy in specimen C1100, both for acetic and nitric acid. Although 100% efficacies were not reached in all the cases (Table 6), they were enough to make the remains unnoticeable to human eye. It is also important to point out that the efficacy of the treatments was very similar, even equal, for both acids tested.
Table 6 Relative variation in the CaCO3 content (%) in the specimens fired at the four temperatures. Calculated efficacy of acid treatments