Utilization Of Electric Arc Furnace Steel Slag As Partial Replacement Of Raw Materials In Ceramic Tile

In this project, electric arc furnace (EAF) steel slag (obtained from SSB) was utilized as partial replacement of raw materials in ceramic tile, as one of efforts to manage the slag in a more sustainable way. In Stage 1, EAF slag had consistent properties among six batches and therefore, suitable fo...

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Main Author:	Teo, Pao Ter
Format:	Thesis
Language:	English
Published:	2016
Subjects:	T Technology
Online Access:	http://eprints.usm.my/45793/1/Utilization%20Of%20Electric%20Arc%20Furnace%20Steel%20Slag%20As%20Partial%20Replacement%20Of%20Raw%20Materials%20In%20Ceramic%20Tile.pdf
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spelling	my-usm-ep.457932021-11-17T03:42:17Z Utilization Of Electric Arc Furnace Steel Slag As Partial Replacement Of Raw Materials In Ceramic Tile 2016-12 Teo, Pao Ter T Technology TA401-492 Materials of engineering and construction. Mechanics of materials In this project, electric arc furnace (EAF) steel slag (obtained from SSB) was utilized as partial replacement of raw materials in ceramic tile, as one of efforts to manage the slag in a more sustainable way. In Stage 1, EAF slag had consistent properties among six batches and therefore, suitable for use in ceramic tile production. In Stage 2, the EAF slag (40 – 60 wt.%), ball clay (30 – 60 wt.%), K-feldspar (10 – 20 wt.%) and silica (10 – 20 wt.%) were wet-mixed, followed by slurry’s drying, crushing of dried slurry, granulation, compaction and firing (1150 °C). Composition F (40 wt.% EAF slag – 30 wt.% ball clay – 10 wt.% K-feldspar – 20 wt.% silica) had the lowest water absorption (0.33%) and apparent porosity (0.78%), accompanied by highest bulk density (2.39 g/cm3) and MOR (55.38 MPa). Factors such as anorthite and wollastonite phases, porosity, glassy phase and micro-cracking affect the final properties. In Stage 3, modification of parameters such as slurry’s milling, variation of EAF slag (30, 40, 50 and 60 wt.%) and firing temperatures (1100, 1150 and 1180 °C) were executed to study functions of EAF slag in influencing ceramic tile formulation. General factorial design proved that amount of EAF slag and firing temperature significantly influenced final properties of tile. EAF slag also functions as fluxing agent to form glassy phase and contributed to formation of anorthite and wollastonite phases during sintering. Composition I (50 wt.% EAF slag – 50 wt.% ball clay, fired at 1180 °C) had the lowest water absorption (0.16%) and apparent porosity (0.48%), accompanied by highest bulk density (2.95 g/cm3) and MOR (92.42 MPa). Leaching test proved that both Compositions F (Stage 2) and I (Stage 3) were non-toxic and environmentally friendly. Upon benchmarking with commercial floor tiles and MS ISO13006:2014 Standard, both tiles were found suitable to be used as high durability green floor tile. 2016-12 Thesis http://eprints.usm.my/45793/ http://eprints.usm.my/45793/1/Utilization%20Of%20Electric%20Arc%20Furnace%20Steel%20Slag%20As%20Partial%20Replacement%20Of%20Raw%20Materials%20In%20Ceramic%20Tile.pdf application/pdf en public phd doctoral Universiti Sains Malaysia Pusat Pengajian Kejuruteraan Bahan & Sumber Mineral
institution	Universiti Sains Malaysia
collection	USM Institutional Repository
language	English
topic	T Technology T Technology
spellingShingle	T Technology T Technology Teo, Pao Ter Utilization Of Electric Arc Furnace Steel Slag As Partial Replacement Of Raw Materials In Ceramic Tile
description	In this project, electric arc furnace (EAF) steel slag (obtained from SSB) was utilized as partial replacement of raw materials in ceramic tile, as one of efforts to manage the slag in a more sustainable way. In Stage 1, EAF slag had consistent properties among six batches and therefore, suitable for use in ceramic tile production. In Stage 2, the EAF slag (40 – 60 wt.%), ball clay (30 – 60 wt.%), K-feldspar (10 – 20 wt.%) and silica (10 – 20 wt.%) were wet-mixed, followed by slurry’s drying, crushing of dried slurry, granulation, compaction and firing (1150 °C). Composition F (40 wt.% EAF slag – 30 wt.% ball clay – 10 wt.% K-feldspar – 20 wt.% silica) had the lowest water absorption (0.33%) and apparent porosity (0.78%), accompanied by highest bulk density (2.39 g/cm3) and MOR (55.38 MPa). Factors such as anorthite and wollastonite phases, porosity, glassy phase and micro-cracking affect the final properties. In Stage 3, modification of parameters such as slurry’s milling, variation of EAF slag (30, 40, 50 and 60 wt.%) and firing temperatures (1100, 1150 and 1180 °C) were executed to study functions of EAF slag in influencing ceramic tile formulation. General factorial design proved that amount of EAF slag and firing temperature significantly influenced final properties of tile. EAF slag also functions as fluxing agent to form glassy phase and contributed to formation of anorthite and wollastonite phases during sintering. Composition I (50 wt.% EAF slag – 50 wt.% ball clay, fired at 1180 °C) had the lowest water absorption (0.16%) and apparent porosity (0.48%), accompanied by highest bulk density (2.95 g/cm3) and MOR (92.42 MPa). Leaching test proved that both Compositions F (Stage 2) and I (Stage 3) were non-toxic and environmentally friendly. Upon benchmarking with commercial floor tiles and MS ISO13006:2014 Standard, both tiles were found suitable to be used as high durability green floor tile.
format	Thesis
qualification_name	Doctor of Philosophy (PhD.)
qualification_level	Doctorate
author	Teo, Pao Ter
author_facet	Teo, Pao Ter
author_sort	Teo, Pao Ter
title	Utilization Of Electric Arc Furnace Steel Slag As Partial Replacement Of Raw Materials In Ceramic Tile
title_short	Utilization Of Electric Arc Furnace Steel Slag As Partial Replacement Of Raw Materials In Ceramic Tile
title_full	Utilization Of Electric Arc Furnace Steel Slag As Partial Replacement Of Raw Materials In Ceramic Tile
title_fullStr	Utilization Of Electric Arc Furnace Steel Slag As Partial Replacement Of Raw Materials In Ceramic Tile
title_full_unstemmed	Utilization Of Electric Arc Furnace Steel Slag As Partial Replacement Of Raw Materials In Ceramic Tile
title_sort	utilization of electric arc furnace steel slag as partial replacement of raw materials in ceramic tile
granting_institution	Universiti Sains Malaysia
granting_department	Pusat Pengajian Kejuruteraan Bahan & Sumber Mineral
publishDate	2016
url	http://eprints.usm.my/45793/1/Utilization%20Of%20Electric%20Arc%20Furnace%20Steel%20Slag%20As%20Partial%20Replacement%20Of%20Raw%20Materials%20In%20Ceramic%20Tile.pdf
_version_	1747821567582142464

Utilization Of Electric Arc Furnace Steel Slag As Partial Replacement Of Raw Materials In Ceramic Tile

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