Optimization Of Physical Characterization Of Malaysian Clay For Ceramic Tile Production

Clay is an important raw material in manufacturing of ceramic tiles. From economical point of view, local clays are important for demand of local ceramic tile industries. However, no comprehensive research work was carried out on Malaysia clays for application in ceramic tiles. The research work is...

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Main Author:	Chin, Chee Lung
Format:	Thesis
Language:	English
Published:	2018
Subjects:	T Technology
Online Access:	http://eprints.usm.my/56059/1/Optimization%20Of%20Physical%20Characterization%20Of%20Malaysian%20Clay%20For%20Ceramic%20Tile%20Production_Chin%20Chee%20Lung.pdf
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spelling	my-usm-ep.560592022-12-20T08:56:51Z Optimization Of Physical Characterization Of Malaysian Clay For Ceramic Tile Production 2018-06-01 Chin, Chee Lung T Technology TN Mining Engineering. Metallurgy Clay is an important raw material in manufacturing of ceramic tiles. From economical point of view, local clays are important for demand of local ceramic tile industries. However, no comprehensive research work was carried out on Malaysia clays for application in ceramic tiles. The research work is aimed to provide scientific data on characterization of Malaysian clays from Ipoh (Perak), Kuala Rompin (Pahang) and Mersing (Johor) and their suitability for ceramic tile industry. The research covered characterization of study clays, effect of ceramic tile processing parameters on properties of studied clays and application in ceramic tiles. The clays were characterized by chemical composition, mineralogy, rheological analysis, physical, thermal and fired properties. Results showed that Ipoh clay is coarser in particle size (14.6 um) than Kuala Rompin (7.2 um) and Mersing clays (6.0 um). For rheological behaviour, sodium tripolyphosphate (STPP) is the most suitable deflocculant for the studied clays with CEC of 16 to 40 meq/100g and optimum deflocculant of 0.10 to 0.24% for manufacturing of ceramic tiles by wet milling process. For mineralogical analysis, kaolinite was present abundantly in Ipoh clay of about 78.7%, while Kuala Rompin and Mersing clays are containing high percentage of quartz (34.1% and 43.9%, respectively) and illite (39.1% and 30.7%, respectively). Mineralogy of clay is greatly affecting the fired properties of studied clays, where Kuala Rompin and Mersing clays shown higher densification (2.3 – 2.5 g/cm3), higher shrinkage (9.0 – 13.0%), lower water absorption (0.0 – 2.0%), higher CTE (8.1 – 8.4 x10-6 'C-1) and darker fired colour (L* of 60 - 70) than Ipoh clay at firing temperature of 1200 'C. For processing parameters, pressing pressure and firing temperature have greater impact to drying and fired properties, while both moisturizing and milling time have minor effect on both drying and fired properties of studied clays. Statistical design of mixture experiment proves that the clays are suitable to be used for production of ceramic tiles but its application is highly dependent to ceramic tile production practice by pressing pressure and firing temperature. For commercial floor tile production practice, studied clays have only fulfilled categories of BIIb and BIII ceramic tiles. For commercial porcelain tile production practice, studied clays have fulfilled almost all the ranges of ceramic tiles from BIa to BIII. The outcome of the research work shows that mineralogy and particle size of clay, pressing pressure and firing temperature have direct influenced on fired properties of studied clays and ceramic tiles body formulation. 2018-06 Thesis http://eprints.usm.my/56059/ http://eprints.usm.my/56059/1/Optimization%20Of%20Physical%20Characterization%20Of%20Malaysian%20Clay%20For%20Ceramic%20Tile%20Production_Chin%20Chee%20Lung.pdf application/pdf en public phd doctoral Universiti Sains Malaysia Pusat Pengajian Kejuruteraan Bahan dan Sumber Mineral
institution	Universiti Sains Malaysia
collection	USM Institutional Repository
language	English
topic	T Technology T Technology
spellingShingle	T Technology T Technology Chin, Chee Lung Optimization Of Physical Characterization Of Malaysian Clay For Ceramic Tile Production
description	Clay is an important raw material in manufacturing of ceramic tiles. From economical point of view, local clays are important for demand of local ceramic tile industries. However, no comprehensive research work was carried out on Malaysia clays for application in ceramic tiles. The research work is aimed to provide scientific data on characterization of Malaysian clays from Ipoh (Perak), Kuala Rompin (Pahang) and Mersing (Johor) and their suitability for ceramic tile industry. The research covered characterization of study clays, effect of ceramic tile processing parameters on properties of studied clays and application in ceramic tiles. The clays were characterized by chemical composition, mineralogy, rheological analysis, physical, thermal and fired properties. Results showed that Ipoh clay is coarser in particle size (14.6 um) than Kuala Rompin (7.2 um) and Mersing clays (6.0 um). For rheological behaviour, sodium tripolyphosphate (STPP) is the most suitable deflocculant for the studied clays with CEC of 16 to 40 meq/100g and optimum deflocculant of 0.10 to 0.24% for manufacturing of ceramic tiles by wet milling process. For mineralogical analysis, kaolinite was present abundantly in Ipoh clay of about 78.7%, while Kuala Rompin and Mersing clays are containing high percentage of quartz (34.1% and 43.9%, respectively) and illite (39.1% and 30.7%, respectively). Mineralogy of clay is greatly affecting the fired properties of studied clays, where Kuala Rompin and Mersing clays shown higher densification (2.3 – 2.5 g/cm3), higher shrinkage (9.0 – 13.0%), lower water absorption (0.0 – 2.0%), higher CTE (8.1 – 8.4 x10-6 'C-1) and darker fired colour (L* of 60 - 70) than Ipoh clay at firing temperature of 1200 'C. For processing parameters, pressing pressure and firing temperature have greater impact to drying and fired properties, while both moisturizing and milling time have minor effect on both drying and fired properties of studied clays. Statistical design of mixture experiment proves that the clays are suitable to be used for production of ceramic tiles but its application is highly dependent to ceramic tile production practice by pressing pressure and firing temperature. For commercial floor tile production practice, studied clays have only fulfilled categories of BIIb and BIII ceramic tiles. For commercial porcelain tile production practice, studied clays have fulfilled almost all the ranges of ceramic tiles from BIa to BIII. The outcome of the research work shows that mineralogy and particle size of clay, pressing pressure and firing temperature have direct influenced on fired properties of studied clays and ceramic tiles body formulation.
format	Thesis
qualification_name	Doctor of Philosophy (PhD.)
qualification_level	Doctorate
author	Chin, Chee Lung
author_facet	Chin, Chee Lung
author_sort	Chin, Chee Lung
title	Optimization Of Physical Characterization Of Malaysian Clay For Ceramic Tile Production
title_short	Optimization Of Physical Characterization Of Malaysian Clay For Ceramic Tile Production
title_full	Optimization Of Physical Characterization Of Malaysian Clay For Ceramic Tile Production
title_fullStr	Optimization Of Physical Characterization Of Malaysian Clay For Ceramic Tile Production
title_full_unstemmed	Optimization Of Physical Characterization Of Malaysian Clay For Ceramic Tile Production
title_sort	optimization of physical characterization of malaysian clay for ceramic tile production
granting_institution	Universiti Sains Malaysia
granting_department	Pusat Pengajian Kejuruteraan Bahan dan Sumber Mineral
publishDate	2018
url	http://eprints.usm.my/56059/1/Optimization%20Of%20Physical%20Characterization%20Of%20Malaysian%20Clay%20For%20Ceramic%20Tile%20Production_Chin%20Chee%20Lung.pdf
_version_	1776101126478757888

Optimization Of Physical Characterization Of Malaysian Clay For Ceramic Tile Production

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