Basalt fiber has been used as a reinforced material in cement-based materials because it has higher mechanical strength and cheaper than common silicate based glass-fibers. However, silicate-based glass fibers have low alkali resistance especially in cement matrix composite. In this work, we studied the improvement of alkali resistance by addition of zirconium silicate (ZrSiO4) in original basalt glass composition. The batch of basalt glass with additional ZrSiO4 contents of 0.00, 2.50, 5.00, 7.50 and 10.00 wt% were melted at 1500 °C. The liquidus temperature (TL) is important in for the fiber glass manufacturing. It need to formulate glass composition which requires a lower melting temperature and is crystallization resistant. TL as a function of composition is usually determined experimentally. In this study, glassy phase was determined by X-ray Diffraction (XRD). The glass transition temperature (Tg), the crystallization temperature (Tc) and TL were analyzed by Differential Thermal Analysis (DTA). The results found that the addition of ZrSiO4 in a basalt glass batch increased Tg while Tc of each sample was closed to original basalt fiber. Moreover, the alkali resistance of these glasses increased with an increasing of ZrSiO4 content. However, excessive ZrSiO4 contents (7.50 and 10.00 wt%) resulted in crystallization of ZrO2 which separated from glassy phase.
Ceramic manufacturers are finding the way to decrease firing temperature and recover their wastes in order to keep production costs down. In this study earthenware ceramic bodies were prepared by adding a soda-lime glass grinding effluent powder (dried sludge) as a fluxing agent at 0–50 wt.% into either sanitary ware sludge powder (from a sanitary ware manufacturing process) or fresh pottery clay from Ang-thong, Thailand. The dried and pressed mixtures were fired at 1100, 1125 and 1150 °C and tested for the firing shrinkage, modulus of rupture, water absorption and bulk density. The formed product microstructure was observed by the scanning electron microscopy, and the phase composition was characterized by X-ray diffractometer. The results revealed that the best condition for adding the glass powder in Ang-thong pottery clay was the inclusion of 10 wt.% soda-lime glass effluent powder in the pottery clay. Its flexural strength increased from 51.25 MPa to 93.40 MPa after firing at 1125 °C with the water absorption of 0.42 wt.% and the firing shrinkage of 10.25 %. The optimum firing temperature and soda-lime glass content in sanitary ware sludge were 1150 °C and 20 wt.%, respectively. Its flexural strength increased from 103.16 MPa to 118.16 MPa with the water absorption of 0.52 wt.% and the firing shrinkage of 13.67 %. The results illustrated the potential to use soda-lime glass cutting sludge and sanitary ware sludge as raw materials for earthenware ceramic body.
In this work, silica-rich basalt from Chai Badan, Lopburi province was melted with lignite bottom ash from Mae Moh power plant as fluxing agent. To improving the alkali resistance, the series of glass batch samples were varied amount of ZrO2 content by 0 wt% to 10 wt%. The batches were melted at 1500℃ and drawn into a fiber. The results found that the alkali resistance of basalt fiber sample increase with increasing of ZrO2 content up to 7.5 wt% ZrO2. The sample with 7.5 wt% ZrO2 performed the highest alkali resistance, while the sample with 5 wt% ZrO2 obtained the highest tensile strength. The alkali resistance of these basalt fibers was given by a formation of stable hydrated zirconium-rich layer retarding the preinitiation of OH- inside the surface. The corrosion of shell thickness of higher ZrO2 content fiber increased at a slower rate according to its higher alkali resistance. The excess addition of ZrO2 content up to 10 wt% in glass composition resulted in an increase of brittleness and weakness of the fiber caused by a defect from undissolved ZrO2 crystal in a fiber and its solubility limit.
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