Optimization Of Physical Characterization Of Malaysian Clay For Ceramic Tile Production
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Date
2018-06-01
Authors
Chin, Chee Lung
Journal Title
Journal ISSN
Volume Title
Publisher
Universiti Sains Malaysia
Abstract
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.