Sinterability, structural evolution and pinhole elimination of high strength self-glazed glass-ceramics sintered from granite sludge by instant glaze firing

  • Changyou Liu School of Power and Energy, Nanchang Hangkong University, Nanchang 330063, China
  • Jian Zhou School of Power and Energy, Nanchang Hangkong University, Nanchang 330063, China
  • Jinshan Lu School of Power and Energy, Nanchang Hangkong University, Nanchang 330063, China
Article ID: 2851
DOI: https://doi.org/10.59400/mtr2851
Keywords: granite sludge; instant glaze firing; glazed glass-ceramic; glaze formation; oversintering; glaze pinhole

Abstract

Granite sludge from the cutting and polishing of granite blocks should be utilized to prevent environmental pollution. This study focuses on the preparation of high-strength self-glazed glass-ceramics from granite sludge by combining dense sintering and instant glaze firing. Thermal analyses including thermogravimetry, differential scanning calorimetry and thermal expansion were used to evaluate the sinterability of the granite powder and to determine the dense sintering temperature. For the instant glaze firing of the sintered glass-ceramics, the structural evolution was analyzed by X-ray diffraction and solid-state nuclear resonance to clarify glaze formation and glass network stability, respectively. Glaze formation resulted from the dissolution of quartz and feldspars and the reduced glass viscosity, as indicated by the thermochemical calculation. As the glaze firing temperature was increased, the thickness of the surface glaze increased. The coefficient of thermal expansion of the glazed glass-ceramics indicates a residual compressive stress in the surface glaze. The elimination of glaze pinholes was achieved by reducing the amount of ferrous minerals and increasing the glaze firing rate. Under the optimum conditions, the flexural strength and surface glossiness of the glazed glass-ceramic were 112.5 MPa and 54.7 GU respectively, enabling the scalable production of high-strength self-glazed glass-ceramics from granite sludge for application in decorative tiles.

References

[1]Careddu N, Siotto G, Siotto R, et al. From landfill to water, land and life: The creation of the Centre for stone materials aimed at secondary processing. Resources Policy. 2013; 38(3): 258-265. doi: 10.1016/j.resourpol.2013.05.001

[2]Hou W, Zhang Q, Zhuang ZB, et al. Sustainable reusing marble powder and granite powder in cement-based materials: a review. ACS Sustainable Chemistry & Engineering. 2024; 12(7): 2484-2510. doi: 10.1021/acssuschemeng.3c06670

[3]Luo YP, Bao SX, Liu S, et al. Enhancing reactivity of granite waste powder toward geopolymer preparation by mechanical activation. Construction and Building Materials. 2024; 414: 134981. doi: 10.1016/j.conbuildmat.2024.134981

[4]Ngayakamo B, Bello A, Onwualu AP. Valorization of granite waste powder as a secondary flux material for sustainable production of ceramic tiles. Cleaner Materials; 2022. doi: 10.1016/j.clema.2022.100055

[5]Sripriyan K, Karthigha M. Influence of granite micro particles on the mechanical, damping and antimicrobial properties of silk-sisal hybrid composites. Scientific Reports. 2024; 14: 15995. doi: 10.1038/s41598-024-63190-w

[6]Sripriyan K, Aravind S, Gopinath S, et al. Effect of granite filler on the mechanical and damping behaviour of silk-sisal hybrid composite for automobile applications. International Journal of Product Sound Quality. 2023; 1(1): 18-28. doi: 10.1504/IJPSQ.2023.133660

[7]Surra E, Sousa J, Correia M, et al. Technical, environmental, and cost assessment of granite sludge valorisation. Applied Sciences. 2023; 13(7): 4513. doi: 10.3390/app13074513

[8]Luo Y, Wang F, Liao Q, et al. Effect of TiO2 on crystallization kinetics, microstructure and properties of building glass-ceramics based on granite tailings. Journal of Non-Crystalline Solids. 2021; 572: 121092. doi: 10.1016/j.jnoncrysol.2021.121092

[9]Tian X, Li A, Li S, et al. Crystallization behavior and mechanical properties of high strength mica-containing glass-ceramics from granite wastes. Ceramics International. 2022; 48(16): 23119-23126. doi: 10.1016/j.ceramint.2022.04.292

[10]Luo Y, Bao S, Zhang Y. Recycling of granite powder and waste marble produced from stone processing for the preparation of architectural glass–ceramic. Construction and Building Materials. 2022; 346: 128408. doi: 10.1016/j.conbuildmat.2022.128408

[11]Xue J, Zhong J, Mao Y, et al. Effect of CuO on crystallisation and properties of red R2O–CaO–MgO–Al2O3–SiO2 glass-ceramics from granite wastes. Ceramics International. 2020; 46(14): 23186-23193. doi: 10.1016/j.ceramint.2020.06.099

[12]Lu J, Li Y, Zou C, et al. Effect of heating rate on the sinterability, crystallization, and mechanical properties of sintered glass–ceramics from granite waste. Journal of Thermal Analysis and Calorimetry. 2018; 135(4): 1977-1985. doi: 10.1007/s10973-018-7346-0

[13]Vakifahmetoglu C, Semerci T, Soraru GD. Closed porosity ceramics and glasses. Journal of the American Ceramic Society. 2020; 103(5): 2941-2969. doi: 10.1111/jace.16934

[14]Zhang J, Liu B, Zhang S. A review of glass ceramic foams prepared from solid wastes: processing, heavy-metal solidification and volatilization, applications. Science of The Total Environment. 2021; 781: 146727. doi: 10.1016/j.scitotenv.2021.146727

[15]Jiang C, Huang S, Li G, et al. Formation of closed-pore foam ceramic from granite scraps. Ceramics International. 2018; 44(3): 3469-3471. doi: 10.1016/j.ceramint.2017.10.180

[16]Deng F, Wang F, Shi X, et al. Synthesis and properties of foam glass-ceramics from granite tailings by using SiC and MnO2 as the mixed foaming agent. Ceramics International. 2023; 49(22): 34647-34656. doi: 10.1016/j.ceramint.2023.08.120

[17]Liu XM, Li B, Wu YF, The pretreatment of non-ferrous metallurgical waste slag and its research progress in the preparation of glass-ceramics. Journal of Cleaner Production. 2023; 404: 136930. doi: 10.1016/j.jclepro.2023.136930

[18]Wilkinson C. Glass and a carbon-free United States: What is glass's role in the upcoming green revolution? Journal of the American Ceramic Society. 2024; 107(3): 1533-1542. doi: doi.org/10.1111/jace.19360

[19]Wang W, Wang K, Zhang J, et al. Effect of process parameters on characteristics and pore structure of foam ceramics prepared from granite sawing dust. Ceramics International. 2024; 50(5): 8378-8389. doi: 10.1016/j.ceramint.2023.12.173

[20]Fabriès J, Conquéré F, Arnaud G. The mafic silicates in the Saint Quay-Portrieux gabbro-diorite intrusion : crystallization conditions of a calc-alkaline pluton. Bulletin de Minéralogie. 1984; 107(6): 715-736. doi: 10.3406/bulmi.1984.7814

[21]Xue B, Calvez L, Allix M, et al. Amorphization by mechanical milling for making IR transparent glass‐ceramics. Journal of the American Ceramic Society. 2016; 99(5): 1573-1578. doi: 10.1111/jace.14150

[22]Qiu B, Wang F, Luo H, et al. Characterization and thermal behavior of granite waste during heating. Ceramics International. 2023; 49(11): 17052-17059. doi: 10.1016/j.ceramint.2023.02.066

[23]Zhan J, Lu J, Wang D, et al. Scalable recycling of feldspar slime into high-quality concentrates by removal of colored minerals using the combined beneficiation processes. Separation and Purification Technology. 2023; 309: 123061. doi: 10.1016/j.seppur.2022.123061

[24]Li C, Smith P, Bai X, et al. Effects of carbonate minerals and exogenous acids on carbon flux from the chemical weathering of granite and basalt. Global and Planetary Change. 2023; 221: 104053. doi: 10.1016/j.gloplacha.2023.104053

[25]Yuguchi T, Hatsukawa H, Suzuki S, et al. Morphological and chemical characterization of secondary carbonates in the Toki granite, central Japan, and the evolution of fluid chemistry. American Mineralogist. 2022; 107(12): 2282-2290. doi: 10.2138/am-2022-8229

[26]Greenwood JP, Hess PC. Congruent melting kinetics of albite: theory and experiment. Journal of Geophysical Research: Solid Earth. 1998; 103(B12): 29815-29828. doi: 10.1029/98jb02300

[27]Lvov BV. Mechanism and kinetics of thermal decomposition of carbonates. Thermochimica Acta. 2002; 386(1): 1-16. doi: 10.1016/S0040-6031(01)00757-2

[28]Zeng L, Sun H, Peng T, et al. The sintering kinetics and properties of sintered glass-ceramics from coal fly ash of different particle size. Results in Physics. 2019; 15: 102774. doi: 10.1016/j.rinp.2019.102774

[29]Lu JS, Liu CY, Zhou J. Recycling of granite sludge for the preparation of high-strength glazed glass-ceramics using stepwise sintering. International Journal of Applied Ceramic Technology. 2024; 21(3): 1583-1592. doi: 10.1111/ijac.14727

[30]Sánchez E, García-Ten J, Sanz V, et al. Porcelain tile: Almost 30 years of steady scientific-technological evolution. Ceramics International. 2010; 36(3): 831-845. doi: 10.1016/j.ceramint.2009.11.016

[31]Geng X, Cao J, Wang Z, et al. Selective controlled precipitation mechanism of canasite and xonotlite in glass-ceramics from silica slag. Journal of Non-Crystalline Solids. 2020; 546: 120283. doi: 10.1016/j.jnoncrysol.2020.120283

[32]Sen P, Pradhan BL, Lodhi L, et al. Precise measurement of Qn species distributions in modified silicate glass using phase-adjusted spinning sideband NMR experiment. Silicon. 2023; 15(18): 8065-8071. doi: 10.1007/s12633-023-02639-5

[33]Tsomaia N, Brantley SL, Hamilton JP, et al. NMR evidence for formation of octahedral and tetrahedral Al and repolymerization of the Si network during dissolution of aluminosilicate glass and crystal. American Mineralogist. 2003; 88(1): 54-67. doi: 10.2138/am-2003-0107

[34]Bao Z, Wang S, Miao L, et al. Preparation, properties and formation mechanism of transparent anorthite-based glass-ceramic glaze with high hardness. Ceramics International. 2024; 50(14): 26182-26192. doi: 10.1016/j.ceramint.2024.04.359

[35]Jiang K, Xia M, Tang Y, et al. Formation of closed pore structure in CaO-MgO-Al2O3-SiO2 (CMAS) porous glass-ceramics via Fe2O3 modified foaming for thermal insulation. Journal of the European Ceramic Society. 2023; 43(4): 1689-1697. doi: 10.1016/j.jeurceramsoc.2022.11.053

[36]Colomban P, Kırmızı B, Simsek Franci G. Cobalt and associated impurities in blue (and green) glass, glaze and enamel: relationships between raw materials, processing, composition, phases and international trade. Minerals. 2021; 11(6): 633. doi: 10.3390/min11060633

[37]Hrma P, Ferkl P, Kruger AA. Arrhenian to non-Arrhenian crossover in glass melt viscosity. Journal of Non-Crystalline Solids. 2023; 619: 122556. doi: 10.1016/j.jnoncrysol.2023.122556

[38]Zhou J, Liu C, Lu J. Influence of Ca(OH)2 modification on the pore structure and properties of porous glass-ceramics stepwise sintered from granite sludge. Construction and Building Materials. 2024; 429: 136436. doi: 10.1016/j.conbuildmat.2024.136436

[39]Cheng X, Ke S, Wang Q, et al. Characterization of transparent glaze for single-crystalline anorthite porcelain. Ceramics International. 2012; 38(6): 4901-4908. doi: 10.1016/j.ceramint.2012.02.081

[40]Huang H, Yu J, Liu F, et al. Preparation of a high-performance frit glaze using high-potassium feldspar. IOP Conference Series: Earth and Environmental Science. 2021; 943(1): 012018. doi: 10.1088/1755-1315/943/1/012018

[41]Hasanuzzaman M, Islam F, Rashid A. Investigation of methods to prevent pin‐holing defect in tableware ceramic industry. International Journal of Ceramic Engineering & Science. 2022; 4(6): 416-425. doi: 10.1002/ces2.10164

[42]Zhong X, Cao L, Huang J, et al. Properties and evolutions of high-performance porcelain thin ceramic plates enhanced by multi-phase microstructure derived from sustainable smoky quartz tailings. Ceramics International. 2023; 49(2): 2540-2548. doi: 10.1016/j.ceramint.2022.09.233

[43]Liu T, Deng C, Song J, et al. Preparation of self-foamed glass ceramics based on the cooperative treatment of various solid wastes: Characterization of structure-properties and analysis of self-foaming behavior. Ceramics International. 2023; 49(2): 2570-2582. doi: 10.1016/j.ceramint.2022.09.236

[44]Amorós JL, Blasco E, Moreno A, et al. Effect of particle size distribution on the sinter-crystallisation kinetics of a SiO2–Al2O3–CaO–MgO–SrO glass-ceramic glaze. Journal of Non-Crystalline Solids. 2020; 542: 120148. doi: 10.1016/j.jnoncrysol.2020.120148

[45]Baila F, Labbilta T, Darmane Y. Feldspar purification from iron impurities: a review of treatment methods. Mineral Processing and Extractive Metallurgy Review. 2023; 45(6): 564-572. doi: 10.1080/08827508.2023.2217322

Published
2025-04-07
How to Cite
Liu, C., Zhou, J., & Lu, J. (2025). Sinterability, structural evolution and pinhole elimination of high strength self-glazed glass-ceramics sintered from granite sludge by instant glaze firing. Materials Technology Reports, 3(1), 2851. https://doi.org/10.59400/mtr2851
Issue
Vol. 3 No. 1 (2025)
Section
Article

Copyright (c) 2025 Author(s)

Creative Commons License

This work is licensed under a Creative Commons Attribution 4.0 International License.