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Investigation on the Utilization of Fly Ash for the Development of Porcelain Ceramics.

Investigation on the Utilization of Fly Ash for the Development of Porcelain Ceramics. Presented by Dr . T. K. Bhattacharya & S . K. Chakraborty . Govt. College of Engg. & Ceramic Technology 73 A. C. Banerjee Lane, Kolkata-10. Fly Ash in 20 th Century / 21 st Century.

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Investigation on the Utilization of Fly Ash for the Development of Porcelain Ceramics.

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  1. Investigation on the Utilization of Fly Ash for the Development of Porcelain Ceramics. Presented by Dr. T. K. Bhattacharya & S. K. Chakraborty. Govt. College of Engg. & Ceramic Technology 73 A. C. Banerjee Lane, Kolkata-10

  2. Fly Ash in 20th Century / 21st Century • Fly ash is an industrial waste material as a by product of thermal power station (annual production 110 million Ton / Annum, Country rank next to China ) • The present scenario in 21st century is that Fly ash is not an industrial waste material but an alternative source of ceramic raw material which can be used to produce value-added ceramic products. • Fly ash is an alumino-silicate type of material with an considerable amount of Fe2O3 , CaO, Na2O, K2Oas a fluxing materials.

  3. Fly Ash based Porcelain Ceramics • Fly ash is a prefired material containing mullite, Quartz and Glass. • The substitution of quartz as well as clay by fly ash due to the composition similarities. • The utilization of fly ash is not only solve the hazardous environmental problem but also maintain the proper reserve of conventional ceramic raw materials like clay, quartz etc.

  4. Application of Fly Ash in Indian Scenario

  5. Application of Fly ash in Ceramic Industry • Whiteware industry • Refractory industry • Glass industry • Glass Ceramics Composite • Others

  6. Table- 1 (Chemical Composition of Raw materials)

  7. XRD of Fly Ash

  8. Batch Composition : Table-2 (Quartz substituted Fly Ash based Porcelain)

  9. Table-3 (Clay substituted Fly Ash based Porcelain)

  10. Materials Processing (Lab scale & Tiny sector Industrial development). Raw Materials : (China Clay, Ball Clay, Fly Ash & Feldspar with proportionate Amount) ↓↓↓↓ Mixing / Wet Grinding in Ball Mill for 10 Hrs. ↓↓↓↓ Slurry ↓↓↓ Drying of the slurry at 1100C ↓↓↓↓ Powder ↓↓↓↓ Fabrication Extrusion ( Lab Scale ) Throwing By Potter Wheel( Pilot Plant) ↓↓↓↓ Drying ( at 1100C) ↓↓↓↓ Firing ( 11100C, 11500C, 12000C) ↓↓↓↓ Fired Product

  11. Characterization of fired body • B. D • A.P • Flexural Strength • Phase Analysis by XRD • Microstructure by SEM

  12. Bulk Density & Apparent Porosity of Fired Product.

  13. Flexural Strength of fired product

  14. Artisan at work on potter’s wheel

  15. glazing

  16. Loading and glost firing

  17. Product ready for glost firing

  18. Finished Product 1

  19. Finished Product 2

  20. Finished Product 3

  21. Conclusion • Incorporation of fly ash in porcelain composition is either by partial or full replacement of quartz or by clay. • The bulk density and apparent porosity is the function of Fly ash weight percent as well as firing temperature from 11000C to 12000C • The optimized percent of fly ash addition in quartz substituted fly ash based porcelain (QP) is 25 weight percent which gives maximum B.D = , A. P = and flexural strength = 52 MPa • The optimized percent of fly ash addition in clay substituted fly ash based porcelain (CP) is 20 weight percent which gives maximum B.D = , A. P = and flexural strength = 45 MPa

  22. The bisque fired body developed by throwing method ( Potter wheel ) shows almost white vitreous luster and the glost fired body shows fine and polished surface finished with a colour glaze. • The main crystalline phases of fired body is mullite together with unconverted quartz detected by XRD analysis • The microstructure of the fired sample is the presence of scaly type primary mullite aggregate together with needle shape secondary mullite crystal embedded in glass and few unconverted quartz rim is detected by SEM analysis.

  23. Acknowledgement • Principal, Faculties and staffs of GovtCollege of Engg. & Ceramic Technology, 73 A. C. Banerjee Lane. • Mr. MoloyDutta – proprietor of Terra Art Centre, Dakshin Para More, HarinathSen Road, Barasat, 24-Prg. (N).

  24. Thank You…..

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