Industrial Waste Application with Silicon as an Aggregate in Ceramic Products

Abstract

Keywords: Experimental; Silicon; Industrial Waste Sludge; Ceramic

1. Introduction

The chemical element used for semiconductor and microelectronic production is silicon (SI), which is also a component found in ceramic materials. During the cutting, lapping, silicon plate polishing and individual chip cutting process for the semiconductor production, an extremely fine particle residue is that composes the industrial

* Corresponding author. E-mail address: marcelo.araujo@cruzeirodosul.edu.br https://doi.org/10.29187/jscmt.2018.32

M. B. Araújo et al./ J Sustain. Construct. Mater. Technol. 4(1) (2019) 286–295

waste sludge. As it is a very fine granular material, the silica particles (silicon oxide) are spherical with diameter 100 times smaller than the cement particles and as they are thinner than the cement, such particles compose a framework with greater homogeneity reducing the spaces in the structure (interstitial) [1].

Due to these special features, the waste can be a different and innovative aggregate when mixed with the ceramic artifact traces.

According to the Brazilian Ceramic Association (ABCERAM), what distinguishes mineral clay from others is the kind of structure andthe substitutions that can occur inside the structure, mainly from aluminum to magnesium or iron, from silicon to aluminum or iron.Consequently, the residual charges are neutralized by different ion electric charges of some cations. This way, there is no replacement in the kaolinite, but there is in the illite and the neutralizing cation is the potassium; there are also replacements in the montmorillonite and the neutralizing cations can be the sodium, calcium, potassium and others. It illustrates the differences in the characteristics of interest for several technological applications. For example, clays that are made up of the mineral kaolinitemainly are the most refractory clays, as they are mostly made up of silicon (SiO2) and alumina (Al2O3), and the others are less refractory due to the presence of potassium, iron and other elements [2].

The proposal of reusing industrial waste can be taken into account as a business opportunity, as the search for ways to reduce the environmental impact created by waste is in the organization’s strategic management as a new innovation line and industrial entrepreneurship. Following this philosophy, we see that with the waste flow designed strategically it’s possible to get to a cycle closing which can be reached by the industrial ecosystem formation in which the power and material consumptionis optimized and the waste from a production process can be used as raw material for other processes [3].

In addition to the economic opportunities that come from reuse, reprocessing, and recycling, the sustainable businesses will lead their strengths in favor of their corporate and business image while societies will defend themselves by means of specific legislation and regulations [4].

2. Objective

In Brazil, this proposal comes with guidelines applicable to solid waste, in Chapter I of the Introductory provision in the National Solid Waste Policy (PNRS), Law No. 12,305/2010, Article 13, for law enforcement purposes, among the industrial waste we can list the industrial waste generated by the production processes and industrial facilities [5].

With regard to industrial waste, there is the concern about the toxicity level of these elements. Ecotoxicology tests must be done to evaluate the contamination risk level to humans and the environment. Tests with industrial waste sludge from the semiconductor industry were carried out to evaluate the possibility of acute toxicity using the bioindicator Eisenia Andrei organism in which no individual death was noted in the concentrations used, stating lack of acute toxicity for these organisms for 14 days [6].

Toxicity refers to the potential of a certain substance, product, or set of substancesto cause harmful effects in the organisms in which they are in contact with. These effects can be from behavioral changes, growth changes, or reproduction changes, evento theorganisms’ death. In order to evaluate the degree of impact that a certain effluent can cause on the receptor body, toxicity tests are carried out and the purpose is to simulate in laboratories the

M. B. Araújo et al./ J Sustain. Construct. Mater. Technol. 4(1) (2019) 286–295

effects that could be noted in the receptor body after the release of the effluent. Toxicity and Ecotoxicological tests are synonyms to set up the main ecotoxicology tool to evaluate effluents toxicity [7].

To evaluate the addition of industrial waste sludge possibility as value-added material to the ceramic artifact traces, tests with the addition of sludge were carried out in laboratories and empirically added in a proportion of 20% from 0 to 100% for clay and for dehydrated silicon waste.

In a study carried out by Ramos regarding clay characterization used for structural ceramics it was noted that most of the samples presented particle-size distribution suitable for structural ceramics production and the samples showed high plasticity level and the materials analyzed are mainly composed of quartz, smectite clay mineral, kaolinite, mica, feldspar and an aluminum silicate hydroxide that concluded that the physical mineralogy is very important to understand the clay processing behavior and evaluate its suitability for the use of industrial ceramic [8].

It’s noted that the ceramic artifacts studies have been increasing in the science field and in academic research from the primary inputs to the recycling.

Ceramic waste can be turned into aggregate ground rocks instead of rough aggregate and the experimental study showed that the ceramic waste recycling is feasible as a gross aggregate for the nonstructural concrete artifacts production [9].

In another research ceramic coating waste in the cement production as tile waste shows pozzolanic properties and chemical and physical properties of the cement and they are in conformity with the cement standard to the addition of 35% of tile waste [10]. As the purpose of this study is to evaluate the performance and dimensional characteristics of mass and resistance for the reuse of waste that comes from the semi-conductor production as a ceramic aggregate, this possibility of reuse can reduce the environmental impact regarding disposal and contribute as new ceramic aggregate materials.

3. Methodology

This research proposal was to evaluate changes in the dimensional characteristics of mass and resistance of the samples for the ceramic artifacts production with the addition of silicon waste from the semiconductor production process. The tests were carried out in May 2016 in the Laboratory of Processing and Material Characterization from the Technology College in São Paulo and the experiment steps were divided as follows: a. b. c.

Industrial waste sludge moisture drying and measurement, Test specimen production and burn, Specimen bending tests.

a– Industrial waste sludge moisture drying and measurement In the sludge drying process two approaches were used (oven and humidity scale) the high content of moisture in the sludge of approximately 92% is seen in Table 1 and Table 2. The sludge dehydration operation occurred for 7 days at 90 ⁰C in a Digital timer multiprocessor oven and the dehydration operation occurred for 30 minutes at 118 ⁰C in the moisture scale.

M. B. Araújo et al./ J Sustain. Construct. Mater. Technol. 4(1) (2019) 286–295

b – Test specimen production and burn For theproduction of the testspecimen, there were 2.5 kilograms of silicon industrial waste sludge in the Digital Timer microprocessor oven Sterilifer at 90 ⁰C for 48 hours for dehydration. After drying, there was a gain of 0.250 kilograms that were ground until obtaining a very fine aggregate as it’s shown in Figure 2.

M. B. Araújo et al./ J Sustain. Construct. Mater. Technol. 4(1) (2019) 286–295

Table 3 shows the mixture proportions of clay and silicon powder for the production of 18 rectangular testpieces in a scale from 0 to 100% of clay and silicon that were produced in a hydraulic press Shimadzu model and 120 kN capacity. The samples were pressed at 40 kN with the following dimensions described in Table 4 and noted in Figure 3.

M. B. Araújo et al./ J Sustain. Construct. Mater. Technol. 4(1) (2019) 286–295

The test specimenwere wrapped in an oven as a muffle furnace for 24 hours at an increasing temperature from 0 to 1000 ⁰C with one hour rest after the burnwas complete, as it’s shown in Figure 4. According to the Brazilian Ceramic Association, after drying, the pieces must undergo a thermal treatment at high temperatures and for most of the products, the temperature is between 800 ⁰C to 1700 ⁰C, in continuous or intermittent ovens.

M. B. Araújo et al./ J Sustain. Construct. Mater. Technol. 4(1) (2019) 286–295

c- Bending test After the cooling of the test specimen as seen in Figure 5, these were subjected to bending test in the universal machine for traction mechanical tests, compression and bending; model EMIC DL-10000, maximum capacity of 100 kN as shown in Figure 6.

4. Results

It was seen that the industrial waste sludge is composed of high humidity reaching 92% in a mass of water. This result may influence in water saving to preparing ceramic mass traces. Even empirically, the burn process of the test specimens suggested a considerable change in the masses. Table 5 shows that as some proportions of residual were added to clay, the average mass has had an important reduction achieving a difference of 2.38 grams, which represents 30.8%. Table 5. Difference in mass and percentage

M. B. Araújo et al./ J Sustain. Construct. Mater. Technol. 4(1) (2019) 286–295

Table 6 shows a variation in the dimensions of the samples after burn which is compatible with the drying process of the mass.

Table 6. Mass and dimensions before and after the samples burn

Table 7 bending tests have shown a significant reduction of the mechanical resistance when residues were added to the clay. In case of ceramic blocks width smaller than 90 mm, the least demanded compressive strength is 2.5 MPa. [11]. To the test specimen with their own dimensions shown in Table 6, after mechanic bend tests, maximum bend load (critical) was obtained as shown in Table 7. We see that as the silicon proportion increases in the traces of materialcomposition of the testspecimen, the mechanical resistance to bending is reduced.

M. B. Araújo et al./ J Sustain. Construct. Mater. Technol. 4(1) (2019) 286–295

5. Conclusion

In the ceramic artifacts industry, the basic material used is clay, which has silicon in its composition. Recyclingindustrial waste sludge as an aggregate will lead to the sanitation of two environmental problems: sludge disposal at the end of the semiconductors production chain, and the obtainment of feedstock to the beginning of the ceramic artifact production chain. We understand that using industrial waste sludge, especially in the ceramics sector, depends on larger studies and research for the production of artifacts. In this regard, it is necessary to perform more mechanical tests following the parameters imposed by Instituto Nacional de Metrologia, Qualidade e Tecnologia (INMETRO). In addition, toxicity tests suggest the possibility of reuse of residue as an opportunity of feedstock to ceramic sector. References 1. Fonseca, G.C., (2010). “Adições minerais e as disposições normativas relativas à produção de concreto no Brasil: Uma abordagem epistêmica”, Tese, Universidade Federal de Minas Gerais. Programa de PósGraduação em Construção Civil, Belo Horizonte 2. Abceram., (2017). “Matérias Prima Naturais”. [ONLINE] Associação Brasileira de Cerâmica. Available at: http://abceram.org.br/materias-primas-naturais/# 3. Costa, M.I.L., Silva, E.R., Mattos, U.A.O., (2012). “20 anos de eco-eficiência no Brasil: De estratégia de negócios a princípio de Política Pública”, Revista Brasileira de Gestão e Desenvolvimento Regional, Vol. 8, No 1, 3-28 4. Leite, P.R., (2009) “Logística reversa: Meio ambiente e competitividade”. São Paulo: Pearson Prentice Hall 5. Brasil., (2010) “Lei nº 12.305 de 2 de agosto de 2010”. Institui a Política Nacional de Resíduos Sólidos. Diário Oficial [da] República Federativa do Brasil 6. Balsamo, P., Martins, C.A., Chagas, R.C.C., Souza, B.S.S., Gomes, A.L.S., Cacuro, T.A., Brejão, A.S., Irazusta, S.P., (2016). “Ecotoxicidade do efluente e lodo da ETE de uma indústria de eletroeletrônicos”. XIV Congresso Brasileiro de Ecotoxicologia. 07-10 de Setembro, Curitiba 7. Arenzon, A., Neto, T.J.P., Gerber, W., (2011). “Manual sobre toxidade em efluentes industriais”. Federação das Indústrias do Rio Grande do Sul – (FIERGS) - Conselho de Meio Ambiente – (CODEMA) – 42 p. Porto Alegre 8. Ramos, S.O., Macedo, R.S., Cartaxo, J.M., Menezes, R.R., Navarro, L.N.L., Neves, G.A., (2010). “Caracterização de argilas usadas para cerâmica estrutural”. Revista Eletrônica de Materiais e Processos, Vol.5, No3, 65-70 9. Tabak, Y., Kara, M., Günay, E., Yildirim, S.T., Yilmaz, Ş., (2012). “Ceramic tile waste as a waste management solution for concrete”. 3rd International Conference on Industrial and Hazardous Waste Management – Crete 10. Ay, N., Ünal, M., (2000). “The use of waste ceramic tile in cement production”. Technical Note. Pergamon. Elsevier Science Inc. Cement and Concrete Research Vol. 30, 2000, pp.497-499.

M. B. Araújo et al./ J Sustain. Construct. Mater. Technol. 4(1) (2019) 286–295

11. Inmetro., (2017). “Bloco Cerâmico”. [ONLINE] Instituto Nacional de Metrologia, Qualidade e Tecnologia. Available at: http://www.inmetro.gov.br/consumidor/produtos/tijolo.asp.

References

1. Fonseca, G.C., (2010). “Adições minerais e as disposições normativas relativas à produção de concreto no Brasil: Uma abordagem epistêmica”, Tese, Universidade Federal de Minas Gerais. Programa de Pós- Graduação em Construção Civil, Belo Horizonte
2. Abceram., (2017). “Matérias Prima Naturais”. [ONLINE] Associação Brasileira de Cerâmica. Available at: http://abceram.org.br/materias-primas-naturais/#
3. Costa, M.I.L., Silva, E.R., Mattos, U.A.O., (2012). “20 anos de eco-eficiência no Brasil: De estratégia de negócios a princípio de Política Pública”, Revista Brasileira de Gestão e Desenvolvimento Regional, Vol. 8, No 1, 3-28
4. Leite, P.R., (2009) “Logística reversa: Meio ambiente e competitividade”. São Paulo: Pearson Prentice Hall
5. Brasil., (2010) “Lei nº 12.305 de 2 de agosto de 2010”. Institui a Política Nacional de Resíduos Sólidos. Diário Oficial [da] República Federativa do Brasil
6. Balsamo, P., Martins, C.A., Chagas, R.C.C., Souza, B.S.S., Gomes, A.L.S., Cacuro, T.A., Brejão, A.S., Irazusta, S.P., (2016). “Ecotoxicidade do efluente e lodo da ETE de uma indústria de eletroeletrônicos”. XIV Congresso Brasileiro de Ecotoxicologia. 07-10 de Setembro, Curitiba
7. Arenzon, A., Neto, T.J.P., Gerber, W., (2011). “Manual sobre toxidade em efluentes industriais”. Federação das Indústrias do Rio Grande do Sul – (FIERGS) - Conselho de Meio Ambiente – (CODEMA) – 42 p. Porto Alegre
8. Ramos, S.O., Macedo, R.S., Cartaxo, J.M., Menezes, R.R., Navarro, L.N.L., Neves, G.A., (2010). “Caracterização de argilas usadas para cerâmica estrutural”. Revista Eletrônica de Materiais e Processos, Vol.5, No3, 65-70
9. Tabak, Y., Kara, M., Günay, E., Yildirim, S.T., Yilmaz, Ş., (2012). “Ceramic tile waste as a waste management solution for concrete”. 3rd International Conference on Industrial and Hazardous Waste Management – Crete
10. Ay, N., Ünal, M., (2000). “The use of waste ceramic tile in cement production”. Technical Note. Pergamon. Elsevier Science Inc. Cement and Concrete Research Vol. 30, 2000, pp.497-499. M. B. Araújo et al./ J Sustain. Construct. Mater. Technol. 4(1) (2019) 286–295 295
11. Inmetro., (2017). “Bloco Cerâmico”. [ONLINE] Instituto Nacional de Metrologia, Qualidade e Tecnologia. Available at: http://www.inmetro.gov.br/consumidor/produtos/tijolo.asp.

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