Preparation and characterization of glazes from combinations of different industrial wastes

The work reported here involves the preparation and characterization of ceramic glazes made from combinations of different industrial wastes. The wastes were float glass, granite and lime shale (a raw material waste from the oil shale industry in São Mateus do Sul, state of Paraná, Brazil), which were used to replace natural raw materials in a proportion of up to 50% in weight. The compositions were formulated using the Seger method and prepared by conventional ceramic processing. The stabilized suspensions were applied in commercial wall tile and porcelain stoneware tile, which were sintered at temperatures of 1080 °C and 1150 °C, respectively, using two different heating cycle. Three compositions were developed, two of which yielded opaque glazes and one a transparent glaze. Linear thermal expansion coefficients (α) of 80.10−7 °C−1 to 100.10−7 °C−1, and glaze softening temperatures of 600–700 °C were characterized by dilatometric analysis. The glaze compositions showed chemical resistance against acid and alkaline attack after 96 h, showing a mass loss of less than 0.1% in weight. The surface hardness of the glazes determined by the Mohs scale, Vickers microhardness and abrasion resistance (PEI indices) were between 6–7, 3–3.7 GPa and 3–4, respectively. These properties are compatible with those of commercial glazes for wall tiles and porcelain stoneware ceramics.