A factorial design was used to evaluate the effects of processing variables on the morphology and microstructural characteristics of titanium dioxide (TiO2) fibers produced by solution blow spinning (SBS). For this, tests were carried out varying TiO2 precursor content, feed rate, air pressure, polymer, and solvent. The TTIP concentration and feed rate statistically influenced the average diameters of the PVC/TiO2 system. The proper combination between polymer and solvent enables the obtaining of TiO2 nanofibers with similar morphologies either using hydrophilic or hydrophobic polymer, however, fiber diameter is influenced by type of system (polymer/solvent) used. Only the anatase crystalline phase was found in the fibers with the PVC polymer and THF solvent, while two crystalline phases were obtained in the fibers with PVP and alcohol, anatase and rutile, indicating that the variation of the polymer and solvent influences the crystalline phases of the TiO2 fibers studied.

The main objective of this work was to study the use of kaolin processing wastes in the production of steatite ceramics, emphasizing mechanical strength and dielectric properties. Steatite ceramics were prepared using mixtures of talc with fine and coarse particle kaolin wastes (7.5, 10 and 12.5 wt.%) sintered at different temperatures (1200, 1250 and 1300°C). After sintering, the specimens were submitted to mineralogical and microstructural characterization. Linear shrinkage, apparent porosity, flexural strength and dielectric properties were also evaluated. Results showed the formation of the crystalline phases protoenstatite and quartz for all produced ceramics. The results verified for porosity, mechanical strength and dielectric properties proved to be suitable for the application of this material in electrical insulation.

In this study, tubular ceramic membranes were prepared from a mixture of ball clay, talc and alumina. The mixture was characterized by the following techniques: particle size analysis, X-ray fluorescence spectroscopy (XRF), X-ray diffraction (XRD) and thermal analysis. Tubular membranes were produced by extrusion process and thermal treated at temperatures between 1025 °C and 1175 °C. The membranes were characterized by XRD, linear shrinkage, apparent porosity, flexural strength, mercury porosimetry, scanning electron microscope (SEM) and contact angle. To evaluate the efficiency of the membranes, permeability tests with distilled water and oil-in-water emulsion were conducted in a tangential flow system. The results showed that the sintering of the specimens promoted the formation of α-cordierite phase and directly influenced the physical and mechanical properties such as linear shrinkage, porosity and flexural strength. Separation tests revealed that these membranes promoted high oil-water separation efficiency with values above 99.0%.

RESUMO Resíduos de MDF (MediumDensityFiberboard) gerados nas indústrias de móveis de madeiras, geralmente, são depositados em locais inadequados, causando impactos ambientais. Este trabalho teve como objetivo desenvolver materiais porosos com a incorporação de resíduo de MDF (5, 10 e 15% de resíduo) em massas cerâmicas estruturais. As características mineralógicas, químicas e térmicas das massas foram analisadas. Corpos de prova (50mm x15mm x 5mm) foram conformados por prensagem uniaxial (13,3 MPa), os quais foram secos à 110 ºC/24 h e sinterizados à 750, 850 e 950 °C. Posteriormente, estes foram submetidos às seguintes caracterizações: absorção de água, densidade aparente, porosidade aparente e módulo de ruptura à flexão. As características mineralógicas e microestruturais, após queima, também foram analisadas. Os resultados evidenciaram que, até 10% do resíduo de MDF em forma de pó, poderá ser incorporado em massas cerâmicas estruturais para produção de materiais cerâmicos, como blocos porosos isolantes acústicos e térmicos. A porosidade aparente foi de 31,7%, a densidade aparente foi de 1,6 g/cm3 e o módulo de ruptura a flexão foi de 11,5 MPa.

ABSTRACT MDF industrial wastes (Medium Density Fiberboard) generated in the wood furniture industries, have been causing serious environmental impacts, since their improperly disponishment in the nature. In light of this, the purpose of this work is to develop new structural ceramic compositions, containing 5, 10 and 15% by mass of MDF waste. The mineralogical, chemical and thermal characteristics of the masses were analyzed. Test bodies (50mm x15mm x 5mm) were shaped by uniaxial press (13.3 MPa), which were dried at 110º C/24h and sintered at 750, 850 and 950 °C. Subsequently, these were subjected to the following characterizations: Water absorption, apparent density, apparent porosity and flexion rupture module. The mineralogical and microstructural characteristics, after firing, were also analyzed. The results showed that up to 10% of the residue of MDF in the form of powder could be incorporated into structural ceramic masses for the productions of ceramic materials, such as acoustic and thermal insulation porous bricks. The apparent porosity was 31.7 %, bulk density was 1.6 g/cm3, the flexural strength was 11.5 MPa.

The development of ceramic membranes with different geometries and compositions extends the possibilities of industrial applications, inducing advantages in terms of increased permeability, membrane area by volume module and chemical, thermal and mechanical resistance. The use of low-cost raw materials is a trend that has grown in scientific research. The aim of this work is to prepare membranes with hollow fiber geometry from alumina and residue of quartzite, by the technique of immersion precipitation in distilled water from a mixture of ceramic mass with a solution of polyethersulfone and, synthesized in temperatures of 1100 ºC to 1500 °C. The hollow fiber membranes were characterized by chemical analysis, X-ray diffraction, particle size distribution, scanning electron microscopy, apparent porosity, flexural strength and permeated water flow by the membranes. The results indicated that the sintering temperature has direct influence on the formation of the mullite phase, and the properties of apparent porosity and permeate flow. The higher the sintering temperature (1400-1500 ° C) increase the formation of the mullite phase, the lower the porosity, as well as the lower the permeate water flow in the membranes. However, there was increase in flexural strength in the hollow fiber membranes with high temperature.

The potential of using quartzite residues in the composition of an industrial ceramic mass for porcelain tile production was investigated through experimental design. Chemical, physical and microstructural analyses were accomplished to understand how the incorporation of quartzite residues affects the material, before and after sintering. Central composite design was used to analyze the effects of firing temperature (1143; 1160; 1200; 1240; 1257ºC) and residue content (1.76; 3; 6; 9; 10.24 wt.%) on the physical-mechanical properties of the material, and regression models correlating these factors to the response variables linear shrinkage, water absorption, apparent density and flexural strength were adjusted. Firing temperature had statistically significant effect on the response variables, so that the elevation of its levels contributed to the properties improvement. Residue content presented non-significant effect. In conclusion, specimens containing quartzite residues, up to 10.24 wt.%, sintered at 1240 and 1257ºC, fulfil the ISO 13006 requirements for porcelain tiles.

The properties of ceramic materials and microstructural changes are dependent on the raw materials from which they are made and on the manner in which they are processed, from the composition to the established thermal treatment, heating rate, and firing temperature. In this study, the influence of some processing parameters (formulation, maturation time, and firing temperature) on the physical-mechanical properties and microstructural aspects of ceramic pieces produced from natural aluminosilicates was investigated. Because Brazil does not have many quality ball clays reserves, bentonite was included as a plasticizing agent in this study. The formulations were submitted to maturation for a period of one to four weeks and their characteristics were determined to evaluate plasticity. Following this, the specimens were extruded and subjected to heat at temperatures of 1200, 1300, and 1400ºC. The physical-mechanical properties determined were: water absorption, linear retraction, and flexural strength. Statistical analysis was applied. The results showed that, for the analyzed masses, neither the maturation time nor the physical and mechanical properties analyzed had influence on plasticity. The firing temperature was the factor that generated the greatest alteration in results, increasing the mechanical resistance and altering the size and interlocking of the mullite needles.

Mineral extraction and processing industries have been cited as sources of environmental contamination and pollution. However, waste recycling represents an alternative recovery option, which is interesting from an environmental and economic standpoint. In this work, recycling of kaolin processing waste in the manufacture of mullite-based ceramics was investigated based on the statistical design of mixture experiments methodology. Ten formulations using kaolin processing waste, alumina and ball clay were used in the experiment design. Test specimens were fired and characterized to determine their water absorption and modulus of rupture. Regression models were calculated, relating the properties with the composition. The significance and validity of the models were confirmed through statistical analysis and verification experiments. The regression models were used to analyze the influence of waste content on the properties of the fired bodies. The results indicated that the statistical design of mixture experiments methodology can be successfully used to optimize formulations containing large amount of wastes.