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ENERGY EFFICIENCY ENHANCEMENT IN THE PRODUCTION OF CERAMICS FOR ADVANCED APPLICATIONS: KEY PRINCIPLES
Abstract
Glass and ceramic industries fall into the category of energy-intensive emitting combustion gases and particulate matter to the air and considered as Integrated Pollution Prevention and Control installations both in the European Union and Russia. Since early 2000s, traditional sub-sectors including tile and brick manufacturing have been participating in a number of pilot projects intended to assess their environmental performance and energy efficiency evaluate opportunities for implementing Best Available Techniques (BATs) at Russian industries. Based on the results of these projects BATs have been identified and first national BAT standards developed. In manufacturing technical ceramics, a comprehensive study is yet to be done, while existing sector-specific BATs comprise mostly general approaches to energy consumption optimization and emissions control. Considering materials for advanced applications such as alumina, zirconia or carborundum, where these levels are determined by strict process parameters, a generally accepted practice is to reduce energy consumption by adjusting firing temperature. This allows on one hand, to improve environmental performance of the installations, and on the other hand, to suggest candidate BATs providing the desired effect, namely batch composition adjustment, liquid-phase sintering, and the use of eutectic sintering aids. The present research addresses a combination of these techniques in production of SiC-based structural ceramics including selection of additives based on their physico-chemical properties (melting point, surface interaction) and the use of pre-fabricated sintering aids with enhanced reactivity. The effects of the additives on sintering behavior were studied for a model material consisting of ultrafine SiC and a eutectic sintering aid in MgO ? Al2O3 ? Y2O3 system. Such ceramics demonstrated excellent mechanical properties (bending strength of 450 MPa, fracture toughness of 4.0 MPaВ·m1/2, and elasticity modulus of 380 GPa), and its sintering temperature didn?t exceed 1900 В°C. Commercially available samples of liquid-phase sintered SiC require firing temperatures above 2100 В°C, which makes this approach a practically suitable basis to develop an energy efficient SiC ceramics processing technology.
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