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UNIVERSITI TEKNIKAL MALAYSIA MELAKA
THE INFLUENCE OF BENTONITE ON GLASS WASTE FILLED
SPENT BLEACHING EARTH (SBE) COMPOSITE.
This report submitted in accordance with requirement of the Universiti Teknikal
Malaysia Melaka (UTeM) for the Bachelor Degree of Manufacturing Engineering
(Engineering Materials) (Hons.)
by
NUR LIYANA BINTI MOHD DAUD
B051110237
880507065312
FACULTY OF MANUFACTURING ENGINEERING
2014
UNIVERSITI TEKNIKAL MALAYSIA MELAKA
BORANG PENGESAHAN STATUS LAPORAN PROJEK SARJANA MUDA
TAJUK: The influence of bentonite on glass waste filled spent bleaching earth (SBE) composite
SESI PENGAJIAN: 2013/14 Semester 2 Saya NUR LIYANA BINTI MOHD DAUD mengaku membenarkan Laporan PSM ini disimpan di Perpustakaan Universiti Teknikal Malaysia Melaka (UTeM) dengan syarat-syarat kegunaan seperti berikut: 1. Laporan PSM adalah hak milik Universiti Teknikal Malaysia Melaka dan penulis. 2. Perpustakaan Universiti Teknikal Malaysia Melaka dibenarkan membuat salinan
untuk tujuan pengajian sahaja dengan izin penulis. 3. Perpustakaan dibenarkan membuat salinan laporan PSM ini sebagai bahan
pertukaran antara institusi pengajian tinggi. 4. **Sila tandakan ( )
SULIT
TERHAD
TIDAK TERHAD
(Mengandungi maklumat yang berdarjah keselamatan atau kepentingan Malaysia sebagaimana yang termaktub dalam AKTA RAHSIA RASMI 1972) (Mengandungi maklumat TERHAD yang telah ditentukan oleh organisasi/badan di mana penyelidikan dijalankan)
Alamat Tetap: No. 24 Kampung Lembah Jamuan
33600 Kuala Kangsar
Perak Darul Ridzuan Tarikh: 23rd June 2013
Disahkan oleh:
Cop Rasmi: Tarikh: _______________________
** Jika Laporan PSM ini SULIT atau TERHAD, sila lampirkan surat daripada pihak berkuasa/organisasi berkenaan dengan menyatakan sekali sebab dan tempoh laporan PSM ini perlu dikelaskan sebagai SULIT atau TERHAD.
FAKULTI KEJURUTERAAN PEMBUATAN
Tel : +606 331 6019 | Faks : +606 331 6431/6411
Rujukan Kami (Our Ref) : Rujukan Tuan (Your Ref) :
23 Jun 2014 Pustakawan Perpustakaan UTeM Universiti Teknikal Malaysia Melaka Hang Tuah Jaya, 76100 Durian Tunggal, Melaka. Tuan/Puan, PENGKELASAN LAPORAN PSM SEBAGAI SULIT/TERHAD LAPORAN PROJEK SARJANA MUDA KEJURUTERAAN PEMBUATAN (MANUFACTURING PROCESS): NUR LIYANA BINTI MOHD DAUD Sukacita dimaklumkan bahawa Laporan PSM yang tersebut di atas bertajuk “The Influnce of Bentonite on Glass Waste Filled Spent Bleaching Earth (SBE) Composite” mohon dikelaskan sebagai *SULIT / TERHAD untuk tempoh LIMA (5) tahun dari tarikh surat ini. 2. Hal ini adalah kerana IANYA MERUPAKAN PROJEK YANG DITAJA OLEH SYARIKAT LUAR DAN HASIL KAJIANNYA ADALAH SULIT. Sekian dimaklumkan. Terima kasih. Yang benar, ________________ Tandatangan dan Cop Penyelia * Potong yang tidak berkenaan
NOTA: BORANG INI HANYA DIISI JIKA DIKLASIFIKASIKAN SEBAGAI SULIT DAN
TERHAD. JIKA LAPORAN DIKELASKAN SEBAGAI TIDAK TERHAD, MAKA
BORANG INI TIDAK PERLU DISERTAKAN DALAM LAPORAN PSM.
DECLARATION
I hereby declare this report entitled THE INFLUENCE OF BENTONITE ON GLASS
WASTE FILLED SPENT BLEACHING EARTH (SBE) COMPOSITE is the result
of my own research except as cited in the references.
Signature :
Author’s Name : NUR LIYANA BINTI MOHD DAUD
Date : 23rd June 2014
APPROVAL
This report is submitted to the Faculty of Manufacturing Engineering of UTeM as a partial
fulfillment of the requirements for the degree of Bachelor of Manufacturing Engineering
(Engineering Materials) (Hons.). The member of the supervisory is as follows:
...................................................................................
Dr. Zurina Binti Shamsudin
(Project Supervisor)
ABSTRAK
Tujuan utama projek ini adalah untuk menganalisa kesan yang dipengaruhi oleh bentonite
apabila digabungkan bersama lebihan peluntur bumi (SBE). Objektif utama projek ini
adalah untuk mengenalpasti komposisi yang paling sesuai untuk kaca komposit dan untuk
menilai sifat-sifat termo-fizikalnya. Selain itu, objektif lain adalah untuk mengkategorikan
mikrostruktur dan fasa di dalam kaca komposit ini. Kaca komposit digunakan kerana
kobinasi di antara kaca soda kapur (SLG), kaca borosilikat (BSG) bersama sisa semulajadi
(SBE) dan kelebihan kaca ini ada ia sangat bergantung kepada mikrostruktur dan fasanya.
Bahan-bahan yang digunakan dalam projek ini adalah SLG, BSG, SBE dan bentonite yang
mana ia digunakan sebagai pengikat. Nisbah peratus berat untuk SLG dan BSG telah
ditetapkan kepada 65% bagi kombinasi kedua-dua gelas. Serbuk kaca ini telah
disumbangkan oleh Pusat Penyelidikan Mineral (PPM) dalam saiz 75μm dan kemudian
ditapis ke saiz 45μm di UTeM. Nisbah peratus berat bentonite adalah 0wt%, 2wt%, 5wt%,
10wt%, 15wt% dan 20wt%; dibakar pada suhu 750°C dan 850°C dengan kadar pemanasan
2°C/minit. Nisbah lebihan sampel adalah SBE. Sampel telah dibentuk menggunakan
kaedah tekanan kering ekapaksi. Beberapa ujian telah dilakukan seperti ujian fizikal
(pemerhatian mata, ketumpatan dan penyerapan air), ujian mekanikal (kekerasan mikro)
dan ujian mikrostruktur (imbasan mikroskop elektron (SEM), tenaga serakan sinar-x
spektroskopi (EDX) dan pembelauan sinar-x (XRD). Selepas pembakaran,hasil sampel
adalah kasar. Walau bagaimanapun, selepas dikurangkan kandungan peratusan bentonite
kepada 0 dan 2wt%, rupa permukaan telah menjadi lebih baik. 10% kandungan bentonite
mempunyai kekerasan yang paling tinggi sebanyak 230kg/mm², yang mana sangat rendah
dan hanya boleh digunakan untuk kegunaan yang lembut seperti alat hiasan dalaman rumah
dan aksesori wanita. Kesimpulannya gabungan di antara komposisi ini tidak sesuai untuk
digabungkan bersama BSG kerana ia cenderung menyebabkan sampel menjadi lembut.
i
ABSTRACT
The aim of this project is to investigate the influence of bentonite on spent bleaching earth
(SBE) composite. The objectives of this project are to determine the suitable batch for glass
composites and to evaluate the thermo-physical properties. Other than that, the objective of
this project is to characterize the microstructure and the phases on the glass composites.
Glass composites are used due to the combination of soda-lime glass (SLG) and borosilicate
glass (BSG) powders with natural waste spent bleaching earth (SBE) and the specialty of
it, is depending on the microstructure and its phases. The materials used in this project
are SLG, BSG, SBE and bentonite which acting as the filler. The weight percent ratio for
SLG and BSG have been fixed to 65% for the combinations of both glasses. The glass
powders were supplied by Pusat Penyelidikan Mineral (PPM) in 75μm and were further
sieved to 45μm in ceramic laboratory. The bentonite weight percent has been
distinguished to 0wt%, 2wt%, 5wt%, 10wt%, 15wt% and 20wt%; sintered at 750°C and
850°C with the heating rate of 2°C/minute. The rest of the weight percent is SBE. The
samples were pressed using the uniaxial dry pressing method. A few testing have been done
like physical testing (optical observation, density and water absorption), mechanical testing
(microhardness) and microstructure analysis (scanning electron microscope-SEM, energy
dispersive X-ray spectroscopy-EDX and X-ray diffraction-XRD). The samples were rough
after the sintering process. However, after reducing the bentonite weight percent ratio to 0
and 2wt%, the surface appearance has improved. 10% of bentonite have the highest
hardness was 230kg/mm², which is very low and only can be used for simple soft
application like indoor home decoration and jewelry. BSG is not suitable to be mixed in
this composition because it caused the samples to be soft.
ii
DEDICATION
For my supportive family, lecturer, friends, UTeM, Pusat Penyelidikan Mineral, and
especially for my religion, race and country.
iii
ACKNOWLEDGEMENT
Bismillahirrahmanirrahim, in the name of Allah, the most gracious and most merciful. First
of all I would like to thank to Allah for his blessing to complete PSM I and PSM II
successfully. I would like to express my gratitude to those who gave me the possibility to
complete this PSM report. I am also grateful to Dr Zurina Binti Shamsudin for showing me
the road and helped me to get me started on the path to this final year project. Her
enthusiasm, encouragement and faith in me throughout have been extremely helpful. She
was also available for my questions and she was positive and gave generously of her time
and vast knowledge. She always knew where to look for the answers to obstacles while
leading me to the right source, theory and perspective.
A special thanks also goes to Pusat Penyelidikan Mineral (PPM) staff, Mr Khor Peng Siong,
Mr Aminudin Bin Mahmud, Tuan Haji Mohamad Haniza Bin Mahmud, Encik Mohd Idham
Bin Mustaffar, Puan Marlinda, Encik Suaid, Puan Zaidah Binti Sulaiman and other staff
for never get bored answering my curiosity and questions. They were also having given me
some materials like SLG, BSG and Bentonite. Other than that, they were also offered me
to use their facilities but due to time and distance constraints, I could not attend to their
offers.
I would also gratitude my thanks to Faculty of Manufacturing Engineering staff and my
project partners for giving full cooperation to complete this project. Last but not least,
thanks to everyone, especially my family for giving me an endless support to complete this
report.
iv
TABLE OF CONTENT
Abstrak i
Abstract ii
Dedication iii
Acknowledgment iv
Table of content v
List of Tables xi
List of Figures xiii
List of Abbreviations, Symbols and Nomenclatures xv
1. CHAPTER 1 : INTRODUCTION
1.1. Background 1
1.2. Problem Statement 4
1.3. Project Objectives 5
1.4. Scope of Studies 5
1.5. Outline of Thesis 6
1.6. Conclusion 7
2. CHAPTER 2 : LITERATURE REVIEW
2.1. Glass Waste 8
2.1.1. Definition of Glass 8
2.1.2. Definition of Glass Waste 9
2.1.3. Types of Glass 9
2.1.3.1. Soda Lime Glass (SLG) 10
v
a) Chemical Composition 11
b) Characteristics 11
c) Applications 11
2.1.3.2. Borosilicate Glass (BSG) 11
a) Chemical Composition 12
b) Characteristics 12
c) Applications 12
2.1.4. Properties of Glass Waste 12
2.1.4.1. Physical Properties 13
a) Density 13
b) Color 14
c) Dimensional Stability 14
2.1.4.2. Mechanical Properties 16
a) Thermal Properties 17
2.1.4.3. Microstructure and Phases 17
2.2. Natural Waste 18
2.2.1. Definition of Natural Waste 18
2.2.2. Spent Bleaching Earth (SBE) 19
2.2.3. Properties of SBE 20
2.2.4. Studies on SBE 20
2.3. Composites 21
2.3.1. Definition of Composites 21
2.3.2. Types of Composites 23
2.3.3. Properties of Composites 24
2.3.4. Studies on Glass Waste Composites 25
vi
2.4. Filler 25
2.4.1. Definition of Filler 25
2.4.2. Bentonite 25
2.4.3. Bentonite Usage in Composites 29
2.5. Properties Characterization 29
2.5.1. Definition of Properties Characterization 29
2.5.1.1. X-ray Diffraction Testing (XRD) 30
a) Working Mechanism 31
b) Advantages of XRD Testing 31
2.5.1.2. Hardness Vickers Testing (HV) 32
a) Working Mechanism 32
b) Advantages of Vikers Testing 33
2.5.1.3. Scanning Electron Microscopy (SEM) 34
a) Working Mechanism 34
b) Advantages of SEM 35
2.5.2. Density, Water Absorption and Porosity 35
2.6. Conclusion 37
3. CHAPTER 3 : METHODOLOGY
3.1. Scope of Project Work 38
3.2. Powder Preparation 40
3.2.1. Glass Waste Powder (SLG and BSG) 40
3.2.2. Spent Bleaching Earth (SBE) 41
3.2.3. Bentonite Powder 41
3.3. Sample Preparation 42
vii
3.3.1. Batching 42
3.3.1.1. Procedures 43
3.3.2. Sieving 43
3.3.2.1. Procedures 43
3.3.3. Pestle Mortar 44
3.3.3.1. Procedures 44
3.3.4. Mixing 45
3.3.4.1. Procedures 45
3.3.5. Forming 46
3.3.5.1. Procedures 47
3.3.6. Sintering 47
3.3.6.1. Procedures 48
3.3.6.2. Sintering Profile 49
3.4. Materials Characterization 50
3.4.1. Bulk Density, Porosity and Water Absorption 51
3.4.1.1. Procedures for Bulk Density 53
3.4.1.2. Procedures for Water Absorption 54
3.4.2. Hardness 55
3.4.2.1. Procedures 55
3.4.3. X-ray Diffraction (XRD) 56
3.4.3.1. Procedures 56
3.4.4. Scanning Electron Microscopy (SEM) 58
3.4.4.1. Procedures 58
3.5. Conclusion 59
viii
4. CHAPTER 4 : RESULTS AND DISCUSSION
4.1. Results 60
4.1.1. Physical Properties 61
4.1.1.1. Optical Observation 61
4.1.1.2. Density, Porosity and Water Absorption 65
4.1.2. Mechanical Properties 68
4.1.2.1. Microhardness Testing 68
4.1.3. Materials Characterization 70
4.1.3.1. X-ray Diffraction (XRD) 70
4.1.3.2. Scanning Electron Microscopy (SEM) and Energy Dispersive X-ray Spectroscopy (EDX) 71
4.2. Discussion 76
4.2.1. Physical Properties Analysis 76
4.2.1.1. Optical Analysis 76
4.2.1.2. Density, Porosity and Water Absorption Analysis 77
4.2.2. Mechanical Properties Analysis 78
4.2.2.1. Microhardness Analysis 78
4.2.3. Materials Characterization Analysis 79
4.2.3.1. XRD 79
4.2.3.2. SEM and EDX 80
4.3. Conclusion 81
5. CHAPTER 5 : CONCLUSION AND RECOMMENDATION
5.1. Optical Observation 82
5.2. Density, Water Absorption and Porosity 83
ix
5.3. Hardness 83
5.4. XRD 84
5.5. SEM and EDX 84
6. REFERENCES 85
7. APPENDICES
Appendix A
A1 Gantt Chart PSM I (Planned)
A2 Gantt Chart PSM I (Actual)
A3 Gantt Chart PSM II (Planned)
A4 Gantt Chart PSM II (Actual)
Appendix B
B1 Data for XRD Analysis
x
LIST OF TABLES
2.1 The most popular types of glasses. 10
2.2 Properties of BSG (Borosilicate Glass - Properties of Borosilicate Glass
(Pyrex/Duran) by Goodfellow Ceramic & Glass Division.
13
2.3 The density comparison between the compounding with and without SLG. 14
2.4 Mechanical Properties of SLG. 16
2.5 Thermal Properties of SLG. 17
3.1 The chemical composition of SLG and BSG. 40
3.2 The chemical composition of SBE. 41
3.3 The chemical composition of bentonite. 42
3.4 The batches for the project. 42
4.1 The optical observations result for sample C1, C2, B1 and B2. 62
4.2 Optical observations among B1, B2, C1, C2 and D1 samples. 64
4.3 The dry mass (D), suspended mass (S) and saturated mass (M) for samples C1, C2,
B1 and B2. 66
4.4 The porosity, water absorption and bulk density for sample C1, C2, B1 and B2.67
4.5 The hardness result for sample B1, B2, C1 and C2. 69
xi
4.6 SEM results for sample B1, B2, C1 and C2 with the magnifications of 50x, 200x and
500x. 72
4.7 EDX results for the element in sample C1, C2, B1, and B2. 74
xii
LIST OF FIGURES
1.1 Types of materials used in this project a) bentonite powder, b) borosilicate glass (BSG), c) soda-lime glass (SLG) and d) spent bleaching earth (SBE) 3
2.1 Shrinkage glass concrete with normal concrete. Mixture composition glass concrete 15
2.2 Life-cycle chain: extraction — production — consumption — waste. 18
2.3 The unprocessed SBE (wet palm oil dreg). 19
2.4 The tree diagram of composites. 23
2.5 The virtual of matrix and reinforcement. 24
2.6 The Classification of silicates. 28
2.7 The inside of XRD Testing Machine. 30
2.8 Hardness Vickers Testing Machine. 32
2.9 The indenter and indentation of HV machine. 32
2.10 The path of the electrons. 35
2.11 The digital balancer machine used to measure the density. 36
3.1 The scope of works for the project. 39
3.2 The pestle mortar. 44
3.3 The ball mill machine in UTeM laboratory. 45
3.4 The uniaxial die pressing machine in UTeM laboratory. 46
xiii
3.5 Schematic for the paths of surface energy reduction in sintering. Path 1 a) coarsening where small particles combine to form larger-sized particles and Path 2 b) the densification of particles followed by grain growth 48
3.6 Sintering profile at 750°C with 5°C per minute for heating rate. 49
3.7 Place the sample in the machine beam. 57
3.8 An example of XRD towards SLG and BSG glass tiles 57
3.9 SEM showing porosity a)through The thickness of the ceramic and b) on the electrode surface of the ceramic. 58
4.1 XRD results for sample B1, B2, B3, B4, C1 and C2. 71
4.2 SEM analysis for sample C1 with 500x magnification. 73
4.3 The porosity, water absorption and bulk density percentages for sample C1, C2, B1
and B2. 78
4.4 The mean hardness for the sample B1, B2, C1 and C2. 79
xiv
LIST OF ABBREVIATIONS, SYMBOLS AND
NOMENCLATURES
ASTM - American Standard Testing Material
B - Bentonite
BSG - Borosilicate glass
CaO - Calcium Oxide
CaAl2Si2O8 - Anorhite
EDX - Energy Dispersion X-ray Spectroscopy
ISO - International Organization for Standardization
K - Kelvin
KAl2(Si3Al)O10(OH,F)2 - Muscovite
LOI - Loss on ignition
mg - Mili gram
MPa - Mega Pascal
Na2O - Natrium Oxide
NaAlSiO4 - Carnegeite
PPM - Pusat Penyelidikan Mineral
xv
SBE - Spent Bleaching Earth
SEM - Scanning Electron Microscopy
SiO2 - Silicon Oxide, Coesite, Cristobalite
SLG - Soda-lime glass
XRD - X-ray Diffraction
Wt. % - Weight percentage
μm - Micron meter
°C - Degree Celsius
xvi
CHAPTER 1
INTRODUCTION
This chapter explains about the introduction of the product, covering the introduction,
problem statement, objectives, scope and the conclusion. Other than that, the structure of
the full report will be discussed in this chapter.
1.1. Background
Glass waste is unique, beauty and function-ability of glass composites has drawn interest
from many researches and manufacturer due to its special mechanical and physical
properties. It has attracted Stoneville to do research on it based on its uniqueness.
Stoneville is a company that produces products using waste glasses. The products are
usually beautiful, innovative, can be applied in many applications and eco-friendly
properties. Other than that, Stoneville is a well-known company for glass tile production,
which is made of waste glasses (Stoneville, 2012).
1
The aim of this project is to turn the waste into a beneficial product. Waste is used as the
main materials in this project. The purposes of using waste are to be environmentally
friendly and to save the cost of manufacturing a new product. Other than that, the usage
of raw materials such as silica can be reduced slowly.
There are several types of glasses, mainly are Borosilicate glass (BSG) and Soda-Lime
glass (SLG). Borosilicate glass waste comes from jars, glass kettle, mugs, cookware and
many more. Soda-lime comes from drinking glasses, bottles, wares and others. Both the
waste glasses are commonly used in production of tiles, slabs, dental composites cookware
and kitchen appliances. It is used for that application because it has low water absorption
(0.2%), low potential for scratches and can be repaired if scratched. Other than that, the
cost of producing a new glass product by using raw materials are increasing. Furthermore,
the source of raw materials is decreasing (J Dent Res, 1999; Condon, 1991).
Recycled Eco Glass compares favorably with that of other types of materials made of
recycled glass that are cheaper. Other benefits of this material include stain resistance,
hardness and color depth that creates a three dimensional effect (Stoneville, 2012).
The waste term also implied to natural resources. In Malaysia, there are a several types of
natural sources. Some of the natural waste in Malaysia are jute, kenaf, palm oil waste and
others. All the natural waste is safe to be used and not hazardous because it does not
contain any chemical composition (Smith and Sch Affer et al., 1999, pp. 761-763).
A recent study by Huda, 2012 reported that spent bleach earth (SBE) powder has
improved the hardness. However the studies only limited to the hardness measurement
based on the formulation between SBE and glass waste (SLG). Moreover, all
compounding needs a filler or also known as binder to increase and improve the properties
and to give a stronger bonding to the compounding.
2
The most important of the appearance of the ceramic product also need to be highlighted.
It has been reported, that additional filler such as Bentonite has shown an improvement in
the color appearance. Bentonite has been used as a binder in this project. Based on
previous studies by Liyana (2013) on BSG and SLG composite, the ideal addition of
Bentonite is between 5 to 10% of the formulation. If the temperature is too high, the
sample revealed burnt and changed in shape. Less Bentonite adding shows changes color
into more whiter. With the increasing of Bentonite, the color turned to brownish but less
change in shape has been observed.The results have proven that 10% of Bentonite have
improved the mechanical properties. The hardness shows approximately 400 HV and
ultimate tensile strength measured by flexural test approximately 35 MPa. Figure 1.1
shows the type of glass waste and filler.
(a)
(b)
(c)
(d)
Figure 1.1: Type of materials used in this project a) Bentonite powder, b) Borosilicate glass (BSG), c)
Soda-lime glass (SLG) and d) Spent Bleaching Earth (SBE) (Vasundhara Industries, 2011; Cargo
Handbook.Com, 2013).
3
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