High-Performance Ceramic Stones from Waste Disposal sites in Eastern Donbass

This article shows the possibilities of using large – sized ceramic stones for modern housing construction. The article includes an overview of raw materials and technologies for their production. It is emphasized, that the most promising technology for the production of large-sized ceramic stones is the technology of rigid extrusion with the possibility of laying raw products on firing trolleys and accelerated modes of drying and firing. The characteristic of the screenings of processing waste heaps of the Eastern Donbass, which are by-products of coal mining, as the main raw material for the production of large-sized ceramic stones is given. The article presents their ceramic properties and the results of the selection of raw materials, including: screenings – 60–65%; siliceous clays – 20–30% coal sludge – 10–15%, based on which it is possible to obtain products with a reduced cost and increased strength for load-bearing wall structures. The features of the microstructure of a ceramic material based on the obtained raw mixtures with optimal porosity are noted. It is also shown that the involvement of waste heaps in the production of ceramic stones will make it possible to obtain products with a density of less than 800 kg/m³, a thermal conductivity of less than 0,20 m·°C) / Watt and a strength grade of M150 and higher, with a minimum net cost. This will create a serious competition for gas silicate products and achieve the level of use of ceramic stones in the total volume of wall products for residential construction of 80%, as in Western Europe.

A.N. BESKOPYLNY, Doctor of Sciences (Engineering),
Kh.S. YAVRUYAN, Candidate of Sciences (Engineering),
E.S. GAISHUN, Student (This email address is being protected from spambots. You need JavaScript enabled to view it.),
A.V. KOTLYAR, Candidate of Sciences (Engineering),
A.S. GAISHUN, Student (Engineering)

Don state University of civil engineering (1, Gagarina Square, Rostov-on-Don, 344010, Russian Federation)

1. Yavruyan Kh.S., Gaishun E.S. Analysis of the state of coal mining waste and its use in the production of ceramic products. Nauchnoe obozrenie. 2016. No. 24, pp. 40–46. (In Russian).
2. Yavruyan Kh.S., Gaishun E.S., Kotlyar V.D. Krupnorazmernyye vysokoeffektivnyye keramicheskiye kamni i bloki iz yacheistykh betonov v sovremennom stroitel’stve i arkhitekture. V kn. Arkhitektura. Stroitel’stvo. Dizayn: istoriya, opyt, novatsii. Monografiya. Kniga 2. [Large-sized high-performance ceramic stones and aerated concrete blocks in modern construction and architecture. In the book. Architecture. Building. Design: history, experience, innovation. Monograph. Book 2.] Voronezh: Voronezh State University. 2018, pp. 26–35.
3. Yavruyan Kh.S., Gaishun E.S., Kotlyar V.D., Serebryanaya I.А., Filippova A.А., Gaishun A.S. Selection of compositions of ceramic masses based on industrial wastes using mathematical planning methods. E3S Web Conf. Topical Problems of Green Architecture, Civil and Environmental Engineering 2019 (TPACEE 2019). 2020. Vol. 164. https://doi.org/10.1051/e3sconf/202016414017
4. Kotlyar V.D., Yavruyan Kh.S., Gaishun E.S., Terekhina Yu.V. Integrated approach to processing coal mining waste in Eastern Donbass. Municipal waste management as an important factor in the sustainable development of a metropolis. 2018. No. 1, pp. 115–118. (In Russian).
5. Yavruyan Kh.S., Gaishun E.S., Teryokhina Yu.V., Kotlyar V.D., The research on the sifting from Donbass refuse heap for manufacturing wall ceramic goods. MATEC Web of Conferences. 2018. Vol. 196(682):04055 DOI: 10.1051/matecconf/201819604055
6. Bozhko Yu.A., Lazareva Ya.V., Gaishun E.S. Phase transformations of siliceous clays in the process of firing ceramics Phase transformations of siliceous clays during ceramics firing. 63rd International Scientific Conference of Astrakhan State Technical University, dedicated to the 25th anniversary of Astrakhan State Technical University. 2019. (In Russian).
7. Fomina O.A., Stolboushkin A.Yu. Approbation of the method for studying the core-shell transition layer of ceramic matrix composites by the example of coal waste. Topical issues of modern construction of industrial regions of Russia. Proceedings of the II All-Russian Scientific and Practical Conference with International Participation. Novokuznetsk, 8–10 October 2019, pp. 123–126. (In Russian).
8. Gaishun E.S., Gaishun A.S., Yavruyan Kh.S. The use of raw coal-based materials for the production of ceramic stones. Aktual’nye problemy nauki i tekhniki. 2019, pp. 762–763. (In Russian).
9. Stolboushkin A.Yu. Perspective direction of development of building ceramic materials from low-grade stock. Stroitel’nye Materialy [Construction Materials]. 2018. No. 4, pp. 24–28. DOI: https://doi.org/10.31659/0585-430X-2018-758-4-24-28 (In Russian).
10. Yavruyan Kh.S., Kotlyar V.D., Gaishun E.S. Medium-fraction materials for processing of coal-thread waste drains for the production of wall ceramics. Materials Science Forum. 2018. Vol. 931, pp. 532–536. DOI: 10.4028/www.scientific.net/MSF.931.532
11. Kotlyar V.D., Yavruyan K.S. Wall ceramic articles on the basis of fine-disperse products of waste pile processing. Stroitel’nye Materialy [Construction Materials]. 2017. No. 4, pp. 38–41. DOI: https://doi.org/10.31659/0585-430X-2017-747-4-38-41. (In Russian).
12. Yavruyan Kh.S., Kotlyar V.D. Gaishun E.S., Complex processing of coal waste of the Eastern Donbass for the production of ceramic products. science-intensive technologies for the development and use of mineral resources. Naukoemkie tekhnologii razrabotki i ispol’zovaniya mineral’nykh resursov. 2019. No. 5, pp. 489–494. (In Russian).
13. Yavruyan Kh.S., Gaishun E.S., Kotlyar V.D., Okhotnaya  A.S. Features of phasea mineralogical conversions when burning wall ceramics on the basis of secondary materials for processing coal deposits of eastern Donbass. Materials Science Forum. 2019, pp. 67–74. https://doi.org/10.4028/www.scientific.net/MSF.974.67
14. Talpa B.V. Anthropogenic resources of carbon series of Eastern Donbass and prospects of their use in ceramic industry. Stroitel’nye Materialy [Construction Materials]. 2018. No. 8, pp. 58–61. DOI: https://doi.org/10.31659/0585-430X-2018-762-8-58-61 (In Russian).
15. Gaishun E.S. Ceramic stones made out of technogenic raw materials of the coal range. Topical issues of modern construction of industrial regions of Russia. 2019, pp. 235-236. (In Russian).