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Applied Clay Science 118 (2015) 212–220

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Applied Clay Science

journal homepage: www.elsevier.com/locate/clay

Identification and traditional ceramic application of clays from the


Chouamekh region in south-eastern Tunisia
A. Bennour a,e, S. Mahmoudi b,⁎, E. Srasra c, N. Hatira b,e, S. Boussen d,e, M. Ouaja b, F. Zargouni d
a
Department of Geology, Faculty of Sciences of Bizerte, Zarzouna 7021, Tunisia
b
Department of Earth Sciences, Faculty of Sciences of Gabes, Zrig 6072, Tunisia
c
Laboratory of Physicochemical of Minerals Materials and its Applications, National Centre of Research in Materials Sciences, BP95, Hammam Lif 2050 Tunisia
d
Department of Geology, Faculty of Sciences of Tunis, 1060 Belvedere, Tunis, Tunisia
e
Industrial Rocks and Useful Substances Direction, National Office of Mines, charguia I, 3023, Tunisia

a r t i c l e i n f o a b s t r a c t

Article history: For the first time, Permo-Triassic clays collected from the Chouamekh region in south-eastern Tunisia have been
Received 8 July 2015 studied for their possible use in the ceramic industry. In terms of mineralogy, they can be considered illitic clays.
Received in revised form 22 September 2015 However, other clay minerals, such as kaolinite, I/Sm mixed-layer and chlorite are also present. The chemical
Accepted 27 September 2015
analysis indicates that these clays are notably siliceous. The alkali content (K2O + Na2O) is high (~4.2%), thus
Available online 22 October 2015
explaining why these clays can be fired at relatively low temperatures. The amount of alumina and iron oxide,
Keywords:
with an average of 15% and 6.3% respectively, is variable. The tests show that these clays have low to medium
Tunisia plasticity values (PI = 11–28%). The firing shrinkage and the expansion are limited. A lower firing and drying
Illitic clays temperature can be translated into significant energy savings. Technical tests show that the properties fall within
Ceramic properties the ceramic International Standards (ISO). Ceramic tiles and bricks prepared from these clays have suitable char-
Tiles and bricks acteristics without defects and can be classified in group BIII according to the European Standard NF EN159
(1991).
© 2015 Elsevier B.V. All rights reserved.

1. Introduction object of our characterization study, and the possibility of determining


their possible applications, are part of the Cheguimi formation. Despite
The clays of Tunisia have a wide range of applications mainly in the fact that the region studied (Tebaga in Médenine) has been the
the refractory and ceramic industries. Following the development subject of several studies (Mathieu, 1949; Termier and Termier, 1974;
and mutations that the Tunisian economy has witnessed, there has Bouaziz, 1995; Mejri et al., 2006), the work on the Permo-Triassic tran-
been insatiable demand for the use of clays in the ceramics industry sition is not abundant since the latter is still unclear due to continuous
(Fig. 1). detrital and a poor-in-fossils sedimentation.
The aim of the project is to contribute to the development of the The area studied is characterized by a red clay mass with a thickness
country's economic potential through the promotion of useful sub- of 240 m and covered of thin Quaternary deposits, and showing impor-
stances, and among them building materials. The project will support tant reserves.
the formal and informal private sector through recommendations and The study area is located 25 km west of the city of Médenine and in
appropriate actions within this context to promote the exploitation the center of the topographic map at 1/100,000 from Matmata, between
and the rational use of local materials. the coordinates UTMC: X = 607,700; Y = 3,693,000. The Chouamekh
There has been insatiable demand for the use of clays in the ceramics area is characterized of its heavy outcrops of gray clay of the late
industry. Accordingly, in the last few decades many studies have Permo-Triassic. These clays, with fine sandy layers, occupy the entire
been made on clays and their applications (Khemakhem et al., area between the towns of Halk el Jemel and Chouamekh. (UTMC: Uni-
2004; Mahmoudi et al., 2008; Baccour et al., 2008; Baccour et al., versal Transverse Mercator: Carthage-Tunisia, zone 32).
2009; Hajjaji et al., 2010; Hammami-Ben Zaied et al., 2015; Bennour
et al., 2015). 2. Materials and methods
The region studied in this work is in the Tunisian south, located in
the northern edge of the Saharan platform bordering the southern 2.1. Sample preparation
folded and faulted regions of the Atlas chain. Red clays, which are the
This study focused to characterize 8 samples named from the base
⁎ Corresponding author. ClayCh1 to tops of the section ClayCh8 taken from sedimentary
E-mail address: salahmahmoudii@yahoo.fr (S. Mahmoudi). Permo-Triassic material. In order to ensure a representative sample no

http://dx.doi.org/10.1016/j.clay.2015.09.018
0169-1317/© 2015 Elsevier B.V. All rights reserved.
A. Bennour et al. / Applied Clay Science 118 (2015) 212–220 213

Fig. 1. (a) The geological location and the synthetic lithostratigraphic log of the studied sector and (b) the importation of ceramic products (National Institute of Statistics of Tunisia).

less than 50 kg of clays are collected. The mixture sample was selected a In order to perform the technological tests, the clays were humidified
being representative of the Chouamekh region underwent a subsequent in 6% water content, mixed and sieved (Ø 1 mm) until a homogeneous
compositional and technological characterization. After extraction, they paste was obtained. Specimen tiles were prepared using 60 g of green
were initially dried at 105 °C until a constant weight was obtained, and material per test piece by pressing them at 200–250 kg/cm2 using
then they were powdered for 30 min. To prepare the oriented aggre- 100 × 50 × 10 mm molds and then drying them in air at room tempera-
gates, the clay fraction was purified through classical methods. The ture for one week and at 105 °C for 24 h.
raw material was completely decarbonated by adding a small amount
of 1 N HCl, and treated with H2O2 to eliminate any organic matter. The 2.2. Methods
material was washed five times with 1 N NaCl and excess salt was re-
moved by dialysis. The fraction b 2 μm was separated in a centrifuge, X-ray diffraction (XRD) patterns were recorded on a Philips X'Pert
and the suspension was dried at 60 °C (Grim, 1962; Srodon, 1981; diffractometer at the Energy Research and Technology Center (CRTE)
Bergaya et al., 2006). using CuKα radiation (1.5418 Å), on the bulk or powder samples and
214 A. Bennour et al. / Applied Clay Science 118 (2015) 212–220

Table 1
Mineralogical, chemical, and physical analyses of the Chouamekh clays.

Analyses Samples ClayCh1 ClayCh 2 ClayCh 3 ClayCh 4 ClayCh 5 ClayCh 6 ClayCh 7 ClayCh 8 Mixture of samples (M)

Raw materials (%) Phyllosilicates 70 43 59 78 63 32 78 73 53


Quartz 18 41 11 15 23 48 12 15 26
Dolomite 6 10 22 2 10 18 2 4 15
Feldspar 1 3 2 0 0 0 2 0 2
hematite 2 1 3 3 2 0 2 6 2
Calcite 0 0 0 0 0 0 0 0 0
Fraction b 2 μm (%) Illite 55 34 48 37 44 18 56 61 39
Kaolinite 14 8 8 9 18 14 16 11 13
Illite/Smectite 0 0 0 0 0 0 0 0 0
Chlorite 0 0 1 31 0 00 5 0 0
Chemical compositions (wt%) SiO2 54.82 64.57 41.2 53.64 48.89 61.89 47.89 48.61 49.51
Al2O3 16.98 11.81 13.91 16.39 14.88 9.75 19.72 18.7 14.95
Fe2O3 7.38 4.26 8.65 9.99 7.78 4.66 8.92 10.17 6.32
CaO 2.36 2.75 7.11 1.12 4.20 4.08 1.31 1.97 4.87
MgO 3.36 2.87 6.69 3.65 4.92 4.49 3.16 3.09 4.42
Na2O 0.28 0.24 0.40 0.28 0.24 0.16 0.92 0.52 0.49
K2O 3.60 2.67 3.15 3.87 3.33 2.62 3.95 3.93 3.08
SO3 0.14 2.67 0.44 0.23 0.16 0.27 0.58 0.19 0.42
LOI 10.09 8.90 17.68 10.12 13.79 10.73 11.65 11.26 13.7
CEC (meq/100 g of air-dried clay) – – – – – – – – 19
SS (m2/g) 73 39 55 51 62 55 87 79 73
Plasticity (%) LL 52 41 39 30 42 32 48 54 41
PL 20 21 25 20 25 19 20 22 22.5
PI 32 20 14 11 17 13 28 32 18.5

on the oriented aggregates (natural (N) and treated with ethylene blue index method. A suspension of 10 g of powdered clay and 100 ml
glycol (EG) and heated to 550 °C for 2 h (H)). The accelerating voltage of distilled water was prepared and mixed with the methylene blue so-
and filament current were maintained at 40 kV and 40 mA, respectively. lution (10 g/l). One drop of this suspension was then placed on a filter
The percentages of the different mineral phases were estimated by mea- paper and the value for the specific surface was derived from the quan-
suring the areas of representative peaks, using X'Pert HighScore Plus tity of the adsorbed methylene blue (Ferrari and Gualteri, 2006). This
software and PDF-4 (JCPDS-ICDD data base). The standard deviation method is commonly used in earth sciences. It is used to classify the ar-
was ±5%. gillaceous fraction activity and to detect sensible clays like smectite.
The major element compositions (SiO2, Al2O3, Fe2O3, K2O, Na2O, The plasticity parameters (liquid limit (LL), plastic limit (PL) and
MgO, CaO, MnO and TiO2) were determined by atomic absorption plastic index (PI), PI = LL − PL) were defined by Proust et al. (2004),
spectroscopy. Ancey (2007), Yu et al. (2007), and Modesto and Bernardin (2008).
Loss on ignition (LOI) was measured from the total weight after igni- These parameters were determined by the Casagrande method
tion at 1000 °C for 2 h. FT-IR spectra were recorded in the region (Casagrande, 1947; LCPC, 1987), in accordance with the French Stan-
400–4000 cm − 1 in an EQUINOX model 55 infrared Fourier transform dard NF P 94-051.
spectrometer, using the KBr pellet technique (about 2 mg of sample and The grain size analysis was carried out by sedimentation using a
200 mg of KBr were used in the preparation of the pellets). laser analyzer.
The cation exchange capacity was measured with the standard ace- The differential thermal analysis and thermal gravimetric DTA/TG
tate ammonium procedure (Meir and Nuesch, 1999; Bergaya et al., were obtained with a SETARAM type 124. The expansion and firing
2006). The specific surface area was determined with the methylene shrinkage were measured using an Adamel Lhomargy DM 15 dila-
tometer. The samples were heated from room temperature to 900 °C
at 10 °C/min.
The technological tests were performed on ten specimens of each
sample.
To determine the linear firing shrinkage, the bending strength and
the water absorption, ten flat pieces (100 mm × 50 mm × 10 mm)
were tested. The linear firing shrinkage was evaluated using the formu-
la: [(lf − ld) / ld] × 100, where ld and lf are the measured length of the
dried and fired samples respectively (ISO 10545-2, 1995). The bending
strength was measured with a three-point flexural method according
to the ISO 10545-4 (2004) norm. The average values of bending
strength were calculated with the equation: MF = 3FL/2bh2, where:
F = breaking load (kg), L = distance between supports (L =
29.67 mm), b = sample width (mm), h = sample thickness (mm).
The water absorption was determined from heated ceramic samples ac-
cording to ISO 10545-3 (1995). The pieces were soaked in water and
heated until boiling point was reached. The ceramic bodies were sepa-
rated from each other after being plunged in water in order to display
the largest free surface possible. The ceramic bodies were kept in the
boiling water for 2 h. When the water reached 35–40 °C, the ceramic
Fig. 2. XRD patterns of the clay fraction of mixture (M). (N) untreated sample; (EG) solvat- bodies were taken out, their surfaces dried, and the bodies weighed.
ed with ethylene glycol; (H) heated at 550 °C and the bulk sample. Q: quartz; Il: illite; Kao: The value of the water absorption (WA) was obtained as follows:
kaolinite; Phy: phyllosilicate; D: dolomite; H: hematite and Feld: feldspar. WA = [(wf − wi) / wi] × 100.
A. Bennour et al. / Applied Clay Science 118 (2015) 212–220 215

Table 2
Cation exchange capacities C.E.C. of common clay minerals.

Minerals Kaolinite Halloysite Illite Montmorillonite Vermiculite Chlorite

C.E.C. meq/100 g of air-dried clay⁎ 3–15 5–10 10–40 80–150 100–150 10–40
C.E.C. meq/100 g of air-dried clay⁎⁎ 1–10 – 10–50 80–200 150–250 b10
s.s. (m2/g)⁎⁎ 10–30 – 70–140 700–800 760 50–150
⁎ Grim (1962).
⁎⁎ Beaulieu (1979).

3. Results and discussion

3.1. Clay characterization

The mineralogical composition of the bulk and b 2 μm fraction is re-


ported in Table 1. All the studied samples show that illite is the major
clay mineral characterized by the (001) and (002) basal reflections at
10.02 and 5.01 Å, respectively (Fig. 2). Illite provides favorable proper-
ties to the clays for ceramic use (Carretero et al., 2002; Ferrari and
Gualteri, 2006; Sedmale et al., 2006; Wattanasiriwech et al., 2009).
See Table 2.
It is clear that the main sources of potassium are the feldspars and
the phyllosilicates. In this case, the distribution of potassium shows
that a great part of this element is probably combined with the illite,
as the positive correlation between illite and potassium suggests
(Fig. 3). This idea can be further confirmed by the low feldspar content
(b3%) and its absence in CH4, CH5, CH6 and CH8. In ceramics, it is pref-
erable not to use clays which are rich in iron oxide (in hematite) on one
hand, because it is an unwanted mineral in this industry due to its red
color (Stepkowska and Jefferis, 1992) and on the other hand, because
it can undergo reactions with the enamel layer to produce an undesir-
able color.
The b2 μm fraction indicates the predominance of illite (37 −
62%), a moderate presence of kaolinite (8 − 19%) and a minor
amount of interstratified I/Sm and chlorite. The total amount of
phyllosilicates ranges from 32 to 79%, whereas the non-clay minerals
in the bulk samples are quartz (11 − 42%), (2 − 23%) and hematite
(0 − 7%).
Fig. 3. Correlation between: (a) potassium and illite; (b) iron oxide and hematite of the
studied clays.

Table 3
Particle-size distribution of the studied samples.

Fraction (μm) Weight (%)

N 600 1.5
400–600 5.1
315–400 4.0
250–315 4.4
160–2500 4.8
100–160 5.2
80–100 5.5
40–80 5.7
b40 63.8

Table 4
Technical parameters of the ceramic bodies prepared from the studied clays.

Product Temperature Drying Firing Water Flexural Weight


(°C) shrinkage shrinkage absorption strength loss
(%) (%) (%) (N/mm2) (%)

Bricks 800 5.71 0.1 14.39 – 5.52


850 0.19 14.33 – 7.59
900 1.78 13.56 – 7.67
Tiles 950 0.74 1.56 13.08 25.67 11.38
Fig. 4. Infrared spectra of mixture (M)of the sample clays from the Chouamekh region
1050 1.56 12.74 26.24 11.8
(a) raw sample and (b) purified sample: wave number ranging between 400 and
1100 2.86 7.77 38.86 11.9
4000 cm−1.
216 A. Bennour et al. / Applied Clay Science 118 (2015) 212–220

The IR spectrum of the raw materials (Fig. 4) shows the presence of


illite and kaolinite as stretching bands at 3698 and 3621 cm−1, respec-
tively. Moreover, the bending bands at 914 and 696 cm−1 are character-
istic of kaolinite and other dioctahedral clay (Caillère et al., 1982). The
main non-clay mineral was quartz detected by the doublet at 779 and
798 cm−1 (Farmer, 1974). The large band near 1035 cm−1 corresponds
to the Si–O stretching vibration. The bending bands are at 535 cm−1 for
Si–O–Al, at 471 cm−1 for Si–O–Mg and at 431 cm−1 for Si–O–Si (Van
Der Marel and Beutelspacher, 1976).
The chemical compositions of the raw materials are reported in
Table 1. All samples contain major amounts of silica (41–65%), alumina
(9–20%) and iron (4–10%). The percentage of potassium (2.6–3.9%) is
also quite high in all samples, suggesting the presence of illite. This
has already been ascertained in the mineralogical analysis. A great
part of the iron content depends on the hematite ratios. A positive cor-
relation between iron and hematite can be observed (Fig. 3). This iron
content (with an average of 6.3%) is homogeneous; it reflects the unifor-
mity and stability of the tonality of color after firing (Klaarenbeek, 1961;
Kreimeyer, 1987).
The loss on ignition varies from 8 to 18% and the detected values are
attributable to the carbonate decomposition. Fig. 6. Bigot curve of mixture (M) of the sample clays from the Chouamekh region.
Concerning the physical parameters (Table 1), the specific surface
area and CEC were found to be on average 73 m2/g and 19 meq/100 g
of air-dried clay. These low values are explained by the presence of im- The grain size distribution of one representative clay mixture (M) of
purities (carbonates, quartz, hematite, etc) in these clays and the abun- eight clay samples was measured (Table 3) showing the following
dance of illite. points:
The plasticity parameters of the studied clays are illustrated in
Table 1 and show that the liquid limit varies between 30 and 52%. The − The fraction below 40 μm is high (63.8%), which plays a crucial role
plastic limit oscillates between 19 and 25%. These parameters, plotted in the properties of fresh pastes and can facilitate cohesion and com-
on a Holtz and Kovacs (1981) diagram (Fig. 5) indicate that these paction.
clays belong to the illitic clays, having poor or low to medium or moder- − The fraction above 40 μm is high (63.8%) showing a homogeneous
ate plasticity. The high content of quartz, the lack of interstratified I/Sm distribution. The problem arising by the presence of high particles
and the absence of expandable or swelling clays such as smectite and can be solved by simply crushing and sifting.
vermiculite tends to decrease the liquid limit, the plasticity index, the
CEC and SS. This result is in agreement with the X-ray diffraction results.
On the other hand, these plasticity values are suitable and encouraging 3.2. Technical characteristics
for optimal behavior in pressing (cohesion) and drying (negligible con-
traction and easy to dry) which are in agreement with the range defined To know the drying behavior, the Bigot curve was obtained for the
in the literature for ceramic production (Van der Merwe, 1964). clay mixture (M) as shown in Fig. 6. The test showed that the studied

Fig. 5. Position of the studied clays on the Holtz and Kovacs diagram.
A. Bennour et al. / Applied Clay Science 118 (2015) 212–220 217

Fig. 7. TGA/TDA curves of mixture (M)of the sample clays from the Chouamekh region.

sample contains 8.6% moisture water and 12.9% interlayer water. The − The second exothermic peak appears at 319 °C, corresponding to the
maximum shrinkage was 5.4% on drying at room-temperature suggest- decomposition of organic matter, with a weight loss of 1.2%.
ing a fast drying property. The parameters of Bigot curve, indicated that − The third endo-reaction for decarbonation is detected at 694 °C and
clay mixture (M) is characterized by moderate drying behavior and is followed by a weight loss of 3.6%.
don't requiring the addition of a degreaser (Bennour et al., 2015). In
the ceramic industry, the clay materials undergo drying and firing Concerning the DA curve of clay mixture (M), Fig. 8 shows a
steps; these processes can be conducted via the Bigot curve, DTA/TGA first expansion near 150 °C due to a departure of water. The heat
and dilatometric analyses DA (Figs. 6, 7 and 8). The Bigot curve is fre- treatment shows the existence of an inflection point between 500
quently used to select the best mixture for a ceramic product and and 600 °C attributed to the polymorphic α to β transition of
gives information on the aptitude of clays to dry and their capacity to quartz. The second expansion is detected between 600 and
expel or retain water (Ratzemberger, 1990; Tari and Ferreira, 1997). 850 °C; typical characteristic plateaus of illitic clays (Cizeron,
Both aspects are very important in the manufacture of a ceramic 1985). The expansion value is 2.8% at 748 °C; this phenomenon is
product. accompanied by rapid shrinkage due to vitrification. The chemical
The DTA/TGA curves of the representative sample of the Chouamekh analyses show a high content of Fe2 O 3 and K 2 O, which accelerate
clays are shown in Fig. 7 with the following effects: the vitrification. This shrinkage is perturbed by an additional expan-
sion which is attributed to the entrapment of CO2 resulting from the
− The first endothermic peaks at 170 and 227 °C, proving the removal decomposition of carbonates (Peters and Iberg, 1978). The final
of weakly bound water, with the weight loss being 2.2 and 1.1%, re- shrinkage is relatively low (0.8%) because the studied clays consist
spectively. mainly of illite and quartz.

Fig. 8. Dilatometric curve of clay mixture (M) of the sample clays from the Chouamekh region.
218 A. Bennour et al. / Applied Clay Science 118 (2015) 212–220

Fig. 9. Powder X-ray diffractograms of clay mixture (M)of the sample clays from the Chouamekh region calcined at 300, 600, 800, 1000 and 1200 °C. Reflections in the diffractograms are
identified as: Q: quartz;Phy: phyllosilicate; K: kaolinite; I: illite, Feld: feldspar; D: dolomite; H: Hematite; An: Anortite; W: wollastonite; Geh: Gehlenite and Sp: Spinel.

3.3. Study of the thermal behavior by XRD The gehlenite (2.85 Å), Ca2 Al2 SiO7, and the anorthite CaAl2 Si2 O8,
are considered the result of the multistage solid state reactions between
The mineralogical changes during the firing process were analyzed the clay matrix and carbonates. Gehlenite is an unstable intermediate
by X-ray diffraction. The X-ray difractograms of the raw clays after phase formed from metakaolinite and calcium oxide recorded in sample
heating at 300, 600, 800, 1000 and 1200 °C for 3 h are given in Fig. 9. clays which are rich in carbonate when processed at 1000 °C. (Azzouz et
Kaolinite disappeared completely at a temperature of 600 °C. Illite, al., 2011). This is in disagreement to what El-Mahhlawy (2008) and
on the other hand, gradually decreased until a temperature of 800 °C Manoharan et al. (2011) published, indicating that the presence of anor-
was reached. Dolomite and feldspar minerals underwent the same pro- thite in the fired specimens demonstrated that the firing process
cess as illite. From this temperature on, the destruction of kaolinite co- reached the equilibrium state thus suggesting that the reaction was
incided with the appearance of an amorphous product which could be completed. At 1200 °C, hematite, anorthite, quartz and spinel were the
metakaolinite (Kakali et al., 2001). Quartz and hematite were the only only crystalline phases in the sample.
minerals that resisted the ambient temperature to 1200 °C.
From 1000 °C onwards, remarkable changes were noticed. Accord- 3.4. Ceramic tests
ingly, new phases such as gehlenite, wollastonite and anorthite ap-
peared. Anorthite began to crystallize at 800 °C after the destruction of The technological properties of the ceramic tiles and bricks prepared
clay minerals and continued to increase until 1200 °C, whereas at this from the Chouamekh clays are reported in Table 4 and Fig. 10. The min-
temperature, gehlenite and wollastonite disappeared (Fig. 9). eralogical, chemical, physical and technical results of the Chouamekh
The hematite reflections appear higher than in the raw material, clays encourage the use of these materials for ceramic production.
suggesting the formation of a secondary iron oxide from the breakdown These results show similar characteristics to other clays which are cur-
of the phyllosilicate (Baccour et al., 2008; Escalera et al., 2014). rently used in Tunisia (e.g. Baccour et al., 2008; Mahmoudi et al.,

Fig. 10. Tested bricks and ceramic tiles of clay mixture (M) of the sample clays from the Chouamekh region.
A. Bennour et al. / Applied Clay Science 118 (2015) 212–220 219

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