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<p>Belle Fourche Shale (BFS) is a large indigenous bentonitic shale deposit located in the northern plains of the United States. Because of the high content of smectite clays in BFS, warpage and shrinkage during the drying and firing processes often results in the cracking of BFS ceramics. Water-soluble polymers have proven effective for clay-abundant soil stabilization and polyacrylamide (PAM) was trialed as an amendment to BFS, but rendered the clay very sticky and unsuitable for further processing; consequently, PAM was abandoned as an amendment option. Consequently, cellulose fiber additives were the focus of this research. Macroscopic visual inspection of samples with 1 wt% cellulose amendment led to no or greatly reduced cracking during drying compared to unamended BFS samples of equivalent water contents. The resulting BFS green bodies, both with and without 1 wt% cellulose fiber addition, were subsequently analyzed with Scanning Electron Microscopy (SEM), X-Ray Diffraction (XRD), Differential Scanning Calorimetry (DSC), Thermogravimetric Analysis (TGA), micro X-ray Computed Tomography (micro-XCT) and mechanical testing to compare the efficacy of the cellulose amendment. It was determined that the fibers reinforce the processed BFS (green body) during drying, thus mitigating cracking. Furthermore, it was demonstrated by DSC/TGA and micro-XCT that the cellulose fibers decompose during the firing process and do not chemically alter the fired ceramic composition. The cellulose decomposition leaves microscopic pores in the ceramic. After firing, the ceramics with cellulose additions exhibited slightly higher bend strength than the plain ceramics. Micro X-ray computed tomography (micro-XCT) was performed to gain a better understanding of porosity in samples that either did not contain fibers or did contain fibers in the initial green body. Both materials (fired at 998&#xa0;°C) show a similar porosity of 2.6% for no paper, and 2.7% with paper. Pores in the unloaded sample appear large and globular while porosity in the fiber loaded sample appears as continuous filament type porosity.</p>

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Amending and Processing Indigenous Shale for Improved Ceramic Performance

  • 期刊论文

  • 发表日期：

    2025年11月13日

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  • Charles Thrift,
  • Brandon Stuber,
  • Jacob Petersen,
  • Jiaqi Jin,
  • Jon J. Kellar

摘要

Belle Fourche Shale (BFS) is a large indigenous bentonitic shale deposit located in the northern plains of the United States. Because of the high content of smectite clays in BFS, warpage and shrinkage during the drying and firing processes often results in the cracking of BFS ceramics. Water-soluble polymers have proven effective for clay-abundant soil stabilization and polyacrylamide (PAM) was trialed as an amendment to BFS, but rendered the clay very sticky and unsuitable for further processing; consequently, PAM was abandoned as an amendment option. Consequently, cellulose fiber additives were the focus of this research. Macroscopic visual inspection of samples with 1 wt% cellulose amendment led to no or greatly reduced cracking during drying compared to unamended BFS samples of equivalent water contents. The resulting BFS green bodies, both with and without 1 wt% cellulose fiber addition, were subsequently analyzed with Scanning Electron Microscopy (SEM), X-Ray Diffraction (XRD), Differential Scanning Calorimetry (DSC), Thermogravimetric Analysis (TGA), micro X-ray Computed Tomography (micro-XCT) and mechanical testing to compare the efficacy of the cellulose amendment. It was determined that the fibers reinforce the processed BFS (green body) during drying, thus mitigating cracking. Furthermore, it was demonstrated by DSC/TGA and micro-XCT that the cellulose fibers decompose during the firing process and do not chemically alter the fired ceramic composition. The cellulose decomposition leaves microscopic pores in the ceramic. After firing, the ceramics with cellulose additions exhibited slightly higher bend strength than the plain ceramics. Micro X-ray computed tomography (micro-XCT) was performed to gain a better understanding of porosity in samples that either did not contain fibers or did contain fibers in the initial green body. Both materials (fired at 998 °C) show a similar porosity of 2.6% for no paper, and 2.7% with paper. Pores in the unloaded sample appear large and globular while porosity in the fiber loaded sample appears as continuous filament type porosity.