FACULTY OF INDUSTRIAL TECHNOLOGY

DEPARTMENT OF CHEMICAL ENGINEERING

5TH YEAR RESEARCH AND DEVELOPMENT PROJECT

PRODUCTION OF CERAMIC TILES FROM BREWER’S

SPENT KIESELGHUR

NAME GARRETT MUTUMHA

STUDENT NUMBER N01522546T
SUPERVISOR MISS BHEBHE
CHAPTER 1: INTRODUCTION

1.0 PROJECT TITLE

Waste management.

1.1 PROJECT TOPIC

Production of ceramic tiles from brewing spent diatomaceous earth.

1.2 AIM
To investigate on the potential use of diatomaceous earth in production of ceramic tiles.

1.3 INTRODUCTION
This research aims at conducting an investigation on the potential use of brewing spent
diatomaceous earth also known as kieselghur in the production of ceramics. Brewing spent
diatomaceous earth is siliceous sediment with yeast and other organic matter restrained during
the filtration phase of beer production process [ CITATION ALB01 \l 1033 ] .Diatomaceous earth
occurs naturally as a deposit of hydrated silica, having originated from the siliceous skeletons of
very small aquatic plants known as diatoms.
Study of the composition of diatomaceous earth indicates that it is rich in silica which are a
critical raw material in ceramic production. The objective of this project is to fully investigate,
and summarize the existing literature in order to develop a comprehensive and solid knowledge
for the potential use of diatomaceous earth from the brewing process in ceramic production. It is
evident from the literature research that diatomaceous earth can be used in ceramic production.
This research will seek to explore this theory.
There is need for sustainable waste management of by-products of the brewing process so as to
safeguard the environment and adhere to environmental management systems requirements. A
step towards achieving the status of cleaner technology approach, diversification of huge waste
production and environmental preservation have focused attention on the recycling and
preservation of bio-resources including the brewer’s diatomaceous earth.
Table 1 COMPOSITION OF A HIGH GRADE DIATOMACEOUS EARTH

Component % Abundance
88.40

2|Page
 ]SiO2
Al2O3 2.05
Fe2O3 1.13
CaO 0.34
MgO 0.52
CO2 and H2O 6.08
[ CITATION HFP03 \l 1033 ]

1.4 STATEMENT OF THE PROBLEM

In the financial year F19 Delta Beverages, a clear beer manufacturer, was facing difficulties with
the sustainable management of diatomaceous earth which is used as a filter aid in the beer
brewing process. As a result temporary measures have been put in place such as disposing the
diatomaceous earth into the drain. Disposal of diatomaceous earth to the environment causes an
imbalance in the ecosystem due to high concentration of organic matter as a result of
biochemical oxygen demand. Hence environmentally friendly and an economically competitive
technology which is most suited to the geological and climatic condition should be explored.
Most of the diatomaceous earth is used for landfilling which is not satisfactory with regard to
environmental care[ CITATION JCo11 \l 1033 ] . Diatomaceous earth from the landfills can be blown
to nearby homesteads. Diatomaceous earth causes respiratory diseases. Exposure to crystalline
silica causes silicosis, a lung disease.

1.5 OBJECTIVES
 To determine the physical and chemical properties of diatomaceous earth
 To produce ceramic tiles from diatomaceous earth through dry pressing and sintering
 To carry out quality tests on ceramic tiles (water absorption, shrinkage, porosity, thermal
conductivity and compressive strength)
 To carry out a cost-benefit analysis

1.6 RESEARCH QUESTIONS

 Is the process technically and economically feasible?
 Is the process environmentally friendly?
 How does this research help my society?

1.7 JUSTIFICATION

3|Page
In recent years reuse and recycle of industrial wastes have attracted significant interest [ CITATION
Kae12 \l 12297 ]. The utilization of brewer’s spent kieselghur in tile production can contribute
significantly environmental and economic growth of the nation. Environmental benefits include
reduced need for disposing of spent kieselghur in landfills and effluent streams whereas the
economic benefits include job creation, value addition to the low value by-product and reduced
costs associated with kieselghur disposal.

Mining of sand is in the rise to meet the increasing demand in the construction sector, use of
diatomaceous earth would relieve sand from ceramic production. As raw materials contribute
greatly to the production of tiles, replacing comparably costly raw materials is attractive to tile
manufacturers (J. L Evanko, 2003).

1.8 SCOPE
This project is based on experimental data obtained from the factory’s effluent stream. It is
analytical and it shades more light on the production of ceramic tiles from kieselghur. All
conclusions and deductions made will be based on experimental results.

2.0 METHODOLOGY
Spent kieselghur is to be collected at Delta lagers, Southerton plant. The collected kieselghur will
be dried and characterized to determine its physical and chemical properties. Tile ceramics are to
be produced at varying sodium oxide concentrations. Product quality test which include hardness
test, thermal and electrical conductivity test and water absorption test are to be carried out to
determine the optimum production conditions

2.1 GANTT CHART

4|Page
5|Page
References
Bush, A., 2001. Diatomaceous Earth. Encyclopedia of Materials: Science and Technology, pp. 1550-1558.

J Coroado, J. S. G. R., 2011. Manufacture of Ceramic Bricks Using Recycled Brewing Spent Kieselguhr.
Materials and Manufacturing Processes , 26(10), p. 2.

Jayakody, S., 2010. What are Ceramic Materials and Their Uses, s.l.: s.n.

Kae-Long Lin, J.-L. S.-M. M., June 2012. Characteristics of Porous Ceramics Produced from Waste
diatomite and Purification Sludge. Environmental Engineering Science, pp. 2-3.

Liebau, F., 2012. Structural Chemistry of Silicates: Structure, Bonding, and Classification. s.l.:Springer.

Maria Cristina Tanzi, G. C., 2019. Organization, Structure, and Properties of Materials. Traditional
Ceramics, pp. 3-103.

Salomon, D., 2014. Advanced Ceramics. Advanced ceramics for Dentistry, pp. 103-22.

Taylor, H. F. P. W. a. L., April 2003. EVALUATION OF KIESELGUHR. EVALUATION OF KIESELGUHR AS BEER

FILTER AID, Volume 59, p. 393.

Wen-Tien Tsai, C.-W. L. K.-J. H., 2006. Colloid and interface science. Characterization and adsorption
properties of diatomaceous earth modified, p. 1.

Yuliya Kan, A. I. S. P. V. S. P. A. S. J. E., March 13-15, 2019. On the Fabrication of Diatomite Earth-based
Ceramics with Multiscale Porosity. Hong Kong, IMECS , p. 2.

6|Page