Clay hydration mechanisms and their effect on dustiness

Abstract Clays are employed in a wide variety of industries such as ceramic industry, manufacture of paper, rubber, etc. In this sense, it is well known that at industrial processes in which clayey materials are used, such as ceramic industry, in order to carry out some specific stages, the wetting of clays is commonly required. Moreover, it is also long established that wetting is an appropriated measure to reduce particulate matter emissions during clays storage and handling. The present study was undertaken to assess the influence of moisture on clay dustiness because, though the complex behaviour of the clay–water system has been known since antiquity, the mechanisms involved in clay hydration and their influence on dustiness are still not well understood. To encompass a wide range of specific surface areas, three clays and a kaolin were studied. Chemical and mineralogical analysis of these four raw materials was performed and their particle size distribution, flowability, true density, plastic limit, and specific surface area were determined. Raw materials dustiness was determined using the continuous drop method. As against what might intuitively be expected, the results showed that the relationship between moisture and dustiness was quite complex and strongly related to the hydration mechanisms. In this regard, to better understand the phenomena involved in the clay hydration process, a specific methodology was developed to estimate the critical points of the clay hydration process (regarding dustiness). This methodology can be readily applied to other clays or even to materials of different nature to predict the optimum moisture and, therefore, it could be employed to propose specific measures which could entail an improvement of outdoor and indoor air quality.