Synthesis and characterization of ceramic refractories based on industrial wastes

Abstract The possibility of reusing ceramic roller waste to produce cordierite and mullite refractories was investigated. Five batches were designed using wastes representing ceramic roller waste, magnesite, and silica sand, shaped and fired at 1300 °C/2 h, and one batch was selected at 1200 °C. The chemical composition and precipitated phases of the used raw materials and the fired batches were analyzed using XRF and XRD techniques, respectively. Densification parameters, morphology, microstructure and electrical properties were also studied to evaluate the effect of the formed phases on the properties of fired materials. Bulk density increases with an increase in mullite and a decrease in cordierite, and it also increases with increasing temperature, whereas porosity and water absorption show a opposite behavior to density (it decreases with an increase in mullite and temperature). The main phases developed after firing at 1300 °C/2 h were cordierite, mullite, corundum, baddeleyite, and spinel. Bending strength increases with increasing mullite percentage and density, and decreasing grain size and porosity. The microstructure develops and becomes finer with increasing mullite percentage and density. The grain size of the crystals was very fine at 1200 °C/2 h and increased at 1300 °C/2 h. Broadband dielectric spectroscopy was employed to study the electrical and dielectric behavior of the investigated samples. The increase in mullite concentration shows a remarkable increase in ε’, especially at lower frequencies, as it is three times higher than that of M10. At f > 103 Hz ε’, frequency independence is accompanied by an increase in mullite concentrations due to the lag of dynamics fluctuations after the alteration of the electric field. The generation of new free ions leads to the enhancement of conductivity as the mullite concentration increases.