Industrial Preparation of Bauxite-based Mullite Raw Material

Bauxite-based mullite grogs were prepared with grade 11 bauxite （ ≤ 3 mm ） and coal gangne （ ≤ 3 mm） as starting materials with formula of w （ Al2O3 ） = 68% - 72 %. Mill the mixture to particle size ≤ 0. 044 mm by wet milling to homogenize chemical composition. After shaping by wet extrusion and drying, the materials were fired at 1 550℃, 1 600℃ and 1 700℃ for 6 hours respectively. After cooling apparent porosity and bulk density of fired materials were tested. The results show as follows： the appropriate sintering temperature for bauxite-based mullite with homogeneous and consistent composition and microstructure and properties is 1 600℃, at which the mullite has apparent porosity ≤ 1.5%, bulk density ≥ 2.81 g · cm^3 and refractoriness under load is 1 610-1 650 ℃. Compared with the laboratory results, the sintering temperature is lowered about 100℃ , bulk density increased 0. 06 g · cm^3. The industrial feasibility of preparing bauxite-based mullite grogs with the processing is confirmed.

Effects of Brown Fused Alumina and Bauxite on Microstructure and Properties of Zero-cement Al_2O_3-SiO_2 Castables

Using brown .used alumina and top grade bauxite as main starting materials, ultrafine alumina, silica fume, and pure calcium aluminate cement as bonding system, the effcts of brown filsed alumina and top grade bauxite additions on the properties and microstructure of zero-cement Al2O3-SiO2 castables after dried at 110 ℃C and fired at 1 250℃ for 3 h were studied. The micro- structure was analyzed and discussed. The results show that the hot modulus of rupture of zero-cement Al2O3 - SiO2 castables at 1 250℃ is up to 22. 1 MPa when the bauxite addition is optimum at 12.5 wt%. The mullite formation mechanism in this castables is dissolutionprecipitation mechanism and the hot modulus of rupture of the castables is closely related to in-situ mullite formation. Compared with brown fused alumina, the top grade bauxite is more helpful to in-situ mullite formation and improvement of hot modulus of rupture of the castables.

Influence of Kyanite Content on Microstructures and Properties of Castables Containing Spherical Lightweight Mullite Aggregates

Five lightweight mullite castables were prepared using the lightweight mullite aggregate（M45A） with narrow particle size distribution and spherical shape,mullite powder（M45P）,kyanite powder,microsilica and Secar 71 cement as raw materials. After the specimens fired at 1100 ℃,1200 ℃ and 1300 ℃ for 3h,respectively,the effects of kyanite contents（ 8%,10%,12%,14%,16% by mass） on the physical properties,phase composition and microstructures were investigated through an X-ray diffractometer（ XRD）,a scanning election microscopy（ SEM） and a microscopy measurement method,etc. The results show that,for the specimens fired at 1300 ℃ with the kyanite content from 8%to16%, the bulk densities and apparent porosities change little,but the cold modulus of rupture and the crushing strengths decrease significantly,and the linear change rates increase from-0.87% to 0.64%. The most apposite mode is the specimen containing 12% kyanite fired at 1300 ℃, which has a high crushing strength of 29.3 MPa,a low linear change of 0.18%,an apparent porosity of 36.8% and a bulk density of 1.73 g/cm^3.

Preparation and Application of Bauxite-based Sintered Mullite Homogenized Grog in Ladle Castable

Preparation of bauxite-based sintered mullite homogenized grog was introduced and its application in ladle castable was studied.Two kinds of bauxite-based sintered mullite homogenized grogs were used,named as GA and GB,respectively.The results show that bauxitebased sintered homogenized grog with uniform components,stable microstructure and mullite as main crystal phase can be prepared using joint process of three-step homogenization,automatic component batching,wet cogrinding,high-temperature calcinations.It also indicates that carbon steel ladle castables with GA or composite aggregate of GA and GB as main materials have the same excellent general performance indicators,great erosion resistance,anti-strip performance and longer service life in field applications,and compared with castables with single aggregate of GA,the castables with aggregate of GA and GB as main materials had higher cost performance because of lower bulk density of GB.

Research on thermal shock resistance of mullite-bauxite-silicon carbide castable refractory

Effects of different silicon carbide contents on thermal shock resistance properties of mullite-bauxite castable refractory were analyzed respectively by taking the mullite,bauxite as main raw materials and taking calcium aluminate cement as a binding system.After 24 h curing in mould and another 24 h curing at 110℃ after demoulding,the samples were heated at 1000,1300 and 1500℃for 3 h in air,respectively.The bulk density,thermal expansion coefficient and thermal shock resistance were examined.The results showed that there was a great effect of content of SiC on bulk density,thermal expansion coefficient and thermal shock resistance of mullite-bauxite castable.Under the experimental conditions,the castable performed the best thermal shock resistance when w(SiC)=5%-10%.

Effect of TiO_2 on the Sinterability and Microstructure of Mullite Sythesized from Al(OH)_3 and SiO_2

Using analytical pure Al（ OH）3 , SiO2 , TiO2 as raw materials, effect of TiO2 on the sinterability and microstructure of mullite synthesized from Al （ OH）3 and SiO2 was investigated in this paper by XRD , SEM and EPAX. Results show that TiO2 can promote the sintering property when the amount is below 6%, the sinterability of samples becomes better with the increase of the amount of TiO2, microstructure of samples densify gradually, and the best effect can be achieved when the amount of TiO2 is 6%. It was shown by XRD analysis that no Al2TiO5 present when the amount of TiO2 is below 6%, TiO2 existed in the form of solid-solution and glass phase; When the amount of TiO2 is up to 6%, the sinterability of samples becomes worse with the increase of TiO2 added, microstructure of samples began to loosen, Al2TiO5 can be observed in samples and its amount increase with the increase of TiO2.

Impact of Bauxite on Performance and Structure of SiC-mullite Brick

SiC- mullite brick is widely used in the upper and lower transitional zones of cement rotary kilns, due to excellent thermal shock resistance, and abrasion resist- ance. The investigation of different bauxites was made on the performance and micro-structure of SiC - mullite brick, especially thermal shock resistance. In two batches of bricks （ G1 and G2 ） , and two grades of bauxites （ L1 and I_2 ）, samples＇ physical and chemical properties were tested, and microstructure and phase composition were studied by SEM and XRD. The results show that raw material I2, containing large numbers of micro- pores smaller than 4 μm, has well developed mullite phase. While using L2 as aggregates and flues, SiC- mullite brick G2 has excellent thermal shock resistance. Therefore, for manufacture of SiC - mullite brick, not only chemical composition, bulk density and open porosi- ty of bauxite are important, but also its microstructure has to be considered, such as phase composition, crystal size and pore size distribution.

Microstructure and properties of mullite-based porous ceramics produced from coal fly ash with added Al_2O_3

Using coal fly ash slurry samples supplemented with different amounts of Al2O3, we fabricated mullite-based porous ceramics via a dipping-polymer-replica approach, which is a popular method suitable for industrial application. The microstructure, phase composition, and compressive strength of the sintered samples were investigated. Mullite was identified in all of the prepared materials by X-ray diffraction analysis. The microstructure and compressive strength were strongly influenced by the content of Al2O3. As the Al/Si mole ratio in the starting materials was increased from 0.84 to 2.40, the amount of amorphous phases in the sintered microstructure decreased and the compressive strength of the sintered samples increased. A further increase in the Al2O3content resulted in a decrease in the compressive strength of the sintered samples. The mullite-based porous ceramic with an Al/Si molar ratio of 2.40 exhibited the highest compressive strength and the greatest shrinkage among the investigated samples prepared using coal fly ash as the main starting material. © 2017, University of Science and Technology Beijing and Springer-Verlag Berlin Heidelberg.

Synthesis of Refractory Cordierite from Calcined Bauxite, Talcum and Quartz

A cordierite was synthesized from calcined bauxite, talcum, and quartz. The properties and microstructure of the cordierite sintered samples were characterized by Archimedes＇ method, thermal dilatometry, X-ray diffraction （XRD）, scanning electron microscopy （SEM）, and so on. The experimental results showed that calcined bauxite could broaden the range of synthesizing temperature from 1300 ℃ to 1420 ℃ and get pure cordierite. The bulk density and linear thermal expansion coefficient of the sample synthesized at 1420 ℃ for 2 h were 1.97 g·cm^-3 and 2.1×10^-6 ℃^-1, respectively. The XRD analysis showed that the major crystalline phase was a-cordierite with almost no glassy matters, the SEM images illustrated a small vent hole and the size were 5 -100 μm, the well-grown hexagonal and granular cordierite grains had the sizes distributed among 0.1-8 ;xm, and providing high mechanical strength and lower linear thermal expansion coefficient.

Changes in distribution and microstructure of bauxite residue aggregates following amendments addition

Bauxite residue is a highly alkaline byproduct which is routinely discarded at residue disposal areas. Improving soil formation process to revegetate the special degraded lands is a promising strategy for sustainable management of the refining industry. A laboratory incubation experiment was used to evaluate the effects of gypsum and vermicompost on stable aggregate formation of bauxite residue. Aggregate size distribution was quantified by fractal theory, whilst residue microstructure was determined by scanning electron microscopy and synchrotron-based X-ray micro-computed tomography. Amendments addition increased the content of macro-aggregates(> 250 μm) and enhanced aggregate stability of bauxite residue. Following gypsum and vermicompost addition, fractal dimension decreased from 2.84 to 2.77, which indicated a more homogeneous distribution of aggregate particles. Images from scanning electron microscopy and three-dimensional microstructure demonstrated that amendments stimulate the formation of improved structure in residue aggregates. Pore parameters including porosity, pore throat surface area, path length, and path tortuosity increased under amendment additions. Changes in aggregate size distribution and microstructure of bauxite residue indicated that additions of gypsum and vermicompost were beneficial to physical condition of bauxite residue which may enhance the ease of vegetation.

Relationships among Preparative Technique,Phase Composition and Bending Strength of Bauxite Porcelain

Bauxite porcelain can be sintered to make its bending strength reach 179Mpa by using sintered bauxite, clay and potash feldspar and albite as the main raw materials in oxidation atmosphere under the normal pressure. XRD, SEM and so on are utilized to study the relationships between factors like the composition of ingot, reduction particle size and heat insulating time at sintering temperature and the phase composition, microstructure and bending strength of ceramic body. The results show that the main phases in bauxite porcelain are corundum, mullite and glass, and the mullite is composed of two parts： primary mullite formed by clay conversion and secondary mullite whiskers precipitating from high temperature melt. The bending strength of ceramic body can be improved by enhancing the content of sintered bauxite in the formula： the smaller the particle size of the ceramic body is, the higher the bending strength will be. The high-temperature heat insulating technique is beneficial to the precipitation of certain quantitative secondary mullite whiskers so as to remarkably improve the strength of glass phase and ceramic body.

Effects of Na_2SiF_6 on Preparing Mullite Material with Sludge from the Aluminum Profile Factory and Pyrophyllite

In this research,the mullite material with sludge from aluminum profile factory and pyrophyllite as primary raw materials was prepared. Based on the optimal formula,optimal calcining temperature and holding time determined in the research,effects of Na2SiF6 mineralizer on crystal structure,microstructure and properties of mullite were discussed to determine the optimal addition of Na2SiF6 mineralizer. With XRD and SEM methods,crystal structure and microstructure of the test samples were characterized; with Rietveld Quantification method,contents of various crystal phases in the test samples were determined; properties of the test samples were tested. In combination with the structural and property analysis results,the optimal Na2SiF6 addition was determined to be 2%. Correspondingly,the content of solid solution of mullite-Al4.59Si1.41O9.7 was 96.9wt%,the bulk density was 2.10 g/cm3,the degree of porosity was 27.0%,the water absorption rate was 12.8%,the rupture strength was 24.30 MPa and primary thermal-shock rupture strength retention rate was 87.4%.

Preparation and Thermal Shock Resistance of Mullite and Corundum Co-bonded SiC Ceramics for Solar Thermal Storage

Mullite and corundum co-bonded SiC-based composite ceramics(SiC-mullite-Al2O3)were prepared by using SiC,calcined bauxite and kaolin via pressureless carbon-buried sintering.The low-cost SiC-based composite ceramics designed in this study are expected to be used as thermal storage materials in solar thermal power generation based on the high density and excellent thermal shock resistance.The influences of calcined bauxite addition and sintering temperature on the microstructures,phase compositions,and physical properties of the samples were investigated.Results demonstrated that the introduction of calcined bauxite containing two bonding phases greatly reduced the lowest sintering temperature to 1400℃.The SiC-mullite Al2O3 composite with 40 wt%calcined bauxite sintered at 1500℃exhibited optimum performance.The density and bending strength were 2.27 g·cm^-3 and 77.05 MPa.The bending strength increased by 24.58%and no cracks were observed after 30 thermal shock cycles,while general clay would reduce the thermal shock resistance of SiC.The SiC-mullite-Al2O3 composites with satisfied performance are expected to be used as thermal storage materials in solar thermal power generation systems.

Preparation of Bauxite Ceramic Microsphere

Ceramic microspheres were prepared by using Chinese bauxite as raw materials through the centrifugal spray drying method. The control technology of microsphere size, degree of sphericity was researched. The ceramic microspheres were sintered by a double sintering process. The microstructure and composition of ceramic microsphere were investigated by X-ray diffraction （XRD）, scanning electron microscopy （SEM） and X-ray energy spectroscopy. The results show that the degree of sphericity of the ceramic microsphere was good and the particle size was 10-100 μm. The XRD analysis reveals that the main crystalline phase of the ceramic microsphere was a-Al2O3 and mullite （3Al2O3·2SiO2）. The product can be used as reinforced material for composite material, especially for antiskid and hard wearing aluminum alloy coating.

Utilization of Bauxite Tailing

The characteristics of bauxite tailing in China were reviewed,and the current utilization methods and the actuality were discussed.It is found that the bauxite tailing is mainly used for production of building materials and chemical products,and extraction of useful component,etc.Meanwhile,the shortages of these utilization methods were analyzed.In order to enlarge the bauxite tailing application,some new utilization paths were proposed,such as preparing zeolite 4A and corundum-mullite composite materials,which are high value added materials.The utilization ways of bauxite tailing were widened,the utilization ratio of resources and the economic benefit were improved.

Effects of BaF_2 on Preparing Mullite with Sludge from the Aluminum Profile Factory and Pyrophyllite

In this study, sludge from the aluminum profile factory and pyrophyllite were used as major raw materials to prepare mullite. Through determining optimum formula, the optimum calcination temperature and optimum temperature retention time as well as the effects of BaF2 mineralizer on the crystal structure, microstructure and properties of mullite were studied and the optimum BaF2 mineralizer dosage was determined. With XRD and SEM methods, the crystal structure and microstructure of each sample were characterized. With Rietveld Quantification method, crystal phase content in each sample was determined and properties of each sample were tested. Based on the comprehensive analysis result, it was determined that optimum BaF2 dosage was 0.5%, the fairly good calcination temperature was 1550 ℃, and the corresponding mullite solid solution content was 95.8%.

Mullite/A1-4.5Cu复合材料中莫来石纤维及界面反应产物研究

用挤压铸造方法制备莫来石(Mullite)短纤维增强A1-4.5Cu复合材料;用X射线衍射仪(XRD)和分析透射电镜(ATEM)对复合材料中纤维的微观结构、复合材料界面及界面反应产物的结构特征、化学组成进行了研究。结果表明,莫来石短纤维由大小不等的小晶粒组成,晶型为正交晶系;复合材料界面存在断续分布的CuAl2O4尖晶石结构的界面反应产物。

MULLITE/AL-CU-SI复合材料界面微结构研究

用挤压铸造方法制备MULLITE/AL-CU-SI复合材料。用分析透射电镜(ATEM)观察了复合材料的微结构及微成分。结果表明:莫来石(MULLITE)纤维由大小不等、位相不同、分布不均的细小晶粒组成;在淬火态“纤维/基体”界面和“SI晶体/基体”界面附近基体一侧中,都可发现高密度位错的存在;在SI含量较高的情况下,MULLITE/AL-CU-SI复合材料界面处没有发现界面产物的存在,而在纤维/基体界面处析出非平衡共晶Θ(AL2CU)相。

Mullite短纤维/Al-Cu-Mg复合材料界面微结构研究

研究用挤压铸造方法制备Mullite/Al-Cu-Mg复合材料,用透射电镜(TEM)观察了淬火态及时效态复合材料的微观组织。结果表明,莫来石(Mullite)短纤维组织致密但分布不均;在淬火态复合材料纤维/基体界面和Si晶体/基体的界面附近基体一侧中发现存在高密度位错;Mullite/Al-Cu-Si复合材料的界面以非平衡共晶MgAl2O4沉淀相为主。

Preparation of Cordierite-mullite Ceramics for Solar Thermal Storage

We developed cordierite-mullite composite ceramic materials to package and encapsulate PCM, and presented a preparation process from raw materials of kaolin, talc and alumina. The properties and microstructre of cordierite-mullite composite ceramic were studied. Due to the strengthening effects of mullite, the sample C2(80 wt% of cordierite and 20 wt % of mullite) sintered at 1 420 ℃ possessed excellent physical properties. Determined by X-ray diffraction(XRD), scanning electron microscope(SEM) and energy dispersive spectroscopy(EDS) analysis, cuboid-shaped cordierite crystals and needle-like or long quadrilateral-prism mullite crystals with staggered patterns were found, which endowed the composites preferable mechanical strength. After 30 cycles of thermal shock(room temperature to about 1 100 ℃, air-cooled), the sample presented superior thermal shock resistance, which is suitable to be applied as solar thermal storage materials.