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Mana Rodchom, Panida Wimuktiwan, Kanit Soongprasit, Duangduen Atong, and Supawan Vichaphund, Preparation and characterization of ceramic materials with low thermal conductivity and high strength using high-calcium fly ash, Int. J. Miner. Metall. Mater., 29(2022), No. 8, pp. 1635-1645. https://doi.org/10.1007/s12613-021-2367-2
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Supawan Vichaphund E-mail: supawank@mtec.or.th
从泰国Mae Moh发电厂收集的高钙粉煤灰（HCFA）被用作陶瓷生产的原料。X射线荧光表征下HCFA主要成分为28.55wt% SiO2、16.06wt% Al2O3、23.40wt% CaO和17.03wt% Fe2O3。由于钙质和铁质含量比例较高，使用HCFA替代钾长石，用量为10wt%–40wt%。研究了替代高钙粉煤灰（0–40wt%）和烧结温度（1000–1200°C）对陶瓷基材料的物理、机械和热性能的影响。结果表明，加入适量的HCFA可以提高陶瓷样品的致密化程度和强度，降低陶瓷样品的导热系数。粉煤灰中高比例的钙质和铁质成分促进了陶瓷样品的玻璃化行为。研究结果说明，在最佳粉煤灰含量和烧结温度下，液相的形成促进了致密化。此外，这些组分还促进了更丰富的莫来石形成，从而提高了陶瓷样品的弯曲强度。在1150–1200°C烧结温度下，添加10wt%–30wt%的粉煤灰，可获得最佳陶瓷性能。在 1200°C、 吸水率几乎为零（0.03%）时，添加粉煤灰10wt%–30wt%（PSW-FA(10)–(30)）的FA陶瓷样品的最大弯曲强度在92.25–94.71 MPa范围内。就隔热材料而言，粉煤灰添加量的增加对热导率有积极的影响，这是因为陶瓷FA样品内部无机分解反应产生的气体产生了更高的孔隙度。在1150°C烧结的陶瓷样品中添加20wt%–40wt%的高钙粉煤灰可将热导率降低14.78%–49.25%，同时保持可接受的弯曲强度值（~45.67–87.62 MPa）。基于其表现出良好的机械和热性能，利用这种高钙粉煤灰作为粘土成分的替代原料制造瓷砖是可行的。
High calcium-fly ash (HCFA) collected from the Mae Moh electricity generating plant in Thailand was utilized as a raw material for ceramic production. The main compositions of HCFA characterized by X-ray fluorescence mainly consisted of 28.55wt% SiO2, 16.06wt% Al2O3, 23.40wt% CaO, and 17.03wt% Fe2O3. Due to high proportion of calcareous and ferruginous contents, HCFA was used for replacing the potash feldspar in amounts of 10wt%–40wt%. The influence of substituting high-calcium fly ash (0–40wt%) and sintering temperatures (1000–1200°C) on physical, mechanical, and thermal properties of ceramic-based materials was investigated. The results showed that the incorporation of HCFA in appropriate amounts could enhance the densification and the strength as well as reduce the thermal conductivity of ceramic samples. High proportion of calcareous and ferruginous constituents in fly ash promoted the vitrification behavior of ceramic samples. As a result, the densification was enhanced by liquid phase formation at optimum fly ash content and sintering temperature. In addition, these components also facilitated a more abundant mullite formation and consequently improved flexural strength of the ceramic samples. The optimum ceramic properties were achieved with adding fly ash content between 10wt%–30wt% sintered at 1150–1200°C. At 1200°C, the maximum flexural strength of ceramic-FA samples with adding fly ash 10wt%–30wt% (PSW-FA(10)–(30)) was obtained in the range of 92.25–94.71 MPa when the water absorption reached almost zero (0.03%). In terms of thermal insulation materials, the increase in fly ash addition had a positively effect on the thermal conductivity, due to the higher levels of porosity created by gas evolving from the inorganic decomposition reactions inside the ceramic-FA samples. The addition of 20wt%–40wt% high-calcium fly ash in ceramic samples sintered at 1150°C reduced the thermal conductivity to 14.78%–49.25%, while maintaining acceptable flexural strength values (~45.67–87.62 MPa). Based on these promising mechanical and thermal characteristics, it is feasible to utilize this high-calcium fly ash as an alternative raw material in clay compositions for manufacturing of ceramic tiles.
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