Abstract
The present study aims to synthesize SiAlON-based composites utilizing coal gangue. Different types of SiAlON-based composites were synthesized using coal gangue by carbothermal reduction nitridation method through control of different reaction atmospheres. The experimental results indicate that the oxygen partial pressure was an essential factor in the manufacture of SiAlON-based composites and under proper control of the atmospheres, SiAlON-based composites with different crystal structures could be synthesized. The optimum conditions of synthesis of different SiAlON-based composites were respectively determined. Based on the laboratory results, a prototype plant was proposed and constructed, and β-SiAlON composite was successfully produced using coal gangue. The synthesized β-SiAlON composite was applied in preparation of iron ladle brick instead of SiC, which showed that the compression strength, refractoriness under load and high temperature bending strength were increased from 44.5 ± 6.7 MPa, 1618 ± 21 °C and 5.4 ± 1.2 MPa to 64.1 ± 2.5 MPa, 1700 ± 28 °C and 7.1 ± 1.6 MPa, respectively. Compared with the traditional synthesis method, the present technique is expected to save energy both in raw materials and technical process.
Highlights
Rapid economic and industrial development result in enormous waste generated and disposed, leading to serious environmental hazards all over the world
According to the thermodynamic assessment, the results show that NC atmosphere is the best parameter for synthesis of β-SiAlON
A systematical investigation of the synthesis of SiAlON, including β-SiAlON, O′-SiAlON, 15R-AlN polytypoid and 12H-AlN polytypoid was carried out using coal gangue as raw materials
Summary
Rapid economic and industrial development result in enormous waste generated and disposed, leading to serious environmental hazards all over the world. A certain percentage of coal gangue finds application primarily in building materials manufacture, such as brick, cement, or concrete, as well as other construction fields, such as landfilling and road construction [10] Such applications are mostly of low economic value and have constrained transportation distance. SiAlON ceramics, including α-SiAlON, β-SiAlON, O′-SiAlON, AlN polytypoid or mixtures of these phases, are of unique physical-chemical properties, especially in high strength, high toughness and chemical inertness at elevated temperatures As a consequence, they can be potentially used as structural ceramics and refractories, which are of high economic value [11,12,13,14,15]. The energy consumption was analyzed based on the industrial data
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