Preparation of α-cordierite through mechanochemical activation of MgO–Al2O3–SiO2 ternary system

Abstract

Samples of the ternary system MgO–Al2O3–SiO2 with stoichiometric composition in relation to α-cordierite (Mg2Al4Si5O18), consisting of 22.2 mol% MgO, 22.2 mol% Al2O3, and 55.6 mol% SiO2, were activated in a low energy mill with a constant speed of 100 rpm, in an aqueous medium. The precursors used were corundum (Al2O3), silica gel HF254 type 60 (SiO2), and periclase (MgO). The objective of the present study was to evaluate the effect of mechanochemical activation on the solid-state synthesis of α-cordierite, using a low energy ball mill. Another objective was to shed light on the effect of mechanochemical activation on the steps of α-cordierite formation. For this end several grinding conditions were evaluated, varying the time and mass ratio of precursors/grinding elements, as well as calcination at different temperatures between 950 °C and 1350 °C for 2 h. The samples were analyzed for the determination of the formed phases by Infrared (IR) and X-ray Diffraction (XRD). The phases identified in uncalcined samples were brucite (Mg(OH)2), forsterite (Mg2SiO4), enstatite (MgSiO3), spinel (MgAl2O3), amorphous silica (SiO2), corundum (α-Al2O3), and zirconia (monoclinic and tetragonal ZrO2). The lowest temperature corresponding to the formation of α-cordierite (α-Mg2Al4Si5O18) was 1150 °C and a considerable amount of this phase (16.2%) was observed at this temperature, for the sample with the higher mechanochemical activation. In a solid-state reaction, α-cordierite is normally obtained at around 1400 °C, therefore, the formation of this phase at 1150 °C confirms that the mechanochemical activation method, using a low-cost ball mill, is efficient in reducing the solid-state reaction temperature.