Preparation of lightweight high-strength thermal insulation and decoration integration porous ceramics using red mud

Abstract

Porous ceramics with lightweight, high strength, thermal insulation, and decoration integration were prepared using red mud, construction waste, polished tile waste, and kaolin as raw materials. The influences of the content of red mud, sintering temperature, and blowing agent on the microstructure, mechanical, and thermal properties of porous ceramic were investigated. According to bulk density, pore morphology, compressive strength, and thermal conductivity, the optimum preparation condition of porous ceramic was determined after selecting the raw materials formulations and process parameters. Multi-functional wall insulation materials have been prepared when the content of red mud was 40%, blowing agent was 3%, and sintering temperature was 1080 °C. The bulk density, porosity, compressive strength, thermal conductivity, and softening temperature of porous ceramics were 0.25 g/cm3, 72.15%, 7.26 MPa, 0.058 W/(m K), and 1160 °C respectively. Their corresponding influence mechanisms of pore structure on mechanical and thermal properties were discussed in detail. It was found from the section images of pore morphology that pore distribution and size were significantly uniform in porous ceramic.