Using Recycled Ceramics to make new Triaxial Ceramics

Abstract

A technology is presented for making a triaxial refractory material with the use of factory wastes as the main component. Mixture design and response-surface analysis were used to decrease the amount of lab work required by determining the range of formulations of the material that is optimum from the standpoint of obtaining the necessary characteristics for the finished product. This approach can also significantly improve the cost/benefit ratio during the formulation stage and help to better understand the relationships between the production, microstructure, and properties of refractories. Among the raw materials that were used were wastes from the production of refractory tiles: coal ash, slag sand, glazing wastes, and a high-alumina refractory that was crushed in edge runners. The methodology used in the study can help identify the region of the ternary diagram in which the service requirements established for refractories are satisfied by the characteristics of the product - characteristics such as linear shrinkage and ultimate flexural strength after firing. The optimized composition that was found for the triaxial refractory has significantly reduced costs compared to the refractories currently being used and has helped improve the environment as well.