Abstract
Aluminum dross is a well-known industrial waste generated in the aluminium industry, and its recycling and reuse is still a worldwide issue. Herein, aluminum dross waste (ADW) was recycled to progressively replace the aggregate fraction of clay at 70, 75, 80, 85, and 90 wt% for the fabrication of Al2O3-SiO2-rich porous castable refractories. Their physical properties and mechanical behavior were assessed by the measurement of linear shrinkage rate, bulk density, apparent porosity, cold crushing strength, and thermal conductivity. The microstructure and phase evolutions were analyzed via scanning electron microscopy (SEM) and X-ray diffraction (XRD). The incorporation of 85 wt% of ADW allowed the development of a waste-containing conventional refractory castable with improved properties as compared to those of the other samples. The sustainable refractory castable exhibited decent thermal conductivity and physical and mechanical characteristics, and is suitable for application as reheating furnace lining. It is a “green” practice to partially replace the traditional raw materials with industrial waste in the manufacture of conventional refractory castables and provides environmental and economic benefits.
Highlights
It is well known that the aggregate is a major component of the ceramic body, and its choice considerably influences the properties of refractory castables [3]
This research aims to use aluminum dross waste (ADW) generated from aluminum industries as a partial replacement for high-in-demand traditional raw material of clay that is used in lightweight
Al2 O3 -SiO2 -rich castable refractories were successfully prepared by using ADW partial substitution of clay
Summary
Due to the advantages of low-cost, easy availability, and abundance, natural sources, such as clays, kaolinites, sillimanites, and bauxites, are the most common aggregates used for Al2 O3 -SiO2 refractory castables [4]. Both the growth in industrial production and the increase in natural consumption have led to a rapid decline in the availability of natural sources. The ceramic industry faces weakening and depleting mineral and non-mineral deposits, which increases ecological problems and costs of mineral raw materials [7] It is a “green” practice to partially replace traditional raw materials with industrial wastes in the manufacturing of conventional refractory, which provides environmental and economic benefits [8]
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