Conversion of caustic red mud (RM, Alumina industry waste) into building materials becoming one of the viable solution for its large scale utilization. The building materials developed using RM often results in efflorescence due to its high alkalinity, which is detrimental for the structural integrity of the buildings. The X-ray shielding tiles developed through ceramic route using the mixtures of RM, BaSO4 and kaolin clay also suffers from severe Na2SO4 efflorescence when sintered above 1000°C. The XRD analysis confirms the formation of Na2SO4 through the solid-state reaction that occurs between BaSO4, Na2Fe2Ti6O16 and NaAlSiO4 at above 1000°C. The formation of Na2SO4 was reduced by adding KOH with the mixtures, which reacts with RM and BaSO4 and form stable K3NaS2O8 and KAlSiO4 phases, as revealed through Rietveld refinement. Eventually, the wt% of Na2SO4 was found to decrease from 3.2% to 0.2% while adding 8% of KOH. Subsequently, the efflorescence has decreased from 90% to 2%. Moreover, the KOH addition assist to increase the density of the shield from 2.8g/cc to 3.6g/cc. It eventually increases both the mechanical strength and X-ray attenuation characteristics of the shield. The flexural strength of the tile has increased from 16.46N/mm2 to 19.46N/mm2 while adding 8% KOH. The 15mm thick tile possess the attenuation equivalent to 2mm lead at 100kV.
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