A series of binary Al2O3–CaO and Al2O3–CaO–CaCO3 systems with Ca/Al molar ratios of 0.05, 0.1, 0.25, 0.5 and 1.0 have been synthesised by the sol–gel technique from aluminium isopropoxide and metallic calcium powder. The rate of the metal reaction is used as a limiting factor to control the binary gel formation. The proposed modification of the traditional sol–gel method was used to examine the influence the effect of the metallic form of the second component as an oxide precursor on the form of the final product. By applying acetic acid instead of mineral acid, calcium acetate is formed and then decomposed to calcium carbonate upon thermal processing. During the synthesis of the binary systems, metallic calcium acts both as a precursor of calcium acetate and as a secondary pH modifier of the gel system. Calcination in air at 600 °C did not produce systems containing only oxides and the calcium carbonate phase was still present. Due to particle size reduction, the CaCO3 to CaO decomposition temperature was lowered. The systems were characterised by X-ray powder diffraction, low-temperature nitrogen adsorption, transmission and scanning electron microscopy (TEM, SEM and SEM/EDS), thermogravimetric analysis (TGA) and FTIR spectra.
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