| Metadata | Details |
|---|
| Publication Date | 2023-05-18 |
| Journal | Ceramics |
| Authors | O. V. Suvorova, N. K. Manakova, A.I. Novikov, D. V. Makarov |
| Institutions | Kola Science Centre |
| Citations | 4 |
| Analysis | Full AI Review Included |
- Core Value Proposition: Demonstrated the successful synthesis of high-performance, heat-insulating foamed glass-ceramics using diamond concentration tailings (mining waste) and recycled waste glass.
- Optimal Composition: The best material properties were achieved using a charge consisting of 50 wt.% tailings, 50 wt.% waste glass, 0.5 wt.% Silicon Carbide (SiC) as the foaming agent, and 1 wt.% Iron Oxide (Fe2O3) as the oxidizer.
- Key Performance Metrics: The optimal material exhibited an apparent density of 0.28 g/cm3, a compressive strength of 1.20 MPa, and an extremely low thermal conductivity (λ) ranging from 0.060 to 0.066 W/mK.
- Process Optimization: Optimal sintering occurred at 1030 °C. The use of the fine fraction of tailings (less than 0.05 mm) was critical for achieving a high foaming ratio and a uniform, closed-pore microstructure.
- Material Classification: Based on its low density and thermal conductivity, the resulting product is classified as a high-quality heat-insulating foam material suitable for dry construction conditions.
- Sustainability Impact: This research provides a viable, energy-efficient pathway for the large-scale recycling of industrial mineral waste and glass cullet into high-demand building materials, supporting global sustainability goals.
| Parameter | Value | Unit | Context |
|---|
| Optimal Sintering Temperature | 1030 | °C | Exposure time: 30 min |
| Apparent Density (Optimal) | 0.28 ± 0.02 | g/cm3 | Target range: 0.23-0.51 g/cm3 |
| Compressive Strength (Optimal) | 1.20 ± 0.02 | MPa | Required for structural integrity |
| Thermal Conductivity (λ) | 0.060-0.066 | W/mK | Classified as heat-insulating |
| Water Absorption (by volume) | 9.5 ± 0.19 | % | Measured property (requires further reduction) |
| Optimal Foaming Agent Content | 0.5 | wt.% | Silicon Carbide (SiC) |
| Optimal Oxidizer Content | 1 | wt.% | Iron Oxide (Fe2O3) |
| Optimal Tailings Particle Size | <0.05 | mm | Fine fraction for efficient foaming |
| Tailings SiO2 Content | 49.95 | wt.% | Primary component of the ceramic matrix |
| Waste Glass SiO2 Content | 74.1 | wt.% | Used to improve sintering and liquid phase formation |
| Optimal Pore Size Range | 0.25-1.25 | mm | Achieved at 1030 °C, uniform distribution |
- Feedstock Preparation: Tailings were processed to isolate the <0.63 mm fraction, which was then reground to a fine powder (<0.05 mm). Waste glass (cullet) was also ground to <0.05 mm.
- Charge Mixing: Optimal components (Tailings, Waste Glass, SiC, Fe2O3) were thoroughly mixed, and 5-8 wt.% water was added as a binder to form cubic samples (3 mm edge length).
- Foaming Analysis (Preliminary): High-temperature optical microscopy (ZEISS MHO-2) was used to observe the initial swelling and foaming behavior of different compositions and particle sizes.
- Sintering Process: Samples were loaded into split ceramic cylinder molds and sintered in an electric furnace (Nabertherm) in the range of 900-1100 °C, with an optimal exposure time of 30 minutes at 1030 °C.
- Phase and Thermal Characterization:
- X-ray Diffraction (XRD) confirmed the presence of quartz, dolomite, calcite, and, after sintering, crystalline phases like diopside and cristobalite.
- TG-DSC analysis identified endothermic effects related to adsorbed water release (86.1 °C) and decarbonization of dolomite/calcite (801.7 °C).
- Property Measurement: Standardized tests (GOST 17177-94) were used to determine apparent density, porosity, and water absorption. Compressive strength was measured using a hydraulic press, and thermal conductivity was measured using an ITP-MG 4 meter.
- High-Efficiency Building Insulation: The primary application is the production of lightweight, highly insulating foam blocks and panels (λ = 0.060-0.066 W/mK) for use in energy-efficient construction, particularly in cold climates.
- Industrial Thermal Barriers: Suitable for insulating high-temperature installations, heat supply lines, and industrial facilities where low thermal conductivity and moderate mechanical strength are required.
- Sustainable Resource Management: Provides a commercially viable solution for the large-scale recycling of two major waste streams: diamond mining tailings (a sandy, argillaceous rock) and mixed waste glass cullet.
- Lightweight Construction Aggregates: The granular form of the foamed material could be used as a lightweight aggregate in concrete or mortar formulations, reducing the overall density of structural elements.
- Acoustic Insulation: Materials with closed, porous microstructures, such as the one developed, often possess excellent sound absorption properties, opening applications in noise reduction barriers and acoustic panels.
View Original Abstract
The possibility of obtaining building foamed glass-ceramic using the diamond concentration tailings of the Lomonosov deposit in Arkhangelsk Region, Russia, is demonstrated here. The effect of the tailingsâ particle size distribution, feed temperature, the addition of a foaming agent, and the content of oxidizer on the feed charge foaming is established. The process conditions for obtaining foamed glass-ceramic materials are described. The specifications of the materials with the optimal composition (tailings 50 wt.%, glass waste 50 wt.%, SiC 0.5 wt.%, Fe2O3 1 wt.%) foamed at 1020-1050 °C were as follows: apparent density 0.23-0.51 g/cm3, compression strength 0.58-2.40 MPa, water absorption (by volume) 8.7-19.0%. Based on the combination of the measured properties when used in dry conditions, the obtained materials can be considered heat-insulating foam materials. The thermal conductivity was 0.060-0.066 W/m·K.
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