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Preparation of Nepheline-Based Ceramic Foams from Basalt Tailing and Black Cotton Soil

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Abstract

A type of ultra-light weighted, low-thermally conductive but mechanically strong ceramic foams (CF) were fabricated via the direct foaming method of using basalt tailings (BT) and black cotton soil (BCS) as main components. The sodium hydroxide (NaOH) dissolved in water glass (Na2SiO3) and calcium carbonate (CaCO3) were used as fluxing and foaming agents, respectively. The product was demonstrated to have excellent strength-to-density properties (compressive strength > 1.82 MPa, density < 0.57 g/cm3) and a low thermal conductivity (0.057 W/m·K), which meets standards of ASTM C552-14 (Grade 24) or GB/T33500-2017 (Grade L). Factors that affect the physicochemical (bulk density, apparent density, and water absorption) and mechanical properties were investigated, which include dosages of BT, NaOH, and CaCO3. Optimum parameters were found as sintering temperature 850 °C, reaction time 45 min, and dosage of BT/(BT + BCS) = 70% wt., NaOH = 13% wt. versus the total weight of BT and BCS (w(BT + BCS)), and foaming agent CaCO3 = 0.1% wt. versus w(BT + BCS). The crystalline phase in the foamed ceramics was confirmed as nepheline which was produced by desilication of orthoclase or plagioclase with presence of NaOH. This direct foaming method of using the BT + BCS system was proven to be an efficient way to prepare foamed ceramics.

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Acknowledgements

We acknowledge the financial supports by the Province/Jilin University co-construction project - funds for new materials - (SXGJSF2017-3), National Natural Science Foundation of China (U1607122, 51874145), Qinghai Basic Program under Grant (2017-ZJ-705), and basalt original rock and product performance testing project (3R218C562416).

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Authors and Affiliations

  1. Key Laboratory of Automobile Materials of Ministry of Education, Jilin Province Solid Waste Utilization Project Center, School of Materials Science and Engineering, Jilin University, Changchun, 130022, Jilin, China

    Yanbin Sun, Jianzhou Shi, Fujie Zhu, Shaonan Xu, Peiping Zhang, Cundi Wei & Shiding Miao

  2. Department of Basic Sciences, Qinghai University, Xining, 810016, China

    Xiaoling Tan

  3. Key Laboratory of Mineral Resources Evaluation in Northeast Asia, Ministry of Land and Resources, Jilin University, Changchun, 130061, China

    Wenqing Li

  4. Jilin Province Huayang New Composite Material Co. Ltd, Changchun, China

    Yang Wang & Ran Zhao

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  1. Yanbin Sun
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Sun, Y., Shi, J., Zhu, F. et al. Preparation of Nepheline-Based Ceramic Foams from Basalt Tailing and Black Cotton Soil. Waste Biomass Valor 11, 2331–2343 (2020). https://doi.org/10.1007/s12649-018-0514-4

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