The effects of addition treated FGD sludge in non-stoichiometric cordierite, by benefiting from its high mechanical strength and good thermal performance, can hold promise for more practical applications of non-stoichiometric cordierite. Treated FGD sludge waste from borosilicate glass industrial were used as a flux to reduce the sintering temperature of cordierite. Cordierite ceramics were prepared using silica (SiO2), alumina (Al2O3), talc, kaolin, magnesia (MgO) and treated FGD sludge via solid-state reaction method. The cordierite were prepared by adjusting the ratio of FGD sludge and magnesia in the cordierite composition, respectively. 4 composition of cordierite with 0%, 1.5%, 3.0% and 4.5% of FGD sludge were prepared to obtain the formation of α-cordierite that can be determine by X-ray diffraction (XRD) analysis. Porosity, density, shrinkage and flexural strength for each of cordierite composition were determined to obtain the best composition of treated FGD sludge required for sintering aids of cordierite. Only FGD 3.0% able to synthesis pure α-cordierite while FGD 1.5 % shows an improvement in both porosity and density. The increasing amount of treated FGD sludge lead to decreasing in mechanical strength of cordierite ceramic due to porous formation.
The porcelain formulation containing percentages of treated FGD sludge waste from 5% up to 15% in replacement of feldspar were prepared. The porcelain mixture formulation were mixed by high energy planatery mill at speed 300 rpm for 1 hours. The powder were compacted by using hydraulic press and sintered at temperature 1200 °C for 3 hours. The sintered samples were characterized using X-ray fluorescene (XRF), X-ray diffraction (XRD), Fourier Transform Infrared (FTIR) and Thermogravimetry/Differential scanning calorimetry (TGA/DCS). The primary effect concerning the addition of treated FGD sludge was the change of intensity composition (gypsum and anhydrate) in porcelain formulation. The XRD analysis has shown that the main component in sludge waste were gypsum and anhydrate.
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