Mullite-based ceramics were produced entirely from industrial wastes. Aluminum dross (AD) is a waste product produced in secondary aluminum refining, and coal fly ash (CFA) which is a waste generated by coal-fired power plant. Both were mixed together in different weight ratio, subsequently compacted and sintered. The effects of the sintering temperature, acid leaching and Al2O3/SiO2 ratio on the chemical, physical, thermal expansion properties of the samples were characterized in detail. The results showed that appropriate mixing ratio and acid leaching had positive effects on the mineralogy, crystallinity, and macromorphology of sintered samples. At sintering temperature of 1500 °C, high mullite content ceramics with good crystallinity were produced. The resultant ceramics exhibited excellent thermal expansion properties with coefficient of thermal expansion (CTE) values ranging from 4.0 to 5.9 × 10−6 °C−1 (average between 30 °C and 1000 °C). This study demonstrated that the production of mullite-based ceramics using entirely CFA and AD was feasible.

Some industrial wastes are shown to be useful in the production of mullite ceramics. These industrial wastes are rich in certain metal oxides such as silica (SiO2) and alumina (Al2O3). This gives wastes the potential to be used as a starting material source for mullite ceramics preparation. The purpose of this review paper is to compile and review various mullite ceramics preparation methods that utilized a variety of industrial wastes as starting materials. This review also describes the sintering temperatures and chemical additives used in the preparation and its effects. A comparison of both mechanical strength and thermal expansion of the reported mullite ceramics prepared from various industrial wastes were also addressed in this work.

Porous mullite ceramics were produced using mullite precursor and modified cenospheres as a non-sacrificial pore-forming agent. The cenospheres used are aluminosilicate hollow spheres with high silica and alumina content, which are obtained from coal-fired power plant. In this study, the cenospheres were modified using aluminum trichloride hexahydrate (AlCl3•6H2O), alkali/acid leaching and heat treatment. Various types and amounts of the modified cenospheres were mixed with mullite precursor to produce porous mullite ceramics for subsequent firing at 1500 °C. Graphite powder, as sacrificial pore-forming agent, was also used to prepare porous mullite ceramics by the same processing conditions for comparison. The study found that the use of graphite powder was unable to increase the porosity of the mullite ceramics as a result of excessive shrinkage. It acted more as a sintering aid rather than as sacrificial pore-forming agent. On the other hand, addition of modified cenospheres as non-sacrificial pore-forming agent leads to the increment of both total porosity and closed porosity, with the reduction of open porosity. The results showed that with the addition of 40 wt% of modified cenospheres to the mullite precursor, the resultant porous mullite ceramic has a total porosity of 50.2%, thermal conductivity of 1.28 Wm−1K−1, linear shrinkage of 4%, and biaxial flexural strength of 45.9 MPa. Porous mullite ceramic with majority closed pores has potential application for high temperature thermal barrier.

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ZnO nanofibers were successfully prepared by electrospinning a precursor mixture of polyvinylpyrrolidone (PVP)/zinc acetate, followed by calcination treatment of the electrospun composite nanofibers. The effect of applied voltage to the morphology of nanofibers was studied. Both PVP/Zn acetate and ZnO nanofibers were characterized by FESEM and XRD. The results show that the diameter of the nanofibers changed with applied voltage. Results found that the optimum calcined temperature was 500°C to produce continuous ZnO nanofibers.

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The capability of zinc oxide (ZnO) as a hydrogen sensing element has been pushed to its limits. Different methods have been explored to extend its sensing capability. In this paper, we report a novel approach which significantly improves the hydrogen sensing capability of zinc oxide by applying a bias voltage to ZnO nanorods as the sensing elements. Zinc oxide in the form of aligned nanorods was first synthesized on an Au-coated Si(111) substrate using a facile method via the galvanic-assisted chemical process. The sensing performance of the zinc oxide nanorods was investigated in response to the applied biasing voltage. It was found that the sensitivity, response time and detection limit of the ZnO sensing elements were dramatically improved with increasing bias voltage. A 100% increment in sensing response was achieved for the detection of 2000 ppm hydrogen gas when the bias voltage was increased from −2 to −6 V with 70% reduction in response and recovery times. This remarkable sensing performance is attributed to the reaction of hydrogen with chemisorbed oxygen ions on the surface of the ZnO nanorods that served as the electron donors to increase the sensor conductance. Higher reverse bias voltages sweep the electrons faster across the electrodes. This shortened the response time and, at the same time, depleted the electrons in the sensor elements and weakens oxygen adsorption. The oxygen ions could then be readily removed by hydrogen, leading to a higher sensitivity of the sensors. This, therefore, envisages a way for high-speed hydrogen gas sensing with high detection sensitivities.