Optimization of mullite-based chamotte production as a result of calcination of a kaolin-boron waste mixture by response surface method and its usability in ceramic

Abstract

This study aims to use kaolin and boron waste in the production of Chamotte material. The usability of the produced chamotte in the FFC (fine fire clay) body in sanitary wares, instead of the chamotte supplied from abroad, was also investigated. The studies were carried out using a statistical experimental design and aimed to reach more information with a small number of experiments. The percentage of boron content, calcination temperature and grinding time factors were examined as independent variables, and the effects of these factors on the percentage of mullite phase, anorthite phase, quartz phase and sodium aluminum silicate phase were examined. Thus, the interaction of the parameters both individually and with each other was revealed, and the process was modeled with a mathematical model that is a function of independent variables. In addition, with an optimization study that provides the desired product feature with the least possible cost, the properties of the vitrified product obtained with both the produced chamotte and the reference chamotte were compared. When the chamotte, produced by optimizing the experimental design, was added to the vitrified body, this product achieved an improvement 32.73% in strength, 5.88% in shrinkage, and 4.67% in water absorption compared to the reference factory chamotte. As a result, with the current study, it has been determined that when both waste kaolin and boron are calcined together, fireclay with better properties can be obtained instead of imported fireclay and can be used industrially.