Development of Structural Ceramics from Fly Ash and Shale

Abstract:

The possibility of using fly ash and shale as alternative raw materials for the production of structural ceramics was investigated. Fly ash is a by-product from coal-burning power plants, and shale is a sedimentary rock that if ground finely enough can exhibit a clay-like plasticity. Ceramic samples containing 10-50 wt% fly ash were formed from mechanical mixing of both kinds of powders that were packed and sintered in the temperature range 950-1200°C. It was verified that powders with larger fly ash content exhibited lower packing density resulting in compacts with a lower sintered density. Although an increase in fly ash content was associated to a larger presence of porosity in the sintered samples, as confirmed by microstructural analysis, all studied compositions when sintered at the highest temperatures exhibited satisfactory values for water absorption (< 10%), for flexural strength (20-64 MPa) and for hardness (20-30 GPa) indicating that they have potential to be applied in the production of structural ceramics.