Abstract The composition-processing-structure-properties relationship of Na2O-Al2O3-SiO2-based geopolymers containing calcium sources is critical for the design of enhanced ceramic binders. This work evaluated the addition of 1-6 wt% of calcium hydroxide (CH) to a metakaolin-based geopolymer (prepared with NaOH 12 M and colloidal silica suspension) and how it affected the performance of the prepared samples after thermal treatments up to 1000 °C. The setting time, mechanical strength, porosity, density, permanent linear change, and phase and bond type evolution of the specimens with temperature were analyzed. The incorporation of 3 or 6 wt% of CH into the designed composition led to a fast hardening of the mixtures (1.7 h), resulting in geopolymers with high green mechanical strength (18.9 to 23.9 MPa). Nepheline and albite generation in the samples containing 6 wt% of CH resulted in a ceramic with improved cold crushing strength (45.2 MPa) and lower linear shrinkage (-10.5%) when compared to the calcium-free composition.

Abstract The possibility of recycling solid wastes in the production of geopolymers and advanced ceramic products has received special attention recently. This work investigated the feasibility of replacing a high amount (70-90 wt%) of metakaolin with roof tile waste (CW) in the production of Na-geopolymer composites. Additionally, the influence of this alternative material, in the phase transformations and properties evolution (elastic modulus, compressive strength, porosity, density, and linear shrinkage) of the prepared compositions after distinct thermal treatments (40-1000 °C) was evaluated. The results showed that the incorporation of CW powder into the geopolymeric compositions enhanced their thermal and mechanical properties up to 1000 °C. The best performance was reached when using 80 wt% of the selected waste, which led to ceramic specimens with high crystallinity (presenting quartz, hematite, and albite phases), compressive strength (39.6 MPa), suitable linear shrinkage (-7.4%), and improved thermal stability (without visual cracks) after firing at 1000 °C.

Abstract Although most of the studies presented in the literature are focused on MgAl2O4 formation and its role on alumina-based refractories performance, ZnO has been reported as a promising spinel inducer. Aiming to investigate the influence of ZnAl2O4 (ZA) and MgAl2O4 (MA) generation on the properties of alumina-based castables, three vibratable compositions containing calcium aluminate cement or hydratable alumina as binders and 1 wt% of silica fume, were evaluated in this work. Flexural strength, apparent porosity, hot elastic modulus, corrosion cup-tests, thermodynamic simulations, were carried out to analyze the performance of such ceramics. The results indicated that ZnAl2O4 was mainly formed above 800 °C, favoring an earlier sintering of the samples. Besides that, the softening of the castables was observed above 1200 °C, which resulted in the elastic modulus decay of the samples during their first heating cycle due to the formation of SiO2-rich liquid phase in the resulting microstructure. Cement-free samples obtained after calcination (600 °C for 5h) presented enhanced corrosion resistance when placed in contact with molten slag at 1500°C. Although, silica fume addition to the castables negatively affected their corrosion performance, it helped to counterbalance the expansion associated with the spinel and calcium aluminates formation.