In the last few years, mineral extraction and processing industries have been mentioned as sources of environmental contamination and pollution. The kaolin processing industry around the world generates large amounts of wastes. This work evaluated the kaolin processing waste suitability as alternative ceramic raw material for the production of mullite bodies. Several formulations composed of kaolin waste and alumina were prepared and homogenized in a ball mill. Test specimens were obtained by uniaxial pressing and sintering at different temperatures. Fired samples were microstructurally analyzed by X-ray diffraction. Sintered samples were characterized to determine their water absorption, apparent density, firing shrinkage and modulus of rupture. The results indicated that the amount of waste in the composition dictates the firing temperature, and that extremely high firing temperatures may lead to overfiring. Mullite formulations with more than 40% of kaolin waste could be used for the production of bodies with high strength, of about 75MPa.
wastes; recycling; kaolin; mullite; alternative raw materials
