Influence of CuO on the formation and coexistence of 3CaO·SiO2 and 3CaO·3Al2O3·CaSO4 minerals

The influence of CuO on the formation and coexistence of 3CaO·SiO₂ and 3CaO·3Al₂O₃·CaSO₄ minerals in Portland cement containing 3CaO·3Al₂O₃·CaSO₄ mineral is reported in this paper. The results show that a suitable amount of CuO can lower the clinkering temperature and improve the burn-ability of clinkers. It can also promote the formation of 3CaO·SiO₂ and 3CaO·3Al₂O₃·CaSO₄ minerals and facilitate the coexistence of the two minerals in the clinkers. But adding 1% CuO to the raw material can cause the decomposition of 3CaO·3Al₂O₃·CaSO₄.     

Large-scale fine structural alumina matrix ceramic guideway materials improved by diopside and Fe2O3

Diopside and Fe₂O₃ were introduced in alumina matrix ceramic materials. Large-scale fine structural alumina matrix ceramic guideway materials were fabricated by the technology of pressureless sintering, during which liquid phase sintering took place and new phases such as 3Al₂O₃·2SiO₂, CaO·Al₂O₃·2SiO₂ and CaO·6Al₂O₃ were produced by the chemical reactions taking place among alumina and the additives. The hardness, the fracture toughness and the bending strength of the guideway products were tested. The influences of diopside and Fe₂O₃ additions were studied by microstructural observations and mechanical properties evaluations. Meanwhile, the expected improvement of mechanical properties compared with pure alumina was indeed observed. The fracture mechanism and porosity of large-scale fine structural alumina matrix ceramic guideway materials were analyzed.     

Fuel mixture approach for solution combustion synthesis of Ca3Al2O6 powders

Single-phase 3CaO·Al₂O₃ powders were prepared via solution combustion synthesis using a fuel mixture of urea and β-alanine. The concept of using this fuel mixture comes from the individual reactivity of calcium nitrate and aluminum nitrate with respect to urea and β-alanine. It was proved that urea is the optimum fuel for Al(NO₃)₃ whereas β-alanine is the most suitable fuel for Ca(NO₃)₂. X-ray diffraction and thermal analysis investigations revealed that heating at 300 °C the precursor mixture containing the desired metal nitrates, urea and β-alanine triggers a vigorous combustion reaction, which yields single-phase nanocrystalline 3CaO·Al₂O₃ powder (33.3 nm). In this case additional annealing was no longer required. The use of a single fuel failed to ensure the formation of 3CaO·Al₂O₃ directly from the combustion reaction. After annealing at 900 °C for 1 h, the powders obtained by using a single fuel (urea or β-alanine) developed a phase composition comprising of 3CaO·Al₂O₃, 12CaO·7Al₂O₃ and CaO.     

Ethanol steam reforming reactions over Al2O3 · SiO2-supported Ni-La catalysts

Nickel-based catalysts supported on Al₂O₃ · SiO₂ were prepared with modification of the second metal involving La, Co, Cu, Zr or Y, of which the catalytic behaviors were assessed in the ethanol steam reforming reaction. Activity test indicated that addition of La resulted in higher selectivity of hydrogen and lower selectivity of carbon monoxide, compared with Co-doped nickel catalyst. Influences of lanthanum amounts on catalytic performance were studied over 30NixLa/Al₂O₃ · SiO₂ (x = 5, 10, 15), and characterizations by XRD, TPR and XPS indicated that low amount of lanthanum additives (5%) was superior to inhibit the crystal growth of nickel as well as beneficial to the reduction of nickel oxide. Finally 100 h test for the optimal catalyst 30Ni5La/Al₂O₃ · SiO₂ indicated its good long-term stability to provide high hydrogen selectivity and low carbon monoxide formation, as well as good resistance to coke deposition at low temperature.     

Chemical zoning of calcium aluminoferrite formed during melt crystallization in CaO-SiO2-Al2O3-Fe2O3 pseudoquaternary system

In the CaO-SiO₂-Al₂O₃-Fe₂O₃ pseudoquaternary system, the solid solutions of Ca₂(Al_xFe_1−x)₂O₅, with x<0.7 (ferrite), Ca₂SiO₄ (belite), Ca₃Al₂O₆ (C₃A) and Ca₁₂Al₁₄O₃₃ (C₁₂A₇), were crystallized out of a complete melt during cooling at 8.3 °C/min. Upon cooling to 1370 °C, both the crystals of ferrite with x=0.41 and belite would start to nucleate from the melt. During further cooling, the x value of the precipitating ferrite would progressively increase and eventually approach 0.7. At ambient temperature, the ferrite crystals had a zonal structure, the x value of which successively increased from the cores toward the rims. The value of 0.45 was confirmed for the cores by EPMA. The chemical formula of the rims was determined to be Ca_2.03[Al_1.27Fe_0.68Si_0.02]_Σ1.97O₅ (x=0.65). As the crystallization of ferrite and belite proceeded, the coexisting melt would become progressively enriched in the aluminate components. After the termination of the ferrite crystallization, the C₃A and belite would immediately crystallize out of the melt, followed by the nucleation of C₁₂A₇. The C₁₂A₇ accommodated about 2.1 mass% Fe₂O₃ in the chemical formula Ca_12.03[Al_13.61Fe_0.37]_Σ13.98O₃₃, being free from the other foreign oxides (SiO₂ and P₂O₅).     

Effects of CaSiO3 addition on sintering behavior and microwave dielectric properties of Al2O3 ceramics

The effects of CaSiO₃ addition on the sintering behavior and microwave dielectric properties of Al₂O₃ ceramics have been investigated. The addition of CaSiO₃ into Al₂O₃ ceramics resulted in the emergence of Ca₂Al₂SiO₇ and CaAl₂Si₂O₈, which acting as liquid sintering aids can effectively lower the sintering temperature of Al₂O₃ ceramic. The Q × f value of Al₂O₃-CaSiO₃ ceramics decreased with the CaSiO₃ addition increasing because of the lower Q × f value of Ca₂Al₂SiO₇ and CaAl₂Si₂O₈. Compared with the pure CaSiO₃ ceramic, the Al₂O₃-CaSiO₃ ceramic with 20 wt% CaSiO₃ addition possessed good dielectric properties of ?_r = 9.36 and Q × f = 13,678 GHz at the similar sintering temperature.     

The solubility of selenate-AFt (3CaO·Al2O3·3CaSeO4·37.5H2O) and selenate-AFm (3CaO·Al2O3·CaSeO4·xH2O)

The Se(VI)-analogues of ettringite and monosulfate, selenate-AFt (3CaO·Al₂O₃·3CaSeO₄·37.5H₂O), and selenate-AFm (3CaO·Al₂O₃·CaSeO₄·xH₂O) were synthesised and characterised by bulk chemical analysis and X-ray diffraction. Their solubility products were determined from a series of batch and resuspension experiments conducted at 25 °C. For selenate-AFt suspensions, the pH varied between 11.37 and 11.61, and a solubility product, log K_so=61.29±0.60 (I=0 M), was determined for the reaction 3CaO·Al₂O₃·3CaSeO₄·37.5H₂O+12 H⁺⇔6Ca²⁺+2Al³⁺+3SeO₄²⁻+43.5H₂O. Selenate-AFm synthesis resulted in the uptake of Na, which was leached during equilibration and resuspension. For the pH range of 11.75 to 11.90, a solubility product, log K_so=73.40±0.22 (I=0 M), was determined for the reaction 3CaO·Al₂O₃·CaSeO₄·xH₂O+12 H⁺⇔4Ca²⁺+2Al³⁺+SeO₄²⁻+(x+6)H₂O. Thermodynamic modelling suggested that both selenate-AFt and selenate-AFm are stable in the cementitious matrix; and that in a cement limited in sulfate, selenate concentration may be limited by selenate-AFm to below the millimolar range above pH 12.     

Matrix–filler interactions in polysilazane-derived ceramics with Al2O3 and ZrO2 fillers

Interactions between a poly(vinyl)silazane and Al₂O₃ or Y₂O₃-stabilised ZrO₂ fillers were studied during the fabrication of polysilazane-derived bulk ceramics in order to investigate the influence of oxide fillers on resulting properties. Specimens were produced by coating of the filler powders with the polysilazane, warm-pressing of the resulting composite powders, and pyrolytic conversion in flowing N₂ at various temperatures between 1000 °C and 1400 °C. Significant differences in densification were observed, depending on the filler used. Reactions between the polysilazane-derived matrix and Al₂O₃ or ZrO₂ at temperatures ≥1300 °C resulted in the formation of Si₅AlON₇ or ZrSiO₄, respectively. Reactivity in the polysilazane-derived component was a result of SiO₂ contamination caused primarily by adsorbed species on the filler particle surface. Knowledge of polysilazane/filler interface processes is found to be decisive for the prediction of properties such as shrinkage and porosity, which heavily influence performance of a material.     

Preparation and thermophysical properties of LaMgAl11O19–Yb3Al5O12 ceramic composites

LaMgAl₁₁O₁₉–Yb₃Al₅O₁₂ ceramic composites were prepared by pressureless sintering process at 1700 °C for 10 h in air. The microstructure and thermophysical properties of the composites were characterized by X-ray diffraction, scanning electron microscopy, high-temperature dilatometer and laser flash diffusivity measurements. LaMgAl₁₁O₁₉–Yb₃Al₅O₁₂ ceramic composites are composed of magnetoplumbite and garnet structures. LaMgAl₁₁O₁₉–Yb₃Al₅O₁₂ ceramic composites exhibit typical linear increase in thermal expansion with the increase of temperature. The measured thermal diffusivity gradually decreases with increasing temperature. Thermal conductivity of LaMgAl₁₁O₁₉–Yb₃Al₅O₁₂ ceramic composites is in the range of 2.6–3.9 W·m⁻¹·K⁻¹ from room temperature to 1200 °C.     

Properties and rapid consolidation of nanostructured Al2O3-Al2SiO5 composites by high frequency induction heated sintering

The rapid sintering of nanostructured Al₂O₃ and Al₂O₃ to Al₂SiO₅ composites was investigated by a high-frequency induction heating sintering process. The advantage of this process is that it allows very quick densification to near theoretical density and inhibition of grain growth. Highly dense nanostructured Al₂O₃ and Al₂O₃ to Al₂SiO₅ composites were produced with simultaneous application of a 80 MPa pressure and induced output current of a total power capacity (15 kW) within 3 min. The sintering behavior, grain size and mechanical properties of Al₂O₃ and Al₂O₃ to Al₂SiO₅ composites were investigated.     

Effects of Al2O3 addition on the sintering behavior and microwave dielectric properties of CaSiO3 ceramics

The effects of Al₂O₃ addition on the densification, structure and microwave dielectric properties of CaSiO₃ ceramics have been investigated. The Al₂O₃ addition results in the presence of two distinct phases, e.g. Ca₂Al₂SiO₇ and CaAl₂Si₂O₈, which can restrict the growth of CaSiO₃ grains by surrounding their boundaries and also improve the bulk density of CaSiO₃-Al₂O₃ ceramics. However, excessive addition (≥2 wt%) of Al₂O₃ undermines the microwave dielectric properties of the title ceramics since the derived phases of Ca₂Al₂SiO₇ and CaAl₂Si₂O₈ have poor quality factor. The optimum amount of Al₂O₃ addition is found to be 1 wt%, and the derived CaSiO₃-Al₂O₃ ceramic sintered at 1250 °C presents improved microwave dielectric properties of ?_r = 6.66 and Q × f = 24,626 GHz, which is much better than those of pure CaSiO₃ ceramic sintered at 1340 °C (Q × f = 13,109 GHz).     

Sintering of Al2O3-SiC composite from sol-gel method with MgO, TiO2 and Y2O3 addition

Al₂O₃-SiC composite ceramics were prepared by pressureless sintering with and without the addition of MgO, TiO₂ and Y₂O₃ as sintering aids. The effects of these compositional variables on final density and hardness were investigated. In the present article at first α-Al₂O₃ and β-SiC nano powders have been synthesized by sol-gel method separately by using AlCl₃, TEOS and saccharose as precursors. Pressureless sintering was carried out in nitrogen atmosphere at 1600 °C and 1630 °C. The addition of 5 vol.% SiC to Al₂O₃ hindered densification. In contrast, the addition of nano MgO and nano TiO₂ to Al₂O₃-5 vol.% SiC composites improved densification but Y₂O₃ did not have positive effect on sintering. Maximum density (97%) was achieved at 1630 °C. Vickers hardness was 17.7 GPa after sintering at 1630 °C. SEM revealed that the SiC particles were well distributed throughout the composite microstructures. The precursors and the resultant powders were characterized by XRD, STA and SEM.     

Alkali-treatment of ZSM-5 zeolites with different SiO2/Al2O3 ratios and light olefin production by heavy oil cracking

Four kinds of ZSM-5 zeolites with different SiO₂/Al₂O₃ ratios are alkali-treated in 0.2 M NaOH solution for 300 min at 363 K. Changes to the compositions, morphologies, pore sizes, and distributions of the zeolites are compared before and after alkali-treatment. The changes observed are largely influenced by the SiO₂/Al₂O₃ ratios with which the zeolites are synthesized. A possible mechanism of desilication during alkali-treatment is proposed. The SiO₂/Al₂O₃ ratio of zeolites is found to influence the yield of light olefins that use heavy oil as feedstock. Alkali-treated ZSM-5 zeolites produce higher yields of light olefins compared to either untreated zeolites or the industry catalyst CEP-1. It is believed that alkali-treatment introduces mesopores to the zeolites and improves their catalytic cracking ability. ZSM-5 zeolites with SiO₂/Al₂O₃ ratios of 50 also present superior selectivity toward light olefins because of their optimized hierarchical pores.     

Support modification to improve the sulphur tolerance of Ag/Al2O3 for SCR of NOx with propene under lean-burn conditions

Ag/Al₂O₃ catalysts with 1 wt% SiO₂ or TiO₂ doping in alumina support have been prepared by wet impregnation method and tested for sulphur tolerance during the selective catalytic reduction (SCR) of NO_x using propene under lean conditions. Ag/Al₂O₃ showed 44% NO_x conversion at 623 K, which was drastically reduced to 21% when exposed to 20 ppm SO₂. When Al₂O₃ support in Ag/Al₂O₃ was doped with 1 wt% SiO₂ or TiO₂ the NO_x conversion remained constant in presence of SO₂ showing the improved sulphur tolerance of these catalysts. Subsequent water addition does not induce significant deactivation. On the contrary, a slight promotional effect on the activity of NO conversion to nitrogen is observed after Si and Ti incorporation. FTIR study showed the sulphation of silver and aluminum sites of Ag/Al₂O₃ catalysts resulting in the decrease in the formation of reactive intermediate species such as –NCO, which in turn decreases NO_x conversion to N₂. In the case of Ag/Al₂O₃ doped with SiO₂ or TiO₂, formation of silver sulphate and aluminum sulphate was drastically reduced, which was evident in FTIR resulting in remarkable improvement in the sulphur tolerance of Ag/Al₂O₃ catalyst. These catalysts before and after the reaction have been characterized with various techniques (XRD, BET surface area, transmittance FTIR and pyridine adsorption) for physico-chemical properties.     

Developments on the mechanical properties of MgO-MgAl2O4 composite refractories by ZrSiO4-3 mol% Y2O3 addition

Improvements and the effects of additions of ZrSiO₄-3 mol% Y₂O₃ into MgO-MgAl₂O₄ composite refractories on mechanical properties and thermal stress resistance parameters were investigated. Significant improvements were achieved on mechanical properties and R-R_st parameters up to ∼2 and ∼3-fold ratios. The major parameters improving mechanical properties and thermal behaviour of refractories were determined as follows: (i) the increase in resistance to crack initiation and propagation due to formation of Mg₂SiO₄ phase after decomposition of zircon; (ii) propagation of the microcracks formed in the structure for a short distance by interlinking each other; (iii) arresting or deviation of microcracks when reaching pores or ZrO₂ grains released after dissociation of zircon, located together with Y₂O₃ particles, and furthermore; (iv) co-presence of both intergranular and transgranular types of cracks, and with incorporation of zircon-Y₂O₃; (v) increase in density; and (vi) a significant reduction in MgO grain size.     

The effect of Cr2O3 and P2O5 additions on the phase transformations during the formation of calcium sulfoaluminate C4A3S¯

The study describes the influence of chromium and phosphorus additions on the phase transformations during the formation of the calcium sulfoaluminate Ca₄Al₆SO₁₆ from CaCO₃-Al₂O₃-CaSO₄ mixtures. The temperatures of decarbonation reaction were measured by means of differential thermal analysis. The enthalpy variations at different heating temperatures were determined by isothermal calorimetry. The results show that the Cr₂O₃ and P₂O₅ additions lower the onset temperature of decarbonation. The energy requirement at high temperature of the doped mixtures is less, compared to that of mixtures without dopants. The formation of solid solutions is followed by X-ray diffraction. The higher concentrations of additives hinder the formation of the C₄A₃S¯ phase.     

Corrosion mechanisms of Al2O3/MgAl2O4 by V2O5, NiO, Fe2O3 and vanadium slag

The effects of V₂O₅, NiO, Fe₂O₃ and vanadium slag on the corrosion of Al₂O₃ and MgAl₂O₄ have been investigated. The specimens of Al₂O₃ and MgAl₂O₄ with the respective oxides above mentioned were heated at 10 °C/min from room temperature up to three different temperatures: 1400, 1450 and 1500 °C. The corrosion mechanisms of each system were followed by XRD and SEM analyses. The results obtained showed that Al₂O₃ was less affected by the studied oxides than MgAl₂O₄. Alumina was only attacked by NiO forming NiAl₂O₄ spinel, while the MgAl₂O₄ spinel was attacked by V₂O₅ forming MgV₂O₆. It was also observed that Fe₂O₃ and Mg, Ni, V and Fe present in the vanadium slag diffused into Al₂O₃. On the other hand, the Fe₂O₃ and Ca, S, Si, Na, Mg, V and Fe diffused into the MgAl₂O₄ structure. Finally, the results obtained were compared with those predicted by the FactSage software.     

Phase diagram of the Al2O3-HfO2-Y2O3 system

The phase diagram of the Al₂O₃-HfO₂-Y₂O₃ system was first constructed in the temperature range 1200-2800 °C. The phase transformations in the system are completed in eutectic reactions. No ternary compounds or regions of appreciable solid solution were found in the components or binaries in this system. Four new ternary and three new quasibinary eutectics were found. The minimum melting temperature is 1755 °C and it corresponds to the ternary eutectic Al₂O₃ + HfO₂ + Y₃Al₅O₁₂. The solidus surface projection, the schematic of the alloy crystallization path and the vertical sections present the complete phase diagram of the Al₂O₃-HfO₂-Y₂O₃ system.     

Improvement of coke resistance of Ni/Al2O3 catalyst in CH4/CO2 reforming by ZrO2 addition

This work investigates the improvement of Ni/Al₂O₃ catalyst stability by ZrO₂ addition for H₂ gas production from CH₄/CO₂ reforming reactions. The initial effect of Ni addition was followed by the effect of increasing operating temperature to 500–700 °C as well as the effect of ZrO₂ loading and the promoted catalyst preparation methods by using a feed gas mixture at a CH₄:CO₂ ratio of 1:1.25. The experimental results showed that a high reaction temperature of 700 °C was favored by an endothermic dry reforming reaction. In this reaction the deactivation of Ni/Al₂O₃ was mainly due to coke deposition. This deactivation was evidently inhibited by ZrO₂, as it enhances dissociation of CO₂ forming oxygen intermediates near the contact between ZrO₂ and nickel where the deposited coke is gasified afterwards. The texture of the catalyst or BET surface area was affected by the catalyst preparation method. The change of the catalyst texture resulted from the formation of ZrO₂–Al₂O₃ composite and the plugging of Al₂O₃ pore by ZrO₂. The 15% Ni/10% ZrO₂/Al₂O₃ co-impregnated catalyst showed a higher BET surface area and catalytic activity than the sequentially impregnated catalyst whereas coke inhibition capability of the promoted catalysts prepared by either method was comparable. Further study on long-term catalyst stability should be made.     

Preparation of nanocrystalline Sr3Al2O6 powders via citric acid precursor

Sr₃Al₂O₆ was synthesized via citric acid precursor. The effects of the molar ratio of citric acid to total metal cations concentration (CA/M) on the formation of Sr₃Al₂O₆ were investigated. Increasing the CA/M promoted the formation of Sr₃Al₂O₆. Single-phase and well-crystallized Sr₃Al₂O₆ was obtained from the CA/M = 1, CA/M = 2 and CA/M = 4 precursor at temperature 1200 °C, 1100 °C and 900 °C, respectively. Differential thermal analysis and thermogravimetric (DTA/TG), X-ray diffractometry (XRD) and field emission scanning electron microscopy (FESEM) were used to characterize the precursors and the derived oxide powders. Sr₃Al₂O₆ nanoparticles with a diameter of about 50-70 nm were obtained.