Mining of Mineral Deposits

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Variations in alumina-based material composition and heating temperature of refractory bricks in mullite formation

David Candra Birawidha1, Muhammad Amin1, Agus Miswanto2, Fery Hendi Jaya3, Sari Utama Dewi3, Mentari Kirana Nariswari4, Devi Mariska Putri4

1Research Center for Mining Technology, National Research and Innovation Agency (BRIN), Lampung, Indonesia

2Geological Resource Research Center, National Research and Innovation Agency (BRIN), Bandung, Indonesia

3Sang Bumi Ruwa Jurai University, Lampung, Indonesia

4Universitas Lampung, Lampung, Indonesia


Min. miner. depos. 2025, 19(4):130-138


https://doi.org/10.33271/mining19.04.130

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      ABSTRACT

      Purpose. This study investigates the effects of varying alumina content and firing temperatures on the formation of mullite in refractory bricks composed of kaolin, alumina, and recycled chamotte. The goal is to develop high-performance, cost-effective refractories using local and recycled materials.

      Methods. Three formulations with different alumina proportions were prepared, pressed, and sintered at 1200 or 1300°C. Characterization was performed using XRF (chemical composition), XRD (phase analysis), FE-SEM/EDX (microstructure), and STA (thermal behavior). Mechanical properties were assessed using a UTM, and chemical resistance was evaluated by exposure to H2SO4 and NaOH solutions.

      Findings. Results show that higher alumina content and firing at 1300°C promote mullite formation, thereby improving mechanical strength, density, and resistance to thermal shock and chemical corrosion. The refractory with 35% alumina, fired at 1300°C, achieved the highest cold crushing strength (26.5 N/mm2) and bulk density (2.13 g/cm3), indicating optimal performance.

      Originality.The novelty of this work lies in the strategic use of recycled chamotte, not merely as a filler, but as a functional mullite precursor that synergizes with local kaolin to enhance sintering. This approach is concretely validated by the optimal performance of the 35% alumina composition fired at 1300°C, which achieved the highest mechanical strength and density, demonstrating a cost-effective and high-performance refractory solution from sustainable sources.

      Practical implications. The findings provide practical solutions for manufacturing high-quality refractories from sustainable, locally sourced materials, thereby reducing dependence on pure alumina and promoting environmental sustai-nability through recycling.

      Keywords: refractory brick, mullite, testing, analysis, alumina


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