A hybrid biomass-natural kaolinite for refractory ceramic manufacturing

The current study investigates the effect of adding a low-cost biomaterial (sawdust biomass) to kaolinite clay on the properties of insulating refractory materials. Natural kaolinite clay from NW Tunisia has been selected for porous ceramic preparation due to its high alumina content (23.64%) with low impurities, especially iron and alkaline oxides. For this study, a set of cylindrical samples were prepared from mixtures of Tabarka clay with different proportions of sawdust (10, 15 and 20%). Those green specimens were pressed and sintered to 1350 °C for 2 h. Experimental data showed that the increase in sawdust proportion increased the open porosity from 24 to 35%. SEM images showed higher important porosity with higher biomass addition. Similarly, bulk density and compressive strength decreased to 1.65 g/cm³ and 17 MPa, respectively. Mullite phase was also generated by the abundant alumina and silica in the raw feed. Several ceramic specimens were also manufactured under optimal conditions: sawdust (20%), pressure (10 kN), and sintering at 1200, 1250 and 1300 °C. The obtained ceramics showed higher porosity (57%), but lower bulk density (1.13 g/cm³). These are the required standards for silica-alumina insulating materials, confirming the possible valorization of kaolinite clay from Tunisia for refractory insulating ceramic.