ECOLOGICAL AND PRACTICAL ASPECTS
OF THE USE OF HIGH-ALUMINA PETROCHEMICAL WASTE PRODUCTS
IN THE PRODUCTION OF ACID-RESISTANT MATERIALS
V. Z. Abdrakhimov
Translated from Novye Ogneupory, No. 1, pp. 40 – 43, January, 2010.
Original article submitted February 24, 2010.
It is established that it is desirable to use petrochemical high-alumina waste products as a shortening material
instead of chamotte in the production of acid-resistant materials. This promotes a significant improvement in
the physicomechanical and chemical properties of acid-resistant materials.
Keywords: acid-resistant materials, high-alumina petrochemical waste products, clay part of zircon-ilmenite
ore gravitation tailings (ZIG), metallographic analysis, x-ray analysis, utilization, environmental protection.
The unlimited possibilities of the most complete utiliza-
tion of high-alumina petrochemical waste products are close
in composition and properties to a natural raw material used
for producing ceramic materials . A considerable part of
the waste materials may be used as a basic raw material or
adjustment components in the manufacture of materials for
general construction or for a special purpose .
One important ecological problem is the creation of
waste-free technology for producing materials that exhibit
improved properties for lining heating units. As is well
known, in almost every enterprise a considerable number of
heating units and boiler devices operate . The linings of
industrial furnaces operate under severe conditions (high
temperature, corrosive gas atmosphere, direct contact of the
lining material with molten metal, alloys and fluxes).
Chamotte is used as a shortening material in the produc
tion of acid-resistant materials in ceramic mixes. It is pre
pared by firing clay in the range 1200 – 1250°C (to water ab
sorption <5%). It is very difficult to prepare a high quality
chamotte based on low-grade refractory clay. Therefore, it is
impossible to prepare high quality acid-resistant materials
from low-grade refractory clays and chamotte. Recently
high-alumina petrochemical waste products have been sug-
gested as an addition for producing acid-resistant materials.
In publications [3 – 5] the fundamental possibility is
demonstrated of using in the production of acid-resistant ma
terials the clay part of zircon-ilmenite ore gravitation tailings
(ZIG) and undressed kaolin of the Chepaesk deposit whose
chemical composition is presented in Table 1.
The exhausted catalyst IM-2201 of the Novokuibyshev
Chemical Combine is a high-alumina petrochemical waste
product, that is an aluminum-chromium finely dispersed
powder of pale green color. The chemical composition of the
exhausted catalyst is presented in Table 1 and its elemental
chemical analysis is shown in Fig. 1.
In order to analyze particle sizes of the test exhausted
catalyst metallographic analysis was performed in a
MIM-8M microscope with a 200-fold magnification. Parti
cles of exhausted catalyst were placed in alcohol, applied to a
glass and photographed. In order to determine the precise
sizes of particles several areas of an object were photo
graphed. By using a micrometer scale (one division equals
0.01 mm) it is possible to determine the absolute particle size
of exhausted catalyst. The average particle size is
0.001 – 0.003 mm (Fig. 2). The microstructure of exhausted
catalyst IM-2201 of the Novokuibyshev Chemical Combine
for specimens of the lightly fuzed clay are shown in Fig. 3.
Refractories and Industrial Ceramics Vol. 51, No. 1, 2010
1083-4877/10/5101-0052 © 2010 Springer Science+Business Media, Inc.
Samara State University of Architecture and Construction, Sama