Cordierite-based refractory ceramics from natural halloysite and peridotite: Insights on technological properties

Cordierite-based ceramics were fabricated from Moroccan natural halloysite clay by using a simple and low-cost manufacturing method. To this end, peridotite and halloysite samples, collected from Beni Bousera and Melilla sites, Morocco, were used as raw materials for ceramics manufacturing. A starting mixture was prepared (76.08 wt% of clay and 23.92 wt% of peridotite), molded and heated to the desired temperature (1250, 1300 and 1350 degrees C) to fabricate cordierite ceramic specimens. Both raw materials (peridotite and halloysite) and final ceramics were analyzed using routine characterization techniques including chemical analysis by XRF, mineralogical analysis by XRD, thermogravimetric analysis, and morphological characteristics using scanning electron microscopy (SEM). The prepared ceramics were investigated regarding their mineralogical composition, thermal and technological properties, chemical resistance, and microstructural characteristics. Our results indicated that peridotite sample is mainly composed of silica (40.25 wt%) and magnesia (38.05 wt%) while halloysite is consisted essentially of silica (38.00 wt%) and alumina (34.13 wt%). This was confirmed by XRD, TG-DTA and FTIR analyses. The prepared ceramic specimens at different sintering temperatures (i.e., 1250, 1300 and 1350 degrees C) have regular cylindrical forms, displaying good ceramic properties. This is consolidated with the main technological tests including porosity (4.56-3.11%), bulk density (2.45-2.78 g/cm3), shrinkage (6.51-10.31%), indirect tensile strength (20.35-27.60 MPa), and low linear thermal expansion coefficient (3.05-2.18 x 10-6/ degrees C). Cordierite specimen prepared at 1350 degrees C provided the best ceramic sample with the highest technological properties, good chemical resistance and thermal properties. Thus, naturally abundant halloysite and peridotite deposits are potential candidates for cordierite-based ceramic manufacture. Therefore, the achieved results have provided cost-effective ceramic bricks with physical, thermal and mechanical properties that are favorable to be used as refractory bricks.