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Abstract Summary
 
 
 
Conference:   105th Annual Meeting & Exposition  
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Symposium:   20. Ceramic Matrix Composites
Session:   Geopolymer Composites - 1:00:00 PM - 5:00:00 PM 4/28/2003
Abs. Title:   Composite Cold Ceramic Geopolymer in a Refractory Application  
Abstract #:   7411  
 
 
 
 
Type:   Invited
Submitted:   11/27/2002 5:31:46 PM
Status:   Accepted
Scheduled?   Yes
Abstract:   Geopolymers are amorphous to semi-crystalline three-dimensional alumino-silicate materials composed of mineral polymers resulting from geochemistry. Polymeric bonds of Si-O-Al-O form under alkaline conditions and in the presence of alumino-silicate oxides. Polysilicate chains form cross-linked 3-dimensional structures which can exhibit high compressive strengths and high thermal stability. It is these characteristics which have led to an examination/assessment of geopolymers for refractory application in the specialty steel industry. The production of ferro-silicon and ferro-manganese products for the specialty steel market includes the casting of final molten metal product at a temperature of 1425 degrees C into large nickel molds. The product is allowed to cool in the mold prior to its extraction. Once de-molded, the material is crunched into minus 5cm chunks for shipment to the end use customer. It is during this crushing process that fines are generated (minus 0.6cm) and can equate to 20-30% of the finished product. These have little value and can only partially be recycled through the furnace. The postulation was therefore derived that if the molten metal could be cast into exact forms suitable to the end user, this could save significantly in the costs of material crushing and in fines management. Based upon this postulation, any mold utilized would need to retain high strength at high temperature (1425 degrees C), maintain dimensional shape and facilitate gravity discharge of the molded metal form. Given Catawba's past involvement in the steel industry through Comrie Engineering Ltd., it was decided to evaluate geopolymer composite cold ceramic materials for construction of the casting mold. This paper will present the resultant characterization of features of the selected geopolymer composite including SEM and TEM results, 29Si MAS NMR and 27Al MAS NMR analysis of the selected potassium system geopolymer created from a specialty selected and prepared kaolin/montmorillinite/hectorite composite incorporating tantalum oxide (Ta2O5). Ultimate thermal stability data as well as compressive strengths achieved at various temperatures will be presented. Actual field trial tests utilizing the composite cold ceramic geopolymer will be discussed in the proceeding.
 
 Abstract Author(s)
 
 
 1   Primary and Presenting   Douglas Comrie - 1011815
Organization   Catawba Resources Inc.
Phone #   905 691 4879
Fax #  
Professional Title   CEO
Street Address  

City   Stow
State   OH
Country   United States
Postal Code  
 
 
 2   Co-Author   Waltraud Kriven - 1000704
Organization   University of Illinois at Urbana-Champaign
Phone #   (217) 333 5258
Fax #   (217) 333 2736
Professional Title   Professor
Street Address   Dept. of Materials Science and Engineering
1304 W. Green St.
City   Urbana
State   IL
Province  
Country   United States
Postal Code   61801
 
 
   

 
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