Synthesis of 3:2 mullite ceramics from silica-enriched filter cake waste via diphasic gels method.

Ermias Abebe Negash, Getinet Asrat Mengesha, Belay Brehane Tesfamariam, Tamirat Addis, Yeabsira Sisay Mekuriya, Sena Tadesse Beyene

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Ermias Abebe NegashDepartment of Materials Science and Engineering, Adama Science and Technology University, Adama, Ethiopia.

Getinet Asrat MengeshaDepartment of Physics, CoNCS, Wolaita Sodo University, Sodo, Ethiopia. getgetuw@gmail.com.

Belay Brehane TesfamariamDepartment of Materials Science and Engineering, Adama Science and Technology University, Adama, Ethiopia.

Tamirat AddisDepartment of Materials Science and Engineering, Adama Science and Technology University, Adama, Ethiopia.

Yeabsira Sisay MekuriyaDepartment of Materials Science and Engineering, Adama Science and Technology University, Adama, Ethiopia.

Sena Tadesse BeyeneDepartment of Materials Science and Engineering, Adama Science and Technology University, Adama, Ethiopia.

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Abstract

Mullite ceramics were synthesized from filter cake waste following the diphasic gel method. Filter cake waste, with over 65% silica content, and aluminum nitrate nonahydrate were utilized as the sources of silica and alumina, respectively. The prepared samples were sintered at various temperatures of 1150, 1250, and 1350 °C. The sintered bodies were then evaluated for porosity, density, compressive strength, and dielectric strength. Differential Thermal Analysis (DTA) revealed exothermic peaks at 970 °C and 1147 °C, corresponding to spinel and mullite formation, which was also confirmed by X-ray diffraction (XRD) analysis. The XRD result also showed single-phase mullite crystallization at 1250 °C. Field Emission-Scanning Electron Microscopy (FESEM) and Energy Dispersive Spectroscopy (EDS) demonstrated morphological changes, grain growth, and uniform elemental distribution in sintered mullite ceramics. The mullite ceramics sintered at 1350 °C exhibited a density of 2.615 g/cm

Indexed as

Advanced ceramicsDiphasic gelsFilter cake wasteMulliteSilica

Identifiers

PMID41530358

DOI10.1038/s41598-026-35281-3

PMCPMC12881530

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