Phase Transformation of Alumina, Silica and Iron Oxide during Carbothermic Reduction of Fly Ash for Ceramics Production

Abstract

Fly ash is a by-product from burning of coal. Utilization of fly ash by carbothermic reduction is an effective way to recover aluminum, silicon, and iron to enhance product-added value. This work is focused on the phase transformation of Al2O3, SiO2 and Fe2O3 during carbothermic reduction of fly ash in air. A comparative analysis of carbothermic reduction of fly ash in air and in nitrogen was made. Thermodynamics analysis was performed to illustrate the possible reactions for residue and condensate. X-ray diffraction (XRD), scanning electronic microscope (SEM), and energy dispersive spectrometry (EDS) were employed to characterize the phase composition, surface morphology, and microstructure of the reduced products. Results show that Fe3Si and Fe2Si appear sequentially with increasing of temperature. Al5O6N is an intermediate compound. Residue of Al9FeSi3, Al, and Si, and condensate of SiC, AlN and C are obtained. β-SiAlON was not found in the residue. Nitrogen is involved in the reduction of Al2O3 but not in the reduction of SiO2 and Fe2O3. Carbothermic reduction of fly ash in air did not behave the same as fly ash in nitrogen.