Chemically-bonded magnesium phosphate ceramics from magnesium oxide-graphite refractory brick waste

Abstract

In Brazil, the production of each ton of steel generates approximately 621 kg of waste and direct co-products. One of the components that generates a high amount of waste is the refractory material used in the steel process. So, in this study, the possibility of using MgO-C refractory waste from steel casting pots after their deterioration for the formation of chemically bonded phosphate ceramics was investigated. This work aims to study the recovery of industrial solid waste from MgO-C refractories by determining the processing conditions necessary to obtain magnesium phosphate ceramics. Three mean particle size of the waste and three potassium monophosphate:MgO ratio in the mixture were adopted. All mixtures showed the formation of the K-struvite phase and a strong relationship between the compressive strength and porosity properties. The highest compressive strength value obtained, 7.51 ± 0.24 MPa, is sufficient for use in several areas of engineering. It was also possible to statistically represent, using a quadratic model, the variation in porosity in relation to the phosphate content and particle size of the waste, obtaining porosities ranging from 14% to 25%. Taking into account this study used a waste, the evaluation of its environmental impact assumed an important role. The waste showed no appreciable toxicity, while some samples W3-20 showed toxicity to Allium cepa L. and Artemia salina. Considering the presented properties, the obtained material could be used as a structural block, filters, support for catalysts, and repair element for cement-based structures and roadways.