The formation of mullite from kaolinite under various reaction atmospheres
1996
Abstract In addition to its importance as a high-technology ceramic, mullite is also an intermediate phase in the formation of non-oxide ceramics (sialons) by carbothermal reduction of clay minerals. This reaction involved the formation of mullite under non-oxidizing atmospheres and in the presence of carbon. The effect of eight different reaction atmospheres on mullite formation from kaolinite in the presence and absence of carbon was studied by X-ray diffraction, 27 Al and 29 Si magic angle spinning nuclear magnetic resonance (MAS NMR) spectroscopy. Generally, a greater amount of mullite is formed at 1200 °C under vacuum and reducing atmospheres, which also produce mullites that are slightly more silica-rich (as deduced from X-ray lattice parameter measurements) but contain higher proportions of tetrahedral 27 Al NMR resonance at ≈ 46 ppm, probably associated with Al ∗ sites. Reaction systems containing either nitrogen or ammonia in the presence of carbon show NMR evidence of previously unreported early stage formation of SiON bonds. Thermodynamic calculations are presented which suggest that the formation of SiO is an important factor in the complex interactions between the various solid and gaseous reactants.
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