Preparation and characterization of porous ceramics prepared by kaolinite gangue and Al(OH)3 with double addition of MgCO3 and CaCO3

Porous ceramics were prepared from kaolinite gangue and Al(OH)₃ with double addition of MgCO₃ and CaCO₃ by the pore-forming in-situ technique. The characterizations of porous ceramics were investigated by X-ray diffractometry, scanning electron microscopy, and mercury porosimetry measurements, etc. It is found that although the decomposition of MgCO₃ and CaCO₃ has little contribution to the porosity, the double addition of MgCO₃ and CaCO₃ strongly affects the formation of liquid phase, and then changes the phase compositions, pore characterization, and strength. The appropriate mode is the sample containing 1.17wt% MgCO₃ and 1.17wt% CaCO₃, which has high apparent porosity (41.0%), high crushing strength (53.5 MPa), high mullite content (76wt%), and small average pore size (3.24 μm).