Mullite production: phase transformations of kaolinite, thermodynamics of the process

The growing demand for mullite raw materials, which meet industrial requirements originates the search for new and alternative sources, as well as efficient technologies for obtaining the target products (nanocomposites). The article suggests a method for obtaining mullite from kaolinite experimentally (Vezhayu-Vorykvinsky deposit, Russia). Structural kaolinite transformations (Al-Si-O-Me system), mineral phases transformations, and thermodynamics of the process have been studied. Based on the estimation of the thermodynamics of the reactions, the preferable reaction of mullite formation was determined. The article shows, that formation of the target product, mullite nanocomposite, has several intermediate phases (metakaolinite, pseudomullite). The transformations of the initial kaolinite structure include the removal of structural water and separation of the silica-oxygen tetrahedral and alumina-oxygen octahedral layers, the decomposition into free oxides, breaking of bonds between the silica-oxygen tetrahedrons and the partial increase in the coordination number of aluminium ions, the formation of mullite and cristobalite from free oxides. The proposed approach controls the ratio of Al2O3 and SiO2 phases at certain stages, which will further improve the mechanical and other properties of the matrix of the obtained raw materials for the target prototypes of industrial products.