Study of Properties of Composite Heat-Protective Refractory Materials Based on Secondary Chamotte

The article is devoted to the study of the properties of the obtained heat-insulating refractory materials, based on fireclay scrap of various fractions (2.5 mm, 1.0 mm, 0.5 mm, and 0.1 mm) using a complex of mineral and oxide additives. The fillers used were titanium dioxide powder and silicon production wastes, which included microsilica powder, aluminum oxide, zinc oxide, zirconium oxide, chromium oxide, iron oxide, cement, lime, and baking soda. The choice of these fillers was due to the fact that they initially have corrosion resistance. Liquid glass acted as a binder. The resulting thermal barrier material was tested to determine its physical and mechanical properties, namely, thermal conductivity, porosity, compressive strength, and microstructure. According to the obtained results for the physical and mechanical properties, the secondary refractory material had properties close to GOST. So, according to GOST 12170-2021, the thermal conductivity values of the obtained materials were included in the 0.03–15.0 W/(m·K) range. The porosity values of the obtained samples complied with GOST 2409-2014 and were not more than 30%. The maximum compressive strength was 171.31 kgf/mm². The microstructure of the material of the obtained samples was very porous, and the pores were evenly distributed throughout the volume, which is extremely important for heat-insulating materials. A distinctive feature of the technology was the absence of a high-temperature firing stage: the required physical and mechanical properties of the material were achieved when heated to 180–300 °C with subsequent slow cooling in the furnace, which significantly reduces energy consumption compared to traditional refractory technologies. The use of waste from the production of chamotte scrap and microsilica will help to reduce negative impacts on the environment, save natural resources, and expand the raw material base.