Sustainable lightweight foams from hazardous aluminum dross

Chayapat WEERAPAKDEE; Makoto NANKO; Yen-Ling  KUO; Sukasem WATCHARAMAISAKUL; Kaito SUZUKI; Seiryu  SUZUKI; Siriwan CHOKKHA

doi:10.55713/jmmm.v36i3.2549

Authors

Chayapat WEERAPAKDEE Suranaree University of Technology, School of Ceramic Engineering, Institute of Engineering, Nakhon Ratchasima, 30000, Thailand https://orcid.org/0009-0000-3538-8074
Makoto NANKO Nagaoka University of Technology, High Temperature Materials Laboratory, Mechanical Engineering, Nagaoka, Niigata, 940-2188, Japan https://orcid.org/0000-0002-2345-2638
Yen-Ling KUO Nagaoka University of Technology, High Temperature Materials Laboratory, Mechanical Engineering, Nagaoka, Niigata, 940-2188, Japan https://orcid.org/0009-0004-4693-3743
Sukasem WATCHARAMAISAKUL Suranaree University of Technology, School of Ceramic Engineering, Institute of Engineering, Nakhon Ratchasima, 30000, Thailand https://orcid.org/0000-0003-1218-7581
Kaito SUZUKI Nagaoka University of Technology, High Temperature Materials Laboratory, Mechanical Engineering, Nagaoka, Niigata, 940-2188, Japan https://orcid.org/0009-0007-5445-3274
Seiryu SUZUKI Nagaoka University of Technology, High Temperature Materials Laboratory, Mechanical Engineering, Nagaoka, Niigata, 940-2188, Japan https://orcid.org/0009-0003-2455-4067
Siriwan CHOKKHA Suranaree University of Technology, School of Ceramic Engineering, Institute of Engineering, Nakhon Ratchasima, 30000, Thailand https://orcid.org/0009-0001-3335-5057

DOI:

https://doi.org/10.55713/jmmm.v36i3.2549

Keywords:

Aluminium dross, Ceramic Foam, Sustainable Materials, Industrial Waste Upcycling

Abstract

Aluminum dross is a hazardous byproduct from aluminum industry that causes environmental problems and high disposal cost. This work presents a sustainable route to upcycle secondary aluminum dross into lightweight ceramic foams for insulating refractory applications. Secondary aluminum dross powder was blended with polyethylene (PE) pore-forming agents (30 vol% to 70 vol%) and polyvinyl alcohol (PVA) binder added as a 7.5 wt% aqueous solution (binder contents: 1 vol% and 3 vol%), followed by pressing and sintering at 1400℃. Increasing PE systematically reduced bulk density and increased open porosity. At 70 vol% PE, the foams reached a bulk density of 0.94 g∙cm^‒3 and open porosity of ~74%, satisfying the Japanese Industrial Standard (JIS) specification for lightweight refractory bricks. The maximum compressive strength was ~2 MPa, sufficient for thermal insulation where load-bearing capacity is secondary. X-ray diffraction confirmed a multiphase matrix of α−Al₂O₃, MgAl₂O₄, and CaAl₁₂O₁₉, indicating solid-state reactions between alumina and Mg/Ca-bearing phases. Morphology revealed a well-connected porous network stabilized by reaction-bonded bridges, indicating strong interparticle bonding and limited pore coalescence during sintering. This approach can divert over 1000 kg of hazardous waste per ton of secondary aluminum dross processed and cut CO₂ emissions by 65% versus alumina routes. The approach promotes circular economy through waste-derived ceramics.

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