Sustainable Production of Mullite Grogs from Industrial By-Products
Abstract
1. Introduction
2. Materials and Methods
2.1. Used Materials
2.2. Experimental Design
- 0%—Control samples without flux addition (V1, V5, V9, V13).
- 4%—Optimal flux content for mullite formation (V2, V6, V10, V14).
- 8%—Optimal flux content for cristobalite elimination (V3, V7, V11, V15).
- 16%—Excessive flux content example (V4, V8, V12, V16).
2.3. Loss of Ignition (L.O.I.)
2.4. X-Ray Fluorescence Analysis (XRF)
2.5. X-Ray Diffraction Analysis (XRD)
3. Results
3.1. Chemical Composition of Input Materials
3.2. Mineralogical Composition
3.3. Recipe Development and Sample Preparation
3.4. Chemical Analysis of Fired Samples
3.5. Firing Results and Mineralogical Analysis
3.5.1. 1380 °C Firing Results
3.5.2. 1700 °C Firing Results
3.6. Mullite Content Comparison
3.7. Material Classification and Colour Assessment
4. Discussion
5. Conclusions
Supplementary Materials
Author Contributions
Funding
Data Availability Statement
Conflicts of Interest
Abbreviations
| L.O.I. | Loss of Ignition |
| XRF | X-ray Fluorescence Analysis |
| XRD | X-ray Diffraction Analysis |
| Max. | Maximum |
References
- Galhano, C.; Lamas, P.; Seixas, D. Use of Industrial Waste for the Optimization of Ceramic Construction Materials. KnE Eng. 2020, 4, 36–48. [Google Scholar] [CrossRef]
- Veiga Simão, F.; Chambart, H.; Vandemeulebroeke, L.; Cappuyns, V. Incorporation of Sulphidic Mining Waste Material in Ceramic Roof Tiles and Blocks. J. Geochem. Explor. 2021, 225, 106741. [Google Scholar] [CrossRef]
- Niepce, J.-C.; Boch, P. (Eds.) Ceramic Materials: Processes, Properties and Applications; ISTE: London Newport Beach, CA, USA, 2007; ISBN 978-1-905209-23-1. [Google Scholar]
- Zhang, L. Production of Bricks from Waste Materials—A Review. Constr. Build. Mater. 2013, 47, 643–655. [Google Scholar] [CrossRef]
- Al Hoseny, N.F.; Amin, S.K.; Fouad, M.M.K.; Abadir, M.F. Reuse of Ceramic Sludge in the Production of Vitrified Clay Pipes. Ceram. Int. 2018, 44, 12420–12425. [Google Scholar] [CrossRef]
- Alves, H.P.A.; Silva, J.B.; Campos, L.F.A.; Torres, S.M.; Dutra, R.P.S.; Macedo, D.A. Preparation of Mullite Based Ceramics from Clay–Kaolin Waste Mixtures. Ceram. Int. 2016, 42, 19086–19090. [Google Scholar] [CrossRef]
- Brasileiro, M.I.; Rodrigues, A.W.B.; Menezes, R.R.; Neves, G.A.; Sant, L.N.L. The Kaolin Residue and Its Use for Production of Mullite Bodies. In Sustainable Development—Energy, Engineering and Technologies—Manufacturing and Environment; Ghenai, C., Ed.; InTech: Singapore, 2012; ISBN 978-953-51-0165-9. [Google Scholar][Green Version]
- Manfredini, T.; Marzola, G.; Nunziello, S.; Pellacani, G.C.; Pozzi, P.; Tubertini, O. The Recycling of Ceramic Sludges in the Production Process: An Option for Ceramic Tile Factories to Reach Zero Pollution. Environ. Technol. 1991, 12, 927–934. [Google Scholar] [CrossRef]
- Kumar, S.; Singh, K.K.; Ramachandrarao, P. Effects of Fly Ash Addition on the Mechanical and Other Properties of Ceramic Tiles. J. Mater. Sci. 2001, 36, 5917–5922. [Google Scholar] [CrossRef]
- Roslee, A.B.; Jamal, N.A.S.; Othman, N.H.; Abdul Razak, N.A.; Alias, N.H.; Mat Shayuti, M.S.; Marpani, F.; Mohd Razlan, M.R.; Jumahat, A.; Othman, M.H.D.; et al. Fabrication of Low-Cost Granite Dust Ceramic Hollow Fibre Membrane: Effects of Sintering Temperature. Mater. Today Proc. 2023, 72, 1234–1241. [Google Scholar] [CrossRef]
- Torres, P.; Manjate, R.S.; Quaresma, S.; Fernandes, H.R.; Ferreira, J.M.F. Development of Ceramic Floor Tile Compositions Based on Quartzite and Granite Sludges. J. Eur. Ceram. Soc. 2007, 27, 4649–4655. [Google Scholar] [CrossRef]
- El-Fadaly, E. Characterization of Porcelain Stoneware Tiles Based on Solid Ceramic Wastes. Int. J. Sci. Res. (IJSR) 2013, 4, 602–608. [Google Scholar]
- Tarhan, B.; Tarhan, M.; Aydin, T. Reusing Sanitaryware Waste Products in Glazed Porcelain Tile Production. Ceram. Int. 2017, 43, 3107–3112. [Google Scholar] [CrossRef]
- Karamanov, A.; Karamanova, E.; Ferrari, A.M.; Ferrante, F.; Pelino, M. The Effect of Fired Scrap Addition on the Sintering Behaviour of Hard Porcelain. Ceram. Int. 2006, 32, 727–732. [Google Scholar] [CrossRef]
- Bazhin, V.Y.; Glaz’ev, M.V. Combined Refractory Materials with Addition of Technogenic Waste for Metallurgical Assemblies. Refract. Ind. Ceram. 2021, 61, 644–648. [Google Scholar] [CrossRef]
- Carvalho, A.C.; Raupp-Pereira, F.; Rodrigues Neto, J.B.; Novaes De Oliveira, A.P. A New Source for Production of Ceramic Filters. Mater. Lett. 2015, 145, 250–252. [Google Scholar] [CrossRef]
- Mohit, M.; Sharifi, Y. Ceramic Waste Powder as Alternative Mortar-Based Cementitious Materials. ACI Mater. J. 2019, 116, 107–116. [Google Scholar] [CrossRef]
- Pticen, F.; Zítko, V. A Method of Treating Soft or Decay Silicate Raw Materials and Waste Products of Raw These Materials. 2017. Available online: https://isdv.upv.gov.cz/webapp/resdb.print_detail.det?pspis=PT/2014-138&plang=EN (accessed on 6 January 2026).
- Gowan, M.; Comyns, R.A. Water in the China Clay Industry. Water Environ. J. 1987, 1, 123–128. [Google Scholar] [CrossRef]
- Ke, S.; Wang, Y.; Pan, Z.; Ning, C.; Zheng, S. Recycling of Polished Tile Waste as a Main Raw Material in Porcelain Tiles. J. Clean. Prod. 2016, 115, 238–244. [Google Scholar] [CrossRef]
- Yuan, Q. Possible recycling options of waste materials in manufacturing ceramic tiles. GEOMATE 2021, 20, 73–80. [Google Scholar] [CrossRef]
- Saif, S.; Mubin, S.; Abbass, W.; Aslam, F.; Alyousef, R. Utilizing Machine Learning to Integrate Silica-Based Production Waste Material in Ceramic Tiles Manufacturing: Progressing toward Sustainable Solutions. Ceram. Int. 2024, 50, 18880–18906. [Google Scholar] [CrossRef]
- Dubois, J.; Murat, M.; Amroune, A.; Carbonneau, X.; Gardon, R. High-Temperature Transformation in Kaolinite: The Role of the Crystallinity and of the Firing Atmosphere. Appl. Clay Sci. 1995, 10, 187–198. [Google Scholar] [CrossRef]
- Nasr, I.; Abdel-Kader, F.M.; Embabi, H.K. Properties of Some High Alumina Refractories Obtained from Different Alumina Sources. Ceram. Int. 1981, 7, 60–64. [Google Scholar] [CrossRef]
- Pticen, F.; Laufek, F.; Lang, K.; Bohdálek, P. Topaz Jako Potenciálně Využitelná Surovina Získávaná Při Úpravě. In Proceedings of the Konference SUROVINY 2023, Prague, Czech Republic, 17–18 May 2023; Česká silikátová společnost: Prague, Czech Republic, 2023. [Google Scholar]
- Schneider, H.; Komarneni, S. (Eds.) Mullite; Wiley-VCH Verlag GmbH & Co. KGaA: Weinheim, Germany, 2005; ISBN 978-3-527-30974-0. [Google Scholar]
- Lecomte-Nana, G.; Bonnet, J.-P.; Soro, N. Influence of Iron on the Occurrence of Primary Mullite in Kaolin Based Materials: A Semi-Quantitative X-Ray Diffraction Study. J. Eur. Ceram. Soc. 2013, 33, 669–677. [Google Scholar] [CrossRef]
- Ye, H.; Li, Y.; Sun, J. Study on Formation Mechanism and Morphology Evolution of Iron-Exsolution Mullite. Mater. Lett. 2019, 246, 9–12. [Google Scholar] [CrossRef]
- ČSN 72 0103 (720103); A Basic Procedure for Silicate Analysis—Determination of Loss on Ignition. Office for Technical Standardization, Metrology and State Testing: Praha, Czech Republic, 2009.
- Santisteban, J.I.; Mediavilla, R.; López-Pamo, E.; Dabrio, C.J.; Blanca Ruiz Zapata, M.; José Gil García, M.; Castaño, S.; Martínez-Alfaro, P.E. Loss on Ignition: A Qualitative or Quantitative Method for Organic Matter and Carbonate Mineral Content in Sediments? J. Paleolimnol. 2004, 32, 287–299. [Google Scholar] [CrossRef]
- Bish, D.L.; Post, J.E. Modern Powder Diffraction; Reviews in mineralogy; Mineralogical Society of America: Washington, DC, USA, 1989; ISBN 978-0-939950-24-9. [Google Scholar]
- Guillemin, F.; Lecomte-Nana, G.; El Hafiane, Y.; Peyratout, C.; Smith, A. Influence of the Firing Atmosphere onto the Thermal Transformation of Iron-Enriched Kaolin. Appl. Clay Sci. 2024, 258, 107512. [Google Scholar] [CrossRef]
- Sutheimer, S.H.; Maurice, P.A.; Zhou, Q. Dissolution of Well and Poorly Crystallized Kaolinites; Al Speciation and Effects of Surface Characteristics. Am. Mineral. 1999, 84, 620–628. [Google Scholar] [CrossRef]
- López, P.V.; Hernández, M.F.; Richard, D.; Conconi, M.S.; Rendtorff, N.M. Porous Acicular Mullite Ceramics Produced from Well and Poorly Crystallized Kaolinite. Appl. Clay Sci. 2023, 238, 106937. [Google Scholar] [CrossRef]
- Kong, L.B.; Chen, Y.Z.; Zhang, T.S.; Ma, J.; Boey, F.; Huang, H. Effect of Alkaline-Earth Oxides on Phase Formation and Morphology Development of Mullite Ceramics. Ceram. Int. 2004, 30, 1319–1323. [Google Scholar] [CrossRef]
- Roy, R.; Das, D.; Rout, P.K. A Review of Advanced Mullite Ceramics. Eng. Sci. 2022, 18, 20–30. [Google Scholar] [CrossRef]
- Montoya, N.; Serrano, F.J.; Reventós, M.M.; Amigo, J.M.; Alarcón, J. Effect of TiO2 on the Mullite Formation and Mechanical Properties of Alumina Porcelain. J. Eur. Ceram. Soc. 2010, 30, 839–846. [Google Scholar] [CrossRef]



| Material | Description |
|---|---|
| Slurry DE | By-product of kaolin production (hydrocyclone drop, 50 mm fraction) |
| Dust-off RON | Unburned fly ash from rotary kilns (600–1000 °C), produced during shale burning up to 1350 °C in České lupkové závody |
| Feldspar dust-off Halamky | Waste dust generated during feldspar grinding at Halamky I deposit |
| Labelling Sample | Red Vidnava Kaolin 0–63 µm | Red Vidnava Kaolin 0–100 µm | Dust-Off RON | Slurry DE | Feldspar Dust-Off Halamky |
|---|---|---|---|---|---|
| V1 | 100 | 0 | 0 | 0 | 0 |
| V2 | 96 | 0 | 0 | 0 | 4 |
| V3 | 92 | 0 | 0 | 0 | 8 |
| V4 | 86 | 0 | 0 | 0 | 16 |
| V5 | 0 | 100 | 0 | 0 | 0 |
| V6 | 0 | 96 | 0 | 0 | 4 |
| V7 | 0 | 92 | 0 | 0 | 8 |
| V8 | 0 | 86 | 0 | 0 | 16 |
| V9 | 0 | 0 | 100 | 0 | 0 |
| V10 | 0 | 0 | 96 | 0 | 4 |
| V11 | 0 | 0 | 92 | 0 | 8 |
| V12 | 0 | 0 | 86 | 0 | 16 |
| V13 | 0 | 0 | 0 | 100 | 0 |
| V14 | 0 | 0 | 0 | 96 | 4 |
| V15 | 0 | 0 | 0 | 92 | 8 |
| V16 | 0 | 0 | 0 | 86 | 16 |
| Sample | Chemical Composition After Drying [%] | ||||||
|---|---|---|---|---|---|---|---|
| SiO2 | Al2O3 | Fe2O3 | TiO2 | CaO | K2O | L.O.I. | |
| Kaolin Vidnava red 0–63 µm | 42.68 | 36.56 | 5.87 | 0.51 | 0.12 | 0.92 | 13.35 |
| Kaolin Vidnava red 0–100 µm | 46.13 | 34.69 | 5.49 | 0.45 | 0.10 | 0.87 | 12.20 |
| Dust-off RON | 51.82 | 33.63 | 3.70 | 2.85 | 0.59 | 0.87 | 6.00 |
| Slurry DE | 51.50 | 31.80 | 2.54 | 0.66 | 0.03 | 1.46 | 12.00 |
| Feldspar dust-off Halamky I 1 | 70.26 | 15.17 | 2.58 | 0.37 | 0.47 | 8.10 | 0.75 |
| Sample | Red Vidnava Kaolin 0–63 µm | Red Vidnava Kalolin 0–100 µm | Dust-Off RON 1 | Slurry DE 2 | Feldspar Dust-Off Halamky |
|---|---|---|---|---|---|
| Mineral | |||||
| Kaolinite | 94.1 | 82.1 | 42.0 | 55.5 | |
| Mica | 3.1 | 12.3 | 4.0 | 19.0 | 7.0 |
| Quartz | 2.5 | 5.6 | 7.0 | 5.0 | 13.3 |
| Na—Ca feldspar | 23.1 | ||||
| K—feldspar | 56.6 | ||||
| Anatase | 0.5 | 0.5 | |||
| Calcite | 0.3 | ||||
| Mullite | 11.5 | ||||
| Amorphous phase | <10.0 | <10.0 | 35.0 | 19.0 | <10.0 |
| Recipe | SiO2 | Al2O3 | Fe2O3 | TiO2 | CaO | K2O | L.O.I | |
|---|---|---|---|---|---|---|---|---|
| Red Vidnava kaolin 0–63 µm | V1 | 49.25 | 42.19 | 6.77 | 0.59 | 0.14 | 1.06 | 13.35 |
| V2 | 50.28 | 41.01 | 6.59 | 0.58 | 0.15 | 1.39 | 12.85 | |
| V3 | 51.31 | 39.83 | 6.41 | 0.57 | 0.17 | 1.71 | 12.34 | |
| V4 | 53.33 | 37.53 | 6.05 | 0.55 | 0.20 | 2.34 | 11.33 | |
| Red Vidnava kaolin 0–100 µm | V5 | 52.58 | 39.54 | 6.26 | 0.51 | 0.11 | 0.99 | 12.20 |
| V6 | 53.46 | 38.49 | 6.10 | 0.51 | 0.13 | 1.32 | 11.74 | |
| V7 | 54.33 | 37.45 | 5.94 | 0.50 | 0.15 | 1.64 | 11.28 | |
| V8 | 56.04 | 35.39 | 5.63 | 0.49 | 0.18 | 2.27 | 10.37 | |
| Dust-off RON | V9 | 55.45 | 35.98 | 3.96 | 3.05 | 0.63 | 0.93 | 6.00 |
| V10 | 56.15 | 35.14 | 3.91 | 2.94 | 0.63 | 1.24 | 5.79 | |
| V11 | 56.85 | 34.30 | 3.85 | 2.83 | 0.62 | 1.55 | 5.58 | |
| V12 | 58.25 | 32.63 | 3.74 | 2.61 | 0.61 | 2.16 | 5.16 | |
| Slurry DE | V13 | 58.53 | 36.14 | 2.89 | 0.75 | 0.03 | 1.66 | 12.00 |
| V14 | 59.14 | 35.24 | 2.88 | 0.73 | 0.05 | 1.95 | 11.55 | |
| V15 | 59.75 | 34.35 | 2.87 | 0.72 | 0.07 | 2.24 | 11.10 | |
| V16 | 60.95 | 32.59 | 2.85 | 0.69 | 0.11 | 2.82 | 10.20 |
| Recipe | Amorphous Phase [%] | Mullite [%] | Quartz [%] | Cristobalite [%] | |
|---|---|---|---|---|---|
| Red Vidnava kaolin 0–63 µm | V1 | 24.0 | 43.0 | 26.0 | 7.0 |
| V2 | 25.6 | 56.8 | 13.3 | 4.3 | |
| V3 | 43 | 42.5 | 14.0 | 0.5 | |
| V4 | 51.0 | 39.8 | 10.0 | 0.2 | |
| Red Vidnava kaolin 0–100 µm | V5 | 32.9 | 38.9 | 23.2 | 5.0 |
| V6 | 25.7 | 60.2 | 8.8 | 5.3 | |
| V7 | 42.0 | 47.5 | 10 | 0.5 | |
| V8 | 49.8 | 43.0 | 7.0 | 0.2 | |
| Dust-off RON | V9 | 40.8 | 36.7 | 18.7 | 3.8 |
| V10 | 35.1 | 47.1 | 15.6 | 2.2 | |
| V11 | 54.0 | 39.0 | 7.0 | 0.0 | |
| V12 | 56.0 | 36.0 | 8.0 | 0.0 | |
| Slurry DE | V13 | 55.2 | 35.3 | 9.5 | 0.0 |
| V14 | 35.8 | 49.3 | 14 | 0.9 | |
| V15 | 55.0 | 39.0 | 6.0 | 0.0 | |
| V16 | 58.0 | 36.0 | 6.0 | 0.0 |
| Recipe | Amorphous Phase [%] | Mullite [%] | Quartz [%] | |
|---|---|---|---|---|
| Red Vidnava kaolin 0–63 µm | V1 | 43.0 | 53.0 | 4.0 |
| V3 | 49.0 | 48.0 | 3.0 | |
| Red Vidnava kaolin 0–100 µm | V5 | 44.0 | 53.0 | 3.0 |
| V7 | 50.0 | 47.0 | 3.0 | |
| Dust-off RON | V9 | 45.0 | 37.0 | 18.0 |
| V11 | 50.0 | 27.0 | 23.0 | |
| Slurry DE | V13 | 46.0 | 46.0 | 8.0 |
| V15 | 54.0 | 42.0 | 4.0 |
Disclaimer/Publisher’s Note: The statements, opinions and data contained in all publications are solely those of the individual author(s) and contributor(s) and not of MDPI and/or the editor(s). MDPI and/or the editor(s) disclaim responsibility for any injury to people or property resulting from any ideas, methods, instructions or products referred to in the content. |
© 2026 by the authors. Licensee MDPI, Basel, Switzerland. This article is an open access article distributed under the terms and conditions of the Creative Commons Attribution (CC BY) license.
Share and Cite
Škvarka, J.; Janáková, I.; Pticen, F.; Kučerová, R. Sustainable Production of Mullite Grogs from Industrial By-Products. Ceramics 2026, 9, 6. https://doi.org/10.3390/ceramics9010006
Škvarka J, Janáková I, Pticen F, Kučerová R. Sustainable Production of Mullite Grogs from Industrial By-Products. Ceramics. 2026; 9(1):6. https://doi.org/10.3390/ceramics9010006
Chicago/Turabian StyleŠkvarka, Josef, Iva Janáková, František Pticen, and Radmila Kučerová. 2026. "Sustainable Production of Mullite Grogs from Industrial By-Products" Ceramics 9, no. 1: 6. https://doi.org/10.3390/ceramics9010006
APA StyleŠkvarka, J., Janáková, I., Pticen, F., & Kučerová, R. (2026). Sustainable Production of Mullite Grogs from Industrial By-Products. Ceramics, 9(1), 6. https://doi.org/10.3390/ceramics9010006

