Usage of mullite and cordierite mullite filter made with sanitaryware kiln wastes for metal casting industry

In this research; the feasibility of cordierite mullite based metal casting filters made from sanitary ware kiln waste additives was studied. An alternative product was manufactured towards cordierite mullite filters used in spherical and lamellar graphite cast iron production companies. The waste utilized in this research was from Ece Banyo Company's tunnel & roller kiln refractory wastes. The wastes were grinded under 250 microns. On the bases of XRF results of the wastes and other selected raw materials, 10 different prescriptions were made according to Seger based on the filter of commercially available equivalences in the market from Republic of China. Plate and roller wastes were used with different amounts in the prescriptions. The prepared prescriptions were sintered at 1230 °C, 1250 °C, 1270 °C and 1290 °C. The characterization of prescriptions were compared with the commercial China filter's analyses. According to the test results, prescription 9 sintered at 1250 °C was determined to have nearly similar properties with respect to China's filter. The 9th prescription materials have been prepared to manufacture mullite cordierite based filter. The produced mullite cordierite based honeycomb filter was tested in a metal casting factory with casting temperature at 1386 °C and performed a successful performance. As a result, it was determined that mullite cordierite based filters manufactured with wastes in laboratory scale has similar chemical composition and phase content to the filters already used in market. It showed about similar performance with respect to the commercially available one. Moreover, the prepared filter decreased the manufacturing costs (approximately 80%) compared to commercially equivalents available in the market and was environmentally friendly. In order to make mass production of this filter and take its place in the market, the needy requirements are stated in the recommendations. In addition to above stated advantages, the conversion of these wastes into value added product such as in this research indicating the feasibility of taking advantages by manufacturing replaced product instead of exported one.