Effects of soda-lime-silica waste glass on mullite formation kinetics and micro-structures development in vitreous ceramics

The effects of soda-lime waste glass, from the recovery of bottle glass cullet, in partial replacement of Na-feldspar for sanitary-ware ceramic production are discussed. Attention is paid to the mullite growth kinetics and to the macroscopic properties of the final output, the latter ones depending on the developed micro-structures and vitrification grade. Measurements have been performed by in situ high temperature X-ray powder diffraction, scanning electron microscopy, thermal dilatometry, water absorption and mechanical testing. Glass substituting feldspar from 30 to 50wt% allows one (i) to accelerate the mullite growth reaction kinetics, and (ii) to achieve macroscopic features of the ceramic output that comply with the latest technical requirements. The introduction of waste glass leads to (i) a general saving of fuel and reduction of the CO2-emissions during the firing stage, (ii) a preservation of mineral resources in terms of feldspars, and (iii) an efficient management of the bottle glass refuse by readdressing a part of it in the sanitary-ware manufacturing. •The replacement of feldspar with glass cullet in the sanitary-ware ceramic sector is considered.•The kinetics of mullite and the study of the microstructure of blends bearing glass are performed.•Glass accelerates the kinetics of mullite growth.•Ceramics bearing glass have mechanical features similar to the traditional ceramics.