Effects of grinding and firing conditions on CaAl₂Si₂O₈ phase formation by solid-state reaction of kaolinite with CaCO₃

The effects of grinding and firing conditions on CaAl₂Si₂O₈ phase formation by solid-state reaction of kaolinite with CaCO₃ were investigated by differential thermal analysis (DTA)-thermogravimetry (TG), X-ray powder diffraction (XRD) and ²⁹Si and ²⁷Al MAS NMR. Unground and ground samples showed similar crystallization behavior at about 850 °C, and the crystallizing temperature was relatively unaffected by grinding. On the other hand, the crystalline products were strongly influenced by the grinding. Gehlenite (Ca₂Al₂SiO₇) was the dominant phase in the unground samples but layer-structured CaAl₂Si₂O₈ was dominant in the ground samples, together with a small amount of anorthite, which is the stable phase. The amount of anorthite gradually increased with higher firing temperature, the sample fired at 1000 °C being almost completely anorthite. Grinding treatment before firing was effective in accelerating the decomposition of CaCO₃ and extending the temperature range for the formation of CaAl₂Si₂O₈, a phase with local structure similar to that of layered CaAl₂Si₂O₈.