Development of a high-temperature inorganic synthetic foam with recycled fly-ash cenospheres for thermal insulation brick manufacturing

Brooks, Adam L.; Shen, Zhenglai; Zhou, Hongyu

doi:10.1016/j.jclepro.2019.118748

Development of a high-temperature inorganic synthetic foam with recycled fly-ash cenospheres for thermal insulation brick manufacturing

Journal Article · Thu Oct 10 00:00:00 EDT 2019 · Journal of Cleaner Production

DOI:https://doi.org/10.1016/j.jclepro.2019.118748· OSTI ID:1799533

Brooks, Adam L. ^[1]; Shen, Zhenglai ^[2]; Zhou, Hongyu ^[3]

Univ. of Tennessee, Knoxville, TN (United States); OSTI
Univ. of Alabama, Huntsville, AL (United States)
Univ. of Tennessee, Knoxville, TN (United States)

In this study, a novel inorganic synthetic solid foam composed of recycled fly-ash cenospheres (FACs) is developed with low-density, good thermal insulation performance, and reasonable mechanical strength. The manufacturing process utilizes low-fraction clay binder materials diluted in water, enabling a self-assembling mechanism assisted by natural capillary effect to form minimal contacts among the FACs. The microstructure and minimal contact formation were confirmed by optical and electron microscope imaging. Both thermal and mechanical properties of the fly-ash cenosphere synthetic solid foam (FAC-SSF) materials were experimentally studied as functions of key material parameters including cenosphere particle size and clay content. A numerical model was developed to predict the effective thermal conductivity of FAC-SSF using a three-step homogenization method which takes into account different thermal percolation paths within the material. The inorganic synthetic foam developed has the potential for thermal insulation applications taking advantage of their relatively simple, low-cost, and scalable manufacturing process, minimal use of binder materials, and relatively high mechanical strength and highly tailorable properties.

View Accepted Manuscript (DOE)

Research Organization:: Univ. of Alabama, Tuscaloosa, AL (United States)

Sponsoring Organization:: USDOE Office of Energy Efficiency and Renewable Energy (EERE), Energy Efficiency Office. Building Technologies Office

Grant/Contract Number:: EE0008677

OSTI ID:: 1799533

Alternate ID(s):: OSTI ID: 1580557

Journal Information:: Journal of Cleaner Production, Journal Name: Journal of Cleaner Production Vol. 246; ISSN 0959-6526

Publisher:: ElsevierCopyright Statement

Country of Publication:: United States

Language:: English

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42 ENGINEERING
fly-ash cenosphere
synthetic foam
thermal insulation
thermal modeling

Development of a high-temperature inorganic synthetic foam with recycled fly-ash cenospheres for thermal insulation brick manufacturing

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