Preparation of Low Density Ceramic Supporter from Coal Fly Ash

Low density ceramic supporter was prepared by using fly ash as a starting material for the application to the biological aerated filter (BAF) system, and the effect of additives and sintering atmosphere on the apparent and bulk density of the carrier was examined. Borax, Na$_2$O and glass powders were added to produce liquid phase. The density of the supporter decreased as the amount of borax increased. The bulk density of 0.79 g/㎤ and the apparent density of 1.10 g/㎤ were obtained when the fly ash with 15% of borax was sintered at 116$0^{\circ}C$ for 15 minutes. The density also decreased as the plate glass powders past through 22${\mu}{\textrm}{m}$ size were mixed. When the fly ash with 12% of grass powder was sintered at 128$0^{\circ}C$ for 10 minutes, the bulk and apparent density were 0.90g/㎤ and 1.00 g/㎤, respectively. Apparent density of 1.6~1.8g/㎤ was obtained when the fly ash was sintered at 120$0^{\circ}C$ in a weak reducing atmosphere. By maintaining the reducing atmosphere and sintering at a high heating rate, the liquid phase was farmed from the reduced composition of fly ash. This resulted in the formation of closed pores that enabled the low apparent density.