Metal stabilization mechanism of incorporating lead-bearing sludge in kaolinite-based ceramics

The feasibility and mechanism of incorporating simulated lead-laden sludge into low-cost ceramic products was investigated by observing the reaction of lead with two kaolinite-based precursors under sintering conditions. To investigate the phase transformation process of lead, lead oxide (PbO) mixed with a kaolinite or mullite precursor were fired at 500-950 °C for 3 h. Detailed X-ray diffraction analysis of sintered products revealed that both precursors had crystallochemically incorporated lead into the lead feldspar (PbAl₂Si₂O₈) crystalline structure. By mixing lead oxide with kaolinite, lead feldspar begins to crystallize at 700 °C; maximum incorporation of lead into this structure occurred at 950 °C. However, two intermediate phases, Pb₄Al₄Si₃O₁₆ and a polymorph of lead feldspar, were detected at temperatures between 700 and 900 °C. By sintering lead oxide with the mullite precursor, lead feldspar was detected at temperatures above 750 °C, and an intermediate phase of Pb₄Al₄Si₃O₁₆ was observed in the temperature range of 750-900 °C. This study compared the lead leachabilities of PbO and lead feldspar using a prolonged leaching test (at pH 2.9 for 23 d) modified from the toxicity characteristic leaching procedure. The results indicate the superiority of lead feldspar in stabilizing lead and suggest a promising and reliable strategy to stabilize lead in ceramic products.