Synthesis, characterization and modeling of new building insulation material using ceramic polishing waste residue

• We produce a new building insulation material by using ceramic polishing waste.
• Sintering processes are composed of matrix densification and closed pore generation.
• There is a change in volume and bulk density at the expansion temperature.
• The additive agents change the sintering process and lower the expansion temperature.
• A random simulation model was applied to predict the effective thermal conductivity.

A new building insulation material was produced using ceramic polishing waste residue (CPR) as a main raw material and synthesized at the sintering temperature range of 1010–1200 °C. Silicon carbide (SiC), tri-sodium phosphate dodecahydrate (Na3PO4·12H2O) and magnesium oxide (MgO) were chosen as additive agents. Effects of the additive agents and sintering temperature on the bulk density and the pore size were systematically investigated, and the corresponding mechanism was also discussed. The results showed that SiC played a key role in the formation of pores due to its decomposition at the proper temperature. The addition of Na3PO4·12H2O and MgO both decreased the expansion temperature of the sample to different extent and resulted in the pronounced variation of bulk density. The thermal conductivities of the samples with different bulk density were predicted using a developed random simulation model and the results were in well accordance with the measurement data by a guarded hot plate apparatus. These results indicated that the present sample has low density and good heat preservation performance, which is expected to be applied as the building insulation material.