Recycling of foundry by-products in the ceramic industry: Green and core sand in clay bricks

Green and core foundry sand are mixed with clay in proportions 0–50% and fired at 850–1050 °C to produce ceramic bricks. The specimens are physically and mineralogically evaluated, the scaling-up analyzed, and an optimization study developed. Clay/green sand bricks fired at 1050 °C have the better physical properties values, while the mineralogy is not significantly affected. The industrial quality brick can be estimated with laboratory trials, and the optimum amount of sand is found to be 35% of green sand and 25% of core sand.

► Clay/foundry (green and core) sands bricks fired at 850–1050 °C are evaluated.
► The physical ceramic properties are better in products incorporating green sands.
► The XRD patterns of clay/sand products are not affected by the sand addition.
► Industrial brick quality can be predicted with laboratory trials.
► GAMS optimization model fixes the amount of sand producing quality bricks in 25–35%.