The presented study is focused on optimization and characterization of a high-alumina refractory aggregate based on natural raw materials—kaolins, claystone, and mullite dust by-product (used to increase the alumina and mullite contents, respectively). In total, four individual formulas with the Al2O3 contents between 45 and 50 wt.% were designed; the samples were subsequently fired, both in a laboratory oven and an industrial tunnel furnace. The effects of repeated firing were examined during industrial pilot tests. Mineral and chemical compositions and microstructures, of both the raw materials and designed aggregates, were thoroughly investigated by the means of X-ray fluorescence spectroscopy, powder X-ray diffraction, and optical and scanning electron microscopies. Porosity, mineral composition, and mullite crystal-size development during the firing process were also studied. Based on the acquired results, the formula with the perspective to be used as a new mullite grog, featuring similar properties as the available commercial products, however, with reduced production expenses, was selected. The quality of grog determines to a large extent the properties of the final product. Hence, optimization of aggregates for specific refractories is of a great importance. The production of engineered aggregates provides the opportunity to utilize industrial by-products.

Although kaolinite is one the most important industrial minerals, the processes of its transformation to mullite have not been completely explained so far. The study is focused on kaolinite crystallinity calculation and its effect on high-temperature phases transitions in the series kaolinite-mullite. Samples of purified natural kaolins from several sites were analysed using X-ray diffraction (XRD). Besides the determination of the complex mineral composition, kaolinite crystallite size was calculated from XRD data by the Rietveld method, Scherrer equation and using the Hinckley crystallinity index. Thermal analysis (DSC/TG) was used as the principal approach to examine endothermic and exothermic effects of kaolinite transformations. The course and maximum temperatures of the observed effects were correlated with the original crystallite size of kaolinite. Two samples with different kaolinite crystallinity were also analysed by high-temperature X-ray diffraction (ht-XRD) to study the formation of mullite. Scanning electron microscope (SEM) was used to visualize morphology of kaolinite.It was found out that the original crystallinity of kaolinite affects all three examined processes-kaolinite dehydroxylation, formation of crystalline phases from metakaolinite and development of mullite crystal structure. Dehydroxylation of samples with higher kaolinite crystallinity takes place at higher temperatures. Similar effect applies for the reaction(-s) at the temperature about 980 °C observed at heat flow curve where crystallization of spinel type phase and mullite with very low crystallinity occurs. Broadening of FWHM of the exothermic effect points to decreasing kaolinite crystallinity. Crystallization of mullite exhibits different dependence on kaolinite crystallinity than the previous processes. The results show that mullite with larger crystallite size develops faster from kaolinite of low crystallinity and vice versa.