US-Egypt Joint Research Grants For Collaborative Research between Central Metallurgical R&D Institute CMRDI, and University of Florida, , USA was recently approved. Associated professor Mohamed M. Rashad,  Head of Electronic and Magnetic Materials Division is the principal investigator from Egypt whereas  Prof.  K. Powers , Materials Science and Engineering Department is the principal investigator from USA. The project started in September 2011 for two years. The overall objective of this project is to process of silica effluents disposed from alum manufacturing in Egypt, silica fume from Ferro-silicon Alloys Company, Al dross from Egyptian Aluminum Company and aluminum effluents disposed from Egyptalum Company for production of mullite nanoparticles 3Al2O3.2SiO2 for different electronic and optical applications. The suggested technology for the conversion of wastes to the mullite nanopowders for different industrial applications is a novel and very interested. The technology depends on the formation of soluble solutions of sodium aluminate NaAlO2 and sodium silicate Na2SiO3 which is chemically treated at certain conditions using co-precipitation and hydrothermal routes. In comparison, the mullite synthesis by both two routes using pure chemicals is also investigated. The effect of synthesis conditions; temperature, time, pH, molar ratio and the crystal modifiers on the crystal structure, crystallite size and microstructure are studied and the optimum conditions are determined. Moreover, the changes in the surface area SBET, DC resistivity, optical and mechanical properties are measured. Thus, this project has the potential to transform a cheap undesirable by-products produced in Egypt into a highly value added product for the global refractory manufacturing industry, sharing in solving water purification problems through expected increase in alum production, encouraging establishment of new plants as kaolin is available in different localities in Egypt in huge reserves and solving the environmental problems arising from the disposal of acidic silica effluents and alkali disposal of aluminum etching effluents. This project also brings together the international expertise of Particles in USA with the particle technology experts in Egypt (CMRDI).

Mullite produced at 1000oC without and with surface active agent