This study investigated crystallization mechanisms for the formation of lead aluminosilicate by sintering lead stabilization with kaolin-based precursors. PbAlSiO was found to be the only stable lead aluminosilicate in low-PbO system and demonstrates its highly intrinsic resistance to acid attack in leaching test. A three-stage PbAlSiO formation mechanism was supported by the results of the changing temperature in the system. Amorphization of sintered products was observed in both PbO/kaolinite and PbO/mullite systems at 600-700°C. When the temperature was increased to 750-900°C, the crystallochemical formation of lead aluminosilicates (i.e., PbAlSiO, PbAlSiO, and PbAlSiO) was observed. PbAlSiO and PbAlSiO were found to be the intermediate phases at 700-900°C. Finally, PbAlSiO was found to be the only crystallite phase to host Pb at above 950°C. A maximum of 80% and 96.7% Pb can be incorporated into PbAlSiO in PbO/kaolinite and PbO/mullite systems, respectively, but the final products exhibited different microstructures. To reduce environmental hazard of lead, this strategy demonstrated a preferred mechanism of immobilizing lead into PbAlSiO structure via kaolin-based precursors.
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