Suppressing the effect of cullet composition on the formation and properties of foamed glass

The process of foaming glass is very dependent on the chemical composition of the glass. In this study we used a foaming-agent/oxidizing-agent couple and a crystallization inhibitor to foam cullets of flat, container and CRT-panel glass. Foamed glass with a density of 110–120 kg m ^–3, a thermal conductivity of 50–52 mW m ^–1 K ^–1 and a homogeneous pore structure was obtained from a mixture of panel glass, 0.33 wt% carbon and 4.45 wt% Fe ₂O ₃. We also showed that it is possible to fabricate foamed glass with the same density or pore structure as mentioned above by adding up to 50 wt% container cullet or 70 wt% flat glass to the mixture. In the foamed samples with a low content of panel glass, crystals form, resulting in an increased open porosity, density and inhomogeneous pore structure. The crystallization can, however, be inhibited by adding calcium phosphate, so enabling the preparation of high-quality foamed glass from flat glass or flat/container-glass mixture. The pore gas is predominantly CO ₂ and the pressure inside the pores is 0.36–0.47 bar. The reduced effect of the composition on the foaming process suggests that there is a great potential for stabilizing the production of foamed glass and ensuring the product's quality.