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The present study aims to synthesize SiAlON-based composites utilizing coal gangue. Different types of SiAlON-based composites were synthesized using coal gangue by carbothermal reduction nitridation method through control of different reaction atmospheres. The experimental results indicate that the oxygen partial pressure was an essential factor in the manufacture of SiAlON-based composites and under proper control of the atmospheres, SiAlON-based composites with different crystal structures could be synthesized. The optimum conditions of synthesis of different SiAlON-based composites were respectively determined. Based on the laboratory results, a prototype plant was proposed and constructed, and β-SiAlON composite was successfully produced using coal gangue. The synthesized β-SiAlON composite was applied in preparation of iron ladle brick instead of SiC, which showed that the compression strength, refractoriness under load and high temperature bending strength were increased from 44.5 ± 6.7 MPa,  1618 ± 21 °C and 5.4 ± 1.2 MPa to 64.1 ± 2.5 MPa, 1700 ± 28 °C and 7.1 ± 1.6 MPa, respectively. Compared with the traditional synthesis method, the present technique is expected to save energy both in raw materials and technical process

Facile and Economical Preparation of SiAlON-Based Composites Using Coal Gangue: From Fundamental to Industrial Application