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<p>The extensive accumulation of solid waste represented by red mud (RM) presents critical environmental threats, while its valorization in high-value material applications remains underexplored. In order to reduce the risks associated with the utilization of solid waste while enhancing the high-value recycling of RM in the field of building materials, this study fabricates core-shell structured ceramsite (C-SRB) via synergistic use of three wastes: RM, spent refractories materials (SRM), and spent cathode carbon blocks (SCCB). Innovatively, SCCB served as an in-situ pore-forming agent, while SRM-bentonite composites formed a dense shell, establishing a core-shell structure that synergistically enhances thermal insulation (porous core) and environmental safety (protective shell). Unlike conventional solid waste-based ceramsites with single-function characteristics, the core-shell structured ceramsite (C-SRB) proposed in this study achieves simultaneous detoxification of red mud and performance enhancement in building materials through its “dense shell-porous core” heterogeneous design. Under the condition of water as extractor, the Cr/Pb leaching amount inhibited by C-SRB during the 24&#xa0;h leaching cycle was more than 99% compared with traditional ceramsite. When replacing 5–10% of sand with C-SRB, thermal conductivity decreased by 22.1–29.4% without compromising 28-day strength (&lt; 5% replacement). The design of core-shell structure opens a new way for the harmless and resource utilization of solid waste in the field of building materials.</p>

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Preparation of Shell-Core Structured Ceramsite from Red Mud and Electrolytic Aluminum Repair Slag to Enhance the Thermal Insulation Performance of Cement Mortar

  • 期刊论文

  • 发表日期：

    2025年5月27日

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  • Fanyu Meng,
  • Peihui Wang,
  • Shilin Deng,
  • Chunheng Chen,
  • Zhenxia Zhao,
  • Jing Li

摘要

The extensive accumulation of solid waste represented by red mud (RM) presents critical environmental threats, while its valorization in high-value material applications remains underexplored. In order to reduce the risks associated with the utilization of solid waste while enhancing the high-value recycling of RM in the field of building materials, this study fabricates core-shell structured ceramsite (C-SRB) via synergistic use of three wastes: RM, spent refractories materials (SRM), and spent cathode carbon blocks (SCCB). Innovatively, SCCB served as an in-situ pore-forming agent, while SRM-bentonite composites formed a dense shell, establishing a core-shell structure that synergistically enhances thermal insulation (porous core) and environmental safety (protective shell). Unlike conventional solid waste-based ceramsites with single-function characteristics, the core-shell structured ceramsite (C-SRB) proposed in this study achieves simultaneous detoxification of red mud and performance enhancement in building materials through its “dense shell-porous core” heterogeneous design. Under the condition of water as extractor, the Cr/Pb leaching amount inhibited by C-SRB during the 24 h leaching cycle was more than 99% compared with traditional ceramsite. When replacing 5–10% of sand with C-SRB, thermal conductivity decreased by 22.1–29.4% without compromising 28-day strength (< 5% replacement). The design of core-shell structure opens a new way for the harmless and resource utilization of solid waste in the field of building materials.