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<p>Foundry dust (FD) and foundry waste ash (FWA) are difficult-to-treat solid wastes discharged from the foundry industry, and their resource utilization has attracted increasing attention. In this paper, high-strength and lightweight ceramsite was fabricated solely using FD and FWA as raw materials via a simple pelleting technology. The activated clay and coal dust within the FD serve as a binder and pore-forming agent, respectively. The internal microporous structure and mechanical properties of ceramsite can be controlled by designing the raw material ratio and sintering process. When the ceramsite was prepared with a material ratio of FD: FWA = 50&#xa0;wt.%: 50&#xa0;wt.% and sintered at 1120 °C for 20 min, it exhibited remarkable physical performance, characterized by a compressive strength as high as 8.51 MPa, one-hour water absorption of 2.97%, and a bulk density and apparent density as low as 0.68 g/cm<sup>3</sup> and 1.23 g/cm<sup>3</sup>, respectively. Microscopic analysis revealed that the optimized sintering process resulted in the formation of a compact enamel shell on the ceramsite surface, leading to uniformly distributed micropores and a dense skeletal structure inside the ceramsite, thereby achieving high-strength and lightweight properties. In addition, the leaching concentration of heavy metals in ceramsite is far below the limited value. This study offers valuable insights for the large-scale and efficient utilization of foundry solid waste, which is beneficial to the green development of the foundry industry.</p>

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Fabrication of High-strength and Lightweight Ceramsite from Foundry Solid Waste: Material Design and Forming Mechanism

  • 期刊论文

  • 发表日期：

    2025年4月26日

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  • Xiaolong Gong,
  • Jianwei Zhao,
  • Kai Liu,
  • Huafang Wang,
  • Zitian Fan

摘要

Foundry dust (FD) and foundry waste ash (FWA) are difficult-to-treat solid wastes discharged from the foundry industry, and their resource utilization has attracted increasing attention. In this paper, high-strength and lightweight ceramsite was fabricated solely using FD and FWA as raw materials via a simple pelleting technology. The activated clay and coal dust within the FD serve as a binder and pore-forming agent, respectively. The internal microporous structure and mechanical properties of ceramsite can be controlled by designing the raw material ratio and sintering process. When the ceramsite was prepared with a material ratio of FD: FWA = 50 wt.%: 50 wt.% and sintered at 1120 °C for 20 min, it exhibited remarkable physical performance, characterized by a compressive strength as high as 8.51 MPa, one-hour water absorption of 2.97%, and a bulk density and apparent density as low as 0.68 g/cm3 and 1.23 g/cm3, respectively. Microscopic analysis revealed that the optimized sintering process resulted in the formation of a compact enamel shell on the ceramsite surface, leading to uniformly distributed micropores and a dense skeletal structure inside the ceramsite, thereby achieving high-strength and lightweight properties. In addition, the leaching concentration of heavy metals in ceramsite is far below the limited value. This study offers valuable insights for the large-scale and efficient utilization of foundry solid waste, which is beneficial to the green development of the foundry industry.