A novel green porous ceramics fabricated simply by utilizing both manganese slag and silicate tailings as raw materials at low-temperature

Abstract

A porous wollastonite ceramic with high porosity and low density has been successfully fabricated at low temperature with silicate tailings and electrolytic manganese slag (MS) as primary raw materials in this study. The influences of calcination temperature, SiC, and MS addition amounts on porosity, water adsorption, pore size distribution, bulk density, and bending strength were systematically studied. The results showed that 0.4 wt% of SiC was optimal for the ceramic foaming at the sintering temperature of 1140 °C. The ceramics of porosity reduced from 78.4% to 63.7%, bulk density elevated from 0.96 to 1.13 g/cm3, and bending strength increased from 8.43 to 11.22 MPa as the MS increased from 8.33 wt% to 41.67 wt%. Moreover, the best corrosion resistance performance reached to 99.55% with 8.33 wt% MS content and a sintering temperature of 1160 °C. This work is of significance for the solid waste utilization.

Keywords

low temperature / manganese slag / porous ceramics / silicate tailings

References

[1] Thomsen L, Jensen L R, Yue Y-zet al. . Crystallinity dependence of thermal and mechanical properties of glass-ceramic foams [J]. Journal of the European Ceramic Society. 2024, 44(13): 7936-7942.

[2] Ma Z-y, Zeng J-y, Chu S-zet al. . Effect of different foam stabilizers on the setting behavior and pore characteristics of CAC-bonded Al₂O₃ foamed ceramics [J]. Ceramics International. 2023, 49(7): 10574-10579.

[3] Deng F-q, Wang F, Shi X-pet al. . Synthesis and properties of foam glass-ceramics from granite tailings by using SiC and MnO₂ as the mixed foaming agent [J]. Ceramics International. 2023, 49(22): 34647-34656.

[4] Taurino R, Martinuzzi S, Padovano Eet al. . Laser additive manufacturing of Al₂O₃ and ZrO₂-based eutectic ceramic oxide: An overview [J]. Journal of the European Ceramic Society. 2025, 45(5): 117133.

[5] Sun H, He B-c, Xu H-xet al. . Experimental investigation on the fracture conductivity behavior of quartz sand and ceramic mixed proppants [J]. ACS Omega. 2022, 71210243-10254.

[6] Xing Z-h, Hu Y-h, Xiang D-pet al. . Porous SiC-mullite ceramics with high flexural strength and gas permeability prepared from photovoltaic silicon waste [J]. Ceramics International. 2020, 46(1): 1236-1242.

[7] Xi C-p, Zhou J-m, Zheng Fet al. . Conversion of extracted titanium tailing and waste glass to value-added porous glass ceramic with improved performances [J]. Journal of Environmental Management. 2020, 261: 110197.

[8] Jiang L, Sun H-j, Peng T-jet al. . Comprehensive evaluation of environmental availability, pollution level and leaching heavy metals behavior in non-ferrous metal tailings [J]. Journal of Environmental Management. 2021, 290112639.

[9] Su C-x, Rana N M, Zhang Set al. . Environmental pollution and human health risk due to tailings storage facilities in China [J]. Science of the Total Environment. 2024, 928172437.

[10] Li Z-y, Wang J, She Z-xet al. . Tailings particle size effects on pollution and ecological remediation: A case study of an iron tailings reservoir [J]. Journal of Hazardous Materials. 2024, 476135024.

[11] Huang Q-x, Liu T-y, Zhang J-set al. . Properties and pore-forming mechanism of silica sand tailing-steel slag-coal gangue based permeable ceramics [J]. Construction and Building Materials. 2020, 253118870.

[12] Hu N-y, Fu F-h, Luo B-yet al. . Preparation, characterization and self-foaming mechanism of total-tailings-based foamed glass-ceramics [J]. Ceramics International. 2023, 49(19): 31881-31890.

[13] Chen R-y, Hei D-q, Li S-jet al. . Environment-oriented low-cost Al₂O₃ ceramics with hierarchical pore structure fabricated from SiC solid waste [J]. International Journal of Applied Ceramic Technology. 2020, 171184-189.

[14] Li L-l, Cao G-y, Zhao R-met al. . High-porosity whisker-mullite/corundum membrane support prepared from recycled industrial waste coal cinder [J]. Ceramics International. 2020, 46(4): 4086-4094.

[15] Fu F-h, Hu N-y, Ye Y-cet al. . Production of lightweight foam ceramics by adjusting sintering time and heating rate [J]. Construction and Building Materials. 2023, 394: 132063.

[16] Li M-k, Huang F-l, Hu Let al. . Efficient activation of peroxymonosulfate by a novel catalyst prepared directly from electrolytic manganese slag for degradation of recalcitrant organic pollutes [J]. Chemical Engineering Journal. 2020, 401126085.

[17] Huang Y-j, Zhang C-p, Lu J-xet al. . Performance improvement of glass-based lightweight aggregates through thermodynamic modelling design and lightweight mortar validation [J]. Cement and Concrete Composites. 2024, 152105662.

[18] Ouyang D-x, Zhuo Y-t, Hu Let al. . Research on the adsorption behavior of heavy metal ions by porous material prepared with silicate tailings [J]. Minerals. 2019, 9(5): 291.

[19] Hou Z-p, Cui B-x, Liu L-let al. . Effect of the different additives on the fabrication of porous Kaolin-based mullite ceramics [J]. Ceramics International. 2016, 421517254-17258.

[20] Zhao L-h, Li Y, Zhang L-let al. . Effects of CaO and Fe₂O₃ on the microstructure and mechanical properties of SiO₂–CaO–MgO–Fe₂O₃ ceramics from steel slag [J]. ISIJ International. 2017, 57115-22.

[21] Li Z, Li X, Tang Yet al. . Sintering behaviour and characterisation of low-cost ceramic foams from coal gangue and waste quartz sand [J]. Advances in Applied Ceramics. 2016, 115(7): 377-383.

[22] Ding L-f, Ning W, Wang Q-wet al. . Preparation and characterization of glass – ceramic foams from blast furnace slag and waste glass [J]. Materials Letters. 2015, 141: 327-329.

[23] Zhou X-y, Zheng F, Li H-get al. . An environment-friendly thermal insulation material from cotton stalk fibers [J]. Energy and Buildings. 2010, 42(7): 1070-1074.

[24] Jiang L-min. Heat treatment parameters of preparing glass-ceramic with electrolytic manganese residue and their properties [J]. Journal of Thermal Analysis and Calorimetry. 2020, 140(4): 1737-1744.

[25] Wang Z-m, Lyu X-j, Yao Get al. . Preparation of Ca – Si – Al – Mg porous ceramics by cooperation of Ca&Mg-contained soda residue and altered rock gold tailings [J]. Journal of Cleaner Production. 2020, 262: 121345.

[26] Zhang J-s, Liu T-y, Huang Q-xet al. . Preparation, properties characterization and structure formation mechanism of silica sand tailings-based ceramic materials [J]. Materials Chemistry and Physics. 2020, 255123611.

[27] Ren B, Li Y-w, Sang S-bet al. . Lightweight design of bauxite-SiC composite refractories as the lining of rotary cement kiln using alternative fuels [J]. Ceramics International. 2017, 43(14): 11048-11057.

[28] Li L-x, Chai W, Kang Jet al. . Utilization of graphite tailings and coal gangue in the preparation of foamed ceramics [J]. International Journal of Applied Ceramic Technology. 2025, 223e15012.

[29] Topateş G. Direct production of Si₃N₄ foams by carbothermal reduction and nitridation of SiO₂ [J]. Ceramics International. 2018, 441620545-20550.

[30] Dong Y-c, Hampshire S, Zhou J-eet al. . Recycling of fly ash for preparing porous mullite membrane supports with titania addition [J]. Journal of Hazardous Materials. 2010, 180(1–3): 173-180.

[31] Ma B-y, Su C, Ren X-met al. . Preparation and properties of porous mullite ceramics with high-closed porosity and high strength from fly ash via reaction synthesis process [J]. Journal of Alloys and Compounds. 2019, 803: 981-991.

[32] Han Y, Zhou L-j, Liang Y-xet al. . Fabrication and properties of silica/mullite porous ceramic by foam-gelcasting process using silicon kerf waste as raw material [J]. Materials Chemistry and Physics. 2020, 240122248.

[33] Kyono A, Ikeda R, Takagi Set al. . Structural evolution of gypsum (CaSO₄·2H₂O) during thermal dehydration [J]. Journal of Mineralogical and Petrological Sciences. 2022, 1171220811.

[34] Liu W-t, Zhang H-t, Zhang B-net al. . New insight into non-isothermal kinetics of oxidation of SiC powders: The effect of particle size [J]. Applied Physics A. 2025, 1319673.

[35] Darabian L M, Gonçalves G R, Schettino M Aet al. . Synthesis of nanostructured iron oxides and study of the thermal crystallization process using DSC and in situ XRD experiments [J]. Materials Chemistry and Physics. 2022, 285126065.

RIGHTS & PERMISSIONS

Central South University