Preparation and alkali excitation mechanism of coal gangue-iron ore tailings non-sintering ceramsite

Non-sintering ceramsite is known for its simplicity in preparation technology and low production costs. The efficient utilization of industrial solid waste for non-sintering ceramsite production has garnered significant attention in green building materials within the framework of low carbon and environmental protection principles. This study focuses on preparing non-sintering ceramsites using non-active solid waste materials, specifically coal gangue and iron ore tailings. Firstly, a single-factor test was conducted to determine the optimal dosage of coal gangue and iron ore tailings. Subsequently, orthogonal tests were performed to investigate the influence of fly ash, NaOH, and aluminum powder on the mechanical properties of non-sintering ceramsite. Finally, the alkali excitation mechanism was elucidated through X-ray diffraction and SEM electron microscope scanning. The results reveal that the optimal proportions for coal gangue and iron ore tailings are 10 % and 35 %, respectively. Among the factors examined, NaOH dosage exerts the most significant impact on the compression strength and bulk density of non-sintering ceramsite, while aluminum powder dosage has the greatest effect on the 1-hour water absorption of the material. The optimal mixing ratio was determined with a total solid waste dosage of 73 %, meeting the national 600-grade standard for non-sintering ceramsite across all performance criteria. Furthermore, the alkali excitation process effectively activates the reactivity of fly ash and coal gangue. This activation leads to the generation of calcium alumina and C-S-H gel, along with other hydration products, which intertwine to form a dense gel structure. This structural enhancement further contributes to the improved performance of non-sintering ceramsite.