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Engineered Ceramic Composites from Electrolytic Manganese Residue and Fly Ash: Fabrication Optimization and Additive Modification Mechanisms

Author

Listed:
  • Zhaohui He

    (Faculty of Environmental Science and Engineering, Kunming University of Science and Technology, Kunming 650500, China)

  • Shuangna Li

    (Faculty of Environmental Science and Engineering, Kunming University of Science and Technology, Kunming 650500, China)

  • Zhaorui Li

    (Faculty of Environmental Science and Engineering, Kunming University of Science and Technology, Kunming 650500, China)

  • Di Zhang

    (School of Resources and Environment, Linyi University, Linyi 276000, China)

  • Guangdong An

    (Faculty of Environmental Science and Engineering, Kunming University of Science and Technology, Kunming 650500, China)

  • Xin Shi

    (Faculty of Environmental Science and Engineering, Kunming University of Science and Technology, Kunming 650500, China)

  • Xin Sun

    (Faculty of Environmental Science and Engineering, Kunming University of Science and Technology, Kunming 650500, China)

  • Kai Li

    (Faculty of Environmental Science and Engineering, Kunming University of Science and Technology, Kunming 650500, China)

Abstract

The sustainable valorization of electrolytic manganese residue (EMR) and fly ash (FA) presents critical environmental challenges. This study systematically investigates the performance optimization of EMR-FA ceramic composites through the coordinated regulation of raw material ratios, sintering temperatures, and additive effects. While the composite with 85 g FA exhibits the highest mechanical strength, lowest porosity, and minimal water absorption, the formulation consisting of 45 wt% EMR, 40 wt% FA, and 15 wt% kaolin is identified as a balanced composition that achieves an effective compromise between mechanical performance and solid waste utilization efficiency. Sintering temperature studies revealed temperature-dependent property enhancement, with controlled sintering at 1150 °C preventing the over-firing phenomena observed at 1200 °C while promoting phase evolution. XRD-SEM analyses confirmed accelerated anorthite formation and the morphological transformations of FA spherical particles under thermal activation. Additive engineering demonstrated that 8 wt% CaO addition enhanced structural densification through hydrogrossular crystallization, whereas Na 2 SiO 3 induced sodium-rich calcium silicate phases that suppressed anorthite development. Contrastingly, ZrO 2 facilitated zircon nucleation, while TiO 2 enabled progressive performance enhancement through amorphous phase modification. This work establishes fundamental phase–structure–property relationships and provides actionable engineering parameters for sustainable ceramic production from industrial solid wastes.

Suggested Citation

  • Zhaohui He & Shuangna Li & Zhaorui Li & Di Zhang & Guangdong An & Xin Shi & Xin Sun & Kai Li, 2025. "Engineered Ceramic Composites from Electrolytic Manganese Residue and Fly Ash: Fabrication Optimization and Additive Modification Mechanisms," Sustainability, MDPI, vol. 17(14), pages 1-22, July.
    • Handle: RePEc:gam:jsusta:v:17:y:2025:i:14:p:6647-:d:1706435
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    References listed on IDEAS

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    1. He, Fang & Wang, Xiaodong & Wu, Dezhen, 2015. "Phase-change characteristics and thermal performance of form-stable n-alkanes/silica composite phase change materials fabricated by sodium silicate precursor," Renewable Energy, Elsevier, vol. 74(C), pages 689-698.
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