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Fabrication and characterization of lightweight aggregate prepared from steel mill sludge in one step

Abstract

The qualified green lightweight aggregate (LWA) was successfully prepared from steel mill sludge (SMS) and fly ash (FAS) in one step using the cost-effective sintering method. The effects of the ratio of FAS and SMS, sintering temperature, and sintering time on the performance of LWA were studied. The results show that the optimal LWA has bulk density of 721 kg m−3, compressive strength of 14.0 MPa, and water absorption of 12.6% under the follow optimized conditions: FAS and SMS mixed at a ratio of 8:2 at the sintering temperature of 1150 °C for 25 min. The mechanisms of mineralogical phases and microstructures formation were proposed. The microstructure of qualified LWA was characterized by a dense surface and a porous structure inside. The presence of mullite and anorthite phase can improve the strength of aggregate.

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Acknowledgements

This work was supported by the National Natural Science Foundation of China-the joint research fund of China Bao-Wu Iron and Steel Group Co., Ltd. (Grant No. U1860108, U1860203), the National Natural Science Foundation of China (Nos. 52022054; 51974181), the Shanghai Rising-Star Program (19QA1403600), and the Program for Professor of Special Appointment (Eastern Scholar) at Shanghai Institutions of Higher Learning (TP2019041) for financial support.

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Correspondence to Shuhua Geng, Yuwen Zhang or Xionggang Lu.

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Hong, J., Chen, Z., Huang, Y. et al. Fabrication and characterization of lightweight aggregate prepared from steel mill sludge in one step. J Mater Cycles Waste Manag 24, 1072–1082 (2022). https://doi.org/10.1007/s10163-022-01385-x

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  • DOI: https://doi.org/10.1007/s10163-022-01385-x

Keywords

  • Lightweight aggregate
  • Steel mill sludge
  • Fly ash
  • Sintering
  • Mullite
  • Anorthite