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

Zhaohui He, Shuangna Li, Zhaorui Li, Di Zhang, Guangdong An, Xin Shi, Xin Sun () and Kai Li
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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

Sustainability, 2025, vol. 17, issue 14, 1-22

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.

Keywords: electrolytic manganese residue; fly ash; ceramic composites; additive engineering (search for similar items in EconPapers)
JEL-codes: O13 Q Q0 Q2 Q3 Q5 Q56 (search for similar items in EconPapers)
Date: 2025
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