Experiment and prediction on performance of all-solid-waste foam ceramics

Abstract

Integrating carbide slag (CS), fly ash, and coal gangue to synthesize fully solid waste foam ceramics provides a viable solid waste management solution. This study analyzes sintering parameters and CS dosage effects on foam ceramic properties: physical traits, pore structure, micromorphology, mineral phases, and sintering behavior. The findings reveal that the carbon content in coal gangue and the Fe₂O₃ present in fly ash function as foaming agents, facilitating a reaction that generates CO₂, thereby inducing a foaming effect. Upon calcination, CS yields CaO, which acts as a flux; an increase in CS content correlates with a reduction in the viscosity of the foam ceramic melt, a decrease in porosity, and an enhancement in thermal conductivity. In terms of sintering parameters, higher sintering temperatures and longer dwell times are conducive to the foaming of ceramics. However, excessively high temperatures and prolonged durations may compromise the structural integrity of the foam ceramics. Optimal performance occurs at 29 wt% CS content, sintered at 1290 °C for 20 min. Additionally, to address challenges from variable solid waste composition and complex performance evaluation, AI algorithms predicted foam ceramic properties with high accuracy, achieving an R² of 0.95.