Development of high-strength ceramsite via sintering of iron ore tailings: Process optimization and properties

This study focuses on the utilization of iron ore tailings for synthesizing high-strength concrete aggregate as a sustainable alternative to conventional stone aggregates, which are often obtained through environmentally harmful quarrying practices. The research investigates the feasibility of producing high-strength ceramsite using iron ore tailings, fly ash, and bentonite as primary raw materials. Through a uniform design method, the study deeply explores the role of iron ore tailings. To understand the relationship between compressive strength and the components used, first- and second-order polynomial equations were developed and thoroughly analyzed using stepwise regression techniques. This approach enabled the optimization of material ratios, leading to the achievement of the desired results. Additionally, the study examines the impact of varying sintering temperatures on the compressive strength, density, and water absorption of the ceramsite. Under optimized conditions, the resulting ceramsite exhibited impressive properties, with an average compressive strength of 52.33 MPa, an apparent density of 2600 kg/m3 , and a water absorption rate of 0 %. This research highlights the potential of iron ore tailings as a sustainable alternative in the construction industry, emphasizing the development of ecofriendly building materials while reducing environmental impacts.