The Composition–Structure Relationship and the Formation of Fly Ash Skeletal-Dendritic Ferrospheres

Ferrospheres (FSs) are a microspherical component of fly ash from pulverized coal combustion. The wide variations in chemical and phase composition, morphology, and the spherical design of FSs suggest their use as functional materials capable of replacing expensive synthesized materials. A general understanding of the formation of FSs from thermochemical transformations of the mineral components of the original coal is important for identifying the most promising sources of FSs with a high content of a certain morphological type active in a specific process. A systematic SEM-EDS study of the composition-structure relationship of the skeletal-dendritic FSs isolated from fly ash has revealed common routes of their formation. These FSs are formed as a result of thermochemical transformations of iron-containing minerals with the participation of aluminosilicates of the original coals. The aluminosilicate precursor that determines the skeletal-dendritic structure is illite. The crystallization of skeletal-dendritic globules occurs due to the "seed" of Al, Mg-ferrospinel formed from the thermochemical transformation of illite. The general trend of change in the structure of globules from a coarse skeletal to a fine dendritic structure is associated with a decrease in the main spinel-forming oxides content and an increase in the silicate melt viscosity.