Preparation of lightweight ceramsite from tungsten tailings: Performance regulation and formation mechanism

Abstract This study presents a sustainable approach to the production of lightweight ceramsite from industrial by‐products, specifically tungsten tailings and fly ash. By integrating these materials with a foaming agent, we successfully synthesized ceramsite with reduced bulk density and improved strength, making it suitable for various applications such as construction. Through orthogonal experiments, we got the best ceramsite, which exhibited a compressive strength of 19.45 MPa, water absorption of 7.63%, and a bulk density of 0.925 g/cm 3 . Additionally, the incorporation of sawdust or stearic acid allowed for the adjustment of ceramsite density, producing a range of products with densities from 700 to 1000 kg/m 3 . The ceramsite complied with standards, exhibiting minimal heavy metal ion leaching. Crystal phase composition and mineral changes during sintering were analyzed, along with microstructure changes affecting ceramsite properties.