Valorization of aluminum-silica-based industrial solid waste to high quality ceramic proppants: waste sources and design strategies

As the industrial economy continues to grow, the accumulation of industrial solid waste has increased significantly, consuming large land areas and posing serious threats to ecosystems. In response to the growing emphasis on green production, the comprehensive utilization of industrial solid waste has become critically important. Simultaneously, high-grade bauxite—a key raw material for ceramic proppants used in oil and gas field development—is experiencing increasing scarcity. Certain industrial solid wastes are rich in Al 2 O 3 and SiO 2 and have a chemical composition similar to that of high-grade bauxite, presenting promising opportunities for the production of ceramic proppants. This review focuses on the state-of-the-art methods for preparing ceramic proppants from aluminum-silica-based industrial solid waste (ASISW). First, the potential for utilizing ASISW in ceramic proppant manufacturing is evaluated. Second, the suitability of ASISW for this purpose is analyzed. Next, the current status of commercializing waste-based ceramic proppants is assessed. Finally, the existing challenges and future research directions are discussed. This research not only promotes the efficient utilization of industrial waste and contributes to environmental sustainability but also reduces production costs for ceramic proppants, providing a novel technical pathway for their manufacturing. • Potential of ASISW for ceramic proppant preparation is analyzed. • Current utilization status of ASISW in proppant preparation is reviewed. • Pros and cons of different types of ASISW for proppant preparation are compared. • Current status of commercial production of waste-based proppants is summarized. • Existing challenges and future work opportunities are discussed.