Transforming waste perlite into super lightweight ceramsite: Ratios optimization via uniform design, and investigating calcium fluoride and silicon carbide effects on foaming

Abstract

The utilization of waste perlite powder generated from mining operations in the construction industry represents a significant step towards enhancing environmental sustainability. This study applies a uniform design of experiments to delve into the apparent density characteristics of super lightweight ceramsite concerning the proportions of solid waste materials, with a particular focus on waste perlite powder. To gain insights into the apparent density, first- and second-order polynomial equations were developed. These equations are founded on the utilization of five core raw materials, including waste perlite powder, fly ash, bentonite, calcium fluoride, and silicon carbide, and were meticulously analyzed using stepwise regression techniques. This approach led to the successful optimization of test ratios, achieving the envisioned outcomes. Additionally, the research explores the influence of calcium fluoride and silicon carbide on the foaming properties of materials under varying maximum sintering temperature conditions. Ultimately, the optimized conditions yielded super lightweight ceramsite with impressive properties, boasting a bulk density of 281 kg/m³, water absorption efficiency of 1.2%, and a compressive strength of 2.72 MPa. This research showcases the potential for utilizing waste perlite powder in the construction industry, not only as a sustainable alternative but also as a means to reduce environmental impact. The development of super lightweight ceramsite underlines the promise of eco-friendly construction materials, driving forward the agenda of environmentally responsible building practices.