Pore-forming Agent Research Articles

Pore structure characteristics and leaching mechanism of Cu and Cr in sustainable porous ceramisite produced from contaminated soil and biomass waste

Contaminated soil (CS) and biomass waste are potential resources. Their secure, scale, resource, and high-value utilization will bring significant socio-economic benefits. In present work, the basic properties, crystalline phases, microstructure and leaching behavior of porous ceramisite (PC) via CS and biomass waste were investigated systematically. The link of pore structure characteristics with leaching behavior of Cu and Cr was revealed. The environmental and economic benefits were also assessed. The results showed that the addition of 5∼15% pore-forming agent (carbon powder or biomass waste) made the matrix looser and the leaching amounts of heavy metals increased. However, the heavy metals leaching amounts was still lower than the critical limits of nonhazardous materials with immobilization rates higher than 97.5%. The leaching mechanism of Cu in the PC was controlled by initial wash-off, diffusion and depletion. The time period of the depletion dominated leaching is prolonged with increasing porosity. The leaching mechanism of Cr in the PC was mainly initial wash-off and depletion. The wash-off dominated the total heavy metal leaching amount, accounted for more than 80% of the total leaching amount. The leaching of Cu and Cr showed a positive correlation with (effective) pore volume of pores large than 1 μm, while demonstrating a negative correlation with the fractal dimension. The economic benefits of PC throughout the production process were analyzed, which showed that the production of PC using CS and biomass waste could eliminate raw material costs and could be subsidized by the government. This study provides an idea for the 100% utilization of CS and biomass waste as well as theoretical support for the disposal of solid waste.

Adsorption site identification and regulation to guide design of N-doped porous carbon-based materials for efficient and selective removal of bisphenol a

Currently, identification and regulation of adsorption sites of carbon-based materials remain a major challenge. In this study, given the properties of the target contaminant, bisphenol A (BPA), we report a novel method for preparing ultra edge N-doped hierarchically porous carbon-based material with rich vacancy defects (HENDC) via a direct pyrolysis of simultaneous EDTA-4Na and g-C3N4. Interestingly, g-C3N4 kills three birds with one stone, including pore-forming agent, nitrogen configuration regulator, and structural defect former. As such, compared with that of MNDC, which was direct pyrolysis of EDTA-4Na (462.5 mg g−1 for BPA and 551.2 mg g−1 for bisphenol S (BPS)), the adsorption capacity of HENDC for BPA was 870.1 mg g−1, which exceeded that for BPS (793.3 mg g−1). Also, HENDC shortened the adsorption process to 10 min for BPA compared with MNDC (30 min) and displayed a promising environmental application potential. Based on experiments and theoretical calculations, the high adsorption performance of HENDC for BPA originated from edge nitrogen doping, defect inducing, and hierarchically porous structures. Specifically, Lewis acid-base interactions of varying strength occurred between both pyridinic-N (stronger) and pyrrolic-N (weaker) with BPA. A strong π-π EDA interaction between pyridinic-N and BPA, which was further facilitated by vacancy defects in adjacent edge nitrogen. The hydrophobic effect promoted the interaction between pyrrolic-N and BPA. This work offers deep insights into effective and selective removal of BPA, suggesting new strategies for exploring cost-effective carbon-based adsorbents.

Tin-antimony/carbon composite porous fibers: electrospinning synthesis and application in sodium-ion batteries

In this work, tin-antimony/carbon composites porous fibers were successfully synthesized by an electrospinning method combined with two-step heat treatment processes, in which SnCl2 and SbCl3 were used as tin and antimony sources, and polyacrylonitrile (PAN) and polymethyl methacrylate (PMMA) were used as binders and pore-forming agents. The as-synthesized tin-antimony/carbon composites were systematically characterized by x-ray Diffraction (XRD), Transmission Electron Microscope (TEM), Scanning Electron Microscope (SEM), Energy-Dispersive Spectrometer (EDS), x-ray Photoelectron Spectroscopy (XPS), and Thermogravimetric Analysis-Differential Scanning Calorimetry (TG-DSC). The results indicate that the composite material consists of one-dimensional nitrogen-doped carbon porous fibers as the main matrix, with a three-dimensional network structure in which Sn, SnO2, and SnSb particles are encapsulated. Furthermore, the tin-antimony/carbon composites porous fibers were utilized as self-supported negative electrode for sodium-ion batteries. The results showed that the SNbM-2 sample electrode calcined at 800 °C demonstrated the best cycling stability and rate capability among all the sample electrodes, with a discharge capacity of 319.5 mAh·g−1 maintained after 100 cycles at a current density of 0.1 A·g−1. The excellent electrochemical performance of the SNbM-2 sample electrode is benefited from its unique porous structure and the carbon fiber network structure encapsulating Sn, SnO2, and SnSb particles, which could effectively shorten the Na+ ion transport distance and mitigate electrode volume expansion.

The Effect of the Pore Former Nature on the Microstructure of Solid-Oxide-Fuel-Cell NiO- and 10YSZ-Based Anodes Formed by Hybrid 3D-Printing

The Effect of the Pore Former Nature on the Microstructure of Solid-Oxide-Fuel-Cell NiO- and 10YSZ-Based Anodes Formed by Hybrid 3D-Printing

Mechanical and Magnetic Properties of Porous Ni50Mn28Ga22 Shape Memory Alloy

A porous Ni50Mn28Ga22 alloy was produced using powder metallurgy, with NaCl serving as the pore-forming agent. The phase structure, mechanical properties, and magnetic properties of annealed bulk alloys and porous alloys with different pore sizes were analyzed. Vacuum sintering for mixed green billets in a tube furnace was employed, which facilitated the direct evaporation of NaCl, resulting in the formation of porous alloys characterized by a complete sinter neck, uniform pore distribution, and consistent pore size. The study found that porous alloys within this size range exhibit a recoverable shape memory performance of 3.5%, as well as a notable decrease in the critical stress required for martensitic twin shear when compared to that of bulk alloys. Additionally, porous alloys demonstrated a 2% superelastic strain when exposed to 353 K. Notably, under a 1.5 T magnetic field, the porous Ni50Mn28Ga22 alloy with a pore size ranging from 20 to 30 μm exhibited a peak saturation magnetization of 62.60 emu/g and a maximum magnetic entropy of 1.93 J/kg·K.

Sintered Wick Heat Pipes with Excellent Heat Transfer Capabilities—Case Study

A sintered wick was formed in a heat pipe through the process of sintering a mixture of copper powder with particle sizes of 100 µm and 200 µm, mixed with a pore-forming agent. The heat pipe’s thermal resistance, which affects its heat transfer efficiency, is determined during manufacturing according to the powder type, thickness of the sintered wick, and filling rate of the working fluid. Heat transfer efficiency was then tested at various inclination angles (0°, 45°, and 90°) to evaluate the performance of heat pipes. Regardless of the filling amount and test angle, the 200 μm copper powder type exhibited superior heat transfer efficiency compared to the 100 μm type. After analyzing heat transfer performance at various filling rates between 20% and 50%, it was determined that the heat pipe’s optimal heat transfer capability occurred at a working fluid filling rate of 30%. The width of the wick was directly related to the heat transfer performance.

Biowaste-alkaline lignin and GO integrated polysulfone ultrafiltration membrane fabrication for Pb2+ and Eosin Y dye removal

The textile industry uses a variety of lead compounds, including lead acetate for textile dyeing, lead chloride for lead salt manufacture, and lead molybdate for pigments. Furthermore, Eosin Y, a water-soluble red dye, is commonly used in textile dyeing and ink production. The presence of Eosin Y dye and lead metal ions in textile industry effluents is prevalent. Integrating adsorbent nanofillers into the membrane matrix serves a dual purpose of membrane filtration and adsorption functionalities. In this study, Lignin/GO incorporated polysulfone composite membranes were fabricated with the phase inversion method and with PEG 6000 as a pore-forming agent. Zeta potential, pure water flux, mechanical strength, and hydrophilicity of the membranes were all improved by the integration of lignin and GO into the membrane matrix. Filtration operations were carried out using an aqueous solution containing both lead (Pb) and Eosin Y dye. Additionally, the influence of their electrostatic interactions on membrane fouling and the regeneration process was examined. The electrostatic interaction, specifically the linking effect between Pb2+ ions and negatively charged Eosin Y molecules, formed larger Eosin-Pb complexes. This led to an enhanced Pb2+ removal through membrane filtration. During the second filtration cycle, the membrane, comprising 0.75 wt% lignin and 0.75 wt% GO, achieved 100 % removal of Pb2+ ions and an 81 % rejection of Eosin Y. A Pb2+ adsorption study was conducted using the optimized lignin/GO membrane. The adsorption process was investigated through Langmuir and Freundlich isotherms exhibiting a superior fit and assured R2 values of 0.977 and 0.994, respectively. According to the isotherm data the adsorption process involves multilayer physisorption. The developed Lignin/GO-incorporated polysulfone composite membranes hold the promise for tackling issues in a variety of domains, including water treatment and biomedical applications, demonstrating versatility and ability to make positive impacts across industries.

An ultrasonic study of the effect of uniaxial green compaction pressure on the elastic anisotropy of porous copper fabricated using the pore-former route

Porous copper is potentially very attractive for various functional applications such as filters and heat exchanger materials. Within the scope of this study, porous copper samples with dual pore morphologies were fabricated following the space holder technique using a 1:2 mixture ratio of K2CO3 to NaCl as pore formers. The initial compaction pressure required for green body fabrication was systematically varied between 120 and 180 MPa, and the influence of this pressure over porosity, pore morphology, volume shrinkage, and longitudinal elastic constants was systematically studied. Three longitudinal elastic constants of the porous Cu samples were determined following the non-destructive ultrasonic phase spectroscopy method through the measurement of the phase shift vs. frequency spectra along the three orthogonal directions in each sample. When the applied pressure is increased from 120 to 160 MPa and the Cu:PF mixture ratios are 70:30 and 60:40, respectively, the elastic constant values in the green compaction direction (C11) decrease from 34.2 GPa to 7.5 GPa and 23.7 GPa–17.9 GPa. However, for Cu:PF mixture ratios of 70:30 and 60:40, under 180 MPa green compaction pressure C11 increases to 30.9 GPa and 21.2 GPa, respectively. As the applied green compaction pressure increased from 120 to 160 MPa, the samples' average elastic anisotropy ratio initially increased from 0.29 to 0.59 and then decreased to 0.55 at 180 MPa pressure. While the initial increase in anisotropy is due to increased pore flattening with increasing green compaction pressure, the decrease in anisotropy ratio in the samples fabricated under 180 MPa green compaction pressure is due to enhanced sample densification. Contour maps for different properties have been proposed to identify the optimum combination of initial powder composition and green compaction pressure for the intended end application.

Manufacturing porous U-10Zr metallic fuels with controllable microstructure by volume control spark plasma sintering

In this paper, the volume control spark plasma sintering tool has been designed and applied to sinter porous U-10Zr metallic fuels, by which the sintered sample volume can be precisely controlled. Ethanol and NH4HCO3 are used to control the powder compact or as pore formers to control the pore size and pore structure. Without pore formers, the fuel pellet displays an inhomogeneous microstructure consisting of highly porous and highly densified areas. Uneven powder stacking in the green body results in a non-uniform microstructure, and in the closed-packed area, Joule heating accelerates the neck formation and densification. The addition of ethanol reduces the friction between the powders, resulting in isolated pores formed by the stacking of powders during the sintering. By adding NH4HCO3, the pore size, and structure can be well controlled, and an interconnected pore structure can be obtained upon the decomposition of the NH4HCO3. A uniform microstructure and pore distributions can be achieved through the U-10Zr fuel pellets by controlling current flow during the volume control SPS sintering. The microstructure and phase characterization of the sintered porous U-10Zr pellets show major phases of α-U and α-Zr for the sample with short dwelling. For the sample with long dwelling (30 min), the ω UZr2 in the Zr-enriched area has been observed. The strategy of volume control SPS sintering with the assistance of pore formers could be used to fabricate porous U-10Zr metallic fuels to mimic the microstructure evolution of irradiated metallic fuels (including porosity) and could enable a possible solution for the design of new sodium-free metallic fuels for high burnup.

Shrinkage Reduction in Nanopore-Rich Cement Paste Based on Facile Organic Modification of Montmorillonite.

The organic modification of montmorillonite was successfully achieved using cetyltrimethyl ammonium bromide under facile conditions. The modified montmorillonite was subsequently used for the fabrication of montmorillonite-induced nanopore-rich cement paste (MNCP), and the shrinkage behavior and fundamental performance of MNCP were also investigated. The results indicate that alkali cations on a montmorillonite layer surface were exchanged by using CTAB under 80 °C, successfully achieving the organic modification of montmorillonite. As a pore-forming agent, the modified montmorillonite caused a reduction in shrinkage: the 28-day autogenous shrinkage at a design density of 400 kg/m3 and 800 kg/m3 was reduced to 2.05 mm/m and 0.24 mm/m, and the highest reduction percentages during the 28-day drying shrinkage were 68.1% and 62.2%, respectively. The enlarged interlamellar pores and hydrophobic effects caused by the organic modification of montmorillonite aided this process. Organic-modified montmorillonite had a minor influence on dry density and thermal conductivity and could contribute to an enhancement of strength in MNCP.

Design and Characterization of an Osmotic Pump System for Optimal Feeding and pH Control in E. coli Culture to Increase Biomass.

Batch cultures used for various purposes, such as expression screening and recombinant protein production in laboratories, usually have some drawbacks due to the bolus addition of carbon sources, such as glucose and buffers, that lead to overflow metabolism, decreased pH, high osmolality, low biomass yield, and low protein production. This study aimed to overcome the problems of batch culture using the controlled release concept by a controlled porosity osmotic pump (CPOP) system. The CPOP was formulated with glucose as a carbon source feeding and sodium carbonate as a pH modifier in the core of the tablet that was coated with a semipermeable membrane containing cellulose acetate and polyethylene glycol (PEG) 400. The release rate was regulated with Eudragit L100 as a retardant agent in the core and PEG 400 as a pore-former agent in the coating membrane. Fourier-transform infrared spectroscopy (FT-IR) and scanning electron microscopy (SEM) were used to elucidate compatibility between components and release mechanism, respectively. The in-vitro release of glucose and Na2CO3 studies were performed for 24 hours in a mineral culture medium (M9). Then, the effectiveness of CPOP in the growth of Escherichia coli (E. coli BL21) as a microorganism model was evaluated. Glucose consumption, changes in medium's pH, and acetate concentration as a by-product were also monitored during the bacterial growth. Fourier-transform infrared spectroscopy confirmed the compatibility between the components in the osmotic pump, and SEM elucidated the release mechanism due to in-situ delivery pores created by dissolving soluble components (PEG 400) on the coated membrane upon contact with the dissolution medium. The in-vitro release studies indicated that the osmotic pump was able to deliver glucose and sodium carbonate in a zero-order manner. The use of CPOP in E. coli (BL21) cultivation resulted in a statistically significant improvement in biomass (over 80%), maintaining the pH of the medium (above 6.8) during the exponential phase, and reducing metabolic by-product formation (acetate), compared to bolus feeding (P < 0.05). The use of CPOP, which is capable of controlled release of glucose as a carbon source and sodium carbonate as a pH modifier, can overcome the drawbacks of bolus feeding, such as decreased pH, increased acetate concentration, and low productivity. It has a good potential for commercialization.

A PEGylated PVDF Antifouling Membrane Prepared by Grafting of Methoxypolyethylene Glycol Acrylate in Gama-Irradiated Homogeneous Solution.

In this study, methoxypolyethylene glycol acrylate (mPEGA) served as a PEGylated monomer and was grafted onto polyvinylidene fluoride (PVDF) through homogeneous solution gamma irradiation. The grafting process was confirmed using several techniques, including infrared spectroscopy (FTIR), thermodynamic stability assessments, and rotational viscosity measurements. The degree of grafting (DG) was determined via the gravimetric method. By varying the monomer concentration, a range of DGs was achieved in the PVDF-g-mPEGA copolymers. Investigations into water contact angles and scanning electron microscopy (SEM) images indicated a direct correlation between increased hydrophilicity, membrane porosity, and higher DG levels in the PVDF-g-mPEGA membrane. Filtration tests demonstrated that enhanced DGs resulted in more permeable PVDF-g-mPEGA membranes, eliminating the need for pore-forming agents. Antifouling tests revealed that membranes with a lower DG maintained a high flux recovery rate, indicating that the innate properties of PVDF could be largely preserved.

Thermal Stability and Weather Resistance of a Bionic Lotus Multiscale Micro-Nanostructure TiC/TiN-Ni/Mo Spectral Selective Absorber Based on Laser Cladding-Induced Melt Foaming.

As the core of a solar collector, a solar selective absorbing coating has become the key material for efficient utilization and development of solar energy. In order to overcome the core scientific problem of poor high-temperature stability of optical properties caused by atomic diffusion between layers in the high-temperature environment of traditional multilayer solar absorption coatings, the multiscale lotus bionic porous structure was constructed by using a TiC/TiN-Ni/Mo material system with excellent intrinsic absorption performance. The melt foam method and laser cladding technology were combined to deposit the multiscale bionic porous structure solar selective absorption coating in situ by a laser-induced melt foaming strategy. It was found that the bubbles in the molten pool were affected by Marangoni force, gravity, buoyancy, and surface tension. The unescaped bubbles formed pores near the surface of the coating and showed a bimodal distribution. For the multiscale addition of 1.8 and 0.4 μm pore-forming agents with a mass fraction of 15 wt %, the multiscale pores enhance the scattering and secondary absorption of light and reduce the amplitude of electromagnetic wave to electron vibration; at the same time, the small-size conductor effect formed by the hole increases the surface electron concentration, strengthens the absorption of light, and enhances the magnetic field strength at the hole, and the structural absorbing effect is significant. The coating absorptivity α reaches 85%, and the temperature stability is excellent. Compared with the substrate, the coating has a smaller corrosion current density, larger polarization resistance, and strong corrosion resistance. The research shows that the laser-induced multiscale bionic porous structure coating obtains the intrinsic absorption-structural absorption composite absorption mechanism and realizes the integration of flexible design and efficient manufacturing of high-temperature solar absorption coatings.

Additive manufacturing of interconnected hierarchically porous zirconia: Utilizing both microspherical and filamentary pore-forming agents via direct ink printing

Osteogenic differentiation and bone regeneration can be effectively aided by porous scaffolds with multiscale cellular structures, making it easier to repair defects in bone tissue. Due to the scarcity of pore-forming agents, it is extremely challenging to fabricate interconnected hierarchically porous zirconia at multi-scale. This work described a novel and straightforward method for directly imprinting a slurry containing two pore-forming agents (microspherical and filamentary) to produce strong and highly porous zirconia (ZrO2) ceramics with four levels of porosity ranging from nanometers to millimeters. The concentration of hemp fibers significantly affected printability when the rheological behavior of a zirconia slurry was examined. Utilizing a scanning electron microscope (SEM) to monitor the development of powder interstices under various sintering techniques. The permeability performance was assessed when simulated plasma had fully filled the scaffolds. The structure had a high compressive strength of 24.18 MPa, a porosity of 80.9 %, an apparent porosity of 55.7 %, and took just 1.11 s to fill a scaffold that was 15 mm high. It is anticipated that the proposed route will be expanded to include various engineering materials for structural and practical applications.

The mechanistic basis of the membrane-permeabilizing activities of the virulence-associated protein A (VapA) from Rhodococcus equi.

Pathogenic Rhodococcus equi release the virulence-associated protein A (VapA) within macrophage phagosomes. VapA permeabilizes phagosome and lysosome membranes and reduces acidification of both compartments. Using biophysical techniques, we found that VapA interacts with model membranes in four steps: (i) binding, change of mechanical properties, (ii) formation of specific membrane domains, (iii) permeabilization within the domains, and (iv) pH-specific transformation of domains. Biosensor data revealed that VapA binds to membranes in one step at pH 6.5 and in two steps at pH 4.5 and decreases membrane fluidity. The integration of VapA into lipid monolayers was only significant at lateral pressures <20 mN m-1 indicating preferential incorporation into membrane regions with reduced integrity. Atomic force microscopy of lipid mono- and bilayers showed that VapA increased the surface heterogeneity of liquid disordered domains. Furthermore, VapA led to the formation of a new microstructured domain type and, at pH 4.5, to the formation of 5 nm high domains. VapA binding, its integration and lipid domain formation depended on lipid composition, pH, protein concentration and lateral membrane pressure. VapA-mediated permeabilization is clearly distinct from that caused by classical microbial pore formers and is a key contribution to the multiplication of Rhodococcus equi in phagosomes.

Design optimization of ceramic membrane filters based on a response surface method

Ceramic membrane filters fabricated from local raw materials are excellent for municipal wastewater treatment. This paper studied the fabrication of ceramic membranes using Response Surface Methodology (RSM). It also looked at the influence of clay, palm kernel shell ash, kaolin, and starch on the properties of ceramic membrane filters. Optimal test conditions and procedures were determined by selecting a fitting model based on experimental data. The Box–Behnken design (BBD) was chosen for its ability to reduce the number of experimental trials, thus making it cost-effective. The BBD design was executed using Design-Expert 13 software (Stat-Ease, Inc., Minneapolis, MN, USA), requiring 29 experimental runs. According to the study, responses such as porosity, flow rate, thickness, and density were used in the model. The fabrication of the 29 ceramic membranes includes formulation, shaping (slip casting method), drying, and sintering. Based on RSM, an optimum ceramic membrane design was proposed: Kaolin = 413 g, Clay = 180 g, Starch 147 g, Palm Kernel shell ash = 13 g. Compared with the test results, this combination possesses favorable and reliable accuracy. The addition of kaolin played a role in creating a porous framework within the ceramic membrane. Clay serves as a binding agent, aiding the consolidation of ceramic particles within the membrane matrix. Starch served as a pore-forming agent during the fabrication process. From the study, the palm kernel shell ash served as a binder and a reinforcing agent, bolstering mechanical strength and structural robustness.

Preparation of ultra-lightweight ceramsite from waste materials: Using phosphate tailings as pore-forming agent

To solve the problems of difficult treatment and environmental pollution of regolith granite sand washing sludge (RGSWS11Regolith granite sand washing sludge.), the study was carried out to prepare ultra-lightweight ceramsite using RGSWS as the main raw material, silica fume as a conditioning agent, red mud as cosolvent, and phosphorus tailings as a pore-foaming agent. The effects of raw meal ratio, sintering temperature (1130–1280 °C), and sintering time (5–25 min) on the properties of ceramsite were investigated. Under the optimal preparation conditions (RGSWS: red mud: silica fume: phosphorus tailings = 60:20:20:10 and sintering at 1220 °C for 15 min). The ceramsite showed a high compressive strength of 2.63 MPa, an expansion rate of 133.7 %, a 1-h water absorption rate of 1.32 %, an apparent density of 792.3 kg/m3, and a bulk density of 349.2 kg/m3. The sintering process transforms the raw meal into substances such as mullite, diopside, and anorthite, which helps to improve the strength of the lightweight ceramsite. At the same time, harmful substances in the raw materials can be effectively solidified in the internal structure of the ceramsite, making the ceramsite have excellent environmental safety. Moreover, the full characterizations have been made to reveal the structure and formation mechanism of ceramsite. This research utilizes four kinds of solid waste to prepare valuable material, which is helpful for the development of environmentally friendly and ultra-lightweight construction materials.

Preparation and Electrocatalytic Hydrogen Evolution Performance of FeCoNiCrMo High-Entropy Alloy Porous Electrode with Different Pore-Forming Agent Content

Preparation and Electrocatalytic Hydrogen Evolution Performance of FeCoNiCrMo High-Entropy Alloy Porous Electrode with Different Pore-Forming Agent Content

Permeability prediction of porous aerostatic bearings through 3D morphology and fractal calculation method

AbstractPorous ceramics for aerostatic bearing restrictors were fabricated using carboxymethyl cellulose and polystyrene microspheres as pore formers. The three‐dimensional morphology of the porous ceramics was nondestructively obtained using laser scanning confocal microscopy, and the processing information was eliminated by fitting the pore area fractal dimensions at different heights. A mathematical model was developed based on the assumption of elliptical tortuous capillaries to relate microstructural pore parameters to permeability by combining fractal theory, Darcy's law, and the gas conservation equation. The calculated permeability closely matched the experimental results, with an error of less than 3.5%. This method has promising potential as an alternative to pressure drop experiments. Moreover, the capacity of the fractal calculation model to establish a correlation between microstructural parameters and permeability paves a new way to design future porous aerostatic bearings.

Preparation of autoclaved-aerated concrete with waste ash of petroleum coke gasification

ABSTRACT In this paper, a novel route for the utilisation of petroleum coke gasification ash in the preparation of autoclaved-aerated concrete (AAC) is presented. The waste ash along with quartz sand, cement, lime, and gypsum are used as the primary raw materials, with aluminium powder paste serving as the pore-forming agent. The effect of incorporating petroleum coke gasification ash on the dry density and thermal conductivity of the resulting AAC was investigated. The results indicate that the thermal insulation performance of AAC is significantly enhanced by reducing the thermal conductivity coefficient upon the addition of treated petroleum coke gasification ash. At a 40% ash content, the AAC exhibits remarkable performance that meet the requirements of A2.5B05 in GB 11,968-2006, with compressive strength higher than 2.5 MPa and dry density lower than 525 kg m−3. Furthermore, the study examined the optimal calcium silicon ratio after the addition of the ash, with the results demonstrating that AAC prepared with a ratio of 0.25–0.26 exhibits the best compressive strength and dry density. The present study offers a novel perspective on waste management, which carries substantial significance for both the environmental and construction industries.