Mechanism of low temperature sintered high-strength ferric-rich ceramics using bauxite tailings

Bauxite tailings are a major type of solid wastes generated in the flotation process. Based on the high Fe2O3 content and low Al2O3 content of bauxite tailings, ferric-rich ceramics were prepared in this study. It has been found that the sintering temperature of the ferric-rich ceramics is only about 1100 °C. Sintering mechanism of ferric-rich ceramics was preliminary analyzed. By optimizing the chemical composition of the ceramic, ferric-rich ceramics performance of flexural strength was reached a maximum of 197.41 MPa sintered only at 1130 °C. Finally, ceramic proppants were successfully prepared with high-strength ferric-rich ceramics. At the best sintering temperature of 1130 °C, the performances were 4.65% of breakage ratio under 52 MPa and 2.78 g/cm3 of apparent density. The properties indicated that the production of high-strength ferric-rich ceramics may be an attractive method for recycling solid waste bauxite tailings. •The study provides a feasible way for the utilization of bauxite tailings.•The sintering temperature of ferric-rich ceramics was only about 1100 °C.•The sintering mechanism of low temperature sintered ceramics was studied.•The flexural strength of ferric-rich ceramics reached 197.41 MPa.•The breakage ratio of ceramic proppants was only 4.65% under 52 MPa.