Reusing blended leach residue by flash sintering method

In this study, the effects of different sintering methodology on grain formation, density, and hardness of blended leach residue (B‐LR) pellets is investigated. For the first time, the flash sintering (FS) method, an environmentally friendly process, is used to make multiphase ceramic composites using B‐LR under 100 V/mm at 675∘$^\circ $C. The outcomes of this study revealed that the FS process is faster and more energy‐efficient than the conventional sintering (CS) methods performed at 800°C for 4 h. The formation of abnormal grain growth is prevented by FS in B‐LR material composition after it is exposed to a max power absorption 61.4 mW/mm3 and whole FS is completed less than 100 s. Besides, FS method does not lead to any melting on grain boundaries due to excessive joule heating, compared with the CS sample. It is noted that FS also provides better density and hardness values for this material system along with compositional integrity in this multiphase system. The significant outcome of this study is reducing lead volatility and emission by decrement on the sintering temperature. Ultimately, this study has planned the practicality of reusage and recycle of this material with green, safe, and eco‐friendly methods.