Evolution mechanism of pore structure in sintered coal gangue ceramsites

Preparation of high-strength densified ceramsites and porous water-retaining ceramsites to replace part of the original gravel aggregates and natural moisturizing materials, respectively, is an effective way for the resource utilization of coal gangue (CG). The pore structure of ceramsites affects their strength, density, porosity, etc. In this paper, CG was used as the sole raw material to prepare ceramsites at different temperatures (600–1220 °C). By using methods of thermogravimetry-differential scanning calorimetry (TG-DSC), X-ray diffraction (XRD), scanning electron microscope (SEM), element analysis (EA), heating microscope (HM), and density tester (DT), the evolution mechanism of pore structure in sintered coal gangue ceramsites (CGCs) was discussed. The results showed that there were two key temperatures: 950 °C and 1160 °C. Below 950 °C, the pore structure of CGCs was in a stable state, and the true, apparent, and closed porosity remained around 45%, 32%, and 12%, respectively. At 950–1160 °C, the true and apparent porosity decreased, and the closed porosity and compressive strength increased. Above 1160 °C, its performance deteriorated. During the heating process, the loss of carbon-containing components, phase transition, high-temperature diffusion and densification would change the pore structure. The appropriate temperature range for the preparation of porous water-retaining CGCs was about 950 °C, while that for preparing high-strength densified CGCs was about 1000–1160 °C. It was proved that qualified CGC products with different prospective applications could be prepared in different temperature regimes.