Co-sintering MSWI fly ash with electrolytic manganese residue and coal fly ash for lightweight ceramisite

The MSWI fly ash (FA) is classified as hazardous waste and electrolytic manganese residue (EMR) as the harmful industrial waste. FA, water-washed FA (WFA), EMR and coal fly ash (CFA) were co-recycled to form lightweight MFCE ceramisites. The effects of FA, WFA and mixed MSWI fly ash on ceramisites were discussed. The approach to mixing FA and WFA increased the recycling amount of MSWI fly ash. The optimal mixture of 34.5% EMR, 24.1% CFA, 20.7% FA and 20.7% WFA sintered at 1160 °C for 12 min with a procedural heating rate (10 °C/min) and belonged to Class 800 artificial lightweight aggregate (GB/T 17431.1-2010); the quantity of MSWI fly ash in ceramisite was as high as 41.4%. Volatilization rates of Cd, Pb, Cu, Zn, Mn and Cr for ceramisite were higher 75.0, 24.2, 62.7, 133, 343 and 764% than FA respectively, attributed to the co-existence of chlorides and sulfates. The remained Zn, Cu, Pb, Mn and Cr were exchanged with Mg²⁺/Ca²⁺/Al³⁺ of diopside and wollastonite to form residual fractions. Our findings provided a feasibility method of co-recycling MSWI fly ash and electrolytic manganese residue to produce green lightweight aggregates.