Preparation of full tailings-based foam ceramics and auxiliary foaming effect of vanadium-titanium magnetite tailings

Abstract In the system of CaO-Al2O3-SiO2 phase diagram, using vanadium-titanium magnetite tailings (VTMT), feldspar tailings (FT), and kaolinite-type pyrite tailings (KTPT) as raw materials, the foam ceramics have been prepared by introducing SiC as foaming agents. Based on X-ray diffraction (XRD), thermogravimetry-differential scanning calorimetry analysis (TG-DSC), scanning electron microscopy (SEM), and properties experiments, the effects of raw materials content and sintering temperature on crystalline phase composition, structure, and properties of foam ceramics are comprehensively investigated. In particular, the auxiliary foaming effect of VTMT, which is the reason for the low usage of foaming agent, is explicated. The sample prepared with 60 wt% of VTMT and sintered at 1140℃ possessed porosity of 79.48%, bulk density of 0.314 g/cm3, and compressive strength of 3.81 MPa, respectively. This study realizes the comprehensive utilization of VTMT, FT, and KTPT, and at the same time provides an idea for full tailings-based foam ceramics with low cost.