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High-Performance Porous Ceramics from Red Mud via Foam-Gelcasting for Efficient Waste Utilization.

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Title: High-Performance Porous Ceramics from Red Mud via Foam-Gelcasting for Efficient Waste Utilization.
Authors: Wang, Yanxiu1,2 (AUTHOR), Wang, Fan1,2 (AUTHOR), Zhang, Ling3 (AUTHOR), Wang, Shipei1,2 (AUTHOR), Yang, Anqi1,2 (AUTHOR), Wang, Chengwen1,2,3 (AUTHOR), Wang, Li1,2 (AUTHOR), Han, Haisheng1,2 (AUTHOR), Sun, Wei1,2 (AUTHOR)
Source: Materials (1996-1944). May2026, Vol. 19 Issue 9, p1817. 13p.
Subjects: Porous materials, Gelcasting, Industrial waste research, Firing (Ceramics), Compressive strength, Environmental protection, Waste recycling
Abstract: Red mud, as a by-product of alkaline regeneration of alumina, has limited application due to its strong alkalinity, fine particle size, and complex composition. In this work, red mud porous ceramics with uniform pore size distribution and high mechanical strength were prepared using a foam-gel casting method. The effects of solid loading and sintering temperature on the microstructure of porous ceramics were systematically investigated. The porosity of red mud-based porousceramics sintered at 1150 °C with a solid content of 60.4% was 33.7%, and the maximum compressive strength was 54.70 MPa, while the porousceramics prepared with a solid loading of 34.1% and sintered at 1050 °C achieved a maximum porosity of 79.7% and a compressive strength of 2.36 MPa. Increasing the solid loading reduced porosity and enhanced compressive strength, allowing for the tailoring of mechanical properties to meet specific application requirements. Higher sintering temperature promoted the formation of the liquid phase, enhanced particle bonding, and further improved the compressive strength. Additionally, toxicity leaching tests confirmed that the ceramics are environmentally safe, with leachate levels well within regulated limits. These results demonstrate the potential of foam-gel casting as an effective route for transforming red mud into value-added porous ceramics, thereby contributing to sustainable waste utilization and broadening the application prospects of red mud-based materials. [ABSTRACT FROM AUTHOR]
Copyright of Materials (1996-1944) is the property of MDPI and its content may not be copied or emailed to multiple sites without the copyright holder's express written permission. Additionally, content may not be used with any artificial intelligence tools or machine learning technologies. However, users may print, download, or email articles for individual use. This abstract may be abridged. No warranty is given about the accuracy of the copy. Users should refer to the original published version of the material for the full abstract. (Copyright applies to all Abstracts.)
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  Data: High-Performance Porous Ceramics from Red Mud via Foam-Gelcasting for Efficient Waste Utilization.
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  Data: <searchLink fieldCode="AR" term="%22Wang%2C+Yanxiu%22">Wang, Yanxiu</searchLink><relatesTo>1,2</relatesTo> (AUTHOR)<br /><searchLink fieldCode="AR" term="%22Wang%2C+Fan%22">Wang, Fan</searchLink><relatesTo>1,2</relatesTo> (AUTHOR)<br /><searchLink fieldCode="AR" term="%22Zhang%2C+Ling%22">Zhang, Ling</searchLink><relatesTo>3</relatesTo> (AUTHOR)<br /><searchLink fieldCode="AR" term="%22Wang%2C+Shipei%22">Wang, Shipei</searchLink><relatesTo>1,2</relatesTo> (AUTHOR)<br /><searchLink fieldCode="AR" term="%22Yang%2C+Anqi%22">Yang, Anqi</searchLink><relatesTo>1,2</relatesTo> (AUTHOR)<br /><searchLink fieldCode="AR" term="%22Wang%2C+Chengwen%22">Wang, Chengwen</searchLink><relatesTo>1,2,3</relatesTo> (AUTHOR)<br /><searchLink fieldCode="AR" term="%22Wang%2C+Li%22">Wang, Li</searchLink><relatesTo>1,2</relatesTo> (AUTHOR)<br /><searchLink fieldCode="AR" term="%22Han%2C+Haisheng%22">Han, Haisheng</searchLink><relatesTo>1,2</relatesTo> (AUTHOR)<br /><searchLink fieldCode="AR" term="%22Sun%2C+Wei%22">Sun, Wei</searchLink><relatesTo>1,2</relatesTo> (AUTHOR)
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  Data: <searchLink fieldCode="JN" term="%22Materials+%281996-1944%29%22">Materials (1996-1944)</searchLink>. May2026, Vol. 19 Issue 9, p1817. 13p.
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  Data: <searchLink fieldCode="DE" term="%22Porous+materials%22">Porous materials</searchLink><br /><searchLink fieldCode="DE" term="%22Gelcasting%22">Gelcasting</searchLink><br /><searchLink fieldCode="DE" term="%22Industrial+waste+research%22">Industrial waste research</searchLink><br /><searchLink fieldCode="DE" term="%22Firing+%28Ceramics%29%22">Firing (Ceramics)</searchLink><br /><searchLink fieldCode="DE" term="%22Compressive+strength%22">Compressive strength</searchLink><br /><searchLink fieldCode="DE" term="%22Environmental+protection%22">Environmental protection</searchLink><br /><searchLink fieldCode="DE" term="%22Waste+recycling%22">Waste recycling</searchLink>
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  Data: Red mud, as a by-product of alkaline regeneration of alumina, has limited application due to its strong alkalinity, fine particle size, and complex composition. In this work, red mud porous ceramics with uniform pore size distribution and high mechanical strength were prepared using a foam-gel casting method. The effects of solid loading and sintering temperature on the microstructure of porous ceramics were systematically investigated. The porosity of red mud-based porousceramics sintered at 1150 °C with a solid content of 60.4% was 33.7%, and the maximum compressive strength was 54.70 MPa, while the porousceramics prepared with a solid loading of 34.1% and sintered at 1050 °C achieved a maximum porosity of 79.7% and a compressive strength of 2.36 MPa. Increasing the solid loading reduced porosity and enhanced compressive strength, allowing for the tailoring of mechanical properties to meet specific application requirements. Higher sintering temperature promoted the formation of the liquid phase, enhanced particle bonding, and further improved the compressive strength. Additionally, toxicity leaching tests confirmed that the ceramics are environmentally safe, with leachate levels well within regulated limits. These results demonstrate the potential of foam-gel casting as an effective route for transforming red mud into value-added porous ceramics, thereby contributing to sustainable waste utilization and broadening the application prospects of red mud-based materials. [ABSTRACT FROM AUTHOR]
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  Label:
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  Data: <i>Copyright of Materials (1996-1944) is the property of MDPI and its content may not be copied or emailed to multiple sites without the copyright holder's express written permission. Additionally, content may not be used with any artificial intelligence tools or machine learning technologies. However, users may print, download, or email articles for individual use. This abstract may be abridged. No warranty is given about the accuracy of the copy. Users should refer to the original published version of the material for the full abstract.</i> (Copyright applies to all Abstracts.)
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        Value: 10.3390/ma19091817
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        Text: English
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        PageCount: 13
        StartPage: 1817
    Subjects:
      – SubjectFull: Porous materials
        Type: general
      – SubjectFull: Gelcasting
        Type: general
      – SubjectFull: Industrial waste research
        Type: general
      – SubjectFull: Firing (Ceramics)
        Type: general
      – SubjectFull: Compressive strength
        Type: general
      – SubjectFull: Environmental protection
        Type: general
      – SubjectFull: Waste recycling
        Type: general
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      – TitleFull: High-Performance Porous Ceramics from Red Mud via Foam-Gelcasting for Efficient Waste Utilization.
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            NameFull: Wang, Yanxiu
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            – D: 01
              M: 05
              Text: May2026
              Type: published
              Y: 2026
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