Investigating effects of sintering mean residence time on engineering properties of coal ash‐based lightweight aggregate

This study examines the effect of sintering mean residence time (MRT) on the engineering properties and morphological structure of lightweight aggregates (LWA) manufactured from waste coal combustion ash (W‐CCA). A thermodynamics‐based framework was used to tune LWA manufacturing processes. A minimum 35% liquid phase (by mass) and a lower bound viscosity of 100 Pa·s of molten material were found necessary to successfully produce LWA. Using W‐CCA's chemical composition and FactSage thermodynamic modeling, the sintering temperature for LWA was set to 1075°C. Green spherical pellets made using a pelletizer were sintered at MRT of 5.1, 14.8, and 25.9 min to test LWA physical‐mechanical properties including, unit weight, specific gravity, water absorption, and compressive strength. Results indicated that unit weight ranged from 752 to 800 kg/m3, providing desirable lightweight properties. Oven dry specific gravity ranged from 1.24 to 1.43, complying with ENI13055 specification for LWA. Water absorption capacity decreased as MRT extended from 5.1 to 14.8 min and then increased as MRT proceeded from 14.8 to 25.9 min, achieving an average absorption capacity of 26% ± 1.5%. The inverse effect was noticed for compressive strength as LWA sintered with an MRT of 14.8 min demonstrated the highest compressive strength of 14.7 ± 1.8 MPa. The initial decrease in water absorption and increase in compressive strength are attributed to the efficient sintering of the LWA's internal structure. The inverse effect observed as MRT proceeded from 14.8 to 25.9 min was believed to be a result of thermal cracking due to extensive heat exposure. MRT of 14.8 min is recommended for LWA production using the coal ash utilized in this study for its buoyancy characteristics, sufficient absorption capability, and higher compressive strength.