A lightweight high-strength ceramsite, comprising solid raw materials and activator as the raw materials, which can be respectively expressed in parts by weight, the solid raw materials: 100 parts, the activator: 1-15 parts; wherein said solid raw materials comprise fly ash: 100 parts, high-alumina fly ash, bauxite and red mud: 6-18 parts, silica fume: 1-5 parts, surfactant: 0.1-3 parts, plasticizer: 6-24 parts; and said activator comprises alkali metal hydroxide: 5-20 parts and alkali metal silicate: 80-95 parts. The lightweight high-strength ceramsite product prepared has a density level of 700-1100 kg/m3 and cylindrical compressive strength of 10-20 MPa, and thus is not susceptible to damage.

Embodiments of the present disclosure generally relate to methods and materials for fabricating building materials and other components from coal. More specifically, embodiments of the present disclosure relate to materials and other components, such as char clay plaster, char brick, and foam glass fabricated from coal, and to methods of forming such materials. In an embodiment is provided a building material fabrication method. The method includes mixing an organic solvent with coal, under solvent extraction conditions, to form a coal extraction residue, and heating the coal extraction residue under pyrolysis conditions to form a pyrolysis char, the pyrolysis conditions comprising a temperature greater than about 500 C. The method further includes mixing the pyrolysis char with water and with one or more of clay, cement, or sand to create a mixture, and molding and curing the mixture to form a building material. Pyrolysis char-containing materials are also disclosed.

A method for preparing ceramsite by using municipal sludge as raw material, including the following specific steps: drying; preparing ingredients including raw sludge, fly ash, kaolinite, steelmaking slag, zeolite, hematite, calcareous shale, waste incineration fly ash, Fe.sub.2O.sub.3, waste glass, calcium carbonate, sodium lauryl sulfate, and sodium benzoate; mixing and stirring uniformly, and putting the stirred materials into a granulating machine for granulation; drying and preheating the material pellets after granulation, and then quickly transferring to a sintering device for first sintering at a low temperature and then sintering at a high temperature; crushing large chunks of the cooled materials; and separating and screening the crushed materials. The method of the present invention reduces the generation of the large chunks of the cooled materials in the obtained ceramsite, thereby reducing the subsequent crushing work and saving energy consumption accordingly.

A ceramic membrane is provided, which may include glass, incinerator fly ash, kaolin and palygorskite. The weight percent of the glass may be 3060 wt %. The weight percent of the incinerator fly ash may be 530 wt %. The weight percent of the kaolin may be 050 wt %. The weight percent of the palygorskite is 030 wt %.

The present invention relates to fabricating lightweight ceramic sand as a building and construction material. More specifically it relates to a novel process of manufacturing sintered synthetic lightweight ceramic sand particulates directly from pond ash and fly ash as a secondary raw material. The said synthetic lightweight ceramic sand can be used as a building material. The novel feature of the invention is to manufacture low cost lightweight sand at high throughput to compete against the fast depleting natural sand and crushed stones.

The present invention relates to fabricating lightweight ceramic sand as a building and construction material. More specifically it relates to a novel process of manufacturing sintered synthetic lightweight ceramic sand particulates directly from pond ash and fly ash as a secondary raw material. The said synthetic lightweight ceramic sand can be used as a building material. The novel feature of the invention is to manufacture low cost lightweight sand at high throughput to compete against the fast depleting natural sand and crushed stones.

A ceramic composition which can be used as a sintering aid includes 1-2 mol % of magnesium oxide (MgO), 5-15 mol % of aluminum oxide (Al.sub.2O.sub.3), 25-40 mol % of silicon dioxide (SiO.sub.2), 40-55 mol % of calcium oxide (CaO), 0.1-8 mol % of ferric oxide (Fe.sub.2O.sub.3), 0.1-2 mol % of sulfur trioxide (SO.sub.3) and 0.1-2 mol % of titanium oxide (TiO.sub.2). Alternatively, the ceramic composition includes 1-8 mol % of MgO, 5-15 mol % of Al.sub.2O.sub.3, 25-40 mol % of SiO.sub.2, 40-55 mol % of CaO, 0.1-8 mol % of Fe.sub.2O.sub.3, 0.1-2 mol % of SO.sub.3 and 0.9-2 mol % of TiO.sub.2.

A ceramsite produced by using a river/lake/sea sludge and seashell powder as raw materials and a preparation method thereof are provided. The ceramsite is made of the following raw materials in parts by weight: 15-50 parts of shell powder, 5-15 parts of kaolin, 1-5 parts of peat ash, 15-30 parts of siliceous shale, 15-40 parts of furnace slag, 10-20 parts of fly ash, 15-40 parts of zeolite, 10-30 parts of river/lake/sea sludge, and 10-25 parts of peat. The shell powder is pulverized to a particle size of 60-200 mesh in fineness. A content of silica in the siliceous shale is 87.0%-89.5%. The preparation method of the ceramsite includes the following steps: taking raw materials, pulverizing, stirring, granulating, calcining, and naturally cooling, so as to obtain the ceramsite.

The invention relates to a construction unit made from various recyclable materials, for example, from recycled waste plasterboard from the construction industry or flue-gas gypsum which is a by-product from fossil-fueled power plants. The construction units are made from a raw mix comprising gypsum, clay and aggregate and methods of making construction units. The invention also relates to a raw mix for making a construction unit; a kit including a construction unit and mortar; and uses of the construction unit to form a structure.

The invention relates to a construction unit made from various recyclable materials, for example, from recycled waste plasterboard from the construction industry or flue-gas gypsum which is a by-product from fossil-fueled power plants. The construction units are made from a raw mix comprising gypsum, clay and aggregate and methods of making construction units. The invention also relates to a raw mix for making a construction unit; a kit including a construction unit and mortar; and uses of the construction unit to form a structure.