Effect of phase evolution and pyroplastic formation behavior on glass-ceramic foam derived from silicomanganese slag and feldspar tailings

Utilizing solid waste to produce foam material has become a significant direction in resource recycling. This study focuses solely on using silicomanganese slag and feldspar tailings as raw materials, utilizing a powder sintering process to produce autocatalytic foaming glass–ceramic foam. We formulated four mix ratios based on the compositional characteristics of the silicomanganese slag and feldspar tailings. The study then explored the evolution of phase formation and macroscopic pore morphology under varying preparation temperatures. Moreover, through multi-phase co-melting experiments, this work unveiled the high-temperature molten mass generation mechanism between silicomanganese slag and feldspar tailings. Our findings reveal that the glass melt generated from silicomanganese slag particles and the 'solid–liquid erosion behavior' of feldspar particles play pivotal roles in the formation of high-temperature co-melt substances. As the sintering temperature increases, the mixed powder exhibits three different states of high-temperature molten mass, which are the reasons for the evolution of the macroscopic pore structure. It is suggested that the addition of silicomanganese slag should be less than 50 %, and the heat treatment temperature should be below 1145 °C in preparing glass–ceramic foam with silicomanganese slag and feldspar tailings. The sample with 40 % silicomanganese slag and 60 % feldspar tailings, treated at 1140 °C, yielded glass–ceramic foam with a compressive strength of 1.68 MPa, apparent density of 0.279 g/cm3, porosity of 81.7 %, and thermal conductivity of 0.074 W·m−1·K−1. In summary, this study provides a novel approach for the high-value utilization of silicomanganese slag and offers an economical route for developing lightweight, eco-friendly structural materials.