Email this article Utilization of fly dust generated during fired shale production for the preparation of aggregates and geopolymers
DOI: https://doi.org/10.20528/cjcrl.2026.01.006
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Fly shale dust (FSD) is a fine secondary powder that is produced during the firing of shales in a rotary kiln. Its use is relatively limited, and therefore it is usually landfilled, despite its chemical composition being similar to chamotte. The main challenge is the wide firing temperature range. As a result, the material partially retains plastic properties and at the same time contains high-temperature phases. The second challenge is the significant fineness of the material, which makes it impossible to burn it in a rotary kiln. To evaluate its suitability, FSD powder was granulated with water and subsequently fired at temperatures ranging from 800 °C to 1650 °C to produce a refractory aggregate. Analysis of the high-temperature product confirmed a high mullite content and low porosity, as well as high refractoriness, which was further improved by the addition of alumina. The next part of the work was focused on the use of FSD for metakaolin production, where granulated material was calcined at 600-850 °C. The sample with the highest pozzolanic activity was selected for geopolymer preparation. Potassium or sodium water glass was used as the activator, blast furnace slag or cement as the hardener, and chamotte aggregate as the filler. The obtained material reached the compressive strength of concrete class C60/75. The results provided important information about the key steps of FSD processing and confirmed its potential for practical application.
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