The work is devoted to the creation of high-strength ceramic materials with technogenic waste fillers.Purpose: Investigation of the ceramic and composite production based on chemical and metallurgical wastes to create new types of high quality constructional ceramics.Methodology/approach: The use of refractory clay with the addition of high-iron bauxite sludge as the main raw material. Bauxite sludge functions in compositions with aluminosilicate raw materials at burning at 1100 to 1200 °С, reduce to sintering due to its melting at 1150 °С.Research findings: Refractory clay compositions with red mud in the amount of 20 to 50 % at the burning temperature of 1050 °С, provide the ceramic formation possessing the compressive strength 1.3 to 1.5 times higher than that of clay samples without additives, i.e., 91 and 122–132 MPa, respectively.Value: The obtained ceramic compositions based on red mud determine a production of high-strength anorthite and anorthite-helenite ceramics using dry pressing.

The growing accumulation of industrial waste and the depletion of natural mineral resources underscore the need for sustainable approaches to producing ceramic and construction materials. Among the most promising secondary raw materials are coal combustion by-products and metallurgical slags, which are suitable for ceramic applications. This review summarizes recent advances in the use of coal ash, blast furnace and steelmaking slags, together with clay-based raw materials, for the fabrication of ceramic and composite materials. Special attention is given to the physicochemical properties of technogenic raw materials and their effects on sintering, porosity, densification, mechanical strength, and thermal stability. Modern processing methods, including pressing and high-temperature firing, are also discussed. The influence of key technological parameters, such as oxide composition, particle size distribution, firing temperature, and activation conditions, is analyzed. In addition, the review examines major challenges related to raw material heterogeneity, structural instability, thermal stress development, cracking, free CaO reactivity, and environmental risks associated with heavy metal leaching. Recent studies show that incorporating industrial waste into ceramic systems reduces waste disposal, natural resource consumption, energy use, and CO₂ emissions, while promoting sustainable and resource-efficient technologies. Ash- and slag-based ceramics therefore remain highly promising materials for construction applications.

The development of the ceramic industry requires the creation of new innovative products with improved properties. Given the growing demand for high-quality finishing materials and the limited availability of traditional raw materials, the search for more efficient technologies for porcelain stoneware production is a relevant challenge. The aim of this study was to develop porcelain stoneware with enhanced performance characteristics. The research presents the results of a study aimed at improving the production technology of porcelain stoneware in Kazakhstan using local raw materials and microsilica. The raw materials from the Turkestan region were examined for their suitability for porcelain stoneware production. The influence of technological parameters (firing temperature, particle size) on the properties of porcelain stoneware was studied. New ceramic compositions with various microsilica contents, a byproduct of silicon production, were investigated. Different compositions with varying raw material mixtures and microsilica content were prepared and fired at temperatures of 1100, 1150, and 1200°C. The optimization of process parameters for producing porcelain stoneware in different compositions showed the degree of yield dependence on firing temperature and time, as well as the effect of microsilica content. The temperature, time, and visually determined parameters at which different yield values were achieved were highlighted in different colors. The results showed that changes in the mixture composition and sintering temperature affect the quality of ceramic tiles. The final experimental conclusions demonstrated that the production of ceramic tiles containing up to 3% microsilica at a firing temperature of 1200°C, with improved engineering characteristics that meet the minimum ISO-13006 standards, is quite feasible. The addition of microsilica increases the flexural strength of porcelain stoneware to 41 MPa (exceeding the standard), reduces water absorption to 0.023%, increases frost resistance to 107 cycles, and also enhances shrinkage. These findings open new prospects for the development of the domestic ceramic industry, the expansion of the product range, and the resolution of environmental issues.

The development of the ceramic industry requires the creation of new innovative products with improved properties. Given the growing demand for high-quality finishing materials and the limited availability of traditional raw materials, the search for more efficient technologies for porcelain stoneware production is a relevant challenge. The aim of this study was to develop porcelain stoneware with enhanced performance characteristics. The research presents the results of a study aimed at improving the production technology of porcelain stoneware in Kazakhstan using local raw materials and microsilica. The raw materials from the Turkestan region were examined for their suitability for porcelain stoneware production. The influence of technological parameters (firing temperature, particle size) on the properties of porcelain stoneware was studied. New ceramic compositions with various microsilica contents, a by-product of silicon production, were investigated. Different compositions with varying raw material mixtures and microsilica content were prepared and fired at temperatures of 1100, 1150, and 1200 °C. The optimization of process parameters for producing porcelain stoneware in different compositions showed the degree of yield dependence on firing temperature and time as well as the effect of microsilica content. The temperature, time, and visually determined parameters at which different yield values were achieved were highlighted in different colors. The results showed that changes in the mixture composition and sintering temperature affect the quality of ceramic tiles. The final experimental conclusions demonstrated that the production of ceramic tiles containing up to 3% microsilica at a firing temperature of 1200 °C. The addition of microsilica increases the flexural strength of porcelain stoneware to 41 MPa (exceeding the standard), reduces water absorption to 0.023%, increases frost resistance to 107 cycles, and also enhances shrinkage. These findings open new prospects for the development of the domestic ceramic industry, the expansion of the product range, and the resolution of environmental issues.