Sintering Evolution, Mechanical Performance and Heavy-Metal Environmental Safety of Coal Gasification Slag-Based Ceramsite

Coal gasification slag (CGS) is rich in Si-Al-Ca components and thus has potential for ceramic utilization, but associated heavy metals may pose environmental risks. In this study, CGS from Yili (Xinjiang, China) was used as the major raw material (80 wt%), with clay and waste glass as additives, to prepare ceramsite by firing green pellets (8–12 mm) at 1000–1200 °C. The phase evolution, microstructure, and heavy-metal migration were characterized, and the leaching safety was evaluated. Increasing temperature leads to progressive quartz consumption, enrichment of feldspar-type crystalline phases, and liquid-phase sintering, which together enhance densification. The apparent density and single-particle compressive strength exhibit an “increase-then-decrease” trend with temperature and reach maxima at 1150 °C, where the compressive strength is 15.38 MPa. Heavy-metal behavior is element-specific: As and Zn show stronger volatilization, whereas Mn, Ba, Ni, and Cu are largely retained in the solid phase; Cr shows intermediate, temperature-dependent volatilization. After firing at ≥1150 °C, the leached concentrations of Cr, Mn, Ni, Cu, Zn, As, and Ba under the sulfuric acid–nitric acid test (HJ/T 299-2007) are below the Class III limits of the Chinese Groundwater Quality Standard (GB/T 14848-2017). Considering phase/structure evolution, mechanical performance, and short-term heavy-metal leaching, 1150 °C is identified as the preferred firing temperature in this work.