Study on the Recycling of Phosphate Ore Waste Rock and Its Impact on Mortar Properties

To promote the resource recovery of phosphate mine tailings and alleviate the pressure caused by the growing scarcity of river sand, this study employs a research methodology combining macroscopic performance analysis with microscopic testing to systematically investigate the effects of three types of recycled sand containing varying proportions of phosphate mine tailings (flint (FS), phosphorite flint (PFS) and dolomitic limestone (DLS)) on the performance of mortar. The study focused on assessing the impact of recycled sand on the workability of mortar, water absorption, mechanical properties, pore structure, cement hydration characteristics, and environmental safety, and conducted a comprehensive evaluation of the project’s feasibility in conjunction with a cost analysis. The effect of DLS was most pronounced in terms of setting time. Water absorption tests show that when the proportions of FS, PFS, and DLS are all 25%, the mortar’s water absorption reaches its minimum value. In terms of mechanical properties, DLS showed a more pronounced increase in early-stage flexural strength, whilst PFS and FS demonstrated a more significant increase in later-stage strength. In terms of compressive strength improvement, PFS outperformed both FS and DLS. XRD and TG-DTA test results show that the three kinds of recycled sand have no adverse effect on cement hydration. SEM and MIP results confirmed that compared with river sand, the porosity of mortar mixed with FS was smaller and the pore structure was denser. Environmental safety assessments have shown that the heavy metal leaching concentrations in the mortar made from the three types of recycled sand are all significantly below the national limits, indicating good environmental compatibility. An economic analysis indicates that the “25% river sand + 75% FS” alternative offers the best economic benefits, resulting in cost savings of 93.27 CNY per cubic metre. In summary, the use of recycled sand derived from phosphate ore tailings as a substitute for river sand in the preparation of mortar is feasible from technical, environmental, and economic perspectives. This approach facilitates the recovery of solid waste resources, conserves natural resources, reduces the environmental burden, and promotes cost optimisation.