Methanol synthesis catalyst (MSC) waste was applied as the principal component (till 70 wt.%) of sustainable ceramics in composites with bauxite processing waste (RM), and waste foundry sand (FS). The results of the initial components' chemical interaction studies by a complex of methods (XRD, SEM/EDS/mapping, AAS and LAMMA) during heating demonstrated the synthesis of amorphous glasslike new formation, their filling of pores and compaction of the ceramic’s structure. In this case, a strong chemical and mechanical binding of all heavy metals and other hazardous elements of the initial industrial waste occurs with their transfer to an insoluble in an acidic environment. The materials with the highest MSC contents have the highest axial resistance values ill 25.98 MPa after firing at 1050°C.

New composites of sustainable ceramic composites from hazardous methanol synthesis catalyst waste, bauxite red mud and ground cooled ferrous slag were developed in this study. The ceramics were sintered at temperatures of 900°, 1000°, 1050°, 1100° and 1150°C for one hour. Almost all ceramic demonstrated fairly high properties, starting from a firing temperature of 1000°C. The best results were obtained after firing at 1050°С, which reached 25.98 MPa of flexural resistance, 8.80% of water absorption, 3.46 g/cm3 and 7.14% of linear shrinkage. Studies of physical – chemical processes of the ceramics’ structure formation by XRD, SEM / EDS / mapping and LAMMA methods show the synthesis of mainly amorphous new formations with strong glass-like structures. Therefore, the result of leaching and solubility of the initial components’ heavy metals in acid environment by the method of atom-absorption spectroscopy indicated their almost complete immobilization, which far exceeded the demands of Brazilian sanitary norms.

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