A synthetic microsphere having a low alkali metal oxide content and
methods of forming the microsphere and its components are provided. The
synthetic microsphere is substantially chemically inert and thus a
suitable replacement for natural cenospheres, particularly in caustic
environments such as cementitious mixtures. The synthetic microsphere can
be made from an agglomerate precursor that includes an aluminosilicate
material, such as fly ash, a blowing agent such as sugar, carbon black,
and silicon carbide, and a binding agent. The synthetic microsphere is
produced when the precursor is fired at a pre-determined temperature
profile so as to form either solid or hollow synthetic microspheres
depending on the processing conditions and/or components used.