Optimization of the solidification/stabilization process of MSW fly ash in cementitious matrices

The solidification/stabilization (S/S) process of municipal solid waste (MSW) fly ash in cementitious matrices was investigated in order to ascertain the feasibility of a washing pretreatment of fly ash with water as a means of maximizing the ash content of cementitious mixtures. Four types of fly ash resulting from different Italian MSW incineration plants and ASTM Type III Portland cement were used in this study. Ash-cement mixtures with different fly ash/cement (FA/C) ratios were made using untreated and washed fly ash. Washing of fly ash with water was realized by a two-stage treatment (liquid/solid=25; mixing time=15 min for each stage). The cementitious mixtures were characterized for water demand, setting time, mechanical strength, and heavy metals leachability. Comparison between the above properties of mixtures incorporating untreated and washed fly ash (particularly, setting characteristics), coupled with economical evaluation of the S/S process when applied to untreated and washed fly ash, proved the feasibility of washing pretreatment as a means of maximizing the incorporation of MSW fly ash in cementitious matrices (ash content up to 75%-90% by weight of total solid).     

Determination of the Cd-bearing phases in municipal solid waste and biomass single fly ash particles using SR-microXRF spectroscopy

By using an excitation energy of 27.0 keV, synchrotron radiation-induced micro-X-ray fluorescence (SR-microXRF) is employed to extract information regarding the composition and distribution of Cd-bearing phases in municipal solid waste (MSW) and biomass fly ashes. Significance of observation is based on statistics of totally more than 100 individual MSW and biomass fly ash particles from a fluidized bed combustion (FBC) plant. Cd concentrations in the parts-per-million range are determined. In general, although previous leaching studies have indicated Cd to be predominant in the smaller-size ash particles, in the present study Cd is more evenly distributed throughout all the particle sizes. For MSW fly ashes, results indicate the presence of Cd mainly as CdBr2 hot-spots, whereas for biomass fly ashes, which exhibit lower CdX2 concentration, a thin Cd layer on/in the particles is reported. For both ashes, Ca-containing matrixes are found to be the main Cd-bearing phases. Support for this observation is found from independent first-principles periodic density functional theory calculations. The observations are condensed into a schematic mechanism for Cd adsorption on the fly ash particles.     

Influence of binders on properties of sintered fly ash aggregate

Sustained research and development work on the utilization of fly ash for various productive uses have been carried out in the past. In the construction industry, major attention has been devoted to the use of fly ash in concrete as a cement replacement. The production of artificial lightweight coarse aggregate using fly ash has potential for its large-scale utilization in the construction industry and this is an area that merits attention in many parts of the world, bearing in mind the rapid dwindling of sources of natural aggregates. As only limited details on manufacture and parameters influencing properties of sintered fly ash aggregates have been reported in the literature, a systematic study was undertaken. In this paper, the relative performance of three binders, viz., cement, lime and bentonite, on the properties of sintered fly ash aggregate is reported. The salient observations are (i) the characterization studies on sintered fly ash aggregates show that the properties of aggregates depend on the type of binder and its dosage, (ii) the significant improvement in strength and reduction in water absorption of sintered fly ash aggregate is observed when bentonite is added with fly ash, (iii) the binders used did not alter the chemical composition, while they influence the microstructure of the aggregate, which results in enhancement in the properties of aggregates.     

Effect of SiO2-Al2O3-flux ratio change on the bloating characteristics of lightweight aggregate material produced from recycled sewage sludge

This study investigates the characteristics of lightweight aggregates sintered from sewage sludge ash by modifying the proportion of the main components (SiO(2)-Al(2)O(3)-flux). The ash of incinerated sludge from a municipal sewage treatment plant (STP) was used as the tested material and sintering temperature ranged from 1050 to 1100 degrees C within a time span of 10-30min. The sludge ash appeared to have a high proportion of SiO(2) (44.89%), Al(2)O(3) (11.62%) and Fe(2)O(3) (6.81%) resembling the dilatable shale. When the sintering temperature was raised to above 1060 degrees C, the blowing phenomenon appeared. The aggregates become lighter in weight by prolonging the sintering time and raising the temperature. Cullet powder (amorphous SiO(2)), Al(2)O(3), and fly ash were added to sludge ash to analyse the characteristic changes of the aggregates. The results showed that amorphous SiO(2) lowered the melting point and increased foaming; Al(2)O(3) raised the compression resistance; fly ash lowered the sintering temperature required. However, the composition of fly ash can vary dramatically, resulting in a less predictable characteristic of aggregates.     

SEM/EDS and XRD characterization of raw and washed MSWI fly ash sintered at different temperatures

The disposal of fly ash generated during municipal solid waste incineration (MSWI) may pose a significant risk to the environment due to the possible leaching of hazardous pollutants, such as toxic metals. Sintering technology attracted more attention than the vitrification process because of its low energy needed. Generally, a preliminary washing treatment of raw fly ash with water was necessary for this sintering technology. This study investigated the composition and morphology of raw fly ash (RFA) and washed fly ash (WFA) at different sintering temperatures, and examined the newly formed minerals during sintering. Toxicity characteristic leaching procedure (TCLP) tests were carried out to investigate the effect of the washing treatment and sintering process on the leaching performance of heavy metals in fly ash. Results showed that, with an increase of sintering temperature more complex aluminosilicates were formed; the incorporation of Mg, Fe and Pb into the aluminosilicates occurred during the sintering process at higher temperatures (800 and 900 degrees C). The washing treatment reduced the leachable concentration of Cd, Pb and Ni, but increased that of Cr. A CaCrO(4) compound was considered as a potential soluble species.     

Strength and elastic properties of structural lightweight concretes

The study presents the influence of characteristics of four aggregate types (two sintered lightweight fly ash aggregates, cold-bonded lightweight fly ash aggregate and normalweight crushed limestone aggregate) on the strength and elastic properties of concrete mixtures. Different models were also used in order to predict the strength and modulus of elasticity values of concretes. The results of this study revealed the achievement of manufacturing high-strength air-entrained lightweight aggregate concretes using sintered and cold-bonded fly ash aggregates. In order to reach target slump and air content, less amount of chemical admixtures was used in lightweight concretes than in normal-weight concrete, leading to reduction in production cost. The use of lightweight aggregates (LWA) instead of normalweight aggregates in concrete production slightly decreased the strength. The models given by codes, standards and software and equation derived in this study gave close estimated values to the experimental results.     

Sintering of MSWI fly ash by microwave energy

This study presents the sintering of municipal solid waste incineration (MSWI) fly ash assisted by microwave energy. The composition of fly ash was investigated by chemical sequential extraction and modified microwave digestion method. Effects of process time, container materials, aging time and salt contents were also discussed. The major elements of fly ash are Ca, Cl, Na, Si, K, Al, Mg, and Zn, and the metal species, Zn, Cr, Pb, Ca, and Cu, are mainly in the oxide phase. Under microwave processing, the fly ash was sintered into a glass-ceramics and the leaching concentrations of heavy metals were restrained. The stabilization efficiency increased with an increase in processing time in most of the cases. Better stabilization efficiency of fly ash was discovered by using the SiO(2) or Al(2)O(3) container than by using the graphite plate/SiC plate. The presence of salt in the fly ash could enhance the sintering and stabilization of fly ash. During the aging time of 0-30 days, negligible Pb in the sintered fly ash was leached out, and the leaching concentration was lower than the criterion.     

Preparation of aluminium-fly ash particulate composite by powder metallurgy technique

Aluminium-fly ash mixtures containing different weight percentages of fly ash were prepared and compacted at pressures from 138–414 MPa. The compacts prepared at 414 MPa were sintered in nitrogen atmosphere at 600, 625 and 645°C, respectively. The time of sintering ranged from 0.5–6 h. The densification parameter and the green densities of the compacts were determined as a function of compacting pressure and fly ash weight per cent. Density, hardness and strength of the sintered compacts were determined as a function of weight per cent of fly ash particles. Volume changes during sintering of green compacts were also evaluated as a function of increasing fly ash weight per cent. Microscopic studies of green and sintered compacts were done to study the effectiveness of sintering. Green and sintered density of the compacts were found to decrease with increasing weight per cents of fly ash. Sintering results in slight decrease in density and increase in volume of green compacts within the range investigated. Strength of the sintered compacts decreased with increasing weight per cent of fly ash under the present experimental conditions; however, the hardness was found to increase slightly up to 10 wt% fly ash, beyond which it decreased. This revised version was published online in November 2006 with corrections to the Cover Date.     

Characterization of various fly ashes for preparation of geopolymers with advanced applications

Fly ashes from different power stations in Australia (Collie, Eraring, Tarong) and Mongolia (4th thermal power station, Ulaanbaatar city) have been characterized by various techniques. It was determined that the Australian fly ashes are class F while the Mongolian fly ashes are class C. Due to their chemical and mineralogical differences, the fly ashes behaved differently when alkali activated to make geopolymers. The influence of various parameters on the preparation of geopolymers have been investigated and the results are used to establish a procedure for the routine manufacture of alkaline activated products. The applicability of using fly ash for building structural elements, corrosion resistant and thermally resistant materials will be presented.     

Decoupling the effects of chemical composition and fineness of fly ash in mitigating alkali-silica reaction

A comprehensive investigation was conducted to determine the individual effects of the chemical composition and particle size of fly ash on alkali-silica reaction (ASR). Test results indicated that the combined oxides content of fly ash showed a better correlation with the ASR expansions than its individual oxides. Mixtures containing finer fly ash fractions registered lower expansions than those containing the corresponding virgin fly ashes or its coarser fractions.Within the usual range of average particle size of 10 to 30 microns, of fly ash, the chemical composition had a more dominant influence on ASR mitigation than the particle size. However, when the average particle size of fly ash decreases below 10 microns, the fineness of fly ash becomes significant in mitigating ASR. In addition, the fineness of fly ash had a more significant influence in mitigating ASR in mixtures containing high-lime fly ashes than those containing low-lime fly ashes. Hence, reducing the particle size of fly ash to finer fractions is an effective strategy to mitigate ASR. The decoupling of the chemical composition of fly ash from its particle size indicated that ASR mitigation can be achieved with any fly ash having a D₅₀ below 5 μm. However, low-lime fly ashes were effective in mitigating ASR even without reducing their particle size.     

Thermal treatment of the fly ash from municipal solid waste incinerator with rotary kiln

Reuse of the fly ash from the municipal solid waste incinerator (MSWI) is a policy of Taiwan EPA. However, the fly ash is often classified as a hazardous waste and cannot be reused directly because the concentrations of heavy metals exceed the TCLP regulations. The main objective of this study is to investigate the continuous sintering behavior of fly ash with a rotary kiln and seek a solution to reduce the concentrations of heavy metal to an acceptable value. The partitions of the heavy metals in the process are also considered. The results of TCLP showed that among the metals of Cr, Cd, Cu and Pb, only the concentrations of Pb in raw fly ash exceeded the regulation. At sintering temperatures of 700, 800 and 900 degrees C, the concentration of Pb decreased in sintering products, however, the concentration of Pb still exceeded the limitation at 700 and 800 degrees C. Additionally, the water-washing was used to pre-treat the fly ash before sintering process. The washing treatment effectively reduced the leaching concentrations of Pb to agree the regulations. Therefore, water-washing followed by a sintering treatment is an available process for detoxifying the fly ash of MSWI.     

Characteristic of polychlorinated dibenzo-p-dioxins and dibenzofurans in fly ash from incinerators in china

Fly ash from municipal solid waste (MSW), medical waste (MW) and electrical power plant (EPP) incinerators were analyzed for polychlorinated dibenzo-p-dioxins and dibenzofurans (PCDD/Fs). The study showed that the PCDD/F levels in fly ash were EPP < MSW < MW. The homologue profiles of PCDD/Fs in fly ash produced from waste incinerators were similar. However, the homologue profiles of PCDD/Fs in fly ash from electrostatic precipitator (ESP) of electrical power plant were different from that from waste incinerator. The strong correlation was found between the concentration of 2,3,4,7,8-PeCDF and the I-TEQ value of fly ash regardless of the different fly ashes sources.     

High-calcium fly ash as the fourth constituent in concrete: problems,solutions and perspectives

Even though Hellenic high-calcium fly ashes of different origin are widely used by the cement industry for the production of several CEM II types of cements according to EN 197-1, their systematic use in concrete still presents some difficulties. This inhibits the establishment of specifications for their addition. Main problems concerning the quality, are focused on variations in chemical and mineralogical composition, necessity for supplementary grinding, high proportion of free-CaO and periodically high proportion of SO₃ content.These problems as well as the solutions, for every day use by the concrete industry, applied during the construction of a dam, are discussed, in this paper. To overcome these problems, untreated fly ash was cheaply upgraded by grinding at a specially designed ball mill, with simultaneously hydration, for the reduction of free-CaO.Details also (i) for fly ash variations in relation to their origin, (ii) the grinding plant and (iii) the industrial production of fly ash, are given. Finally, in a separate chapter of this paper, aiming to explain the treatment of fly ashes followed during their industrial production, data of the mechanical strength of mixtures of cements incorporating fly ashes with different treatment, concerning their free-CaO and their fineness, are given.     

Disposal of MSWI fly ash through a combined washing-immobilisation process

The objective of this work was to investigate the feasibility of a combined washing-immobilisation process as a means of optimising the disposal of fly ash resulting from municipal solid waste incineration (MSWI) in cementitious matrices. Two different types of Italian MSWI fly ash and an ordinary Portland cement (ASTM Type I) were used. Washing pre-treatment of fly ash with water always produces a wastewater that can be successfully treated by reducing the pH to values of 6.5-7.5. This treatment is capable of removing the detected contaminants (Al, Cd, Pb, Zn) through two different mechanisms: precipitation of aluminium hydroxide and adsorption of cadmium, lead and zinc ions onto floc particles of Al(OH)(3). Setting and leaching tests on cementitious mixes prove that the hazardous sludge produced from wastewater treatment can be completely mixed with washed fly ash and this mixture can be incorporated into cementitious matrices to a great extent (75 wt.% of total solid) without the risks of an unacceptable delay of cement setting and an excessive heavy metals leachability from solidified products. The better performance of the combined washing-immobilisation process as compared to the immobilisation process of unwashed fly ash may be ascribed primarily to the ability of the washing step in promoting the formation of hydrate phases that incorporate and/or convert heavy metal compounds into less reactive forms and, secondarily, to its ability of removing significant amounts of alkali chlorides and sulphates from fly ash. As a result, MSWI fly ash is transformed into a material that adversely affects cement hydration to a much lower extent than unwashed fly ash.     

Dust explosion hazard of pulverized fuel carry-over

This paper reports the results of experiments done to examine the explosibility of the waste products (fly ash and bottom ash) from pulverized fuels (coal and petroleum coke). Tests were conducted for the fly and bottom ashes alone and also for selected fly ashes blended with the fuels. The explosion parameters of interest were explosion pressure and rate of pressure rise. The fly ashes showed no propensity to explode, whereas one of the bottom ashes did show limited explosibility. Both findings can be explained with reference to the volatile matter content of the ashes. Admixture of either coal or petroleum coke with fly ash resulted in explosible mixtures at volatile contents in the range of 7-13%, with the value being dependent on the composition of the mixture components and their particle sizes.     

Effect of fly ash preliminary calcination on the properties of geopolymer

The influence of preliminary calcination of fly ashes on the geopolymerisation process has been studied. Preliminary calcination at 500 and 800 degrees C causes decarbonation of the fly ash while it also leads to a decrease of the amorphous content of the fly ashes from 60 to 57%. Geopolymer prepared using raw fly ash exhibited a compressive strength 55.7(9.2)MPa, while for 500 and 800 degrees C calcined samples it reduced to 54(5.8) and 44.4(5.4)MPa, respectively. The decrease in compressive strength of the geopolymers is discussed in terms of partial surface crystallisation of the fly ash particles. Reactivity of the fly ash also has been correlated with the shrinkage rate and presence of efflorescence on the surface of geopolymers.     

Comparison of the characteristics of bottom and fly ashes generated from various incineration processes

This study analyzed and compared the characteristics of bottom and fly ashes from three municipal solid waste incinerators (MSWIs) in Taiwan. Different incineration furnaces were investigated, including: (1) fluidized bed, (2) mass-burning, and (3) mass-burning linked rotary kiln. The particle size distribution, morphology, mineralogical and chemical composition, and leaching behavior of heavy metals of ash samples were evaluated. The results revealed that three types of incineration processes have different characteristic for ashes due to transportation and mixing system inside furnace. Particle size distribution indicated that 28.5% of MSWI-B bottom ash has lower than 180 microm and 61.2% of MSWI-A fly ash has larger than the 250 microm. The leaching concentration of Pb exceeded the regulatory level set by the Taiwan EPA in fly ashes from MSWI-B and MSWI-C, and thus must be considered hazardous wastes. Specifically, the leaching concentration of heavy metals of fly ashes from MSWI-A (fluidized bed incinerator) was lower than that of the others, and was corresponded to the regulatory levels. Therefore, a fluidized bed incineration process appears a potential of handling heavy metals for ashes. The result was also provided the valuable information for incinerator design and operation.     

Modification of MSW fly ash by anionic chelating surfactant

This paper elucidates a study on the re-utilization and stabilization of municipal solid waste (MSW) fly ash in producing a high value-added product by the surface modification of anionic chelating surfactant on the particles. After modification, MSW fly ash can be expected using as a filler of ultra-high molecular weight polymers. The effects of anionic chelating surfactants (ACS) on surface modification of MSW fly ash and fixing capacity for heavy metals were explored. Meanwhile, the interaction mechanism between surfactants and MSW fly ash was suggested. The results showed that anionic chelating surfactants can be used to effectively modify MSW fly ash particles and achieve a high active ratio. At the same time, they also exhibited a strong fixing capacity for heavy metals. Of the two modified MSW fly ash, ED3A-modified MSW fly ash has a much higher active ratio than MAP-modified MSW fly ash at over 95%, although its fixing capacity for heavy metals was a shade lower than MAP-modified MSW fly ash.     

Production of lightweight aggregates from mining residues, heavy metal sludge, and incinerator fly ash

In this study, artificial lightweight aggregate (LWA) manufactured from recycled resources was investigated. Residues from mining, fly ash from an incinerator and heavy metal sludge from an electronic waste water plant were mixed into raw aggregate pellets and fed into a tunnel kiln to be sintered and finally cooled rapidly. Various feeding and sintering temperatures were employed to examine their impact on the extent of vitrification on the aggregate surface. Microstructural analysis and toxicity characteristic leaching procedure (TCLP) were also performed. The results show that the optimum condition of LWA fabrication is sintering at 1150 degrees C for 15 min with raw aggregate pellets fed at 750 degrees C. The rapidly vitrified surface envelops the gas produced with the increase in internal temperature and cooling by spraying water prevents the aggregates from binding together, thus forming LWA with specific gravity of 0.6. LWA produced by sintering in tunnel kiln shows good vitrified surface, low water absorption rate below 5%, and low cylindrical compressive strength of 4.3 MPa. In addition, only trace amounts of heavy metals were detected, making the LWA non-hazardous for construction use.     

Structural Characterization of Four South African Fly Ashes and Their Structural Changes with β-Cyclodextrin

This article examines the structural characteristics of four South African fly ashes and their structural changes with β-cyclodextrin so as to compare their structural responses to fly ash-β-cyclodextrin (FA-βCD) composite. The four different fly ashes, obtained from different power stations in South Africa were subjected to x-ray fluorescence (XRF), particle size distribution, x-ray diffraction (XRD), and Fourier transform infrared spectroscopy (FTIR) analysis. FA-βCD composites were subjected to XRD and FTIR analyses. The XRF analysis showed that all the fly ash samples used are in class F with SiO₂ + Al₂O₃ + Fe₂O₃ greater than 70%. The average particle sizes of all fly ash samples were less than 0.075 mm; the major mineral phase in all fly ash samples was quartz (SiO₂). The FTIR analysis showed Si-O-Si asymmetric and Al-O symmetric stretching vibrations in all fly ash samples. FA-βCD composites for all the fly ashes revealed additional upcoming peaks between diffraction angles (2θ) 10° and 25°, which was not in the raw fly ashes. Shift in FTIR spectra frequencies and an additional peak at approximately 1155 cm^?1 attributed to O-Si-O bending vibration were observed in all the composite samples.