Effect of shale addition on properties of sintered coal fly ash

Shale can be used as a substitute for clay in sintered fly ash, due to the similar physical and chemical property to clay. In this paper, these characteristics of sintered fly ash with or without shale (binder) were investigated by physical property, X-ray diffraction and scanning electron microscopy. The results show that shale addition ranging from 30% to 50% (in weight) can be beneficial for properties of sintered products at temperature ranging from 950 to 1050 °C. However, a higher amount of shale easily caused significant bloating at 1100 °C. Considering energy saving and best performance, the sintering mix for shale and fly ash (50% in weight respectively, the same as below) fired at 1000 °C for 2 h was an optimal option. XRD results of the sintering mix show that intensity of hercynite increases with the increasing temperature, but intensity of quartz decreases on sintering. SEM confirms that addition of shale can improve microstructure and sintering of fly ash.     

Hybrid effect of carbon nanotube and nano-clay on physico-mechanical properties of cement mortar

In this work, several nanomaterials have been used in cementitious matrices: multi wall carbon nanotubes (MWCNTs) and nano-clays. The physico-mechanical behavior of these nanomaterials and ordinary Portland cement (OPC) was studied. The nano-clay used in this investigation was nano-kaolin. The metakaolin was prepared by thermal activation of nano-kaolin clay at 750 °C for 2 h. The organic ammonium chloride was used to aid in the exfoliation of the clay platelets. The blended cement used in this investigation consists of ordinary Portland cement, carbon nanotubes and exfoliated nano metakaolin. The OPC was substituted by 6 wt.% of cement by nano metakaolin (NMK) and the carbon nanotube was added by ratios of 0.005, 0.02, 0.05 and 0.1 wt.% of cement. The blended cement: sand ratio used in this investigation was 1:2 wt.%. The blended cement mortar was prepared using water/binder ratio of 0.5 wt.% of cement. The fresh mortar pastes were first cured at 100% relative humidity for 24 h and then cured in water for 28 days. Compressive strength, phase composition and microstructure of blended cement were investigated. The results showed that, the replacement of OPC by 6 wt.% NMK increases the compressive strength of blended mortar by 18% compared to control mix and the combination of 6 wt.% NMK and 0.02 wt.% CNTs increased the compressive strength by 29% than control.     

Granulated foam glass–ceramic material from zeolitic rocks

The objective of this research work was to investigate the production of granulated foam glass–ceramic material from zeolitic rocks. The investigations have shown that grinding raw materials to particle size less than 0.5 mm and adding 13.8% of alkali content provide production of material with the following properties: particle density – 340 kg/m³, strength – 1.6 MPa and water adsorption – 13% at firing temperature of 850 °C. Expanded zeolite with alkali content is a material of glass–ceramic composition with amorphous part of 38.6% and crystalline part of 61.4% that gives higher strength in comparison with sponge glass.     

Modified MSWI ash-mix slag for use in cement concrete

In this study, fly- and scrubber-ash from a municipal solid waste incinerator (MSWI) were mixed uniformly in their production weight proportions; then, the mixture was added to waste glass frit and melted to form a glassy slag. The toxicity characteristic leaching procedure test results for the glassy slag revealed that the amount of leached heavy metals was far below the regulatory threshold. The slag-blended cement concrete (SBCC) specimens were manufactured with 20 wt.% of the cement replaced by slag powder. Three water/cementitious ratios, 0.48, 0.58 and 0.68, were selected to mold the specimens for compressive strength testing. The strengths of the SBCC specimens were close to or higher than those of the ordinary Portland cement concrete (OPCC) specimens at an age of 28 days and were 5–10% higher than those of the OPCC specimens at ages of 56 and 90 days. The experimental results demonstrated the feasibility of recycling MSWI fly- and scrubber-ash with waste glass.     

Utilization of Mn–Fe solid wastes from electrolytic MnO2 production in the manufacture of ceramic building products

The aim of this work is to evaluate the utilization of Mn–Fe solid wastes, originating from electrolytic manganese oxide production plants, as raw materials in the manufacturing process and on the properties of traditional ceramic building products such as bricks, roof or floor tiles. The Mn–Fe solid wastes are chemically and morphologically characterized. Subsequently, ceramic test specimens incorporating 2.5, 5, 7.5 and 10 wt.% solid wastes are made. Two different shaping technologies are used, namely compaction and extrusion. The green specimens are finally fired to different peak temperatures ranging from 950 to 1100 °C. The final products are characterized concerning important properties such as modulus of rupture, water absorption, weight loss and color. It appears that Mn–Fe solid wastes when used up to a percentage of 7.5 wt.% improve the basic properties of traditional building ceramic products. The results of this study are demonstrated by the successful pilot production of real size ceramic products.     

Direct utilization of liquid slag from phosphorus-smelting furnace to prepare cast stone as decorative building material

Discharge of huge amount of liquid slag from phosphorus-smelting electric furnace has posed serious threat to the environment. In this study, a novel approach of directly recycling the liquid slag to prepare cast stone as decorative building material was proposed and experimentally tested. In our lab experiments, 76 wt.% water-quenched slag was re-melted at 1400 °C for 0.5 h (thus simulating liquid slag from phosphorus-smelting electric furnace), and then mixed with 18 wt.% quartz powder and 6 wt.% calcined kaolinitic clay, and subsequently melted together at 1450 °C for 1 h into modified liquid slag which was cast, heat-treated, annealed and transformed into cast stone. The optimal temperature for heat-treating cast stone ranges from 850 to 900 °C. And as-prepared samples present excellent properties of bending strength, acid resistance and alkali resistance. ESEM images show that their microstructures are composed of spherical granules with particle sizes of about 0.2–0.4 μm, which are non-crystalline as indicated by the results of XRD analysis. EDS results show that the contents of major elements in the granule are different from those in its background area. Results of TCLP test show that heavy metals from raw slag have been solidified in the cast stone. The practical feasibility of the new technology was examined further by on-site experiments, in which fresh liquid slag from phosphorus-smelting electric furnace was directly mixed with quartz and kaolinitic clay to produce cast stone. The results were quite stable and consistent with those of lab experiments, proving that the proposed approach of direct utilization of both energy and material of liquid phosphorus slag to produce cast stone as decorative building material is feasible, cost-effective and environment-friendly.     

Nanostructured zonolite–cementitious surface compounds for thermal insulation

This paper investigates the effect of zonolite loadings on the thermal resistivity and indirect tensile strength of nanostructured cementitious compounds. The main objective of this research is to develop a structural lightweight compound that can be used on building skins and cores for pre fabricated structural insulated panels (SIPs). The application of this compound is intended to improve the thermal resistivity of the building envelope with suitable mechanical performances. The zonolite dosage was added to the cement-nano clay blend at different dosages up to 40% by weight. The nano clay reinforcement used is montmorillonite clay (Hydrated sodium calcium aluminum silicate). The mixes were prepared using water of consistence. The wet compounds were molded in PVC cylindrical molds, having 50 mm inside diameter and 27 mm height, and left for 24 h, then demolded and cured in humid air (20 ± 1 °C&100% RH) for 28 days. The samples were then dried at 105 ± 5 °C for 24 h before testing using a forced convection oven. The thermal resistivity and indirect tensile strength of the different compounds were evaluated. Results demonstrate that the thermal resistivity at 40% zonolite loading enhanced by about 2.9 folds compared to the control samples. An increase of more than 30% in the indirect tensile strength was also achieved when a 0.5% by weight of polycarboxylate superplasticizer was used.     

Effect of grog addition on the properties and microstructure of a red ceramic body for brick production

In the present paper crushed fired brick waste, known as grog, was used in mixtures with clayey body to make typical red ceramics for bricks. The effect of the grog addition up to 20 wt% on the extrusion stage as well as on properties and microstructure of bricks fired at 700 °C was evaluated. The results indicate that the extrusion of the unfired clayey body was not impaired by the grog addition. Additions above 5 wt% decreased the mechanical strength of both the dry body and the fired ceramic pieces. This is associated with the increase in porosity during the firing stage due to the grog behavior.     

Preparation of eco-friendly construction bricks from hematite tailings

With the objective of reducing the negative impacts on environment and utilizing the secondary resource of tailings, the possibility of making construction bricks by using the hematite tailings from western Hubei province of China was investigated. Besides hematite tailings, the additives of clay and fly ash were added to the raw materials to improve the brick quality. Through the process of mixing, forming, drying and firing, the bricks were produced. The optimum conditions were found to be that the hematite tailings content were as high as 84%, forming water content and forming pressure were respectively in the range of 12.5–15% and 20–25 MPa, and the suitable firing temperature was ranged from 980 to 1030 °C for 2 h. Under these conditions, the mechanical strength and water absorption of the reddish fired specimens were 20.03–22.92 MPa and 16.54–17.93%, respectively, and the other physical properties and durability were well conformed to Chinese Fired Common Bricks Standard (GB/T5101-2003). The phases and morphologies of the green tailings and fired specimen were characterized by XRD and SEM. The results showed that the main mineral phases of the product were hematite, quartz, anorthite and tridymite, which were principally responsible for the mechanical strength of bricks.     

Effects of calcination temperature of kaolinite clays on the properties of geopolymer cements

The aim of this work is to determine the most convenient calcination temperature of kaolinite clays in view of producing geopolymer cements. In this light, the clay fractions of three kaolin minerals were used. The clay fractions were characterized (chemical and thermal analyses and X-ray diffraction) and then calcined in the temperature range of 450 and 800 °C. The obtained amorphous materials were dissolved in a strongly alkaline solution in order to produce geopolymer cements whose pastes were characterized by determining their setting time, linear shrinkage and compressive strength. Hardened geopolymer cement paste samples were also submitted to X-ray diffraction, Fourier transform infrared spectroscopy and scanning electron microscopy analyses. The setting time of geopolymer cement pastes produced from the clay fractions calcined at 450 °C was very long (test samples could be handled easily only after 21 days at the ambient atmosphere of the laboratory). For the clay fractions calcined between 500 and 700 °C, the setting time of geopolymer cement pastes reduced with increasing temperature and varied between 130 and 40 min. Above 700 °C, the setting time began to increase. The linear shrinkage of the hardened geopolymer cement paste samples aged between 21 and 28 days attained its lowest value around 700 °C. Above 700 °C, the linear shrinkage began to increase. The compressive strength of the hardened geopolymer cement paste samples was between 11.9 and 36.4 MPa: it increased with samples from the clay fractions calcined between 500 and 700 °C but dropped above 700 °C.It can be concluded that the most convenient temperature for the calcination of kaolinite clays in view of producing geopolymer cements is around 700 °C.     

Effectiveness of technogenic waste usage in products of building ceramics and expanded clay concrete

In this paper the influence of the burned and the unburned mullite wool waste on the properties of ceramics and expanded clay concrete has been analysed. It has been determined, that this waste could be successfully used in the manufacture of expanded clay concrete and wall ceramic products. Increasing the quantity of mullite wool in the mix of expanded clay concrete, the forecasted frost resistance decreased and the water absorption increased. Products without waste and those having 10% of the waste have similar compressive strength. The performed research has shown that the unburned mullite wool waste is the active micro filler, however it does not decrease the quantity of portlandite formed, but performs a framing function. Modifying the composition of ceramics with the burned mullite wool waste, the density of samples decreased, but the parameters of water absorption and compressive strength increased. To receive stronger ceramic products, 15% of the burned mullite wool waste should be added, then the compressive strength is 23 MPa, however the forecasted frost resistance of such ceramic body would be only 65 cycles. The highest frost resistance (about 200 cycles) of ceramic samples was received applying 5% of the waste additive, then compressive strength is about 16 MPa. The unburned mullite wool waste decreases the frost resistance and density of expanded clay lightweight concrete samples, and increases the water absorption. Replacing 10% of cement with the unburned mullite wool waste almost does not change the compressive strength and density, but decrease frost resistance 36% and increase water absorption 4%.     

Assesment of clay bricks compressive strength using quantitative values of colour components

This study was conducted to assess the relationships among firing temperature, colour components and compressive strength of bricks. Lightness (L*) and chromaticity (a* and b*) of 10 replicated brick samples fired at temperatures 700–1050 °C in steps of 25 °C under free access of air, were measured with a colorimeter, which uses an L* a* b* colour space. Increasing firing temperature significantly increased the compressive strength of bricks. The values of L* slightly increased with firing temperature up to around 800 °C then decreased as temperature increased further. The values of b* and a* increased with increasing firing temperature up to around 900 °C then rapidly decreased with further increases in firing temperature. A negative relationship occurred between each of L*, a*, and b* and compressive strength. Compressive strength was adequately described by colour components of L* and b* by linear regression equations (R² = 0.87 for L*, and R² = 77 for b*). However, the relationship occurred between a* and compressive strength was quite poor. It was concluded that the numerical values of colour components of L* and b* may be used to predict and judge the compressive strength of bricks. However, the method can not be generalized before its calibrated with different raw materials under different firing conditions.     

Thaumasite formation in sugary solutions: Effect of temperature and sucrose concentration

Thaumasite formation in cementitious environments is attributed to sulphate attack (internal or external). Thaumasite is characterized by the presence of octahedrally coordinated silicon, but is formed from the silicate phases of cement, (mainly C–S–H gel), whose silicon atoms are tetrahedrally coordinated. Thaumasite formation is favoured at low temperatures and from recent studies sugar solutions increases calcium solubility and also increases the velocity of formation of thaumasite. The aim of the present study is to explore the effect of temperature (5 °C and 25 °C) and sucrose concentration (5%; 10% and 20% wt) on thaumasite formation from lime and sodium carbonate, sulphate, silicate sugary solutions. Precipitates formed different ages were characterized by XRD and FTIR. At 5 °C larger proportions of thaumasite were formed in 10% sucrose however at 25 °C, the 20% sugary solution generates more thaumasite at shorter times.     

Experiments and predictions of physical properties of sand cemented by enzymatically-induced carbonate precipitation

A grouting technique that utilizes precipitated calcium carbonate as a cementing material is presented. The enzyme urease is used to enhance the rate and the magnitude of the calcium carbonate precipitation. Evolutions in the mechanical and the hydraulic properties of treated sand samples are examined through unconfined compression and permeability tests, respectively. The grout is mainly composed of urease, which bio-catalyzes the hydrolysis of urea into carbon dioxide and ammonia, urea, and calcium chloride solutions. This method employs chemical reactions catalyzed by the enzyme, and ultimately acquires precipitated calcium carbonate within soils. The mechanical test results show that even a small percentage of calcium carbonate, precipitated within soils of interest, brings about a drastic improvement in the strength of the soils compared to that of untreated soils—the unconfined compressive strength of the samples treated with <10 vol% calcium carbonate precipitation against the initial pore volume ranges from ∼400 kPa to 1.6 MPa. Likewise, the hydraulic test results indicate the significant impervious effects of the grouting technique—the permeability of the improved samples shows more than one order of magnitude smaller than that of the untreated soils. Evolutions in the measured hydraulic conductivity and porosity are followed by a flow simulator that accounts for the solute transport process of the injected solutions and the chemical reaction of the calcite precipitation. Predictions of the changes in permeability with time overestimate the test measurements, but those of the changes in porosity show a good agreement with the actual measurements, indicating that such simulations should become a significant supplementary tool when considering real site applications.     

Properties of sintered low calcium bottom ash aggregate with clay binders

This paper focuses on the properties of sintered aggregates with low calcium bottom ash from coal fired thermal power plants using a wide range of clay binders through pelletization process. The experimental runs were designed using central composite design of response surface methodology. The aggregate was produced using a disc pelletizer. The pelletized aggregate was sintered at 800–1100 °C for 30–120 min. Sintered aggregates were tested for bulk density, 10% fines value and water absorption. The factors involved in the process are moisture content, binder, Ca(OH)₂ dosage, sintering temperature and duration. It was observed that an increase in binder dosage and sintering temperature resulted in aggregates with higher 10% fines value and low water absorption. The properties of aggregates depended on the type of binder used. Aggregate with kaolinite and metakaolin binders resulted in high 10% fines value. The results indicate the potential for manufacturing high quality lightweight aggregate from bottom ash using clay binders.     

Formulation of blended cement: Effect of process variables on clay pozzolanic activity

Chemical, physical and mineralogical properties of crude and calcined local kaolinitic clay were studied in detail in order to use it as an artificial pozzolan. The aim of this study was to investigate and optimize the properties of mortars in which calcined clay is employed as a pozzolan.A three variable (calcination time: X1, calcination temperature: X2 and % of calcined clay in the blended cement: X3) rotatable orthogonal composite design was set up. It was concluded that the compressive strengths were governed by the calcination temperature and the percentage of the calcined clay in the blended cement. It was proven that the strengths could be improved by increasing simultaneously the percentage of incorporation and the calcination temperature of the clay. It was also demonstrated that at temperatures lower than 700 °C, the increase of the calcination time, improved the compressive strength, while above 700 °C, the opposite effect was observed. Finally, a blended cement composition has been formulated and optimized using the desirability functions. The optimized blended cement contains 25% of calcined clay, heated for 3 h at a temperature of 750 °C.     

Investigation of the physico-chemical and microscopic properties of Ottoman mortars from Erzurum (Turkey)

Ottoman mortar is the long-established binding material used for centuries and there are many historical buildings as evidence of its use by Ottomans in Erzurum (Eastern Turkey). The physico-chemical and microscopic properties of the Ottoman mortars in Erzurum have been studied in detail as part of an investigation of the mineral raw materials present in the territory of Turkey. For this purpose, SEM, XRD and EDS analyses of six main types of mortars were carried out showing the presence of organic fibers and calcite, quartz and muscovite minerals. The chemical analyses of the specimens showed that higher SiO₂ + Al₂O₃ + Fe₂O₃ contents yielded in higher values of hydraulicity and cementation indices. A significant result of this investigation was that mortars with higher hydraulicity and cementation indices had higher compressive strengths. Most probably this is the main reason why historical Ottoman buildings were resistant against serious earthquakes.     

Stress-dependence of the permeability and porosity of sandstone and shale from TCDP Hole-A

We utilize an integrated permeability and porosity measurement system to measure the stress dependent permeability and porosity of Pliocene to Pleistocene sedimentary rocks from a 2000 m borehole. Experiments were conducted by first gradually increasing the confining pressure from 3 to 120 MPa and then subsequently reducing it back to 3 MPa. The permeability of the sandstone remained within a narrow range (10^?14–10^?13 m²). The permeability of the shale was more sensitive to the effective confining pressure (varying by two to three orders of magnitude) than the sandstone, possibly due to the existence of microcracks in the shale. Meanwhile, the sandstone and shale showed a similar sensitivity of porosity to effective pressure, whereby porosity was reduced by about 10–20% when the confining pressure was increased from 3 to 120 MPa. The experimental results indicate that the fit of the models to the data points can be improved by using a power law instead of an exponential relationship. To extrapolate the permeability or porosity under larger confining pressure (e.g. 300 MPa) using a straight line in a log–log plot might induce unreasonable error, but might be adequate to predict the stress dependent permeability or porosity within the experimental stress range. Part of the permeability and porosity decrease observed during loading is irreversible during unloading.     

Stiffness and strength parameters for hardening soil model of soft and stiff Bangkok clays

A comprehensive set of experimental data on Bangkok subsoils from oedometer and triaxial tests are analysed in this paper in order to determine the stiffness and strength parameters for Hardening Soil Model. The parameters determined are the Mohr–Coulomb effective stress strength parameters together with the stiffness parameters; tangent stiffness for primary oedometer loading, secant stiffness in undrained and drained triaxial tests, unloading/reloading stiffness and the power for stress level dependency of stiffness. The oedometer data are obtained from three different Bangkok soil layers: soft clay at 6–8 m depths; medium clay at 12–14 m depths; and stiff clay at 15.5–18 m depths. The triaxial tests data are carried out for soft and stiff clays at depths of 5.5–6 m and of 16–18 m under both undrained and drained conditions, respectively. Finally, two sets of parameters for soft and stiff Bangkok clays are numerically calibrated against undrained and drained triaxial results using PLAXIS finite element software.     

Enhancement of unconfined compressive strength of sand test pieces cemented with calcium phosphate compound by addition of various powders

To improve the unconfined compressive strength (UCS) of a novel chemical grout composed of a calcium phosphate compound (CPC-Chem), we performed UCS tests and scanning electron microscopy (SEM) observations on sand test pieces cemented with CPC-Chem and four kinds of powders (tricalcium phosphate, TCP; magnesium phosphate, MgP; calcium carbonate, CC and magnesium carbonate, MgC) as seed crystals. The UCS of the CPC-Chem test pieces cemented with TCP and CC was significantly greater than that of the test pieces with no added powders. The UCS of the test pieces with TCP and CC additives exceeded the targeted value of 100 kPa and increased to a maximum of 261.4 kPa and 209.7 kPa for the test pieces with TCP and CC additives, respectively. Furthermore, the UCS of test pieces with 1 wt% or 5 wt% TCP and 1 wt% CC additives was maintained at a level exceeding 200 kPa for 168 days. SEM observations revealed net-like and three-dimensional structures in segments of test pieces cemented with 1 wt% or 5 wt% TCP and 1 wt% CC in CPC-Chem, which could have been the reason of the long-term stability of UCS (over 200 kPa for 168 days) observed in this study. These results suggest that the addition of TCP and CC significantly enhances the ground improvement afforded by CPC-Chem.