Fabrication of ceramic bioscaffolds from fly ash cenosphere by susceptor-assisted microwave sintering

Cenospheres (CS) are ceramic hollow microspheres and have been used to prepare composite foams for applications such as medical implants. However, its potential standalone application in the biomedical field is not fully explored. Herein, a susceptor-assisted microwave (SMW) sintering approach was used for producing CS foam scaffolds. Owing to the hybrid heating mechanism offered by the SMW process, sintering of the low-dielectric cenospheres was realized. We found that sintering was initiated at a lower temperature (1100 °C) compared to conventional heating (1250 °C) as reported in the literature, probably due to the lower activation energy required by SMW sintering. The physical and compositional properties of the sintered CS specimens were examined, and in vitro studies were performed. The as-fabricated CS foam possessed minimal effect on cell viability. Cells migrated and adhered well within the pores of the specimens, which indicates the potential of the CS as scaffold materials for cell engineering applications.     

Composition and microstructure of alkali activated fly ash binder: Effect of the activator

The alkali activation of fly ashes is a chemical process by which the glassy component of these powdered materials is transformed into very well-compacted cement. In the present work the relationship between the mineralogical and microstructural characteristics of alkaline activated fly ash mortars (activated with NaOH, Na₂CO₃ and waterglass solutions) and its mechanical properties has been established. The results of the investigation show that in all cases (whatever the activator used) the main reaction product formed is an alkaline aluminosilicate gel, with low-ordered crystalline structure. This product is responsible for the excellent mechanical-cementitious properties of the activated fly ash. However the microstructure as well as the Si/Al and Na/Al ratios of the aluminosilicate gel change as a function of the activator type used in the system. As a secondary reaction product some zeolites are formed. The nature and composition of these zeolites also depend on the type of activator used.     

High-porosity mullite ceramic foams prepared by selective laser sintering using fly ash hollow spheres as raw materials

A novel method to prepare high-porosity mullite ceramic foams by selective laser sintering (SLS) using fly ash hollow spheres (FAHSs) as raw materials was reported. The complex-shaped FAHS green bodies and ceramic foams without delamination or cracks were prepared by SLS. The influence of sintering temperatures on linear shrinkage, phase composition, porosity and mechanical properties was investigated. With the increase of sintering temperature from 1250?°C to 1400?°C, the compressive strength of ceramic foams increased from 0.2?MPa to 6.7?MPa causing the fracture mechanism change from fracturing along FAHSs to across FAHSs, while the porosity of ceramic foams decreased from 88.7% to 79.9% which was higher than those of ceramic foams prepared by the conventional methods. The relatively high porosity of ceramic foams was resulted from the inner hollow structure of FAHSs, the interspaces between stacking FAHSs, and the gaps between FAHSs directly related to SLS. The results above indicated that the fabrication of high-porosity FAHS ceramic foams by SLS could achieve the advanced utilization of FAHS solid waste.     

A new way to increase the long-term bond strength of new-to-old concrete by the use of fly ash

The short-term and long-term bond strengths of new-to-old concrete were experimentally investigated with an emphasis on the influence of new concretes and binders. These new concretes included ordinary Portland cement concrete, expansive concrete and high-volume fly ash concrete, while the binders included pure cement paste (C-binder), expansive binder (E-binder) and fly ash mortar (F-binder). The results showed that the short-term bond strength of all specimens with fly ash concrete was lower than that with ordinary Portland cement concrete, which in turn was lower than that with expansive concrete. The bond strength of the specimens with F-binder was the lowest at the age of 7 days. However, the long-term bond strength of all specimens with added fly ash was the highest and strength losses were observed in the specimens repaired with expansive concrete or E-binder at the age of 3 years. The microstructure of the transition zone with F-binder was also studied by using both scanning electron microscopy (SEM) and energy dispersive spectroscopy (EDS) at the ages of 28 days and 1 year, respectively.     

Recycling of waste fly ash for production of porous mullite ceramic membrane supports with increased porosity

Low-cost porous mullite ceramic membrane supports were fabricated from recycling coal fly ash with addition of natural bauxite. V₂O₅ and AlF₃ were used as additives to cause the growth of mullite crystals with various morphologies via an in situ reaction sintering. Dynamic sintering, microstructure and phase evolution of the membrane supports were characterized in detail and open porosity, pore size, gas permeation and mechanical properties were determined. It showed the membrane support with 3 wt.% V₂O₅ and 4 wt.% AlF₃ addition exhibits an open porosity of ∼50%, mechanical strength of 69.8 ± 7.2 MPa, an interlocking microstructure composed of anisotropically grown mullite whiskers with an aspect ratio of 18.2 ± 3.6 at 1300 °C. Addition of more V₂O₅ lowered the secondary mullitization temperature, resulting in more mullite formation at lower temperatures. The fabricated membrane supports feature high porosity without mechanical strength degradation, possible strengthening mechanism of the mullite whiskers was further discussed.     

Variation in fly ash properties with milling and acid leaching

Coal-burning power plants that consume pulverized solid fuels produce large amounts of fly ash as a residue. Fly ashes have been used in construction, agriculture, metal recovery and water pollution control. This paper considers the variation in properties of fly ashes to be used in the field of construction.The fly ashes produced in two coal-burning power plants in Asturias (Spain) were physically and chemically characterized in order to determine their pozzolanic activity and reactivity. Fly ashes are used as hydraulically active additives as they are a finely divided inorganic material. They were examined to determine whether they could be used as special preservatives in cements and concretes. To improve their properties, they are mechanically activated by wet milling as well as chemically activated by leaching with 30% by weight sulfuric acid at different temperatures and times.     

Utilization of fly ash with silica fume and properties of Portland cement-fly ash-silica fume concrete

This paper reports the normal consistency, setting time, workability and compressive strength results of Portland cement-fly ash-silica fume systems. The results show that water requirement for normal consistency was found to increase with increasing SF content while a decrease in initial setting time was found. Workability, measured in term of slump, was found to decrease with silica fume content (compared to blends without silica fume). However, it must be noted that despite the reduction in the slump values, the workability of Portland cement-fly ash-silica fume concrete in most cases remained higher than that of the Portland cement control concrete. Furthermore, the utilization of silica fume with fly ash was found to increase the compressive strength of concrete at early ages (pre 28 days) up to 145% with the highest strength obtained when silica fume was used at 10 wt%. Moreover, scanning electron micrographs show that utilization of fly ash with silica fume resulted in a much denser microstructure, thereby leading to an increase in compressive strength.     

Fly ash effects: I. The morphological effect of fly ash

The morphological effect is an important part of fly ash effects. The paper analyzes emphatically this effect and points out that it is composed of the filling role, surface role and lubricating role. For different fly ash, these roles are different. They must be considered synthetically when the morphological effect is analyzed. Analyzing result shows that the filling role is relative to the particle size, the surface role is relative to the specific surface area and the water affinity and the lubricating role is relative to the shape of particle. The morphological effect of fly ash is the synthetical embodiment of these roles.     

Fabrication and characterization of porous cordierite ceramics prepared from fly ash and natural minerals

Low cost, single-phase porous cordierite ceramics are successfully synthesized by in-situ solid-state reactions from fly ash, quartz, and magnesite. The effects of sintering temperature and magnesite content on phase transformation, open porosity, bulk density, mechanical properties, and microstructure are carefully investigated. Factsage analyses are carried out to calculate the isopleth diagrams, and the results agree well with the experimental outcomes. Thermal gravimetric and differential scanning calorimeter analyses (TG-DSC) are performed to characterize the weight loss and transient behaviors of the raw materials. Linear thermal expansion properties are also studied. The α-cordierite phase is the only phase observed in S-3 (magnesite content 25%) sintered at 1300 °C for 2 h, and its linear thermal expansion coefficient (2.71 × 10⁻⁶ K⁻¹) is close to that of typical cordierite. Both the compressive strength (72.64 MPa) and flexural strength (23.92 MPa) of the as-synthesized samples are high with an open porosity of 33.16% and a bulk density of 1.61 g/cm³.     

Effect of porous structure and surface functionality on the mercury capacity of a fly ash carbon and its activated sample

The effect of porous structure and surface functionality on the mercury capacity of a fly ash carbon and its activated sample has been investigated. The samples were tested for mercury adsorption using a fixed‐bed with a simulated flue gas. The activated fly ash carbon sample has lower mercury capacity than its precursor fly ash carbon (0.23 vs. 1.85 mg/g), although its surface area is around 15 times larger, 863 vs. 53 m²/g. It was found that oxygen functionality and the presence of halogen species on the surface of fly ash carbons may promote mercury adsorption, while the surface area does not seem to have a significant effect on their mercury capacity.     

Use of zeolite, coal bottom ash and fly ash as replacement materials in cement production

In this research, the effects of zeolite, coal bottom ash and fly ash as Portland cement replacement materials on the properties of cement are investigated through three different combinations of tests. These materials are substituted for Portland cement in different proportions, and physical properties such as setting time, volume expansion, compressive strength and water consistency of the mortar are determined. Then, these physical properties are compared with those of PC 42.5. The results showed that replacement materials have some effects on the mechanical properties of the cement. The inclusion of zeolite up to the level of 15% resulted in an increase in compressive strength at early ages, but resulted in a decrease in compressive strength when used in combination with fly ash. Also, setting time was decreased when zeolite was substituted. The results obtained were compared with Turkish Standards (TS), and it was found that they are above the minimum requirements.     

Fly ash effects: III. The microaggregate effect of fly ash

In this paper, the microaggregate effect of fly ash is studied systematically by micromechanics, the hypothesis of center particle and pore size distribution. It is pointed out that the microaggregate effect is an important effect of fly ash. It is strengthened with the increase of content of fly ash, but weakened with age. At early age, fly ash cannot fine the pore structure. At late age, fly ash may fine the pore structure. However, in general, the fining role is only a relative fining role.     

An experimental study on strength development of concrete containing fly ash and optimum usage of fly ash in concrete

This paper presents a laboratory study on the strength development of concrete containing fly ash and optimum use of fly ash in concrete. Fly ash was added according to the partial replacement method in mixtures. A total of 28 mixtures with different mix designs were prepared. 4 of them were prepared as control mixtures with 250, 300, 350, and 400 kg/m³ cement content in order to calculate the Bolomey and Feret coefficients (K_B, K_F). Four groups of mixtures were prepared, each group containing six mix designs and using the cement content of one of the control mixture as the base for the mix design. In each group 20% of the cement content of the control mixture was removed, resulting in starting mixtures with 200, 240, 280, and 320 kg/m³ cement content. Fly ash in the amount of approximately 15%, 25%, 33%, 42%, 50%, and 58% of the rest of the cement content was added as partial cement replacement. All specimens were moist cured for 28 and 180 days before compressive strength testing. The efficiency and the maximum content of fly ash that gives the maximum compressive strength were obtained by using Bolomey and Feret strength equations. Hence, the maximum amount of usable fly ash amount with the optimum efficiency was determined.This study showed that strength increases with increasing amount of fly ash up to an optimum value, beyond which strength starts to decrease with further addition of fly ash. The optimum value of fly ash for the four test groups is about 40% of cement. Fly ash/cement ratio is an important factor determining the efficiency of fly ash.     

Geopolymeric materials prepared using Class F fly ash and elevated temperature curing

This paper reports the results of the study of the influence of elevated temperature curing on phase composition, microstructure and strength development in geopolymer materials prepared using Class F fly ash and sodium silicate and sodium hydroxide solutions. In particular, the effect of storage at room temperature before the application of heat on strength development and phase composition was studied. X-ray diffraction (XRD), Fourier transform infrared spectroscopy (FTIR) and SEM were utilised in this study.Long precuring at room temperature before application of heat was beneficial for strength development in all studied materials, as strength comparable to 1 month of curing at elevated temperature can develop in this case only after 24 h of heat curing. The main product of reaction in the geopolymeric materials was amorphous alkali aluminosilicate gel. However, in the case of sodium hydroxide activator in addition to it, traces of chabazite, Linde Type A, Na-P1 (gismondine) zeolites and hydroxysodalite were also present. The type of zeolite present and composition of aluminosilicate gel were dependent on the curing history.     

The leachability of heavy metals in hardened fly ash cement and cement-solidified fly ash

The effect of mix proportion, leachant pH, curing age, carbonation and specimen making method etc. on the leaching of heavy metals and Cr(VI) in fly ash cement mortars and cement-solidified fly ashes has been investigated. In addition, a method for reducing the leaching of Cr(VI) from cement-solidified fly ashes is proposed. The results mainly indicate that: (1) either Portland cement or fly ash contains a certain amount of heavy and toxic metals, and the leaching of them from hardened fly ash incorporated specimens exists and is increased with fly ash addition and water to cement ratio; (2) the leachability of some heavy metals is greatly dependent on leachant pH; (3) when carbonation of cement mortars occurs the leaching of chromium ions is increased; (4) the amount of heavy metals leached from cement-solidified fly ashes depends more on the kind of fly ash than their contents in fly ash; and (5) with ground granulated blast furnace slag addition, the leaching of Cr(VI) from solidified fly ashes is decreased.     

Triboelectrostatic separation of fly ash and charge reversal

Triboelectrostatic separation has been investigated as a method for separating unburned carbon from coal combustion fly ash. It was found that when a fly ash is exposed to moisture before it undergoes separation, the charging properties of the components of the fly ash change significantly. The mineral and carbon components of the fly ash appear to charge oppositely to how they were charged before exposure to moisture. A correlation was found between the degree of charge reversal and the relative amounts of leachable ions, especially calcium and sodium ions, present on the surface of the ash.     

Enhanced mechanical properties of wood ash and fly ash as supplementary cementitious materials

The incorporation of fly ash (FA) and wood ash (WA) in concrete as supplementary cementitious materials (SCM) was studied. The chemical composition of ordinary Portland cement, FA and WA was determined according to ASTM C-114. SEM and optical microscopy were used for the analysis of concrete. Setting time, compressive strength, water absorption and acid resistance of the concrete with different percentages of SCM ranging from 0 to 60% were evaluated. The results obtained showed that setting time and rate of water absorption increased with the increase in percentage of SCM. After 7 and 28 days, the compressive strength of concrete with 20% FA as SCM was higher than that with substitution with 20% WA. Resistance of concrete against sulphate attack increased with an increase in the percentage of FA. It was found that incorporating more than 20% WA resulted in a decrease in sulphate attack resistance.     

Mineralogy and geochemistry of Greek and Chinese coal fly ash

In this paper the mineralogy and geochemistry of Greek and Chinese coal fly ash are examined. Annual production of fly ash in China is around 160 Mt while in Greece lignite fly ash accounts around 10 Mt. Even though the mineralogical and chemical composition of the fly ashes coming from these two countries differs, there are common questions on the utilization of this material. The variation of the Greek fly ash’ chemical composition, from Ca-poor to Ca-rich fly ash, has resulted to applications such as dam construction, use in cement and possibly in concrete and road construction. The Chinese fly ash, which is rich in mullite, is broadly applied for brick making.     

Biomass fly ash in concrete: Mixture proportioning and mechanical properties

ASTM C 618 prohibits use of biomass fly ashes in concrete. This document compares the properties of biomass fly ashes from cofired (herbaceous with coal), pure wood combustion and blended (pure wood fly ash blended with coal fly ash) to those of coal fly ash in concrete. The results illustrate that with 25% replacement (wt%) of cement by fly ash, the compressive strength (one day to one year) and the flexure strength (at 56th day curing) of cofired and blended biomass fly ash concrete is statistically equal to that of two coal fly ash concrete in this investigation (at 95% confidence interval). This implies that biomass fly ash with co-firing concentration within the concentration interest to commercial coal-biomass co-firing operations at power plants and blended biomass fly ash within a certain blending ratio should be considered in concrete.