Manufacture of artificial aggregate using MSWI bottom ash

Recycling of Contaminated Marine Sediment and Industrial By-Products through Combined Stabilization/Solidification and Granulation Treatment

Stabilization/solidification (S/S) is becoming increasingly important, as it allows the remediation of contaminated sediments and their recovery into materials for civil engineering. This research proposes a cement-free cold granulation process for manufactured low-cost aggregates from marine sediments contaminated with organic compounds and metals. After the chemo-physical characterization of the study materials, two mix designs were prepared in a rotary plate granulator by adding two industrial by-products as geopolymer precursors, coal fly ash (CFA) and Blast Furnace Slag (BFS), but also alkaline activation solutions, water, and a fluidizer. The results indicated that sediments treated with mix 1 (i.e., with a higher percentage of water and fluidifier) represent the optimal solution in terms of metal leachability. The metal leachability was strictly influenced by aggregates' porosity, density, and microstructure. The technical performance (such as the aggregate impact value > 30%) suggested the use of granules as lightweight aggregates for pavement construction. The results indicated that cold granulation represents a sustainable solution to recycling contaminated marine sediments, CFA, and BFS into lightweight artificial aggregates.

Effect of alkaline washing treatment on leaching behavior of municipal solid waste incineration bottom ash

This study aimed to find an effective, inexpensive, and safe washing treatment for municipal solid waste incineration bottom ash (MSWIBA) in order to reduce its potential harmful effects in disposal and recycling. The washing solutions, namely tap water (TW), saturated lime water (SLW), and wastewater from concrete batching plant (WW) were used to wash MSWIBA at different liquid-solid (L/S) ratios and for different durations. Leaching behavior of some heavy metals, chloride, and sulfate from MSWIBA was tested and evaluated. From the TCLP leaching test, when the L/S ratio was above 5, WW was the most effective solution in reducing As, Cd, Se, and Sb emissions from MSWIBA. The calcium and iron ions present in the WW were essential for controlling the leaching of As, Cd, and Sb from MSWIBA due to the formation of stable crystalline pharmacosiderite, cadmium hydroxide sulfate, and hydromeite during the washing process. Using WW showed the best effect in removing sulfate from MSWIBA. At a L/S ratio of 10, about 83% of the sulfate could be removed from MSWIBA after 20 min of washing. The L/S ratio was most influential in removing chloride from MSWIBA. The three washing treatments chosen were effective in reducing the chloride level in MSWIBA to below the level of hazardous waste. Nevertheless, there were still substantial amounts of chloride remaining in the treated MSWIBA. Under the Dutch Building Materials Decree, the treated MSWIBA may be used as a building material in parts which allow isolation, control, and monitoring (ICM).

Resource utilization of municipal solid waste incineration fly ash - cement and alkali-activated cementitious materials: A review

The increase in municipal solid waste (MSW) production has led to an increase in MSW incineration fly ash (MSWIFA) production. MSWIFA contains toxic and harmful substances such as heavy metals and dioxins, which can cause harm to the environment if not treated properly. Only a few MSWIFAs will be landfilled directly, and the rest will need to be treated by other methods. The treatment of MSWIFA can be divided into three types: separation, stabilization/solidification (S/S), and thermal treatment, which are either not fully developed or too costly. Resource utilization is a sustainable means of treating MSWIFA. MSWIFA is used in the production of cement and alkali-activated cementitious materials as a means of resource utilization with significant advantages. This can alleviate the consumption of nature and reduce greenhouse gas emissions in conventional cement production. Compared with MSWIFA cement, MSWIFA alkali-activated cementitious material can be achieved with almost no consumption of natural resources, which is worthy of further research to realize the large-scale application of MSWIFA. At the end of the paper, the perspective of separation of dioxins from MSWIFA, co-processing of MSWI ash, and production of "MSWIFA green materials" is presented.

Review of alternative ash aggregates in concrete-solution towards waste management and environmental protection

Owing to the depletion of natural resources, new alternative materials are emerging in construction industry. Especially, development of alternative binders and aggregates using industrial by-products paves way for the development of eco-friendly concrete. As aggregates occupy about 60-70% of the volume of concrete, new alternative materials developed as a substitute for aggregates are considered as need of the day for achieving sustainability in concrete industry. In the past few decades, many industrial by-products are researched as an alternative for natural aggregates. Ash being the largely produced by-products from different industries, it has huge potential in the development of artificial aggregates. Nevertheless, ashes produced from different sources such as coal, municipal solid waste and biomass have different characteristics and affect the properties of aggregates made out of them. The volume of research works reported on development of ash aggregates all over the globe shows that there is a faster growth rate in the development of alternative aggregates and its utilization in concrete. In this context, the current study aims to review the literature reported on mortar/concrete made of ash aggregates from various sources such as thermal power stations, biomass and municipal solid waste incinerator. The characteristics of different types of ash, development of aggregate and its properties in mortar/concrete are reviewed. Based on the review, future recommendations and directions are provided to utilize more of ash aggregates in the place of natural aggregates to prevent depletion of natural resources.

Properties of Cold-Bonded and Sintered Aggregate Using Washing Aggregate Sludge and Their Incorporation in Concrete: A Promising Material

The aggregate makes up about 65–75% of the total volume of concrete and the use of artificial aggregates manufactured from waste and by-product materials, as an alternative to natural aggregate, has attracted considerable research interest. Washing aggregate sludge (WAS) is obtained as a waste during the process of washing the aggregates, which is disposed or used as landfill. The utilization of WAS as a major component to manufacture artificial aggregates remains unexplored. Therefore, the focus has been directed towards the production of cold-bonded and sintered aggregates using WAS and their incorporation in concrete. The fresh pellets were manufactured using WAS, ground granulated blast furnace slag (GGBFS) and ordinary Portland cement (OPC) and kept in the laboratory conditions at 20 ± 2 °C and 95 ± 5% relative humidity to obtain cold-bonded aggregates, whereas WAS and GGBFS were utilized to manufacture sintered aggregate by heating the fresh pellets up to 1150 °C. The manufactured aggregate properties were characterized through physical, mechanical, chemical, and microstructural analysis. Concrete specimens were also produced by introducing the artificial aggregates in replacement with the coarse aggregate. The results showed that the concrete containing artificial aggregates can be produced with lower oven-dry density and comparable mechanical properties to efficiently utilize WAS.

Influence of Waste Fly Ash on the Rheological Properties of Fresh Cement Paste and the Following Electrical Performances and Mechanical Strengths of Hardened Specimens

Waste fly ash (WFA) is a kind of solid waste without reasonable disposition. The WFA with active substance can promote the cement hydration, therefore, WFA may enhance the mechanical strengths of cement-based materials. In this paper, the rheological properties (slump flow and plastic viscosity) of fresh cement paste with WFA ranging from 0% to 25% by mass ratio of cement were studied. The alternating current (AC) electrical resistance and direct current (DC) resistance time curves were determined. The AC impedance spectroscopy curves of the specimens cured for 1 day and 28 days were obtained. Finally, the mechanical strengths of hardened cement paste cured for 1 day, 3 days, 7 days, and 28 days were tested. The results showed that the slump flow was decreased and the plastic viscosity was increased by the addition of WFA and the increasing curing time. The AC electrical resistance increased in the form of the quadratic function with the cuing age. Meanwhile, the addition of WFA demonstrated an enhancing effect on the electrical conduction of cement paste. The variation rate of DC electrical resistance during the testing time increased with the increasing dosages of WFA and the curing age. The mechanical strengths increased with the addition of curing time and the content of WFA. The increasing rate of mechanical strengths increased with the addition of WFA (0~15%) and decreased with curing time. However, when the dosage of WFA increased from 15% to 25%, the increasing rate decreased.

Exploring the Potential for Utilization of Medium and Highly Sulfidic Mine Tailings in Construction Materials: A Review

Medium and highly sulfidic tailings are high-volume wastes that can lead to severe environmental damage if not properly managed. Due to the high content of sulfide minerals, these tailings can undergo weathering if put in contact with oxygen and water, generating acid mine drainage (AMD). The moderate-to-high sulfide content is also an important technical limitation for their implementation in the production of construction materials. This paper reviews the use of sulfidic tailings as raw material in construction products, with a focus on cement, concrete, and ceramics. When used as aggregates in concrete, this can lead to concrete degradation by internal sulfate attack. In building ceramics, their implementation without prior treatment is undesirable due to the formation of black reduction core, efflorescence, SOx emissions, and their associated costs. Moreover, their intrinsic low reactivity represents a barrier for their use as supplementary cementitious materials (SCMs) and as precursors for alkali-activated materials (AAMs). Nevertheless, the production of calcium sulfoaluminate (CSA) cement can be a suitable path for the valorization of medium and highly sulfidic tailings. Otherwise difficult to upcycle, sulfidic tailings could be used in the clinker raw meal as an alternative raw material. Not only the SO3 and SiO2-rich bulk material is incorporated into reactive clinker phases, but also some minor constituents in the tailings may contribute to the production of such low-CO2 cements at lower temperatures. Nevertheless, this valorization route remains poorly explored and demands further research.

Applying Mixture of Municipal Incinerator Bottom Ash and Sewage Sludge Ash for Ceramic Tile Manufacturing

Municipal incinerator bottom ash (MIBA) and sewage sludge ash (SSA) are secondary wastes produced from municipal incinerators. Landfills, disposal at sea, and agricultural use have been the major outlets for these secondary wastes. As global emphasis on sustainability arises, many have called for an increasing reuse of waste materials as valuable resources. In this study, MIBA and SSA were mixed with clay for ceramic tile manufacturing in this study. Raw materials firstly went through TCLP (Toxicity Characteristic Leaching Procedure) to ensure their feasibility for reuse. From scanning electron microscopy (SEM), clay’s smooth surface was contrasted with the porous surface of MIBA and SSA, which led to a higher water requirement for the mixing. Specimens with five MIBA mix percentages of 0%, 5%, 10%, 15%, and 20% (wt) and three SSA mix percentages of 0%, 10%, and 20% (wt) were made to compare how the two waste materials affected the quality of the final product and to what extent. Shrinkage tests showed that MIBA and SSA contributed oppositely to tile shrinkage, as more MIBA reduced tile shrinkage, while more SSA encouraged tile shrinkage. However, as the kiln temperature reached 1150 °C, the SiO2-rich SSA adversely reduced the shrinkage due to the glass phase that formed to expand the tile instead. Both MIBA and SSA increased water tile absorption and reduced its bending strength and wear resistance. Increasing the kiln temperature could effectively improve the water absorption, bending strength, and wear resistance of high MIBA and SSA mixes, as SEM showed a more compact structure at higher temperatures. However, when the temperature reached 1100 °C, more pores appeared and seemingly exhausted the benefit brought by the higher temperature. Complex interactions between kiln temperature and MIBA/SSA mix percentage bring unpredictable performance of tile shrinkage, bending strength, and water absorption, which makes it very challenging to create a sample meeting all the specification requirements. We conclude that a mix with up to 20% of SSA and 5% of MIBA could result in quality tiles meeting the requirements for interior or exterior flooring applications when the kiln temperature is carefully controlled.

A Review on Cementitious Materials Including Municipal Solid Waste Incineration Bottom Ash (MSWI-BA) as Aggregates

Waste management is a vital environmental issue in the world today. Municipal solid wastes (MSWs) are discarded in huge quantities on a daily basis and need to be well controlled. Incineration is a common method for reducing the volume of these wastes, yet it produces ashes that require further assessment. Municipal solid waste incineration bottom ash (MSWI-BA) is the bulk byproduct of the incineration process and has the potential to be used in the construction sector. This paper offers a review of the use of MSWI-BA as aggregates in cementitious materials. With the growing demand of aggregates in cementitious materials, MSWI-BA is considered for use as a partial or full alternative. Although the physical and chemical properties of MSWI-BA are different than those of natural aggregates (NA) in terms of water absorption, density, and fineness, they can be treated by various methods to ensure suitable quality for construction purposes. These treatment methods are classified into thermal treatment, solidification and stabilization, and separation processes, where this review focuses on the techniques that reduce deficiencies limiting the use of MSWI-BA as aggregates in different ways. When replacing NA in cementitious materials, MSWI-BA causes a decrease in workability, density, and strength. Moreover, they cause an increase in water absorption, air porosity, and drying shrinkage. In general, the practicality of using MSWI-BA in cementitious materials is mainly influenced by its treatment method and the replacement level, and it is concluded that further research, especially on durability, is required before MSWI-BA can be efficiently used in the production of sustainable cementitious materials.

Preparation and Physico-Chemical Performance Optimization of Sintering-Free Lightweight Aggregates with High Proportions of Red Mud

Sintering-free lightweight aggregates were prepared with high proportions of red mud and a binder material derived from whole solid wastes through rolling granulation at room temperature. The preparation process was optimized by changing the material matching and size parameters of the SFLAs. The physico-chemical performance, including the density, mechanical strength, water absorption, hydration products, heavy metal leaching, and microstructure were evaluated by jointly employing X-ray Fluorescence, X-ray Diffraction, and Inductively Coupled Plasma Optical Emission Spectrometry, Shadow Electron Microscope, etc. The results indicated that the red mud and waste-based binders were highly compatible in the granulation process, with up to 80% red mud being successfully added. The sintering-free lightweight aggregates products at the binder content of 30% and the size coverage of 10-16 mm exhibited a bulk density of 900-1000 kg·m-3, a 28 d cylinder compressive strength of 9.2-11.3 MPa, and water absorption of less than 10%. Owing to the formation of important hydration products, ettringite, the heavy metal leaching of the sintering-free lightweight aggregates was also proven to be environmentally acceptable. This work provides a promising pathway to prepare low-cost, high-strength, and green lightweight aggregates through the large-scale utilization of solid waste red mud.

The Production of Sustainable Concrete with the Use of Alternative Aggregates: A Review

The concrete industry is a core element of the building sector, but it has to deal with the increasing attention on the environmental issues related to the production process: increasing energy efficiency and the adoption of alternative fuels or raw materials represent the most relevant solutions. The present work analyses physical, mechanical, and environmental performances of concrete incorporating residues derived from four main sources (construction and demolition waste, residues from waste treatment, metallurgical industry by-products, and others), as substitutes of either fine or coarse aggregates. Fine aggregates showed the highest number of alternatives and replacement level, with the relevant impact on concrete properties; coarse aggregates, however, always reach a complete replacement, with the exclusion of glass that highly affects the mechanical performance. Construction and metallurgical industry categories are the main sources of alternative materials for both the components, with ceramic and lead slag reaching a full replacement for fine and coarse aggregates.

Recycling municipal solid waste incineration slag and fly ash as precursors in low-range alkaline cements

Application of municipal solid waste incineration (MSWI) products - fly ash (MSW-FA) and bottom ash (MSW-BA), is increasingly popular, mostly due to the need to reintroduce it in the industrial chain, but also because its technical performance is constantly enhanced by a growing research effort. This paper deals with the less popular application of these wastes without the addition of a more competent precursor. Several pastes based on MSW-FA, MSW-BA or MSW-FA+MSW-BA were prepared, using sodium silicate or sodium hydroxide. Their overall performance was then assessed through mechanical (uniaxial compressive strength - UCS and seismic wave velocity), environmental (leaching) and durability tests (freeze-thaw and wetting-drying). Cement stabilised MSW-BA pastes were also tested, for reference. Results showed that a preliminary mechanical activation, achieved by milling, is fundamental; the activation with silicate is more effective than with hydroxide, especially in the case of the MSW-BA pastes, when the UCS values are more than triplicated (3-10 MPa); the MSW-BA is a more competent precursor than the MSW-FA and the durability and leachability of the alkali activated pastes is similar to that obtained with cement. The most performing paste, in terms of UCS, was obtained with BA activated exclusively with sodium silicate, with an activator/precursor weight ratio of 0.5. In general, the low-cost solidification/stabilisation proposed in this study showed competitive with the alternative use of up to 30% cement and should be regarded as a valid alternative for simple storage or low-range applications, in substitution of Portland cement.

Comparison of the processing conditions and the properties of granules made from fly ash of lignite and coal

The article presents the results pertaining to granulation of two types of fly ash from (1) coal (hard coal) incineration and (2) lignite (brown coal) combustion. The physical, chemical and mechanical properties of granules were compared to obtain the good quality of aggregates. Three types of binders were added to the ash blends: hydrated lime, Portland cement and phosphogypsum. The experimental technological line was used for pelletizing the fine mixtures; then, the obtained granules were tested immediately after their manufacturing (in fresh state) as well as after curing. The addition of binder improved their mechanical properties. Granulation of powders regimented with strictly defined shares of grains fraction. The axial compression test was conducted to find the best toughness, with consideration of the curing time of granules. Granules in the diameter of 15-18 mm were obtained using a disc granulator. The comparison revealed that the granulation of coal fly ash was more effective because of the processing conditions, and the obtained bodies were characterized by better mechanical properties then those made of the lignite fly ash.

Compositional modelling and crushing behaviour of MSWI bottom ash material classes

At present, in Europe, 18 million tonnes of MSWI Bottom Ash (BA) is annually stockpiled or used in low-grade applications (e.g. in road bases). Therefore, alternative applications, such as aggregate or as a cement component in concrete, are stimulated. Physical and chemical characteristics remaining after treatment, however, prevent its extensive application in building materials. Hence, knowledge is needed on the distinct properties of the material classes making up a heterogeneous BA, enabling the assessment of its characteristics and the resulting applicability. Furthermore, a user-friendly composition assessment procedure is necessary to evaluate the output of physical treatment processes. Crushing is a commonly applied treatment and its effect on the material classes comprising BA is still unknown. In this paper, the latter are identified and classified into slag, magnetic slag, glass, refractory, metals, and unburned material classes. The individual characteristics of each material class are identified and a suitable tracer for tracking these classes in heterogeneous samples is defined. Furthermore, a fast method to quantify the distribution of material classes based just on the oxide composition is developed and applied to approximate the changes in the configuration of BA through crushing. It is concluded that, although the jaw crushing of BA results in a more homogeneous distribution, beneficiation of material classes occurs and selective crushing is possible in order to improve the quality of the BA and therefore its subsequent application.

Effect of sintering temperature on mineral composition and heavy metals mobility in tailings bricks

In this study, the mixing mechanism and phase transition process of different metals during the sintering of tailings bricks with four different metal oxides (CuO, PbO, ZnO, and CdO) at temperatures ranging from 700 to 1100 °C for 2 h were investigated. The properties of the sintered product was characterized and analyzed, and the results showed that the main crystalline phases are quartz, cristobalite, hematite, and mullite while the metal oxides are ascribed to copper ferrite spinel (CuFe₂O₄), gahnite (ZnAl₂O₄), zinc ferrite spinel (ZnFe₂O₄), lead feldspar (PbAl₂Si₂O₈), and cadmium feldspar (CdAl₂Si₂O₈). Further analysis indicates that the heavy metals were transited into spinel or silicate structures with favorable efficiency. This indicates a good heavy-metal fixation effect from the structural change after the sintering process. Finally, the leaching experiments of the sintered samples suggest that the metal leaching decreased to a low and stable value when the sintering temperature was higher than 950 °C, which meets the China standard (GB 5085.3-2007). The above results indicate that the sintering process facilitates the combination of Cu, Zn, Pb and Cd offering an effective and safe method for the application of materials that contain tailings.

Binders alternative to Portland cement and waste management for sustainable construction - Part 2

The paper represents the "state of the art" on sustainability in construction materials. In Part 1 of the paper, issues related to production, microstructures, chemical nature, engineering properties, and durability of mixtures based on binders alternative to Portland cement were presented. This second part of the paper concerns the use of traditional and innovative Portland-free lime-based mortars in the conservation of cultural heritage, and the recycling and management of wastes to reduce consumption of natural resources in the production of construction materials. The latter is one of the main concerns in terms of sustainability since nowadays more than 75% of wastes are disposed of in landfills.

Life cycle assessment of recycled concretes: A case study in southern Italy

Concrete industry is responsible of the most significant contribution to the global warming due to the large amount of substances with environmental impacts produced during its entire life cycle (production process, construction, maintenance, dismantlement, and scrapping). The most important issue characterizing the concrete industry is related to the constant growth of consumption of natural aggregates. The purpose of the present research is to apply the standard protocol of life cycle assessment to 3 different concrete mixtures composed by wastes from construction and demolition (C&D), marble sludge and cement kiln dust (CDK) in order to compare the environmental and energy impacts. The main purpose is to analyze the potentials (capabilities/benefits) of recycled aggregate concrete. The proposed model analyses 37 recovery possible scenarios. The results were analyzed with the software SimaPro© and with the life cycle impact assessment method Eco Indicator 99. The results show how it is possible to decide for the optimal solution in order to reduce emissions and impacts due to the concrete production.

The Use of Municipal Solid Waste Incineration Ash in Various Building Materials: A Belgian Point of View

Huge amounts of waste are being generated, and even though the incineration process reduces the mass and volume of waste to a large extent, massive amounts of residues still remain. On average, out of 1.3 billion tons of municipal solid wastes generated per year, around 130 and 2.1 million tons are incinerated in the world and in Belgium, respectively. Around 400 kT of bottom ash residues are generated in Flanders, out of which only 102 kT are utilized here, and the rest is exported or landfilled due to non-conformity to environmental regulations. Landfilling makes the valuable resources in the residues unavailable and results in more primary raw materials being used, increasing mining and related hazards. Identifying and employing the right pre-treatment technique for the highest value application is the key to attaining a circular economy. We reviewed the present pre-treatment and utilization scenarios in Belgium, and the advancements in research around the world for realization of maximum utilization are reported in this paper. Uses of the material in the cement industry as a binder and cement raw meal replacement are identified as possible effective utilization options for large quantities of bottom ash. Pre-treatment techniques that could facilitate this use are also discussed. With all the research evidence available, there is now a need for combined efforts from incineration and the cement industry for technical and economic optimization of the process flow.

Effects of Wastes from the Brewing Industry in Lightweight Aggregates Manufactured with Clay for Green Roofs

This study investigates the effects of sieved wastes generated from the brewing industry on lightweight aggregates manufactured with clay. Sludge from a wastewater treatment plant, bagasse and diatomaceous earth were used to obtain the samples. These wastes are usually dumped in landfills, but the current increase in restrictions on dumping and interest in improving the environment make our proposal for gaining value from these wastes a significant contribution. Laboratory tests show that the new aggregate has low bulk density and increased water absorption and porosity. The thermographic camera results provide evidence that new aggregates have significant insulating properties and are suitable for use on green roofs.

Integral recycling of municipal solid waste incineration (MSWI) bottom ash fines (0-2mm) and industrial powder wastes by cold-bonding pelletization

The cold-bonding pelletizing technique is applied in this study as an integrated method to recycle municipal solid waste incineration (MSWI) bottom ash fines (BAF, 0-2mm) and several other industrial powder wastes. Artificial lightweight aggregates are produced successfully based on the combination of these solid wastes, and the properties of these artificial aggregates are investigated and then compared with others' results reported in literature. Additionally, methods for improving the aggregate properties are suggested, and the corresponding experimental results show that increasing the BAF amount, higher binder content and addition of polypropylene fibres can improve the pellet properties (bulk density, crushing resistance, etc.). The mechanisms regarding to the improvement of the pellet properties are discussed. Furthermore, the leaching behaviours of contaminants from the produced aggregates are investigated and compared with Dutch environmental legislation. The application of these produced artificial lightweight aggregates are proposed according to their properties.

Solidification/stabilization of fly ash from city refuse incinerator facility and heavy metal sludge with cement additives

Solidification and stabilization are well-known technologies used for treating hazardous waste. These technologies that use cementitious binder have been applied for decades as a final treatment procedure prior to the hazardous waste disposal. In the present work, hazardous waste like fly ash containing high concentrations of heavy metals such Zn (4715.56 mg/kg), Pb (1300.56 mg/kg), and Cu (534.72 mg/kg) and amounts of Ag, Cd, Co, Cr, Mn, and Ni was sampled from a city refuse incinerator facility. This fly ash was utilized in the solidification/stabilization of heavy metal sludge since fly ash has cement-like characteristics. Cement additives such as sodium sulfate, sodium carbonate, and ethylenediaminetetraacetic acid (EDTA) was incorporated to the solidified matrix in order to determine its effect on the solidification/stabilization performance. The solidified matrix was cured for 7, 14, 21, and 28 days prior for its physical and chemical characterizations. The results show that the solidified matrix containing 40% fly ash and 60% cement with heavy metal sludge was the formulation that has the highest fly ash content with a satisfactory strength. The solidified matrix was also able to immobilize the heavy metals both found in the fly ash and sludge based on the toxicity characteristic leaching procedure (TCLP) test. It also shows that the incorporation of sodium carbonate into the solidified matrix not only further improved the compressive strength from 0.36 MPa (without Na₂CO₃) to 0.54 MPa (with Na₂CO₃) but also increased its leaching resistance.

High performance of treated and washed MSWI bottom ash granulates as natural aggregate replacement within earth-moist concrete

Municipal solid waste incineration bottom ash was treated with specially designed dry and wet treatment processes, obtaining high quality bottom ash granulate fractions (BGF) suitable for up to 100% replacement of natural gravel in concrete. The wet treatment (using only water for separating and washing) significantly lowers the leaching of e.g. chloride and sulfate, heavy metals (antimony, molybdenum and copper) and dissolved organic carbon (DOC). Two potential bottom ash granulate fractions, both in compliance with the standard EN 12620 (aggregates for concrete), were added into earth-moist concrete mixtures. The fresh and hardened concrete physical performances (e.g. workability, strength and freeze-thaw) of high strength concrete mixtures were maintained or improved compared with the reference mixtures, even after replacing up to 100% of the initial natural gravel. Final element leaching of monolithic and crushed granular state BGF containing concretes, showed no differences with the gravel references. Leaching of all mixtures did not exceed the limit values set by the Dutch Soil Quality Degree. In addition, multiple-life-phase emission (pH static test) for the critical elements of input bottom ash, bottom ash granulate (BGF) and crushed BGF containing concrete were assessed. Simulation pH lowering or potential carbonation processes indicated that metal (antimony, barium, chrome and copper) and sulfate element leaching behavior are mainly pH dominated and controlled, although differ in mechanism and related mineral abundance.

LCA of management strategies for RDF incineration and gasification bottom ash based on experimental leaching data

The main characteristics and environmental properties of the bottom ash (BA) generated from thermal treatment of waste may vary significantly depending on the type of waste and thermal technology employed. Thus, to ensure that the strategies selected for the management of these residues do not cause adverse environmental impacts, the specific properties of BA, in particular its leaching behavior, should be taken into account. This study focuses on the evaluation of potential environmental impacts associated with two different management options for BA from thermal treatment of Refuse Derived Fuel (RDF): landfilling and recycling as a filler for road sub bases. Two types of thermal treatment were considered: incineration and gasification. Potential environmental impacts were evaluated by life-cycle assessment (LCA) using the EASETECH model. Both non-toxicity related impact categories (i.e. global warming and mineral abiotic resource depletion) and toxic impact categories (i.e. human toxicity and ecotoxicity) were assessed. The system boundaries included BA transport from the incineration/gasification plants to the landfills and road construction sites, leaching of potentially toxic metals from the BA, the avoided extraction, crushing, transport and leaching of virgin raw materials for the road scenarios, and material and energy consumption for the construction of the landfills. To provide a quantitative assessment of the leaching properties of the two types of BA, experimental leaching data were used to estimate the potential release from each of the two types of residues. Specific attention was placed on the sensitivity of leaching properties and the determination of emissions by leaching, including: leaching data selection, material properties and assumptions related to emission modeling. The LCA results showed that for both types of BA, landfilling was associated with the highest environmental impacts in the non-toxicity related categories. For the toxicity related categories, the two types of residues behaved differently. For incineration BA the contribution of metal leaching to the total impacts had a dominant role, with the highest environmental loads resulting for the road scenario. For the gasification BA, the opposite result was obtained, due to the lower release of contaminants observed for this material compared to incineration BA. Based on the results of this study, it may be concluded that, depending on the type of BA considered, its leaching behavior may significantly affect the results of a LCA regarding its management strategies.

Use of leaching tests to quantify trace element release from waste to energy bottom ash amended pavements

A series of roadway tests strips were paved on-site at a landfill in Florida, U.S. Waste to energy (WTE) bottom ash was used as a partial course aggregate replacement in a hot mix asphalt (HMA) and a Portland cement concrete (PCC) pavement, along with control HMA and PCC sections. This allowed for a comparison of the relative degree of leaching between both materials (HMA and PCC) as well as between the ash-amended and control pavements. Batch and monolithic tank leaching tests were conducted on the pavements. Testing of the PCC samples demonstrated that Mo and Al were elevated above regulatory thresholds for both the control and ash amended samples. Further leach testing demonstrated that the release of Mo was likely from the PCC and not a result of the inclusion of the BA into pavement. Batch leach testing of ash-amended HMA samples revealed Sb as a constituent of potential concern. The results of the monolith leaching test displayed leaching of Sb within the same order of magnitude as the regulatory threshold. Calculation of the leachability index (LI) for Sb found that it would have limited mobility when incorporated in the HMA matrix.

Recycling of MSWI fly ash by means of cementitious double step cold bonding pelletization: Technological assessment for the production of lightweight artificial aggregates

In this work, an extensive study on the recycling of municipal solid waste incinerator fly ash by means of cold bonding pelletization is presented. The ash comes from an incineration plant equipped with rotary and stoker furnaces, in which municipal, hospital and industrial wastes are treated. Fly ash from waste incineration is classified as hazardous and cannot be utilized or even landfilled without prior treatment. The pelletization process uses cement, lime and coal fly ash as components of the binding systems. This process has been applied to several mixes in which the ash content has been varied from 50% (wt.%) up to a maximum of 70%. An innovative additional pelletization step with only cementitious binder has been performed in order to achieve satisfactory immobilization levels. The obtained lightweight porous aggregates are mostly suitable for recovery in the field of building materials with enhanced sustainability properties. Density, water absorption and crushing strength ranged from 1000 to 1600 kg/m(3), 7 to 16% and 1.3 to 6.2 MPa, respectively, and the second pelletization step increased stabilization efficiency. The feasibility of the process has been analyzed by testing also concrete specimens containing the artificial aggregates, resulting in lightweight concrete of average performance.

A road pavement full-scale test track containing stabilized bottom ashes

This paper reports the results of a road pavement full-scale test track built by using stabilized bottom ash (SBA) from an Italian municipal solid waste incinerator as the aggregate in granular foundation, cement-bound mixes and asphalt concretes. The investigation focused on both the performance and the environmental compatibility of such mixes, especially with regard to the effects of mixing, laying and compaction. From the road construction point of view, the performance related to the effects of mixing, laying and compaction on constructability was assessed, as well as the volumetric and the mechanical properties. Environmental aspects were investigated by leaching tests. The results suggested that SBA meets the environmental Italian law for the reuse of non-hazardous waste and could be used as road material with the procedures, plants and equipment currently used for road construction.

Diffuse Reflectance Infrared Fourier Transform Spectroscopy for the Determination of Asbestos Species in Bulk Building Materials

Diffuse reflectance infrared Fourier transform (DRIFT) spectroscopy is a well-known technique for thin film characterization. Since all asbestos species exhibit intense adsorptions peaks in the 4000-400 cm^-1 region of the infrared spectrum, a quantitative analysis of asbestos in bulk samples by DRIFT is possible. In this work, different quantitative analytical procedures have been used to quantify chrysotile content in bulk materials produced by building requalification: partial least squares (PLS) chemometrics, the Linear Calibration Curve Method (LCM) and the Method of Additions (MoA). Each method has its own pros and cons, but all give affordable results for material characterization: the amount of asbestos (around 10%, weight by weight) can be determined with precision and accuracy (errors less than 0.1).

Coal Combustion Wastes Reuse in Low Energy Artificial Aggregates Manufacturing

Sustainable building material design relies mostly on energy saving processes, decrease of raw materials consumption, and increase of waste and by-products recycling. Natural and lightweight artificial aggregates production implies relevant environmental impact. This paper addresses both the issues of residues recycling and energy optimization. Particularly, three coal combustion wastes (Weathered Fly Ash, WFA; Wastewater Treatment Sludge, WTS; Desulfurization Device Sludge, DDS) supplied by the Italian electric utility company (ENEL) have been employed in the manufacture of cold bonded artificial aggregates. Previously, the residues have been characterized in terms of chemical and mineralogical compositions, water content, particle size distribution, and heavy metal release behavior. These wastes have been used in the mix design of binding systems with the only addition of lime. Finally, the artificial aggregates have been submitted to physical, mechanical, and leaching testing, revealing that they are potentially suitable for many civil engineering applications.

Synthesis and Characterization of Novel Epoxy Geopolymer Hybrid Composites

The preparation and the characterization of novel geopolymer-based hybrid composites are reported. These materials have been prepared through an innovative synthetic approach, based on a co-reticulation in mild conditions of commercial epoxy based organic resins and a metakaolin-based geopolymer inorganic matrix. This synthetic strategy allows the obtainment of a homogeneous dispersion of the organic particles in the inorganic matrix, up to 25% in weight of the resin. The materials obtained present significantly enhanced compressive strengths and toughness with respect to the neat geopolymer, suggesting their wide utilization for structural applications. A preliminary characterization of the porous materials obtained by removing the organic phase from the hybrid composites by means of heat treatments is also reported. Possible applications of these materials in the field of water purification, filtration, or as lightweight insulating materials are envisaged.

Recycling of Pre-Washed Municipal Solid Waste Incinerator Fly Ash in the Manufacturing of Low Temperature Setting Geopolymer Materials

In this work, three samples of municipal solid waste incinerators fly ash (MSWI-FA) have been stabilized in systems containing coal fly ash to create geopolymers through a polycondensation reaction. Monolithic products have been obtained with both MSWI fly ash as received and after the partial removal of chloride and sulfate by water washing. The polycondensation products have been characterized qualitatively by means of Fourier transform infrared spectroscopy, X-ray diffraction and scanning electron microscopy and quantitatively, through the determination of the volume of reacted water and silicate. Furthermore, the heavy metals and chloride releases together with the physico-mechanical properties have been evaluated on the hardened products. In conclusion, considering the technological and environmental performances of the obtained geopolymers, they could be suitable for many non-structural applications, such as backfilling of abandoned quarries, decorative materials or brick fireplaces, hearths, patios, etc.

Use of Cement Kiln Dust, Blast Furnace Slag and Marble Sludge in the Manufacture of Sustainable Artificial Aggregates by Means of Cold Bonding Pelletization

In this work, three different samples of solid industrial wastes cement kiln dust (CKD), granulated blast furnace slag and marble sludge were employed in a cold bonding pelletization process for the sustainable production of artificial aggregates. The activating action of CKD components on the hydraulic behavior of the slag was explored by evaluating the neo-formed phases present in several hydrated pastes. Particularly, the influence of free CaO and sulfates amount in the two CKD samples on slag reactivity was evaluated. Cold bonded artificial aggregates were characterized by determining physical and mechanical properties of two selected size fractions of the granules for each studied mixture. Eighteen types of granules were employed in C28/35 concrete manufacture where coarser natural aggregate were substituted with the artificial ones. Finally, lightweight concretes were obtained, proving the suitability of the cold bonding pelletization process in artificial aggregate sustainable production.

Preparation and Characterization of New Geopolymer-Epoxy Resin Hybrid Mortars

The preparation and characterization of metakaolin-based geopolymer mortars containing an organic epoxy resin are presented here for the first time. The specimens have been prepared by means of an innovative in situ co-reticulation process, in mild conditions, of commercial epoxy based organic resins and geopolymeric slurry. In this way, geopolymer based hybrid mortars characterized by a different content of normalized sand (up to 66% in weight) and by a homogeneous dispersion of the organic resin have been obtained. Once hardened, these new materials show improved compressive strength and toughness in respect to both the neat geopolymer and the hybrid pastes since the organic polymer provides a more cohesive microstructure, with a reduced amount of microcracks. The microstructural characterization allows to point out the presence of an Interfacial Transition Zone similar to that observed in cement based mortars and concretes. A correlation between microstructural features and mechanical properties has been studied too.

Use of stabilized bottom ash for bound layers of road pavements

This paper reports about the lab scale results obtained by using stabilized bottom ash (SBA) from an Italian municipal solid waste incinerator as aggregates in cement-bound mixes and asphalt concretes for road pavements. The investigation focused on SBA content. From the road construction point of view, performance related to compaction, volumetric and mechanical properties were assessed. The environmental aspects were investigated performing leaching tests. The results suggested that SBA satisfied the environmental Italian law for reuse of non-hazardous waste but affected significantly the stress-strain behavior of the final products. Therefore a maximum percentage of 10% was suggested.

Application-Oriented Chemical Optimization of a Metakaolin Based Geopolymer

In this study the development of a metakaolin based geopolymeric mortar to be used as bonding matrix for external strengthening of reinforced concrete beams is reported. Four geopolymer formulations have been obtained by varying the composition of the activating solution in terms of SiO₂/Na₂O ratio. The obtained samples have been characterized from a structural, microstructural and mechanical point of view. The differences in structure and microstructure have been correlated to the mechanical properties. A major issue of drying shrinkage has been encountered in the high Si/Al ratio samples. In the light of the characterization results, the optimal geopolymer composition was then applied to fasten steel fibers to reinforced concrete beams. The mechanical behavior of the strengthened reinforced beams was evaluated by four-points bending tests, which were performed also on reinforced concrete beams as they are for comparison. The preliminary results of the bending tests point out an excellent behavior of the geopolymeric mixture tested, with the failure load of the reinforced beams roughly twice that of the control beam.

Effect of natural ageing on volume stability of MSW and wood waste incineration residues

This paper presents the results of a study on the effect of natural weathering on volume stability of bottom ash (BA) from municipal solid waste (MSW) and wood waste incineration. BA samples were taken at different steps of treatment (fresh, 4 weeks and 12 weeks aged) and then characterised for their chemical and mineralogical composition and for volume stability by means of the mineralogical test method (M HMVA-StB), which is part of the German quality control system for using aggregates in road construction (TL Gestein-StB 04). Changes of mineralogical composition with the proceeding of the weathering treatment were also monitored by leaching tests. At the end of the 12 weeks of treatment, almost all the considered samples resulted to be usable without restrictions in road construction with reference to the test parameter volume stability.

Effects of different SRT on anaerobic digestion of MSW dosed with various MSWI ashes

This study investigated different solid retention time (SRT) on municipal solid waste (MSW) anaerobic digestion with various MSW incinerator fly ash (FA) and bottom ash (BA) addition. Results showed that biogas production rates (BPRs, ≈ 200 to ≈ 400 mL/gVS) with organic loading rate of ≈ 0.053 gVS/gVS(reactor) (Day 1-435, SRT 20 days, SRT20) at FA 1g/d (FA1), BA 12 g/d (BA12) and BA 24 g/d (BA24) dosed bioreactors increased after adaptation. BPRs with SRT10 and SRT5 decreased while BPRs with SRT40 showed to increase compared to initial BPRs (≈ 200 mL/gVS) with SRT20. SRT5 operation reduced the BPRs (≈ 10 - ≈ 90 mL/gVS) significantly and only BA12 and BA24 dosed bioreactors could recover the BPRs (≈ 100 - ≈ 200 mL/gVS) after SRT20 operation (Day 613-617) compared to FA1 and FA3 and control. Released levels of Co, Mo and W at BA12 and BA24 dosed bioreactors showed most potential to improve MSW anaerobic digestion.

Properties of municipal solid waste incineration ashes with respect to their separation temperature

Fly ashes generated by power and heating plants are commonly used in the production of building materials in some countries, mainly as partial replacement of cement or aggregates in concrete. The ashes from municipal solid waste incinerators can be applied in a similar way. However, their chemical and mineralogical composition, granulometry and toxic constituents have to be taken into account. In this paper, four types of municipal solid waste incinerator (MSWI) ashes produced by the modern MSWI facility in Liberec, Czech Republic, were investigated. The relationship between the particular ash properties (morphology, chemical composition) and its separation temperature in the incinerator line is discussed. A coal fly ash (class F) is characterized as well, for a comparison because its utilization in building industry is more developed. The studied MSWI ashes exhibit high concentration of chlorides and sulfates which is an unfavourable feature for a potential concrete admixture. On the other hand, three of four ashes are found to be pozzolanic active and certain hydration reactions are indicated.