Thermal co-treatment of combustible hazardous waste and waste incineration fly ash in a rotary kiln

Applicability assessment of a plasma melting technology for a fly ash recycling system in the Republic of Korea

ABSTRACTThe Ministry of Environment of Korea has proposed a ban on landfill disposal of municipal solid waste (MSW) from 2026. Thus, it is inferred that the amount of incineration ash will increase drastically. Against this backdrop, this study assessed the applicability of a plasma melting process to fly ash. Fly ash was collected from 14 incineration facilities to analyze its basic properties and perform melting experiments. Furthermore, scanning electron microscope (SEM) analysis and economic feasibility assessment were conducted. The molten fly ash slag exhibited a pH value of 9.9, and the ignition loss of fly ash was found to range from 14.5 to 25.7 wt.%. None of seven toxic elements (arsenic (As), cadmium (Cd), cyanide (CN), mercury (Hg), hexavalent chromium (Cr(VI)), copper, and lead (Pb)) was detected from the molten slag. In addition, 99.3 wt.% of chloride ion (Cl-), 97.9 wt.% of fluoride ion (F-), and 98.1 wt.% of sulphate ion (SO42-) were removed. The contents in the molten slag were found to be 0.19, 7.8, 27.8, 33.1, and 38 mg/kg for Cd, Pb, zinc, nickel, and F, respectively, and none of CN, Hg, and As was detected, thereby meeting the criteria for soil pollution. All of the environmental standards were met, and SEM analysis confirmed stable quality with high density and no surface pore. In the economic feasibility assessment, a profit of approximately 152.4 $/ton was also estimated compared to landfill disposal.

Complementary vitrification of municipal solid waste incineration fly ash from grate furnaces and fluidised bed incinerators via a co-reduction process

The increasing application of municipal solid waste incineration (MSWI) emphasises the need for MSWI fly ash (FA) safe treatment. Based on the compositional complementarity of FA from grate furnaces (G-FA) and fluidised bed incinerators (F-FA), we proposed a co-reduction process to treat G-FA and F-FA together for producing vitrified slag and ferroalloys. The clean vitrified slag and Fe-Cr-Ni-Cu alloy were obtained with the mass ratios of 1:9 ∼ 6:4 (G-FA:F-FA) at 1300℃, which is about 300℃ lower than the conventional G-FA vitrification. The metals Zn, Cd, and Pb were mostly volatilised into the flue gas for potential recovery from the secondary FA. The thermodynamic SiO2-Al2O3-CaO ternary system demonstrated that an optimal mass ratio of the two complementary FA types contributes to the system shifting to the low-temperature melting zone. The co-reduction process of G-FA and F-FA could be a promising option for FA beneficial reutilization with environmental advantages.

Effects of organic matter and dewaterability changes on sludge calorific value during acid treatment

Acid treatment can increase the sludge calorific value to some extent by separating inorganic elements. In order to determine the mechanism by which acidification affects the sludge calorific value from an organic perspective, we investigated the changes in organic matter and dewaterability under different pH conditions. The results of this study showed that acidification conditioning retained organic matter while removing a greater amount of inorganic elements. Furthermore, acid treatment significantly increased the zeta potential and particle size of sludge particles and facilitated the precipitation of biological organic components from the supernatant to the surface of sludge particles. Acid-treated sludge exhibited a lower moisture content and a higher proportion of organic matter, and sludge treated with H2SO4, HCl, and HNO3 exhibited respective increases in calorific values of 12.14%, 7.92%, and 8.01% under pH 2. The calorific value of the acid-treated sludge was higher, making it more suitable for subsequent incineration. The findings of this study serve as a reference and foundation for efficient sludge incineration.

MSWIFA and cement cooperate in the disposal of soft soil - experimental study on silty sand and silty clay

Municipal solid waste incineration fly ash (MSWIFA) can be reused as a positive additive to strengthen soft soil. In this study, MSWIFA was initially used as a supplementary solidification material in combination with ordinary Portland cement to prepare fly ash cement-stabilized soil (FACS) with silty sand and silty clay, respectively. The ratio of MWSIFA to total mass was 5%, 10%, and 15%, and the cement content was set as 10% and 15%. The mechanical properties of FACS were evaluated by unconfined compressive strength test. The heavy metal-leaching test was conducted to estimate the environmental risk of FACS. The scanning electron microscope was used to test the micro-structure of FACS. The X-ray diffraction was performed to analyze material composition of FACS. The result indicates that the collaborative solidification of soft soil with MSWIFA and cement is feasible. Regarding the silty clay, the FA had positive effects on the silty clay in the service age (between 50 and 100% with 15% MSWIFA), as the MSWIFA reformulated the initial silty clay structure, resulting in interconnection and pore fill between particles. It can be founded that C-S-H and ettringite are the main products of MSWIFA and cement hydration, which are formed by the hydration of C3S and C2S. Regarding the silty sand, the MSWIFA decreased the peak strength (between 35 and 48% with 15% MSWIFA) but increased the ductility of the stabilized cement. Under the same mix proportions, the leaching toxicities of Zn and Pb in FACS of silty clay were obviously lower than were those of silty sand. Generally, the leaching concentrations of tested metals under all the mix proportions were well below the limit value set by GB 18598-2019 for hazardous waste landfill. Thus, the reuse of MSWIFA in cement-stabilized soil would be one of the effective methods in soft soil treatment and solid waste reduction.

The current status and future of solid waste recycled building bricks

Solid waste (SW) has become a problem hindering the economic and social development. Achieving the full green cycle from raw material to production of recycled building bricks (RBB) using SW is the focus of future research. In this paper, the research results of RBB manufacturing using SW in recent years are reviewed. According to the consolidation principle of RBB, the effects of different types of SW on the physicochemical properties and microstructure of RBB are summarized based on the recycled unsintered brick (RUSB) and recycled sintered brick (RSB). By comparing and evaluating the two consolidation methods, it is proposed that RSB has good practicality due to its higher SW utilization rate, higher strength, and faster consolidation speed. Furthermore, the difference between MWS and conventional sintering (CS) is analyzed, and the research on the application of MWS in SW-RBB manufacturing in recent years is reviewed in detail. It is pointed out that microwave sintering (MWS) technology can solve many drawbacks in traditional sintering technology and has great prospects in manufacturing SW-RBB due to the low energy consumption, low pollution, and high efficiency. Finally, the shortcomings and possible challenges in the current research on manufacturing SW-RBB using MWS technology are discussed, which provides guidance for the future development of SW-RBB manufacturing.

Preparation of Activated Boron Nitride and Its Adsorption Characteristics for Zn, Cu, and Cd in Flue Gas

Developing non-carbon-based adsorbents is essential for removing heavy metals from post-incineration flue gas. In this study, a new high-temperature-resistant adsorbent-activated boron nitride (BN) was prepared using precursors combined with a high-temperature activation method. The adsorption characteristics of BN for Zn, Cu, and Cd in simulated flue gas and sludge incineration flue gas were investigated using gas-phase heavy metal adsorption experiments. The results showed that BN prepared at 1350 °C for 4 h had defect structures, abundant pores, functional groups, and a high specific surface area of 658 m2/g. The adsorption capacity of BN in simulated flue gases decreases with increasing adsorption temperature, whereas it is always higher than that of activated carbon (AC). The total adsorption capacities for Zn, Cu, and Cd were the highest at 50 °C with 48.3 mg/g. BN had strong adsorption selectivity for Zn, with a maximum adsorption capacity of 54.45 mg/g, and its adsorption process occurred mainly on the surface. Cu and Cd inhibited Zn adsorption, leading to a decrease in the Zn adsorption capacity. In sludge incineration flue gas, BN can quickly reach adsorption equilibrium. The BN had a synergistic disposal capacity for heavy metals and fine particulate matter. The maximum adsorption capacity was reduced compared to the simulated flue gas adsorption capacity, which was 5.1 mg/g. However, BN still exhibited a strong adsorption selectivity for Zn, and its adsorption capacity was always greater than that of AC. The rich functional groups and high specific surface area enable BN to physically and chemically double-adsorb heavy metals.

Erosion behaviour of rotary kiln refractory and its effects on ringing during steel-rolling oily sludge incineration

Rotary kiln incineration is a desirable disposal option for steel-rolling oily sludge. However, ringing remains a key challenge in the highly efficient operation of rotary kilns. This study investigates the erosion behaviour of refractory bricks in a rotary kiln during steel-rolling oily sludge incineration and its effects on ringing. The degree of refractory brick erosion (i.e. iron permeation-depth and quantity) depends on the roasting temperature and time. The iron permeation-depth (3.1 mm) after 36 h of roasting at 1350 °C is greater than that (0.7 mm) after 12 h of roasting at 1200 °C. In the same zones of the refractory bricks, iron permeation increases with the roasting temperature and time. This is because the molten substances generated from the steel-rolling oily sludge erode the refractory bricks, whereas the loosened surface of the eroded refractory bricks is conducive to the continual permeation of molten substances in the refractory bricks. Steel-rolling oily sludge is mixed with refractory brick powder to produce briquettes, which are then used to simulate the permeation and erosion processes. Adding 20% refractory bricks to the briquettes decreases the cohesion strength of the briquettes from 9.07 to 11.71 kN to 2.97-4.44 kN when roasting is performed at 1250 °C for 5-30 min. Although haematite contributes to the high cohesive strength of the rings, the primary components of the refractory brick are transformed into eutectic substances, which decreases the cohesive strength of the rings. These findings provide a useful reference for developing ringing mitigation methods for rotary kilns.

Co-incineration effect of sewage sludge and municipal solid waste on the behavior of heavy metals by phosphorus

The effects of sewage sludge phosphorus (P) content on heavy metal behavior during co-incineration of sewage sludge and municipal solid waste (MSW) were evaluated. Thermogravimetric differential thermal analysis revealed that MSW incineration was mainly caused by organic matter and fixed carbon, while sewage sludge incineration was caused by volatile matter. During co-incineration, the peak weight loss at 460 °C shifted to slightly higher temperatures and the sludge ratio increased, indicating that interaction effects during co-incineration delayed pyrolysis and polymer/fixed carbon incineration. The residual heavy metal ratios after mono-incineration of sewage sludge were higher than those after MSW mono-incineration. The Cl content of MSW (0.757%) was much higher than that of sewage sludge (0.068%), which resulted in the conversion of heavy metals into metal chlorides and then volatilized during MSW mono-incineration. A synergistic effect of co-incineration was evident for Cu, but not for lead (Pb) or cadmium (Cd). X-ray absorption fine structure (XAFS) measurement revealed that Cu in MSW ash was in the form of CuO(s), but was Cu₃(PO₄)₂ in sewage sludge and co-incineration ashes. CuO(s) is relatively unstable and may be transformed to CuO(g) or CuCl(s) before volatilizing at high temperature or in the presence of Cl. Phosphorus has the effect of stabilizing Cu in sewage sludge during co-incineration.

Co-disposal and reutilization of municipal solid waste and its hazardous incineration fly ash

Compared to landfill, MSW incineration (MSWI) not only eliminates its innate secondary pollution and land occupation, but also yields a net emission reduction. Regretfully, MSWI produces hazardous incineration fly ash (IFA) enriched with potentially toxic elements and dioxins. Given these, a harmless integrated scenario of co-disposal and resource reutilization of MSW and its hazardous IFA is proposed and subjected to technical and economic analysis. It introduces an IFA melting furnace, as an onsite modular integration, which serves as a bridge between the MSW incinerator and the commercial rock wool production line. The incinerator burns MSW for heating and electricity supply. The melting furnace further burns out the highly toxic dioxins adsorbed on IFA, as well as solidifying the potentially toxic elements into the molten slag, which substitutes for basalt as raw materials used for high value-added rock wool production. That achieves collaborative reduction, stabilization, harmlessness and resource reutilization of MSW as an energy source, and its IFA as energy-saving materials, as well as a net carbon emission reduction and high economicbenefits. Even more exciting, as opposed to the serious losses of the other existing scenarios, it is profitable even without the feed-in tariff and fiscal subsidy, both that are the dominating income source of other scenarios including conventional MSWI & IFA landfill and demonstration MSWI with IFA melting & landfill. Discounted Cash Flow technique shows that the profit is ∼ 9.2 RMB per ton of MSW, and it increases with insulation price, feed-in tariff, and fiscal subsidy. With the feed-in tariff and fiscal subsidy, the existing two scenarios and the proposed harmless integrated scenario can produce revenue of 103.8, 98.1-110.5, and 145.0 RMB per ton of MSW, respectively. Nonetheless, several challenges are posed for future industrial applications, such as liquid slag discharge, unstable combustion and possible environmental issues.

MSWI Fly Ash Multiple Washing: Kinetics of Dissolution in Water, as Function of Time, Temperature and Dilution

Municipal solid waste incineration fly ash (FA) can represent a sustainable supply of supplementary material to the construction industries if it is pre-treated to remove hazardous substances such as chloride, sulfate, and heavy metals. In this paper, the phenomenology associated with a water washing multi-cycle treatment of FA is investigated, focusing attention upon the mineral dissolution process. The efficacy of the treatment is assessed by leaching tests, according to the European Standard, and discussed in light of the occurring mineral phases. The water-to-solid (L/S) ratio is a crucial parameter, along with the number of washing cycles, for removing halite and sylvite, whereas quartz, calcite, anhydrite, and an amorphous phase remain in the solid residue. The sequential extraction method and dissolution kinetics modelling provide further elements to interpret leaching processes, and suggest that dissolution takes place through a two-step mechanism. Altogether, multi-step washing with L/S = 5 is effective in reducing contaminants under the legal limits for non-hazardous waste disposal, while the legal limits for non-reactive or reusable material cannot be completely reached, owing to sulfate and some heavy metals which still leached out from the residue.

Fate and emission behavior of heavy metals during hazardous chemical waste incineration

The fate and emission behavior of heavy metals (As, Cd, Co, Cr, Cu, Ni, Pb, Se, and Zn) from a hazardous chemical waste incinerator were systematically explored. The results show that the main components of incineration fly ashes and slags contain minerals such as salt, plagioclase, pyroxene, gypsum, calcite, and slaked lime. The elements As, Cd, Pb, and Se are enriched in the fly ash particles during flue gas condensation. Co and Ni are more likely to be deposited in the rotary kiln slag and cooling tower slag owing to their lower volatility. Zn, Cr, and Cu are usually volatilized into the flue gas as oxides or chlorides are condensed and enriched in the slag of the cooling tower during the flue gas cooling process. The content of As, Cd, Pb, Ni, Cr, and Se increase with decreasing fly ash particle size. After the flue gas purification equipment was employed, the concentration of particulate metals significantly reduced. In the exhaust flue gas, the concentrations of Cu and Zn are 29.85 and 28.47 μg/m³, those of As, Cr, Ni, Pb, and Se range from 2.54 to 9.25 μg/m³, and those of Co and Cd are 0.42 and 0.13 μg/m³, respectively.

Fungi Can Be More Effective than Bacteria for the Bioremediation of Marine Sediments Highly Contaminated with Heavy Metals

The contamination of coastal marine sediments with heavy metals (HMs) is a widespread phenomenon that requires effective remediation actions. Bioremediation based on the use of bacteria is an economically and environmentally sustainable effective strategy for reducing HM contamination and/or toxicity in marine sediments. However, information on the efficiency of marine-derived fungi for HM decontamination of marine sediments is still largely lacking, despite evidence of the performance of terrestrial fungal strains on other contaminated matrixes (e.g., soils, freshwater sediments, industrial wastes). Here, we carried out for the first time an array of parallel laboratory experiments by using different combinations of chemical and microbial amendments (including acidophilic autotrophic and heterotrophic bacteria, as well as filamentous marine fungi) for the bioremediation of highly HM-contaminated sediments of the Portman Bay (NW Mediterranean Sea), an area largely affected by long-term historical discharges of mine tailings. Our results indicate that the bioleaching performance of metals from the sediment is based on the addition of fungi (Aspergillus niger and Trichoderma sp.), either alone or in combination with autotrophic bacteria, was higher when compared to other treatments. In particular, fungal addition allowed obtaining bioleaching yields for As eight times higher than those by chemical treatments and double compared with the addition of bacteria alone. Moreover, in our study, the fungal addition was the only treatment allowing effective bioleaching of otherwise not mobile fractions of Zn and Cd, thus overtaking bacterial treatments. We found that the lower the sediment pH reached by the experimental conditions, as in the case of fungal addition, the higher the solubilization yield of metals, suggesting that the specific metabolic features of A. niger and Trichoderma sp. enable lowering sediment pH and enhance HM bioleaching. Overall, our findings indicate that fungi can be more effective than acidophilic autotrophic and heterotrophic bacteria in HM bioleaching, and as such, their use can represent a promising and efficient strategy for the bioremediation of marine sediments highly contaminated with heavy metals.

Stabilization of heavy metals in municipal solid waste incineration fly ash via hydrothermal treatment with coal fly ash

The environmental risk of heavy metals in hazardous municipal solid waste incineration fly ash (FA) is one of the most important concerns for its safely treating and disposing. This study investigated the stabilization behavior of heavy metals in FA using coal fly ash (CFA) as an additive via hydrothermal treatment. The effects of water washing pre-treatment and FA/CFA ratio on leaching behavior, speciation evolution, and risk assessment of heavy metals were studied. The results showed that 96.6-98.0 % of Cl can be effectively removed by water washing pre-treatment and hydrothermal treatment. Most heavy metals (Cr, Cu, Ni, Pb and Zn) (>91.5 %) were stabilized in the hydrothermal product, rather than transferred to liquid phase. Tobermorite can be synthesized by adjusting Ca/Si ratio with the addition of CFA. The heavy metals were transferred into more stable residue fractions with increasing CFA addition, which resulted in the significant reduction of leaching concentrations and risk assessment code (RAC) of heavy metals. Among, the product with 30% CFA exhibited the most superior performance with the lowest leaching concentrations of heavy metals and RAC was at no risk level (<1). In addition, the economic performance of hydrothermal treatment exhibited a potential advantage by comparing with FA-to-cement, FA-to-glass slags and FA-to-chelating agent & cement solidification/stabilization. Therefore, the hydrothermal treatment coupled with water washing pre-treatment would be a promising method for the detoxification of FA, as well as synergistic treatment of FA and CFA.

Simulation of heavy metals behaviour during Co-processing of fly ash from municipal solid waste incineration with cement raw meal in a rotary kiln

Fly ash produced from incineration of municipal solid wastes (MSW) contains heavy metals, such as Cd and Pb, that make this material difficult to manage and dispose of safely. Because the composition of fly ash is similar to cement raw meal, partial replacement of raw meal with fly ash may be a feasible way to reduce the health and environmental hazards of the ash, provided that the heavy metals can be effectively stabilized in the solid phase. This research employs proprietary thermochemical software to simulate the thermodynamic behavior and single-step fixation of Cd and Pb in industrial cement kilns. The effect of Cd, Pb and Cl loadings on the fixation and/or evaporation of Cd and Pb during the sintering process is analyzed using data from industrial cement kilns. A simplified model is created based on elemental mass balance to evaluate multi-step fixation of Cd and Pb with cement kiln dust recycle.The results indicate that Cd forms Cd(OH)₂(g) in a highly alkaline environment, while nearly 90% Pb is volatilized as PbCl₂(g). In the clinker, increased Cl^-1 decreased the proportion of Pb and Cd, moreover, Pb and Cd increased in kiln dust with Cl^-1 increased; Calculations using a kiln dust recycle model showed that, the concentrations of Pb and Cd in both kiln dust and clinker increased sharply after recycling of kiln dust in steady state. Under unstable conditions, the concentrations of Pb and Cd in kiln dust increased, as well as the heavy metals re-entering the cement kiln.

Ash formation and the inherent heavy metal partitioning behavior in a 100 t/d hazardous waste incineration plant

Hazardous waste incineration (HWI) ash is also defined as hazardous waste and its disposal performance depends largely on the ash compositions as well as the potential environmental risk of heavy metals. In this work, HWI ashes of four sampling sites were collected in a 100 t/d hazardous waste incineration plant with rotary kiln over three consecutive days. The formation characteristics of ash samples including heavy metal partitioning were given, with further discussions on the melting disposal of HWI ash mixtures. Results showed significant differences in the ash compositions among the sampling sites. Caused by NaHCO₃ injection as de-acidizing adsorbent, the sum of Na, S and Cl content in bag filter ash even exceeded 70%. Cu/Mn/Cr tended to transfer into the bottom ash due to low volatilities, while Zn/Pb/Cd/Se/As were more likely to be enriched in the ash particles. In particular, chemical adsorption at medium- to high- temperature range was dominant for As enrichment in the waste heat boiler ash. Despite the complexity and diversity of raw hazardous wastes, little difference was found in the melting temperature of bottom ash during the sampling period. However, it could vary by more than 200 °C for fly ash due to the fluctuation of alkali components in raw wastes. Moreover, slagging medium was encouraged in order to achieve rapid and complete melting of ash mixtures. The objective of this study is to gain knowledge on the HWI ash formation and inherent heavy metal partitioning behavior, expecting to provide guidelines on the deep harmless disposal of HWI ash in future.

Emission characteristics of dioxins during iron ore Co-sintering with municipal solid waste incinerator fly ash in a sintering pot

The disposing of municipal solid waste incineration(MSWI) fly ashes containing dioxins is an intractable problems. Co-sintering is one of the most ideal methods to dispose MSWI fly ash, because it not only degrades the dioxins but also makes it possible to re-utilize MSWI fly ashes. In the present study, MSWI fly ash(FA) and water washed MSWI fly ash(WFA) were added into the sinter raw mixture in a lab-scale sintering pot. Different effects of fly ash and water washed fly ash on emission characteristics of dioxins were studied, and possible pathways to form dioxins were discussed in detail. During co-sintering, at least 88.9%, 99.1% of dioxins brought in by FA, WFA was decomposed, respectively, and re-synthesis with a significant distribution characteristic of dioxins originated from sintering process. In the preheating and dry zone, the recombination and condensation reaction of precursors were the main formation pathways of 2,3,7,8-PCDDs in the sintering process and 2,3,7,8-PCDFs were formed by de novo synthesis. In addition, the resynthesis process was affected by chlorine and calcium brought in by fly ash. Sufficient chlorine boosted the chlorination of reactants while calcium increased the residence time, causing the emission concentration of toxic dioxins and the adding ratio were nonlinearly dependent. Therefore, the maximum proportion of water washed MSWI fly ash that can be added into the sintering process was 0.5 wt.%. Besides, the possible pathways to form dioxins were proposed.

A review on modern and smart technologies for efficient waste disposal and management

In the current scenario, the word waste management holds much importance in every individual's life. Pollution and the generation of vast waste quantities with no proper waste management process have become one of humanity's biggest threats. This review article provides a complete review of the innovative technologies currently employed to handle and dispose of the waste successfully. This work aims to include the different solid, liquid, gaseous, and radioactive waste management processes. The novel and improved plasma gasification concepts, transmutation, incineration, bio-refineries, microbial fuel cells (MFC) have been thoroughly explained. In addition, some new techniques like Mr. Trash Wheel and the Smart bin approach provide much hope of adequately managing waste. The work's novelty lies in adopting several successful methods of various countries for waste disposal and management. To incorporate or improve India'sIndia's same techniques and processes, we have to tackle the ever-increasing waste disposal problems and find economic and eco-friendly ways of waste management.

Fabrication of Carbon-Alumina Composites via Catalytic Pyrolysis of Pine Sawdust on Aluminum Dross for Cr(VI) Removal

Carbon-alumina composites are prepared for the efficient removal of Cr(VI) from wastewater. Pristine and acid-treated alumina dross (AD and AAD) are copyrolyzed with pine sawdust to form the respective composites, ADPC and AADPC. Excellent absorption properties with Cr(VI) removal efficiency of 95.08% are demonstrated at 60 °C for an initial concentration of 6 μg/mL. The composites combine the merits of char, which provides a high surface-to-volume ratio with abundant functional groups on the surface, and alumina, which provides metal ions for coprecipitation. Carbon structures of pine, char, and composite were analyzed semiquantitatively using ¹³C NMR by a curve-fitting method. Cr(VI) adsorption is accurately described with chemisorption by the Langmuir isotherm model and a pseudo-second-order kinetic model. The results show that AADPC has more alcohol hydroxyl groups substituted to glucosyl units in amorphous cellulose assigned to the peak at 80 ppm and hemicellulose assigned to peaks at 97 and 101 ppm. Also, it has more phenolic groups in lignin distributed at syringyl units assigned to peaks at 129 and 146 ppm. These oxygen-containing functional groups have a significant influence on Cr(VI) adsorption and reduction to Cr(III) governed by the mechanisms of diffusion, adsorption, complexation, reduction, and coprecipitation. The results of this work provide a new direction for the reuse of biomass and industrial solid wastes to fabricate higher value-added products, i.e., adsorption materials for Cr(VI) removal and stabilization.

Treatment of municipal solid waste incineration fly ash: State-of-the-art technologies and future perspectives

Municipal solid waste incineration (MSWI) fly ash is considered as a hazardous waste that requires specific treatment before disposal. The principal treatments encompass thermal treatment, stabilization/solidification, and resource recovery. To maximize environmental, social, and economic benefits, the development of low-carbon and sustainable treatment technologies for MSWI fly ash has attracted extensive interests in recent years. This paper critically reviewed the state-of-the-art treatment technologies and novel resource utilization approaches for the MSWI fly ash. Innovative technologies and future perspectives of MSWI fly ash management were highlighted. Moreover, the latest understanding of immobilization mechanisms and the use of advanced characterization technologies were elaborated to foster future design of treatment technologies and the actualization of sustainable management for MSWI fly ash.

Addressing environmental sustainability of plasma vitrification technology for stabilization of municipal solid waste incineration fly ash

Fly ash from municipal solid waste incineration is considered as a hazardous waste, which would raise great threats on environmental safety due to the inherent toxic heavy metals and organic pollutants. In this study, we applied the life cycle assessment to evaluate the thermal plasma vitrification process for stabilization of fly ash from municipal solid waste incineration. We established four scenarios: (i) plasma vitrification, including centralized and off-site plasma treatment, (ii) fuel-based vitrification, (iii) water-washing treatment followed by a rotary kiln, and (iv) conventional solidification and landfill. We found that the environmental impacts, especially toxicity to ecosystem quality and human health, could be significantly reduced by deploying plasma vitrification technology. We also found that centralized plasma vitrification facilities possessing larger treatment capabilities with clean electricity could further reduce the environmental impacts. In contrast, the water-washing treatment exhibited the highest environmental impacts due to the emissions of vaporized heavy metals. Based on the LCA and sensitivity analysis, we confirmed that the thermal plasma vitrification should be considered as an environmentally-friendly solution to sustainable treatment of fly ash from municipal solid waste incineration. Lastly, we provided several perspectives and prospects of plasma vitrification for realizing the sustainable materials management.

Comparing Fly Ash Samples from Different Types of Incinerators for Their Potential as Storage Materials for Thermochemical Energy and CO2

This study aims to investigate the physical and chemical characterization of six fly ash samples obtained from different municipal solid waste incinerators (MSWIs), namely grate furnaces, rotary kiln, and fluidized bed reactor, to determine their potential for CO₂ and thermochemical energy storage (TCES). Representative samples were characterized via simultaneous thermal analysis (STA) in different atmospheres, i.e., N₂, air, H₂O, CO₂, and H₂O/CO₂, to identify fly ash samples that can meet the minimum requirements, i.e., charging, discharging, and cycling stability, for its consideration as TCES and CO₂-storage materials and to determine their energy contents. Furthermore, other techniques, such as inductively coupled plasma optical emission spectroscopy, X-ray fluorescence (XRF) spectrometry, X-ray diffraction (XRD), scanning electron microscopy, leachability tests, specific surface area measurement based on the Brunauer–Emmett–Teller method, and particle-size distribution measurement, were performed. XRF analysis showed that calcium oxide is one of the main components in fly ash, which is a potentially suitable component for TCES systems. XRD results revealed information regarding the crystal structure and phases of various elements, including that of Ca. The STA measurements showed that the samples can store thermal heat with energy contents of 50–394 kJ/kg (charging step). For one fly ash sample obtained from a grate furnace, the release of the stored thermal heat under the selected experimental conditions (discharging step) was demonstrated. The cycling stability tests were conducted thrice, and they were successful for the selected sample. One fly ash sample could store CO₂ with a storage capacity of 27 kg CO₂/ton based on results obtained under the selected experimental conditions in STA. Samples from rotary kiln and fluidized bed were heated up to 1150 °C in an N₂ atmosphere, resulting in complete melting of samples in crucibles; however, other samples obtained from grate furnaces formed compacted powders after undergoing the same thermal treatment in STA. Samples from different grate furnaces showed similarities in their chemical and physical characterization. The leachability test according to the standard (EN 12457-4 (2002)) using water in a ratio of 10 L/S and showed that the leachate of heavy metals is below the maximum permissible values for nonhazardous materials (except for Pb), excluding the fly ash sample obtained using fluidized bed technology. The leachate contents of Cd and Mn in the fly ash samples obtained from the rotary kiln were higher than those in other samples. Characterization performed herein helped in determining the suitable fly ash samples that can be considered as potential CO₂-storage and TCES materials.

Experimental and Numerical Simulation Study on Co-Incineration of Solid and Liquid Wastes for Green Production of Pesticides

A large amount of solid and liquid waste is produced in pesticide production. It is necessary to adopt appropriate disposal processes to reduce pollutant emissions. A co-incineration scheme for mixing multi-component wastes in a rotary kiln was proposed for waste disposal from pesticide production. According to the daily output of solid and liquid wastes, the proportion of mixing was determined. An experiment of the co-incineration of solid and liquid wastes was established. Experimental results showed that the mixed waste could be completely disposed at 850 °C, and the residence time in the kiln exceeded 1 h. A model method for mixture and diesel oil-assisted combustion was proposed. Numerical simulation was performed to predict the granular motion and reveal the combustion interactions of the co-incineration of mixed wastes in the rotary kiln. Simulation results reproduced movements, such as rolling and cascading, and obtained the optimum rotational speed and diesel oil flow for the rotary kiln incineration operation. The simulation showed that the temperature in the kiln was maintained at 850 °C, and the mass fraction of CO and O2 at the outlet reached the standard for the complete combustion of the waste. Finally, the rotary kiln incineration and flue gas treatment processes were successfully applied in engineering for green production of pesticides.

Characteristics of incineration ash for sustainable treatment and reutilization

Municipal solid waste incineration (MSWI) generates bottom ash, fly ash (FA), and air pollution control (APC) residues as by-products. FA and APC residues are considered hazardous due to the presence of soluble salts and a high concentration of heavy metals, and they should be appropriately treated before disposal. Physicochemical characterization using inductively coupled plasma mass spectroscopy (ICP-MS), X-ray diffraction (XRD), and X-ray fluorescence (XRF) have shown that FA and APC have potential for reuse after treatment as these contain CaO, SiO₂, and Al₂O₃. Studies conducted on treatment of FA and APC are categorized into three groups: (i) separation processes, (ii) solidification/stabilization (S/S) processes, and (iii) thermal processes. Separation processes such as washing, leaching, and electrochemical treatment improve the quality and homogeneity of the ash. S/S processes such as chemical stabilization, accelerate carbonation, and cement solidification modify hazardous species into less toxic constituents. Thermal processes such as sintering, vitrification, and melting are effective at reducing volume and producing a more stable product. In this review paper, the treatment processes are analyzed in relation to ash characteristics. Issues concerning mixing FA and APC residues before treatment, true treatment costs, and challenges are also discussed to provide further insights on the implications and possibilities of utilizing FA and APC as secondary materials.

Application and Selection of Remediation Technology for OCPs-Contaminated Sites by Decision-Making Methods

The production and use of organochlorine pesticides (OCPs) for agricultural and industrial applications result in high levels of their residues, posing a significant risk to environmental and human health. At present, there are many techniques for OCP-contaminated soil remediation. However, the remediation of contaminated sites may suffer from a series of problems, such as a long recovery cycle, high costs, and secondary pollution, all of which could affect land redevelopment and reuse. Therefore, the selection of an appropriate technology is crucial for contaminated sites. In order to improve and support decision-making for the selection of remediation techniques, we provide a decision-making strategy for the screening of remediation techniques of OCP-contaminated sites. The screening procedure is proposed based on combining the analytic hierarchy process (AHP) and the technique for order preference by similarity to ideal solution (TOPSIS). The screening indexes include economic indicator, environmental indicator, and technical indicator. The assessment results show that co-processing in cement kiln obtained the highest overall score and was thus considered to be the most sustainable option. This suggested remediation technology was similar to the practical remediation project, indicating that the screening method could be applied for the selection of remediation technologies for sites contaminated with persistent organic pollutants.

Municipal solid waste incineration (MSWI) fly ash composition analysis: A case study of combined chelatant-based washing treatment efficiency

The challenge of sustainable use of MSWI residues such as fly ash is particularly acute. One of the possible uses of these residues in making secondary building materials. However, MSWI fly ash is highly contaminated with toxic elements such as Pb, Zn, Cd, Cu, etc. Its treatment to reduce the environmental impact is required before reuse or disposal. Here, the efficiency of a new three-step combined treatment with two complexing agents (ethylenediaminetetraacetate and gluconate) to increase the toxic-element elution from fly ash in contrast to conventional water-only treatments is shown. The compositions of raw and differently treated (reagent-combined and water-only treatments) MSWI fly ash were compared by macro- and microelemental, mineralogical, and microstructure analysis, in addition to the standard leaching test. The relevancy for such comprehensive analysis of MSWI fly ash prior and after treatments to minimize the environmental risks is shown. For Cd, Cu, and Zn, the combined treatment is proved to be 10-1000-fold more efficient than the water-only one. It was shown that the same WFA, which seems non-hazardous according to the leaching test after being washed with water, proves to be extremely hazardous when more properties are taken into account. Thus, it is relevant not only to study the leaching of WFA components and the factors affecting it, but also to pay detailed attention to amounts of elements remaining in the material after treatments.

Technologies for the management of MSW incineration ashes from gas cleaning: New perspectives on recovery of secondary raw materials and circular economy

Environmental policies in the European Union focus on the prevention of hazardous waste and aim to mitigate its impact on human health and ecosystems. However, progress is promoting a shift in perspective from environmental impacts to resource recovery. Municipal solid waste incineration (MSWI) has been increasing in developed countries, thus the amount of air pollution control residues (APCr) and fly ashes (FA) have followed the same upward trend. APCr from MSWI is classified as hazardous waste in the List of Waste (LoW) and as an absolute entry (19 01 07*), but FA may be classified as a mirror entry (19 0 13*/19 01 14). These properties arise mainly from their content in soluble salts, potentially toxic metals, trace organic pollutants and high pH in contact with water. Since these residues have been mostly disposed of in underground and landfills, other possibilities must be investigated to recover secondary raw materials and products. According to the literature, four additional routes of recovery have been found: detoxification (e.g. washing), product manufacturing (e.g. ceramic products and cement), practical applications (e.g. CO₂ sequestration) and recovery of materials (e.g. Zn and salts). This work aims to identify the best available technologies for material recovery in order to avoid landfill solutions. Within this scope, six case studies are presented and discussed: recycling in lightweight aggregates, glass-ceramics, cement, recovery of zinc, rare metals and salts. Finally, future perspectives are provided to advance understanding of this anthropogenic waste as a source of resources, yet tied to safeguards for the environment.

Effects of the addition of municipal solid waste incineration fly ash on the behavior of polychlorinated dibenzo-p-dioxins and furans in the iron ore sintering process

Raw materials were co-sintered with municipal solid waste incineration (MSWI) fly ash through iron ore sintering to promote the safe treatment and utilization of MSWI fly ash. To assess the feasibility of this co-sintering method, in this study, the effects of the addition of MSWI fly ash on the formation and emission of polychlorinated dibenzo-p-dioxins and furans (PCDD/Fs) were estimated via iron ore sintering pot experiments. During co-sintering, most of the PCDD/Fs in the added MSWI fly ash were decomposed and transformed into PCDD/Fs associated with iron sintering, and the concentrations of lower- and mid-chlorinated congeners increased. As there was a sufficient chlorine source and the sintering bed permeability was decreased by the addition of MSWI fly ash, the PCDD/F concentration in the exhaust gas increased. The mass emission of PCDD/Fs decreased; however, the emission of toxic PCDD/Fs increased beyond the total emissions from the independent MSW incineration and iron ore sintering processes due to the transformation of PCDD/F congeners. The co-sintering may be an important solution after technological improvements in the flue gas cleaning system and PCDD/F formation inhibition procedures.

Combined disc pelletisation and thermal treatment of MSWI fly ash

An environmentally friendly and cost efficient way for the management of municipal solid waste incineration (MSWI) fly ash represents its thermal co-treatment together with combustible waste. However, the safe introduction and storage of MSWI fly ash in the waste bunker is challenging and associated with severe problems (e.g. dust emissions, generation of undefined lumps and heat in case of moistened MSWI fly ash). Therefore, the aim of this study is to investigate the suitability of pelletisation as a pretreatment of MSWI fly ash. In particular, MSWI fly ash was characterised after sampling, pelletisation and thermal treatment and the transfer of constituents to secondary fly ash and flue gas was investigated. For this purpose, MSWI fly ash pellets with a water content of about 0.15 kg/kg and a diameter of about 8 mm have been produced by disc pelletiser and treated in an electrically heated pilot-scale rotary kiln at different temperatures, ranging from 450 °C to 1050 °C. The total contents of selected elements in the MSWI fly ash before and after thermal treatment and in the generated secondary fly ash have been analysed in order to understand the fate of each element. Furthermore, leachable contents of selected elements and total content of persistent organic pollutants of the thermally treated MSWI fly ash were determined. Due to the low total content of Hg (0.7 mg/kg) and the low leachate content of Pb (<0.36 mg/kg), even at the lowest treatment temperature of 450 °C, thermally treated MSWI fly ash pellets can be classified as non-hazardous waste. However, temperatures of at least 650 °C are necessary to decrease the toxic equivalency of PCDD/F and DL-PCB. The removal of toxic heavy metals like Cd and Pb is significantly improved at temperatures of 850 °C, 950 °C or even 1050 °C. The observed metal removal led to relatively high contents of e.g. Cu (up to 11,000 mg/kg), Pb (up to 91,000 mg/kg) and Zn (up to 21,000 mg/kg) in the secondary fly ash. This metal enriched secondary fly ash might represent a potential raw material for metal recovery (e.g. via acidic leaching). Due to the high content of total dissolved solids observed in the leachate of thermally treated MSWI fly ash pellets, a wet extraction procedure is suggested to enable its safe disposal at non-hazardous waste landfills.

Comparative life cycle assessment of MSWI fly ash treatment and disposal

Municipal solid waste incineration (MSWI) fly ash constitutes a hazardous waste. The possibilities for managing this waste comprise disposal at underground deposits or at above-ground landfills after cement stabilisation, application of the FLUREC process, thermal treatment in a dedicated furnace or thermal co-treatment together with combustible hazardous waste. A comparative life cycle assessment (LCA) study was conducted in order to assess the environmental impact of these five MSWI fly ash disposal options with regard to two different time horizons (100years, indefinite). The uncertainties of the input parameters were propagated by Monte Carlo simulations (MCS). As could be shown by the discernibility analysis, the FLUREC process has the lowest impact in more than 90% of the MCS results. In case long-term emissions (beyond 100years) are neglected, the second lowest impact is caused by thermal co-treatment in more than 90% of the MCS results. Consideration of long-term emissions indicates the disposal at underground deposits as second best option. Furthermore, it is shown that stabilisation with cement has the second highest and thermal treatment in a dedicated furnace has the highest environmental impact, mostly due to high CO₂ emissions. Therefore these two treatment options should be avoided in the future. Besides the comparative evaluation of the different options, it could be shown that uncertainty analysis is useful to determine the relevance of long-term emissions for the ranking of different systems.

Fate and significance of phthalates and bisphenol A in liquid by-products generated during municipal solid waste mechanical-biological pre-treatment and disposal

Samples of liquid by-products generated by municipal solid waste plants (MSWPs) were tested for the presence of phthalates (PAEs) and bisphenol A (BPA). The results indicated that the wastewater generated during mechanical (sorting unit - SU) and biological (composting unit - CU) pre-treatment (MBT) of residual (mixed) solid waste is a significant source of these compounds. The concentrations of PAEs (up to 32222μg/L) and BPA (up to 1795μg/L) in the SU and CU wastewaters were generally higher than those in landfill leachates tested in this and other studies. To date, MBT wastewaters have been poorly studied and are usually overlooked. However, in this study, despite their relatively small quantities, they constituted an important load of ammonia (up to 1610mg/L) and organic matter (COD up to 52980mg/L). Thus, to apply an effective treatment, it is critical to monitor the current quality and quantity of all liquid by-products generated at MSWPs and to prioritize the (micro)pollutants of concern.