Resource utilization of stone waste and loess to prepare grouting materials

Loess, a terrestrial clastic sediment, is formed essentially by the accumulation of wind-blown dust, while stone waste (SW) is an industrial waste produced during stone machining. Utilising loess and SW to prepare environmentally-friendly supplementary cementitious materials can not only address environmental issues caused by solid waste landfills but also meet the demand of reinforcement of coal-seam floor aquifer for grouting materials. In this paper, the effects of the loess/SW mass ratio and calcination temperature on the transformation of calcined products are investigated and their pozzolanic activities are evaluated. The workability, environmental impact and cost of grouting materials based on cement and calcined products are also assessed. Experimental results reveal that higher temperatures favour the formation of free lime and periclase, which tend to be involved in solid-state reactions. Higher temperature and loess/SW mass ratio strengthens the diffraction peaks of dodecalcium hepta-aluminate (C12A7), dicalcium ferrite (C2F) and dicalcium silicate (C2S). The clay minerals in loess become completely dehydroxylated before 825 °C, generating amorphous SiO2 and Al2O3. Covalent Si-O bonds are interrupted and that disordered silicate networks are generated in the calcined products, which is confirmed by the increased strength of the Si29 resonance region at -60 ppm to -80 ppm. Although co-calcined loess and SW contain the most four-fold aluminium at 950 °C, recrystallisation depresses the pozzolanic activity. Hence, the loess/SW sample designated LS2-825 exhibits the better hydration activity. Additionally, grouting materials composed of cement and LS2-825 exhibit good setting times, fluidity, strength and a low carbon footprint in practical engineering applications, and they also provide the additional benefit of being cost effective.

Physicochemical and pozzolanic properties of municipal solid waste incineration fly ash with different pretreatments

Swelling caused by gas generated from municipal solid waste incineration fly ash (MSWIFA) when it is mixed with alkali limits its uses. Besides, the leaching of anion salts and heavy metals contained in MSWIFA poses a high risk to environment. This study presents the feasibility of a one-step alkaline washing, one-step thermal quenching and two-step combination of alkaline washing and thermal quenching pretreatment methods in altering the key properties of MSWIFA for promoting its reusability. It was found that apart from H₂(gas), NH₃(gas) was also generated during the alkaline washing of the MSWIFA. Besides, pretreatments led to the reduction in particle size, the increase in pore volume and specific surface area of the MSWIFA, as well as the removal of chloride and sulfate anions. All the pretreatment methods were effective in reducing leaching of heavy metals to below levels of nonhazardous waste except Cd and Pb with alkaline washing. Furthermore, both the chemical Frattini test and the mechanical activity index test showed improvement in pozzolanic activities of the MSWIFA after the pretreatments. Overall, the combined pretreatment method was most effective in eliminating gas emission, and reducing leaching of metal ions and anions from the ash, while enhancing the pozzolanic activity of the ash.

The pozzolanic activity of calcined oil-based drilling cuttings-aluminosilicate composites

In order to reduce the environmental impact of shale gas production and towards the attenuation of artificial pozzolanic materials production cost, new oil-based drilling cuttings (OBDCs) pozzolanic materials have been introduced. After calcination, the chemical composition and the pozzolanic activity of oil-based drilling cuttings residue (OBDCRs) were investigated. The combination of X-ray diffraction (XRD), thermogravimetric analysis (TG), and Fourier transform infrared (FTIR) techniques shed light on impacts of pretreatment, calcination temperature, and Ba²⁺ on minerals' structure and pozzolanic activity. The results showed that, after high temperature calcination, the components of Si or Al in the OBDCRs particle surface and structure were activated and recombined to produce corresponding activity. Ba²⁺ could promote the pozzolanic activity of OBDCRs. The 28-day-compressive strength of OBDCRs was bigger than 31.33Mpa, and the compression strength ratios of cement mortar were bigger than 65%. Therefore, the pozzolanic reactivity of the treated OBDCs was competitive with that of conventional shale, which indicates that the heat treatment of OBDCs produces a cement substitute without any secondary pollution.

Municipal solid waste incineration fly ash to produce eco-friendly binders for sustainable building construction

Municipal solid waste incinerator (MSWI) fly ash is a residue of municipal solid waste incineration whose recycling is currently a worldwide problem. Therefore, considerable efforts are being made to establish effective recovery techniques so MSWI can be used as a substitute for natural resources in construction, as in masonry blocks, roads and so on, or in the manufacture of new materials. MSWI fly ashes contain elements such as Ca, Si and Al, which make it possible for them to be used as raw material to manufacture cements. This paper presents the results obtained from the physicochemical characterization of two MSWI fly ashes from two Spanish cities. The research aims to explore the feasibility of using MSWI fly ash as raw material for sintering belite cements. The results show that MSWI fly ashes have a suitable composition. However, appropriate pre-treatment will be required to eliminate chloride and possible traces of heavy metals and to improve pozzolanic activity. Furthermore, the addition of vitreous silica in the proper proportions is required. The phases generated after calcination of the blend at 800 °C are not those corresponding to pure belite cements. Nevertheless, the possibility of using these ashes as supplementary cementitious material in the manufacture of eco-cements should be contemplated.

Characterization of sewage sludge incineration ashes from multi-cyclones and baghouse dust filters as possible cement substitutes

Incineration is not a final disposal method for sludge management since a significant amount of ash is generated. Although some published literature reported on the use of sewage sludge ashes (SSAs) as a cement replacement, none of them referred to the air pollution control unit of the incinerator where the SSA is collected. The properties of SSAs from different air pollution control units were investigated with the purpose of usage as a cement replacement in the present study. The SSA samples obtained from multi-cyclone units (MC-SSA), where SSA is collected at the bottom of the unit with the help of inertia and centrifugal forces, and baghouse dust filters (BHD-SSA), where SSA is collected at the fabrics of the unit, of the sludge incinerator were analyzed for chemical and physical characteristics, including heavy metal leaching, mineralogy (XRD), and particle morphology (scanning electron microscopy). Mortar samples were prepared with 15 and 30% of MC-SSA and BHD-SSA additions and analyzed for workability, strength activity, strength development, and freeze-thaw resistance. Heavy metal leaching results of both of the MC-SSA and BHD-SSA and their mortars were below the legal requirements of landfills, inferring that the toxic elements in SSA would not be of environmental concern in case SSA is used in cement matrices. The present study identified the variability of the physical and chemical properties of both SSAs over time and their differences. Incompliances of the SSAs to the pozzolanic material standards were observed, although moderate pozzolanic activity was concluded. In order to obtain the required flow value, different amounts of polycarboxylate ether-based superplasticizer were used in all of the mixtures. The levels of amorphous phases were found to be 23.3 and 39.3% for MC-SSA and BHD-SSA, respectively. MC-SSA exhibited less porosity with larger agglomerates than BHD-SSA. Ninety-day compressive strength levels of MC-SSA mortars with 15% replacement, which was found as 50.53 MPa, was higher than that of BHD-SSA mortars by 6% (47.65 MPa). The freeze-thaw resistance and water adsorption capacity of SSA mortars were comparable with that of the cement mortars. It was inferred that the contribution of SSA substitution to the strength development was influenced by hydraulic activity more than pozzolanic activity.Graphical abstract.

A novel process for preparing fireproofing materials from various industrial wastes

In the current study, the possibility of incorporating various industrial wastes into fireproofing materials was investigated. It was found that the newly developed materials showed excellent air sealing and fireproofing performance, with air permeability coefficients 3 to 4 orders of magnitude smaller than traditional fire prevention materials. The influence of different parameters on the air permeability was investigated, and the air sealing mechanisms were clarified through microstructure analysis. In addition, the workability and mechanical properties of the fireproofing materials for practical application in coal mine were studied. The new materials derived from industrial wastes had a compact and monolithic structure, and the excellent air tightness could be attributed to the pozzolanic activity of the industrial wastes and the film-forming property of organic polymers. Among the industrial wastes examined, a special coal fly ash with high pozzolanic activity and little free calcium oxide derived the best product with air permeability coefficient, tensile strength and breaking elongation of 4.17 × 10^-8 m²/s, 2.14 MPa and 48.90%, respectively. This study provides an economical, environmentally friendly and promising approach for industrial wastes recycling.

Change in re-use value of incinerated sewage sludge ash due to chemical extraction of phosphorus

The potential of six different extractants to recover phosphorus (P) from incinerated sewage sludge ash (ISSA) was evaluated. Secondary effects such as the co-dissolution of Zn and Cu were also considered. The residual ISSA from each study was assessed in particular detail, focusing on the leachability of remaining Zn and Cu, major element composition, crystalline phases and overall degree of crystallinity and particle size distribution. The residual ISSA was also evaluated as a pozzolanic material using a Strength Activity Index (SAI) test with mortars containing Portland cement with a 20% substitution by ISSA. All results were compared to tests with untreated ISSA. Overall, the use of 3 of the 6 extractants could be ruled out due to poor P recovery potential and/or a serious compromise of the potential reuse of residual ISSA in Portland cement-based materials. The results highlight the added value of considering the potential reuse of residual ISSA when trying to optimize P recovery from ISSA by wet methods.

Use of ancient copper slags in Portland cement and alkali activated cement matrices

Some Chilean copper slag dumps from the nineteenth century still remain, without a proposed use that encourages recycling and reduces environmental impact. In this paper, the copper slag abandoned in landfills is proposed as a new building material. The slags studied were taken from Playa Negra and Púquios dumps, both located in the region of Atacama in northern Chile. Pozzolanic activity in lime and Portland cement systems, as well as the alkali activation in pastes with copper slag cured at different temperatures, was studied. The reactivity of the slag was measured using thermogravimetric analysis (TGA), scanning electron microscopy (SEM), X-ray diffraction (XRD), electrical conductivity and pH in aqueous suspension and Fourier Transform Infrared Spectroscopy (FTIR). Furthermore, copper slag-Portland cement mortars with the substitution of 25% (by weight) of cement by copper slag and alkali-activated slag mortars cured at 20 and 65 °C were made, to determine the compressive strength. The results indicate that the ancient copper slags studied have interesting binding properties for the construction sector.