Utilization of cement kiln dust (CKD) in cement mortar and concrete—an overview

Solid waste management is one of the major environmental concerns around the world. Cement kiln dust (KKD), also known as by-pass dust, is a by-product of cement manufacturing. The environmental concerns related to Portland cement production, emission and disposal of CKD is becoming progressively significant. CKD is fine-grained, particulate material chiefly composed of oxidized, anhydrous, micron-sized particles collected from electrostatic precipitators during the high temperature production of clinker. Cement kiln dust so generated is partly reused in cement plant and landfilled. The beneficial uses of CKD are in highway uses, soil stabilization, use in cement mortar/concrete, CLSM, etc.Studies have shown that CKD could be used in making paste/mortar/concrete. This paper presents an overview of some of the research published on the use of CKD in cement paste/mortar/concrete. Effect of CKD on the cement paste/mortar/concrete properties like compressive strength, tensile strength properties (splitting tensile strength, flexural strength and toughness), durability (Freeze–thaw), hydration, setting time, sorptivity, electrical conductivity are presented. Use of CKD in making controlled low-strength materials (CLSM), asphalt concrete, as soil stabilizer, and leachate analysis are also discussed in this paper.     

Use of silicon and ferrosilicon industry by-products (silica fume) in cement paste and mortar

With increased environmental awareness, recycling/utilization of industrial byproducts is gaining ground. One such by-product is silica fume (SF), which is byproduct of the smelting process in the silicon and ferrosilicon industry. By-products of the production of silicon metal and the ferrosilicon alloys having silicon contents of 75% or more contain 85-95% non crystalline silica. Silica fume is very useful in the design and development of high quality cement paste/mortar and concrete.This paper presents comprehensive details of the physical, chemical, properties, and its reaction mechanism. It also covers the hydration characteristics, consistency, setting times, workability and compressive strength of cement paste and mortar.     

A review on the use of waste glasses in the production of cement and concrete

The use of recycled waste glasses in Portland cement and concrete has attracted a lot of interest worldwide due to the increased disposal costs and environmental concerns. Being amorphous and containing relatively large quantities of silicon and calcium, glass is, in theory, pozzolanic or even cementitious in nature when it is finely ground. Thus, it can be used as a cement replacement in Portland cement concrete. The use of crushed glasses as aggregates for Portland cement concrete does have some negative effect on properties of the concrete; however, practicle applicability can still be produced even using 100% crushed glass as aggregates. The main concerns for the use of crushed glasses as aggregates for Portland cement concrete is the expansion and cracking caused by the glass aggregates. This paper summarizes the progresses and points out the directions for the proper uses of waste glasses in Portland cement and concrete.     

Utilisation of high volumes of limestone quarry wastes in concrete industry (self-compacting concrete case)

In limestone quarries, considerable amounts of limestone powders are being produced as by-products of stone crushers. High amounts of powders are being collected and utilisation of this by-product is a big problem from the aspects of disposal, environmental pollution and health hazards. In conventional concrete, the introduction of high volumes of limestone quarry dust to concrete mixes is limited due to its negative effects on water demand and strength of concrete. However, these fines can be efficiently utilised as viscosity enhancer particularly in special concrete (like self-compacting concrete—SCC) applications. Thus, the successful utilisation of this quarry dust in SCC could turn this material into a valuable resource.In this paper the usability of a quarry dust limestone powder in self-compacting paste and concrete applications was investigated. In the first part, the physical and mechanical properties of cement pastes incorporating quarry waste limestone powder (QLP) and a powder produced by direct grinding of limestone (PLP) were compared. In the second part, the performance of quarry waste limestone powder in SCC applications were tested and discussed. Results showed that, it is possible to successfully utilise high amounts of quarry waste limestone powder in producing normal-strength SCCs. Among its observed mechanical advantages, employment of quarry waste limestone powders improved the economical feasibility of SCC production.     

Properties of steel foundry electric arc furnace dust solidified/stabilized with Portland cement

Electric arc furnace dust from steel production is generated in considerable amounts worldwide and needs to be treated as hazardous waste. The aim of this study was to investigate the properties of electric arc furnace dust solidified/stabilized by using Portland cement. Mortar and paste samples were prepared with varying waste-to-binder ratios between 0% and 90%. A comprehensive experimental program was designed including XRF characterization, setting time, unconfined compressive strength, and toxicity characteristics leaching procedure (TCLP), synthetic precipitation leaching procedure (SPLP), and acid neutralization capacity (ANC) tests. The results were evaluated in order to determine if the solidified /stabilized product can be disposed of at a landfill site with domestic waste or at a segregated landfill. The effect of using sand on S/S performance was also investigated. The results indicated that the solidification /stabilization process using PC helps the heavy metals to be bound in the cement matrix, but the TCLP leaching results exceeded the EPA landfilling limits. The SPLP leaching results conformed to the limits implying that the waste or S/S products can be disposed of at a segregated landfill; however the low ANC of the S/S products reveals that there may be leaching in the long-term. The sand used in the mortar samples adversely affected the S/S performance, causing higher heavy metal leaching levels, and lower pH levels in the leachate after the TCLP extraction than those measured in the leachate of the paste samples.     

The implementation of wood waste ash as a partial cement replacement material in the production of structural grade concrete and mortar: An overview

The timber manufacturing and power generation industry is gradually shifting towards the use of biomass such as timber processing waste for fuel and energy production and to help supplement the electrical energy demand of national electric gridlines. Though timber processing waste is a sustainable and renewable source of fuel for energy production, the thermal process of converting the aforementioned biomass into heat energy produces significant amounts of fine wood waste ash as a by-product material which, if not managed properly, may result in serious environmental and health problems. Several current researches had been carried out to incorporate wood waste ash as a cement replacement material in the production of greener concrete material and also as a sustainable means of disposal for wood waste ash. Results of the researches have indicated that wood waste ash can be effectively used as a cement replacement material for the production of structural grade concrete of acceptable strength and durability performances. This paper presents an overview of the work carried out by the use of wood waste ash as a partial replacement of cement in mortar and concrete mixes. Several aspects such as the physical and chemical properties of wood waste ash, properties of wood waste ash/OPC blended cement pastes, rheological, mechanical and the durability properties of wood waste ash/OPC concrete mix are detailed in this paper.     

Reuse of de-inking sludge from wastepaper recycling in cement mortar products

This paper presents results of an investigation into the use of de-inking sludge from a paper recycling mill as feedstock material in the manufacture of cement mortar products, including masonry blocks and mortar renders. Both physical and mechanical properties of mortar specimens containing various amounts of de-inking sludge were investigated. It was observed that the addition of de-inking sludge to cement mortar at a fixed water-to-cement ratio significantly reduced flow properties and increased setting time. Water absorption and volume of permeable voids of cement mortar increased with increased dosage of de-inking sludge, with a corresponding reduction of bulk density. The 91-day compressive strength of mortar samples with 2.5 wt% and 20 wt% de-inking sludge loadings retained 83% and 62% respectively of the reference mortar strength. The corresponding drying shrinkage increased by up to 160% compared to reference samples. However, a de-inking sludge loading of up to 2.5 wt% did not significantly alter measured physical and mechanical properties. The results demonstrate that despite the high moisture absorbance of de-inking sludge due to its organic matter and residual cellulose fibre content, it serves as a potential supplementary additive and its cellulosic content proving to be an active set retardant to cementitious masonry products.     

Evaluation of sulfate resistance of cement mortars containing black rice husk ash

In this paper, black rice husk ashes (BRHAs), which are agrowastes from an electricity generating power plant and a rice mill, were ground and used as a partial cement replacement. The durability of mortars under sulfate attack including expansion and compressive strength loss were investigated. For parametric study, BRHA were used as a Portland cement Type 1 replacement at the levels of 0%, 10%, 30%, and 50% by weight of binder. The water-to-binder ratios were 0.55 and 0.65. For the durability of mortar exposed to sulfate attack, 5% sodium sulfate (Na₂SO₄) and magnesium sulfate (MgSO₄) solutions were used. As a result, when increasing the percentage replacement of BRHA, the expansion and compressive strength loss of mortar decreased. At the replacement levels of 30% and 50% of BRHA, the expansion of the mortars was less than those mixed with sulfate-resistant cement. However, the expansion of the mortars exposed to Na₂SO₄ was more than those exposed to MgSO₄. Increasing the replacement level of BRHA tends to reduce the compressive strength loss of mortars exposed to Na₂SO₄ attack. In contrary, under MgSO₄ attack, when increasing the replacement level of BRHA, the compressive strength loss increases from 0% to 50% in comparison to Portland cement mortar. Results show that ground BRHA can be applied as a pozzolanic material to concrete and also improve resistance to sodium sulfate attack, but it can impair resistance to magnesium sulfate attack.     

Utilisation of high volumes of limestone quarry wastes in concrete industry (self-compacting concrete case)

In limestone quarries, considerable amounts of limestone powders are being produced as by-products of stone crushers. High amounts of powders are being collected and utilisation of this by-product is a big problem from the aspects of disposal, environmental pollution and health hazards. In conventional concrete, the introduction of high volumes of limestone quarry dust to concrete mixes is limited due to its negative effects on water demand and strength of concrete. However, these fines can be efficiently utilised as viscosity enhancer particularly in special concrete (like self-compacting concrete—SCC) applications. Thus, the successful utilisation of this quarry dust in SCC could turn this material into a valuable resource.In this paper the usability of a quarry dust limestone powder in self-compacting paste and concrete applications was investigated. In the first part, the physical and mechanical properties of cement pastes incorporating quarry waste limestone powder (QLP) and a powder produced by direct grinding of limestone (PLP) were compared. In the second part, the performance of quarry waste limestone powder in SCC applications were tested and discussed. Results showed that, it is possible to successfully utilise high amounts of quarry waste limestone powder in producing normal-strength SCCs. Among its observed mechanical advantages, employment of quarry waste limestone powders improved the economical feasibility of SCC production.     

Recycling contaminated soil as alternative raw material in cement facilities: Life cycle assessment

Volcanic soil can be used to remove metals from wastewaters. Once used, it is disposed in landfills. The utilization of this material in the cement industry as an alternative raw material was evaluated using life cycle assessment (LCA) methodology. This possibility has been studied from an environmental point of view in a Chilean cement facility, representative of the current operation state of art, including both technical and economic analysis. Two scenarios were compared: Scenario 1, which corresponds to the existing cement production process, and Scenario 2, which represents cement production using spent volcanic soil. With the exception of the categories of carcinogens (C) and minerals (M), the comparative results are favourable to Scenario 2, specially regarding to the category of ecotoxicity (E), mainly due to the avoided landfilling emissions of the volcanic soil. When considering the damage assessment, damage to human health (HH), ecosystem quality (EQ) and resources (R) are lower in Scenario 2. In addition, sensitivity analyses were performed to study the influence of particular parameters (i.e., transport of spent volcanic soil, CO₂ emissions from the clinkerization process and heavy metals leaching from the spent volcanic soil) on the results of the assessment. The use of alternative raw materials (in this case, spent volcanic soil), which present the advantage to be wastes from other technical systems, appear to allow the development of cement production in a more sustainable way, slightly improving the economy of the process. The spent volcanic soil can be treated with zero cost for the wastewater treatment plant with savings of 0.23€ for each tonne of clinker production. Establishing a sound management way for the spent volcanic soil could foment its possible use as mineral adsorbent in industrial wastewater treatment facilities.     

Mechanism for the stabilization/solidification of arsenic-contaminated soils with Portland cement and cement kiln dust

In this study, the mechanism for the stabilization/solidification (S/S) of arsenic (As)-contaminated soils with Portland cement (PC), and cement kiln dust (CKD) using 1 N HCl extraction fluid, X-ray powder diffraction (XRPD), X-ray absorption near edge structure (XANES) and Extended X-ray absorption fine structure (EXAFS) spectroscopy was investigated. The degree of As immobilization after stabilization was assessed using a 1 N HCl extraction on the basis of the Korean Standard Test (KST). After 1 day of curing with 30 wt% PC and 7 days of curing with 50 wt% CKD, the concentration of As leached from the amended soils was less than the Korean countermeasure standard (3 mg L^?1). The As concentrations in the leachate treated with PC and CKD were significantly decreased at pH > 3, indicating that pH had a prevailing influence on As mobility. XRPD results indicated that calcium arsenite (Ca–As–O) and sodium calcium arsenate hydrate (NaCaAsO₄·7.5H₂O) were present in the PC- and CKD-treated slurries as the key phases responsible for As(III) and As(V) immobilization, respectively. The XANES spectroscopy confirmed that the As(III) and As(V) oxidation states of the PC and CKD slurry samples were consistent with the speciated forms in the crystals identified by XRPD. EXAFS spectroscopy showed As–Ca bonding in the As(III)-PC and As(III)-CKD slurries. The main mechanism for the immobilization of As-contaminated soils with PC and CKD was strongly associated with the bonding between As(III) or As(V) and Ca.     

涪陵页岩气田钻井岩屑资源化利用实践

总结了涪陵页岩气田开发初期钻井岩屑采用固化填埋方式处置存在占地面积大且易产生二次污染隐患等问题,因地制宜地探索钻井岩屑的资源化利用。分析了水基岩屑随钻预处理和油基岩屑热脱附技术,结合钻井岩屑的理化性质,开展了水基岩屑脱水后干渣制路基材料、制砖及水泥窑协同处置,油基岩屑灰渣制混凝土、制砖及水泥窑协同处置的探索和实践,基于环境安全、技术稳定可靠、消纳量大的原则,最终形成了涪陵页岩气田钻井岩屑资源化方案:水基岩屑"随钻预处理、水泥窑协同处置",油基岩屑"热脱附、水泥窑协同处置",实现了钻井岩屑的资源化综合利用。     

The reuse of municipal solid waste incinerator fly ash slag as a cement substitute

The results of the treatment of fly ash from a municipal solid waste incinerator (MSWI) by melting are described, and the safety and the effectiveness of using the slag produced by this melting treatment are studied. The properties of the MSWI fly ash slag were analyzed, to evaluate the feasibility of its reuse as a substitute for part of the cement required in mortar preparation. This MSWI fly ash slag was found to be comprised mainly of SiO₂ and CaO, which can be substituted for up to 20% of the cement content in mortar, without sacrificing the quality of the resultant concrete. In fact, the concrete thus produced has greater compressive strength, 10% higher than that without the substitution. The setting time of the fresh mortar becomes lengthens as increasing amounts of cement are replaced; while the spread flow value increases with the increasing percentage of cement substitution. X-ray diffraction analysis reveals that when the W/C=0.38 and the curing AGE=28 days, the crystal patterns in the mortar samples, prepared with different amounts of cement having been replaced by MSWI fly ash slag are similar. According to the results of the toxic characteristic leaching procedure analysis, MSWI fly ash slag should be classified as general non-hazardous industrial waste, that meets the effluent standard. Therefore, the reuse of MSWI fly ash slag is feasible, and will not result in pollution due to the leaching of heavy metals.     

An overview of waste materials recycling in the Sultanate of Oman

Various wastes and by-product materials are generated in the Sultanate of Oman including reclaimed asphalt pavement (RAP) aggregate, demolition concrete, cement by-pass dust (CBPD), copper slag, petroleum-contaminated soils (PCS), discarded tires, incinerator ash, and others. Recycling of such materials in construction is not practiced. Research data are also minimal into the potential use of selected materials in construction applications. This paper will present the results of several laboratory studies conducted into the use of PCS in asphalt concrete mixtures; on the use of CBPD in soil stabilization and flowable fill mixtures; on the utilization of copper slag and CBPD as cementitious materials; on the use of incinerator ash in cement mortars; and on the use of RAP aggregate in road bases and sub-bases. Laboratory data generally indicate that it is feasible to partially reuse some of these materials in construction provided that economic incentives and environmental concerns are taken into consideration.     

浅谈3000t/d水泥生产线窑尾收尘系统改造

介绍了南阳航天水泥厂3000t/d水泥生产线窑尾收尘系统的改造背景、技术方案、施工方案和工程造价。改造采用了在原窑尾反吹风高温玻纤袋收尘器旁并联一台同类型单排袋式收尘器的方案,以增大窑尾袋收尘器过滤面积和降低过滤风速。该窑尾收尘系统的改造取得了明显的成效。     

An analysis of the use of life cycle assessment for waste co-incineration in cement kilns

Life cycle assessment, LCA, has become a key methodology to evaluate the environmental performance of products, services and processes and it is considered a powerful tool for decision makers. Waste treatment options are frequently evaluated using LCA methodologies in order to determine the option with the lowest environmental impact. Due to the approximate nature of LCA, where results are highly influenced by the assumptions made in the definition of the system, this methodology has certain non-negligible limitations. Because of that, the use of LCA to assess waste co-incineration in cement kilns is reviewed in this paper, with a special attention to those key inventory results highly dependent on the initial assumptions made. Therefore, the main focus of this paper is the life cycle inventory, LCI, of carbon emissions, primary energy and air emissions. When the focus is made on cement production, a tonne of cement is usually the functional unit. In this case, waste co-incineration has a non-significant role on CO₂ emissions from the cement kiln and an important energy efficiency loss can be deduced from the industry performance data, which is rarely taken into account by LCA practitioners. If cement kilns are considered as another waste treatment option, the functional unit is usually 1 t of waste to be treated. In this case, it has been observed that contradictory results may arise depending on the initial assumptions, generating high uncertainty in the results. Air emissions, as heavy metals, are quite relevant when assessing waste co-incineration, as the amount of pollutants in the input are increased. Constant transfer factors are mainly used for heavy metals, but it may not be the correct approach for mercury emissions.     

Particulates pollution management and economic analysis of small rural enterprises in mountain areas: A case study of Wenquan town in China

At present, many rural enterprises in China's mountainous areas are developing rapidly, and due to poor planning and improper management, in an uncontrolled manner. These small enterprises are making atmospheric pollution far more serious and more difficult to control than before. Thus, as is the case with most developing countries, China is facing the challenge of managing the increased environmental pollution that is accompanying its economic development. This paper examines the case of cement dust pollution in the town of Wenquan in Sichuan province in order to determine how to adjust the relationship between development of rural enterprises and atmospheric environmental pollution in mountainous areas. Using the single objective linear programming method, and based on the principle of overall optimization, an optimal control plan for different pollution sources was worked out and an economic assessment on reclamation of cement dust was completed. According to our analysis, after implementation of this plan for four years, two months, the concentrations of suspended particles in Wenquan will achieve the requirement of the national third-order ambient air quality standard; the current serious dust pollution will be completely controlled; and the reclamation of cement dust will totally compensate for the cost of dust control and will result in 92,000 yuan of pure profit per year. At that time, the economy and environment will be in harmony.     

Energetic valorization of SRF in dedicated plants and cement kilns and guidelines for application in Greece and Cyprus

A debate is still open on issues of waste to energy methodologies aiming to answer to questions of particular relevance, such as whether the concept of SRF/RDF production can be applied directly to MSW through the Mechanical–Biological Treatment (MBT) process, when selective collection acts as a virtual pre-treatment of the same, or if the use of SRF/RDF as alternative fuel in cement kilns is the most sustainable solution. In this study, two scenarios were analyzed and compared: (a) the use of SRF in a new dedicated thermal plant for electricity production and (b) the use of SRF as an alternative fuel in an existing cement plant. The comparative assessment was based on principles of Sustainable Waste Management embracing technical and cost issues, environmental protection, industrial ecology and symbiosis. The application of SWOT analysis showed that the use of SRF in cement kilns is more sustainable compared to its use in a new dedicated plant for electricity production.     

Formulation of criteria for pollution control on cement products produced from solid wastes in China

The process of producing cement products from solid waste can increase the level of pollutants in the cement products. Therefore, it is very important to establish a pollution control standard for cement products to protect the environment and human health. This paper presents acceptance limits for the availability of heavy metals in cement products which have been produced from solid wastes and explains how the limits have been calculated. The approach and method used to formulate these criteria were based on EN 12920. The typical exposure scenarios used in this paper involve concrete being used for drinking water supply pipelines and concrete pavements and are based on an analysis of typical applications of cement in China, and the potential for contact with water. The parameters of a tank test which was based on NEN 7375 were set in accordance with the environmental conditions of typical scenarios in China. Mechanisms controlling the release of heavy metals in concrete and a model for that release were obtained using the leaching test. Finally, based on acceptance criteria for drinking water and groundwater quality in China, limit values for the availability of heavy metals in concrete were calculated.     

Air pollution by concrete dust from the Great Hanshin Earthquake

Air pollution in the areas affected by the Great Hanshin Earthquake (Hyogo, Japan) of 17 Jan. 1995 was quite serious. We performed three investigations of dust. In the first investigation, we measured the total suspended particulate (TSP) concentration in the greatly damaged areas, located around the Sannomiya Station where a few hundred thousand people walked by during the daytime of 3 February. The maximum concentration at five points reached 150 microg/m3. In the second investigation, eight samples, which were classified into three groups (concrete, mortar, and soil dusts) as sources, were analyzed elementally by X-ray fluorescence. The elements found in concrete dust (Ca and S) were similar to those found in mortar dust. These differed from those found in soil dust (Ti, Fe, and Zr). The elements found in soil dust were important from the viewpoint of heavy metal contamination. In the third investigation, the alkalinity of concrete dust was observed by dissolution. This solution was equivalent to pH 11 to 12 and electrical conductivity 20 to 30 microS/m. We suspect that the alkaline component in the dust from debris in all the devastated areas was approximately comparable with the alkaline solution by which the acid rain falling over the Hanshin district of Osaka Megalopolis in one year could be neutralized into water of pH 7.0.