Fly ash of mineral coal as ceramic tiles raw material

The aim of this work was to evaluate the use of mineral coal fly ash as a raw material in the production of ceramic tiles. The samples of fly ash came from Capivari de Baixo, a city situated in the Brazilian Federal State of Santa Catarina. The fly ash and the raw materials were characterized regarding their physical chemical properties, and, based on these results; batches containing fly ash and typical raw materials for ceramic tiles were prepared. The fly ash content in the batches varied between 20 and 80 wt%. Specimens were molded using a uniaxial hydraulic press and were fired. All batches containing ash up to 60 wt% present adequate properties to be classified as several kinds of products in the ISO 13006 standard () regarding its different absorption groups (pressed). The results obtained indicate that fly ash, when mixed with traditional raw materials, has the necessary requirements to be used as a raw material for production of ceramic tiles.     

Coal fly ash as raw material for the manufacture of geopolymer-based products

In this work coal fly ash has been employed for the synthesis of geopolymers. Two different systems with silica/alumina ratios stoichiometric for the formation of polysialatesiloxo (PSS, SiO2/Al2O3=4) and polysialatedisiloxo (PSDS, SiO2/Al2O3=6) have been prepared. The alkali metal hydroxide (NaOH or KOH) necessary to start polycondensation has been added in the right amount as concentrated aqueous solution to each of the two systems. The concentration of each alkali metal solution has been adjusted in order to have the right liquid volume to ensure constant workability. The systems have been cured at four different temperatures (25, 40, 60, and 85 degrees C) for several different times depending on the temperature (16-672 h at 25 degrees C; 72-336 h at 40 degrees C; 16-120 h at 60 degrees C and 1-6h at 85 degrees C). The products obtained in the different experimental conditions have been submitted to the quantitative determination of the extent of polycondensation through mass increase and loss on ignition, as well as to qualitative characterization by means of FT-IR spectroscopy. Furthermore, physico-structural and mechanical characterization has been carried out through microscopic observations and the determination of unconfined compressive strength, elasticity modulus, apparent density, porosity and specific surface area. The results have indicated that the systems under investigation are suited for the manufacture of pre-formed building blocks at room temperature.     

Sustainable red ceramic block: recycling of a sewage sludge as raw material

Journal of Material Cycles and Waste Management - Sewage sludge (SS) is a residue resulting from wastewater treatment, which is widely increasing due to population growth and economic development....     

Recycling of iron foundry sand and glass waste as raw material for production of whiteware.

The purpose of this study was to evaluate the production feasibility of triaxial whiteware using sand from cast iron moulds as a raw material instead of silica, and recycled glass in place of feldspar. Formulations were prepared using sand, glass waste, and white-firing clay such that only 50% of the composition was virgin material (clay). The ceramic bodies were formed by pressing and fired at different temperatures (between 1100 and 1300 degrees C). Specimens were characterized in terms of green density prior to firing; and their flexural strength, linear shrinkage, and water absorption were measured after firing. The microstructure was determined by scanning electron microscopy. Possible environmental impacts of this recycling process were also evaluated, through solubility and leaching tests, according to Brazilian standards. Gaseous emissions during the firing process were also analysed. The results showed that it is possible to produce triaxial ceramics by using such alternative raw materials.     

The clayey quarry sludge from a waste to a valuable raw material for red ceramics

Journal of Material Cycles and Waste Management - This study aims to evaluate the reuse of clayey quarry sludge generated during the washing process of aggregates in crushing plants as a raw...     

Fly ash from biomass combustion as replacement raw material and its influence on the mortars durability

Journal of Material Cycles and Waste Management - Several types of industrial solid waste have been used as byproducts in the construction and materials industries. Some of the applications seem to...     

Gypsum treated fly ash as a liner for waste disposal facilities

Fly ash has potential application in the construction of base liners for waste containment facilities. While most of the fly ashes improve in the strength with curing, the ranges of permeabilities they attain may often not meet the basic requirement of a liner material. An attempt has been made in the present context to reduce the hydraulic conductivity by adding lime content up to 10% to two selected samples of class F fly ashes. The use of gypsum, which is known to accelerate the unconfined compressive strength by increasing the lime reactivity, has been investigated in further improving the hydraulic conductivity. Hydraulic conductivities of the compacted specimens have been determined in the laboratory using the falling head method. It has been observed that the addition of gypsum reduces the hydraulic conductivity of the lime treated fly ashes. The reduction in the hydraulic conductivity of the samples containing gypsum is significantly more for samples with high amounts of lime contents (as high as 1000 times) than those fly ashes with lower amounts of lime. However there is a relatively more increase in the strengths of the samples with the inclusion of gypsum to the fly ashes at lower lime contents. This is due to the fact that excess lime added to fly ash is not effectively converted into pozzolanic compounds. Even the presence of gypsum is observed not to activate these reactions with excess lime. On the other hand the higher amount of lime in the presence of sulphate is observed to produce more cementitious compounds which block the pores in the fly ash. The consequent reduction in the hydraulic conductivity of fly ash would be beneficial in reducing the leachability of trace elements present in the fly ash when used as a base liner.     

Assessment of mechanical,durability and microstructural properties of geopolymer concrete containing ceramic tile waste

Journal of Material Cycles and Waste Management - The amount of ceramic waste being generated is increasing day by day, and ceramic waste management is one of the most challenging issues for many...     

Recycling of combined coal-biomass ash from electric power plant waste as a cementitious material: characteristics and improvement

Combined coal-biomass ash has an enormous impact on environmental quality near electric power plants. This paper describes an alternative to disposal in which the ash is used to produce cementitious materials. Ash was obtained from combustion of coal and biomass containing four mass ratios of anthracite, bitumen, rice husks, and eucalyptus bark. The cement-forming properties were systematically characterized including compressive strength development, durability, and expansion in water. The ash samples were ground to increase the specific surface area, and then used to partially replace ASTM Type I Portland cement in mixtures containing 15, 30, or 45 % ash by mass. The water-binder material's (Portland cement with or without combined coal-biomass ash) ratios (w/c) were held constant at 45, 55, or 65 % by mass. Types A, B, and D ash behaved similarly, while the properties of type C ash were slightly different. Increasing the ash fraction in Portland cement mixtures increased the water requirement and resulted in lower compressive strength. Thorough mechanical grinding reduced the porosity and significantly enhanced the material properties.     

Aggregate material formulated with MSWI bottom ash and APC fly ash for use as secondary building material

The main goal of this paper is to obtain a granular material formulated with Municipal Solid Waste Incineration (MSWI) bottom ash (BA) and air pollution control (APC) fly ash to be used as secondary building material. Previously, an optimum concrete mixture using both MSWI residues as aggregates was formulated. A compromise between the environmental behavior whilst maximizing the reuse of APC fly ash was considered and assessed. Unconfined compressive strength and abrasion resistance values were measured in order to evaluate the mechanical properties. From these results, the granular mixture was not suited for certain applications owing to the high BA/APC fly ash content and low cement percentages used to reduce the costs of the final product. Nevertheless, the leaching test performed showed that the concentrations of all heavy metals were below the limits established by the current Catalan legislation for their reutilization. Therefore, the material studied might be mainly used in embankments, where high mechanical properties are not needed and environmental safety is assured.     

Recycling MSWI bottom and fly ash as raw materials for Portland cement

Municipal solid waste incineration (MSWI) ash is rich in heavy metals and salts. The disposal of MSWI ash without proper treatment may cause serious environmental problems. Recently, the local cement industry in Taiwan has played an important role in the management of solid wastes because it can utilize various kinds of wastes as either fuels or raw materials. The objective of this study is to assess the possibility of MSWI ash reuse as a raw material for cement production. The ash was first washed with water and acid to remove the chlorides, which could cause serious corrosion in the cement kiln. Various amounts of pre-washed ash were added to replace the clay component of the raw materials for cement production. The allowable limits of chloride in the fly ash and bottom ash were found to be 1.75% and 3.50% respectively. The results indicate that cement production can be a feasible alternative for MSWI ash management. It is also evident that the addition of either fly ash or bottom ash did not have any effect on the compressive strength of the clinker. Cement products conformed to the Chinese National Standard (CNS) of Type II Portland cement with one exception, the setting time of the clinker was much longer.     

Mechanical and thermal properties of bottom ash-based porous geopolymer as thermal insulation material for construction

Journal of Material Cycles and Waste Management - A geo-polymer is a cement-like material that can be used instead of Portland cement, requiring less energy, and emitting less CO2 in its...     

Some limitations of sluiced fly ash as a liming material for acidic soils

Innovative methods are currently being sought to safely utilize and reduce the amount of sluiced fly ash stored in on-site facilities at thermal electric power facilities in Ontario, Canada. The objective of this study was to investigate the possibility of utilizing sluiced fly ash as a liming material on acidic soils. A greenhouse experiment was established to examine the influence of the ash on soil pH values and the yield and chemical composition of corn, soybeans, wheat and alfalfa grown on amended soil.The sluiced ash had an initial pH value of 9.1 (1:1 H₂O) and contained an equivalent CaCO₃ content of 11.5% (±0.2%) based on total content of Ca and Mg in the ash. Fly ash was applied at rates of up to 167 tonnes ha⁻¹ to samples of the surface horizon (0–15 cm) of an acidic clay textured soil found local to the power plant. Application of fly ash increased soil pH values but a high concentration of boron in the added ash limited plant growth. Results indicated that the sluiced ash could be used as a liming material at application rates of up to 110 tonnes ha⁻¹, on acidic, clay textured soils provided boron tolerant crops such as alfalfa were grown. Further research is required to establish the potential for leaching of boron to ground water and to determine the potential for plant uptake of other trace elements such as As and Se.     

Use of rubber and bentonite added fly ash as a liner material

In many countries regulations require all hazardous waste disposal facilities to be lined with suitable impermeable barriers to protect against contamination. In this study, a series of laboratory tests on rubber and bentonite added fly ash were conducted. The aim of the tests was to evaluate the feasibility of utilizing fly ash, rubber and bentonite as a low hydraulic conductivity liner material. Type C fly ash was obtained from Soma thermal power plant in Turkey; rubber in pulverized form was waste from the retreading industry. To investigate the properties of rubber and bentonite added fly ash, hydraulic conductivity, leachate analysis, unconfined compression, split tensile strength, one-dimensional consolidation, swell and freeze/thaw cycle tests were performed. The overall evaluation of results have revealed that rubber and bentonite added fly ash showed good promise and a candidate for construction of a liner.     

Cement-based materials as containment systems for ash from hospital waste incineration

Waste generation has increased considerably worldwide in the last decades. As a consequence, incineration became an alternative for reducing waste volume, leading to the generation of ash as a new type of waste. The new cement-ash composite systems have been tested for future applications in building materials. Having in mind the previous data and scientific reports, the objective of the present study is oriented to evaluate the additions of hospital waste ash in cement matrices to be potentially used as construction elements. This involved the assessment of the effect of the additions (different proportions of ash and metal-spiked ash) on the physico-mechanical properties of the building materials and the leachability of metals. The experiences show the feasibility of including hospital waste ashes in masonry blocks or other similar products.     

Supporting circular economy through the use of red ceramic waste as supplementary cementitious material in structural concrete

Journal of Material Cycles and Waste Management - This paper investigates the potential application of red ceramic waste as supplementary cementitious materials in structural concrete as a strategy...     

Determinants of waste characterization in Lebanon and material recovery potential

Journal of Material Cycles and Waste Management - Waste represents a largely untapped source of raw material in many countries, as resource recovery rates remain generally low despite most of the...