Artificial lightweight aggregates as utilization for future ashes - A case study

In the future, more electricity in the Netherlands will be produced using coal with co-combustion. Due to this, the generated annual ash volume will increase and the chemical composition will be influenced. One of the options for utilization if present markets are saturated and for use of fly ashes with different compositions, is as raw material for lightweight aggregates. This was selected as one of the best utilizations options regarding potential ash volume to be applied, environmental aspects and status of technology. Because of this, a study has been performed to assess the potential utilization of fly ash for the production of lightweight aggregate. Lightweight aggregate has been produced in a laboratory scale rotary kiln. The raw material consisted of class F fly ash with high free lime content. An addition of 8% clay was necessary to get green pellets with sufficient green strength. The basic properties of the produced lightweight aggregate and its behaviour in concrete have been investigated. The concrete has a good compressive strength and its leaching behaviour meets the most stringent requirements of Dutch environmental regulations. The carbon foot print of concrete will be negatively influenced if only the concrete itself is taken into account, but the reduction of the volume weight has advantages regarding design, transport emissions and isolation properties which may counteract this. In the Dutch situation the operational costs are higher than expected potential selling price for the LWA, which implies that the gate fee for the fly ash is negative.     

Synthetic aggregates from combustion ashes using an innovative rotary kiln

This paper describes the use of a number of different combustion ashes to manufacture synthetic aggregates using an innovative rotary 'Trefoil' kiln. Three types of combustion ash were used, namely: incinerated sewage sludge ash (ISSA); municipal solid waste incinerator bottom ash (MSWIBA-- referred to here as BA); and pulverised fuel ash (Pfa). The fine waste ash fractions listed above were combined with a binder to create a plastic mix that was capable of being formed into 'green pellets'. These pellets were then fired in a Trefoil kiln to sinter the ashes into hard fused aggregates that were then tested for use as a replacement for the natural coarse aggregate in concrete. Results up to 28 days showed that these synthetic aggregates were capable of producing concretes with compressive strengths ranging from 33 to 51 MPa, equivalent to between 73 and 112% of that of the control concrete made with natural aggregates.     

Lightweight aggregate made from sewage sludge and incinerated ash

In this study, sewage sludge ash (SSA), with similar characteristics to expansive clay, was used as the principal material and sewage sludge (SS) as the admixture to sinter lightweight aggregate and to study the influences of raw material composition on pelletising, sintering effect and aggregate properties. Results showed that both SS and SSA could be sintered to produce synthetic aggregates individually or mixed. Increasing the amount of SS would decrease the pelletising ratio. Under the consideration of energy saving, the mixture of SSA was better for sintering normal weight aggregate. On the contrary, the mixture that added 20-30% of SS was more adequate to make lightweight aggregates. Adding SS would enhance the oxidation-reduction reaction and lower the bulk density and sintering temperature of aggregates to save energy. Sintering temperature affected the properties of sewage sludge ash lightweight aggregate (SSALA) more than retention period did. Prolonging the retention period could improve bloating effect.     

Influence of pelletization process on the properties of fly ash aggregates

A pelletization process is used to manufacture artificial lightweight coarse aggregate using fly ash. Pelletization depends on the size of particles and their distribution, the wettability of particles and moisture content, along with the process related parameters. A review indicates that only limited studies have been reported on the pelletization of fly ash aggregates. The influence of the following parameters has been studied: (i) speed of revolution of pelletizer disc, (ii) angle of pelletizer disc, (iii) moisture content, and (iv) duration of pelletization. Fractional factorial experiments using the concept of Taguchi's orthogonal array is used in this study, which uses an orthogonal array table to arrange multifactor experiments and uses statistical methods to analyze the experimental results. The relative influence of the factors above and their interaction effects on the strength, water absorption and size growth of fly ash aggregates are discussed.     

Reuse of thermosetting plastic waste for lightweight concrete

This paper presents the utilization of thermosetting plastic as an admixture in the mix proportion of lightweight concrete. Since this type of plastic cannot be melted in the recycling process, its waste is expected to be more valuable by using as an admixture for the production of non-structural lightweight concrete. Experimental tests for the variation of mix proportion were carried out to determine the suitable proportion to achieve the required properties of lightweight concrete, which are: low dry density and acceptable compressive strength. The mix design in this research is the proportion of plastic, sand, water-cement ratio, aluminum powder, and lignite fly ash. The experimental results show that the plastic not only leads to a low dry density concrete, but also a low strength. It was found that the ratio of cement, sand, fly ash, and plastic equal to 1.0:0.8:0.3:0.9 is an appropriate mix proportion. The results of compressive strength and dry density are 4.14N/mm(2) and 1395kg/m(3), respectively. This type of concrete meets most of the requirements for non-load-bearing lightweight concrete according to ASTM C129 Type II standard.     

Influence of aggregate pre-wetting and fly ash on mechanical properties of lightweight concrete

This study has examined the mechanical properties of lightweight aggregate concrete with a density of 1800 kg/m3. The effects of the following parameters on the concrete properties have been analyzed: the pre-wetting time of the lightweight aggregate and the percentage of pulverized fly ash used as cementitious replacement material. The strength of the lightweight aggregate was found to be the primary factor controlling the strength of high-strength lightweight concrete. An increase in the cementitious content from 420 to 450 kg/m3 does not significantly increase the strength of lightweight aggregate concrete. The relationship between the flexural and compressive strength at 28 days can be represented by the equation fr=0.69/fck. The elastic modulus was found to be much lower than that of normal weight concrete, ranging from 15.0 to 20.3 GPa. The addition of PFA increases the slump and density of lightweight aggregate concrete.     

Investigation of gamma ray absorption levels of composites produced from copper mine tailings,fly ash,and brick dust

To date, heavyweight concretes have been produced from various heavy aggregates as radiation insulation materials, and their gamma ray absorption levels have been investigated. Many of the studies have used heavy aggregates instead of cement or coarse aggregates from composite material components. The present study prepared lightweight concretes using copper mine tailings, clay brick dust, and fly ash instead of fine aggregates. Some mechanical tests (density, compressive strength, and ultrasonic pulse velocity) were performed on composite blocks with dimensions of 5*5*5 cm, and radiation interaction parameters [linear absorption coefficient (cm⁻¹), mass attenuation coefficient (cm²/gr), HVL (half-value layer) (cm), MFP (cm), and permeability (%)] were measured. Radiation interaction parameters were obtained using a HPGe gamma detector. Radiation measurements were performed at five different photon energies: 583 keV (¹³³Ba), 609 keV (¹³³Ba), 662 keV (¹³⁷Cs), 911 keV (133^Ba), 1173 keV (⁶⁰Co), and 1332 keV (⁶⁰Co). Additionally, the compressive strength and UPV values of composite materials were associated with their gamma ray permeability. Tests revealed that samples with the addition of copper mine tailings yielded the best energy absorption at all energy levels and that absorption decreased as the energy level increased. For example, with the increasing of the energy level, mass attenuation coefficients decreased. The highest mass attenuation coefficients were obtained as 0.128 cm²/g at an energy level of 583 keV in composites produced from copper mine tailings. On the other hand, it was measured at the same energy level as 0.069 cm²/g (a 46% decrease) in the composites produced with fly ash. In addition, it was observed that fly ash used as a fine aggregate did not have a significant effect on mass attenuation coefficient and could be used as a gamma shield if the material thickness was increased to an average of 14 cm. This study revealed that tailings materials could be used as radiation shields. This study also demonstrated that not using heavy aggregates and producing lightweight concrete in radiation shield production significantly reduced shield production cost.

     

Evaluation of concrete incorporating bottom ash as a natural aggregates replacement

A study on the incorporation of coal bottom ash from thermoelectric power stations as a substitute material for natural sand in the production of concrete is here presented. The normally coarse, fused, glassy texture of bottom ash makes it an ideal substitute for natural aggregates. The use of bottom ash in concrete presents several technical challenges: the physical and mineralogical characteristics of the bottom ash; the effect on water demand and the participation on cements hydratation. In the production of the concrete, substitutions in volume were used. Two different ways to employ bottom ash were used to make up the mix proportions: one considering the natural humidity present in the porous particles and the other not considering it, seeking to maintain the same strength. These considerations are fundamental given that the process of bottom ash extraction is carried out through moisture. Mechanical tests by compressive strength were performed and the elastic modulus was determined. An analysis of the influence of bottom ash in the formation of pores was carried out through tests for the water loss by air drying and water uptake by capillary absorption. The results show that the higher the bottom ash contents in the concrete, the worse the performance regarding moisture transport. However, for one bottom ash concrete type, the mechanical properties were maintained.     

Utilization of power plant bottom ash as aggregates in fiber-reinforced cellular concrete

Recently, millions tons of bottom ash wastes from thermoelectric power plants have been disposed of in landfills and coastal areas, regardless of its recycling possibility in construction fields. Fiber-reinforced cellular concrete (FRCC) of low density and of high strength may be attainable through the addition of bottom ash due to its relatively high strength. This paper focuses on evaluating the feasibility of utilizing bottom ash of thermoelectric power plant wastes as aggregates in FRCC. The flow characteristics of cement mortar with bottom ash aggregates and the effect of aggregate type and size on concrete density and compressive strength were investigated. In addition, the effects of adding steel and polypropylene fibers for improving the strength of concrete were also investigated. The results from this study suggest that bottom ash can be applied as a construction material which may not only improve the compressive strength of FRCC significantly but also reduce problems related to bottom ash waste.     

Recovery of MSWI and soil washing residues as concrete aggregates

The aim of the present work was to study if municipal solid waste incinerator (MSWI) residues and aggregates derived from contaminated soil washing could be used as alternative aggregates for concrete production.Initially, chemical, physical and geometric characteristics (according to UNI EN 12620) of municipal solid waste incineration bottom ashes and some contaminated soils were evaluated; moreover, the pollutants release was evaluated by means of leaching tests. The results showed that the reuse of pre-treated MSWI bottom ash and washed soil is possible, either from technical or environmental point of view, while it is not possible for the raw wastes.Then, the natural aggregate was partially and totally replaced with these recycled aggregates for the production of concrete mixtures that were characterized by conventional mechanical and leaching tests. Good results were obtained using the same dosage of a high resistance cement (42.5R calcareous Portland cement instead of 32.5R); the concrete mixture containing 400 kg/m³ of washed bottom ash and high resistance cement was classified as structural concrete (C25/30 class). Regarding the pollutants leaching, all concrete mixtures respected the limit values according to the Italian regulation.     

An investigation on the use of shredded waste PET bottles as aggregate in lightweight concrete

In this work, the utilization of shredded waste Poly-ethylene Terephthalate (PET) bottle granules as a lightweight aggregate in mortar was investigated. Investigation was carried out on two groups of mortar samples, one made with only PET aggregates and, second made with PET and sand aggregates together. Additionally, blast-furnace slag was also used as the replacement of cement on mass basis at the replacement ratio of 50% to reduce the amount of cement used and provide savings. The water–binder (w/b) ratio and PET–binder (PET/b) ratio used in the mixtures were 0.45 and 0.50, respectively. The size of shredded PET granules used in the preparation of mortar mixtures were between 0 and 4 mm. The results of the laboratory study and testing carried out showed that mortar containing only PET aggregate, mortar containing PET and sand aggregate, and mortars modified with slag as cement replacement can be drop into structural lightweight concrete category in terms of unit weight and strength properties. Therefore, it was concluded that there is a potential for the use of shredded waste PET granules as aggregate in the production of structural lightweight concrete. The use of shredded waste PET granules due to its low unit weight reduces the unit weight of concrete which results in a reduction in the death weight of a structural concrete member of a building. Reduction in the death weight of a building will help to reduce the seismic risk of the building since the earthquake forces linearly dependant on the dead-weight. Furthermore, it was also concluded that the use of industrial wastes such as PET granules and blast-furnace slag in concrete provides some advantages, i.e., reduction in the use of natural resources, disposal of wastes, prevention of environmental pollution, and energy saving.     

Recycled lightweight concrete made from footwear industry waste and CDW

In this paper two types of recycled aggregate, originated from construction and demolition waste (CDW) and ethylene vinyl acetate (EVA) waste, were used in the production of concrete. The EVA waste results from cutting off the EVA expanded sheets used to produce insoles and innersoles of shoes in the footwear industry. The goal of this study was to evaluate the influence of the use of these recycled aggregates as replacements of the natural coarse aggregate, upon density, compressive strength, tensile splitting strength and flexural behavior of recycled concrete. The experimental program was developed with three w/c ratios: 0.49, 0.63 and 0.82. Fifteen mixtures were produced with different aggregate substitution rates (0%, 50% EVA, 50% CDW, 25% CDW–25% EVA and 50% CDW–50% EVA), by volume. The results showed that it is possible to use the EVA waste and CDW to produce lightweight concrete having semi-structural properties.     

Properties of lightweight aggregate concrete prepared with PVC granules derived from scraped PVC pipes

This paper aims to investigate the fresh and hardened properties of lightweight aggregate concretes that are prepared with the use of recycled plastic waste sourced from scraped PVC pipes to replace river sand as fine aggregates. A number of laboratory prepared concrete mixes were tested, in which river sand was partially replaced by PVC plastic waste granules in percentages of 0%, 5%, 15%, 30% and 45% by volume. Two major findings are identified. The positive side shows that the concrete prepared with a partial replacement by PVC was lighter (lower density), was more ductile (greater Poisson's ratios and reduced modulus of elasticity), and had lower drying shrinkage and higher resistance to chloride ion penetration. The negative side reveals that the workability, compressive strength and tensile splitting strength of the concretes were reduced. The results gathered would form a part of useful information for recycling PVC plastic waste in lightweight concrete mixes.     

Alkali-silica reactions of mortars produced by using waste glass as fine aggregate and admixtures such as fly ash and Li2CO3

Use of waste glass or glass cullet (GC) as concrete aggregate is becoming more widespread each day because of the increase in resource efficiency. Recycling of wastes is very important for sustainable development. When glass is used as aggregate in concrete or mortar, expansions and internal stresses occur due to an alkali-silica reaction (ASR). Furthermore, rapid loss in durability is generally observed due to extreme crack formation and an increase in permeability. It is necessary to use some kind of chemical or mineral admixture to reduce crack formation. In this study, mortar bars are produced by using three different colors of glass in four different quantities as fine aggregate by weight, and the effects of these glass aggregates on ASR are investigated, corresponding to ASTM C 1260. Additionally, in order to reduce the expansions of mortars, 10% and 20% fly ash (FA) as mineral admixture and 1% and 2% Li(2)CO(3) as chemical admixture are incorporated by weight in the cement and their effects on expansion are examined. It is observed that among white (WG), green (GG) and brown glass (BG) aggregates, WG aggregate causes the greatest expansion. In addition, expansion increases with an increase in amount of glass. According to the test results, it is seen that over 20% FA and 2% Li(2)CO(3) replacements are required to produce mortars which have expansion values below the 0.2% critical value when exposed to ASR. However, usages of these admixtures reduce expansions occurring because of ASR.     

Evaluation on the applicability of dry processed bottom ash as lightweight aggregate for construction fields

Currently, wet bottom ash is not sufficiently utilized due to its content of unburned coal, chloride and moisture. In contrast, bottom ash discharged from the recently introduced dry process spends a longer time on the clinker conveyer in the lower part of the boiler and consequently contains a significantly smaller amount of unburned coal. Consequently, it has high potential for use as a lightweight aggregate for construction material because of properties such as high porosity, low unburned coal content, non-chloride, and non-moisture. However, it is not frequently used for construction because the ash particle has a flat and thin shape, coarse surface and unfavorable structural strength. Against this backdrop, this study has conducted a range of experiments to identify the shapes, structure, density, absorption, percentage of floating particles, unit volume weight, solid volume, characteristics of air bubbles and micro pores, crushing strength of bottom ash, and the following results were observed. Though the dry bottom ash has sharp and angular edges, its flat and thin shapes lead to vulnerable structures. Dry bottom ash of the size of 0.6 mm or larger has 50–60 % of the total pore rate and 30–50 % of the closed pore rate. Considering these qualities, by removing the relatively fragile surface parts and making the particles more globular, dry bottom ash can be used as a lightweight aggregate for construction field having outstanding performance in terms of light weight and insulation.     

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.     

Studies on recycled aggregates-based concrete.

Reduced extraction of raw materials, reduced transportation cost, improved profits, reduced environmental impact and fast-depleting reserves of conventional natural aggregates has necessitated the use of recycling, in order to be able to conserve conventional natural aggregate. In this study various physical and mechanical properties of recycled concrete aggregates were examined. Recycled concrete aggregates are different from natural aggregates and concrete made from them has specific properties. The percentages of recycled concrete aggregates were varied and it was observed that properties such as compressive strength showed a decrease of up to 10% as the percentage of recycled concrete aggregates increased. Water absorption of recycled aggregates was found to be greater than natural aggregates, and this needs to be compensated during mix design.     

Manufacture of artificial aggregate using MSWI bottom ash

This paper reports the results of an investigation on material recovery by stabilization/solidification of bottom ash coming from a municipal solid waste incineration plant. Stabilization/solidification was carried out to produce artificial aggregate in a rotary plate granulator by adding hydraulic binders based on cement, lime and coal fly ash. Different mixes were tested in which the bottom ash content ranged between 60% and 90%. To avoid undesirable swelling in hardened products, the ash was previously milled and then granulated at room temperature. The granules were tested to assess their suitability to be used as artificial aggregate through the measurement of the following properties: density, water absorption capacity, compressive strength and heavy metals release upon leaching. It was demonstrated that the granules can be classified as lightweight aggregate with mechanical strength strongly dependent on the type of binder. Concrete mixes were prepared with the granulated artificial aggregate and tested for in-service performance, proving to be suitable for the manufacture of standard concrete blocks in all the cases investigated.     

Production of lightweight aggregate from industrial waste and carbon dioxide

The concomitant recycling of waste and carbon dioxide emissions is the subject of developing technology designed to close the industrial process loop and facilitate the bulk-re-use of waste in, for example, construction. The present work discusses a treatment step that employs accelerated carbonation to convert gaseous carbon dioxide into solid calcium carbonate through a reaction with industrial thermal residues. Treatment by accelerated carbonation enabled a synthetic aggregate to be made from thermal residues and waste quarry fines. The aggregates produced had a bulk density below 1000 kg/m³ and a high water absorption capacity. Aggregate crushing strengths were between 30% and 90% stronger than the proprietary lightweight expanded clay aggregate available in the UK. Cast concrete blocks containing the carbonated aggregate achieve compressive strengths of 24 MPa, making them suitable for use with concrete exposed to non-aggressive service environments. The energy intensive firing and sintering processes traditionally required to produce lightweight aggregates can now be augmented by a cold-bonding, low energy method that contributes to the reduction of green house gases to the atmosphere.     

Development of lightweight aggregate from dry sewage sludge and coal ash

In this study, dry sewage sludge (DSS) as the principal material was blended with coal ash (CA) to produce lightweight aggregate. The effects of different raw material compositions and sintering temperatures on the aggregate properties were then evaluated. In addition, an environmental assessment of the lightweight aggregate generated was conducted by analyzing the fixed rate of heavy metals in the aggregate, as well as their leaching behavior. The results indicated that using DSS enhanced the pyrolysis–volatilization reaction due to its high organic matter content, and decreased the bulk density and sintering temperature. However, the sintered products of un-amended DSS were porous and loose due to the formation of large pores during sintering. Adding CA improved the sintering temperature while effectively decreasing the pore size and increasing the compressive strength of the product. Furthermore, the sintering temperature and the proportion of CA were found to be the primary factors affecting the properties of the sintered products, and the addition of 18–25% of CA coupled with sintering at 1100 °C for 30 min produced the highest quality lightweight aggregates. In addition, heavy metals were fixed inside products generated under these conditions and the As, Pb, Cd, Cr, Ni, Cu, and Zn concentrations of the leachate were found to be within the limits of China’s regulatory requirements.