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.     

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.     

Photocatalytic activity of titanium dioxide modified concrete materials – Influence of utilizing recycled glass cullets as aggregates

Combining the use of photocatalysts with cementitious materials is an important development in the field of photocatalytic air pollution mitigation. This paper presents the results of a systematic study on assessing the effectiveness of pollutant degradation by concrete surface layers that incorporate a photocatalytic material – Titanium Dioxide. The photocatalytic activity of the concrete samples was determined by photocatalytic oxidation of nitric oxide (NO) in the laboratory. Recycled glass cullets, derived from crushed waste beverage bottles, were used to replace sand in preparing the concrete surface layers. Factors, which may affect the pollutant removal performance of the concrete layers including glass color, aggregate size and curing age, were investigated. The results show a significant enhancement of the photocatalytic activity due to the use of glass cullets as aggregates in the concrete layers. The samples fabricated with clear glass cullets exhibited threefold NO removal efficiency compared to the samples fabricated with river sand. The light transmittance property of glass was postulated to account for the efficiency improvement, which was confirmed by a separate simulation study. But the influence of the size of glass cullets was not evident. In addition, the photocatalytic activity of concrete surface layers decreased with curing age, showing a loss of 20% photocatalytic activity after 56-day curing.     

Concrete block production from construction and demolition waste in Tanzania

In Tanzania, construction and demolition (C&D) waste is not recycled and knowledge on how it can be recycled especially into valuable products like building materials are still limited. This study aimed at investigating the possibility of recycling the C&D waste (mainly cementitious rubble) into building material in Tanzania. The building materials produced from C&D waste was concrete blocks. The concrete blocks were required to have a load bearing capacity that meets the building material standards and specifications. Eight C&D waste samples were collected from C&D building sites, transported to the recycling site, crushed, and screened (sieved) to get the required recycled aggregates. Natural aggregates were also used as control. The recycled aggregates were tested in the laboratory following the standard methods as specified in Tanzanian standards. The physical, mechanical and chemical characteristics were determined. The physical and mechanical results showed that recycled aggregates were weaker than natural aggregates. However, chemically they were close to natural aggregates and therefore suitable for use in new concrete block production. In the production process, each experiment utilized 100% recycled aggregates for both fine and coarse portions to replace natural aggregates. The Fuller's maximum density theory was used to determine the mix proportions of materials in which a method that specifies concrete mix by system of proportion or ratio was used. The concrete blocks production processes included batching, mixing (that was done manually to get homogeneous material), compacting and moulding by hand machine and curing in water. After 28 days of curing, the concrete blocks were tested in the laboratory on compressive strength, water absorption ratio and density. The results showed that the blocks produced with 100% recycled aggregates were weaker than those with natural aggregates. However, the results also showed that there is a possibility of recycling the C&D waste into building material because 85% of the tested concrete block specimens from recycled aggregates achieved a compressive strength of 7 N/mm², which is defined as the minimum required load bearing capacity in Tanzania. Therefore, the C&D waste could be a potential resource for building material production for sustainable construction in Tanzania rather than discarding it. Further work should focus on the economic feasibility of production of concrete blocks with recycled aggregates in Tanzania.     

The economic and environmental benefits of increased use of pfa and granulated slag

It is commonly claimed that increased use of pulverised fuel ash (pfa) and ground granulated blast-furnace slag in concrete as partial replacement for Portland cement can have economic, amenity and technical advantages. Many factors need to be considered is such an analysis and this paper is offered as a contribution to the debate of this issue, and not as a definite solution. In the long-term the major benefit may be in the savings of the energy that would otherwise be required for increased production of Portland cement.     

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.     

Usage of polystyrene disposable food dishes in the lightweight concrete making

The increasing use and subsequent accumulation of polystyrene containers has triggered a substantial environmental problem. This study investigated using varied percentages of solid waste polystyrene disposable food dishes in the production of lightweight concrete samples with 350 kilograms per cubic meter (kg/m³) of cement and a density of 1,300 kg/m³. The polystyrene disposable dishes were ground into beads of 0–3 millimeters (mm) and 3–6 mm in size. First, the characteristics of Type II Portland cement, polystyrene, and aggregates were examined. The following characteristics of concrete using ASTM International and British Standards Institution standards were tested: slump, compressive strength, ability to resist chloride ion penetration, and resistance of concrete to rapid freezing and thawing cycles. Scanning electron microscopy (SEM) and energy dispersive X‐ray spectroscopy analytical techniques were also used. The slump of samples varied between 40 and 70 mm and was not dependent on either the polystyrene percentage or the size of the polystyrene beads in the concrete samples (p‐value > .05). The compressive strength of the concrete samples after 90 days of curing, and using different percentages of polystyrene, varied between 96 and 113 kilograms per square centimeter (kg/cm²). The resistance of the samples to the freezing and thawing cycle and chloride ion penetration were affected unfavorably by the presence of the polystyrene. The SEM technique indicated that concrete samples containing 15% and 25% polystyrene had denser crystals and less void than concrete samples with 40% and 55% polystyrene.     

Mix proportions and properties of CLSC made from thin film transition liquid crystal display optical waste glass

In this study, controlled low-strength concrete (CLSC) is mixed using different water-to-binder (W/B) ratios (1.1, 1.3 and 1.5) and various percentages of sand substituted by waste LCD glass sand (0%, 10%, 20% and 30%). The properties of the fresh concrete, including compressive strength, electrical resistivity, ultrasonic pulse velocity, permeability ratio and shrinking of the CLSC, are examined. Results show that increases in amount of waste glass added result in better slump and slump flow, longer initial setting time and smaller unit weight. Compressive strength decreases with increasing W/B ratio and greater amounts of waste glass added. Both electrical resistivity and ultrasonic pulse velocity increase with increases in amount of waste glass and decreases in W/B ratio. On the contrary, the permeability ratio increases with increases in W/B ratio, but decreases with greater amounts of waste glass added. CLSC specimens cured for different durations show little changes in length with shrinkage below 0.025%. Our findings reveal that CLSC mixed using waste LCD glass in place of sand can meet design requirements. Recycling of waste LCD glass not only offers an economical substitute for aggregates, but also an ecological alternative for waste management.     

Economic comparison of recycling over-ordered fresh concrete: A case study approach

Recycling of construction material helps save the limited landfill space. Among various types of materials, concrete waste accounts of about 50% of the total waste generation. Current off-site practices for ready mixed concrete batching plant generate a significant quantity of fresh concrete waste through over-order from construction sites. The use of concrete reclaimer is one of the methods to reclaim these concrete wastes, which separates coarse aggregate, sand and cement from fresh concrete. Although there are some concrete producers in Hong Kong providing concrete reclaimers in their plants, they are only used to flush and dilute the cement slurry from the concrete, which will still be ultimately send all to dumping areas. The reluctance of most concrete producers in reclaiming aggregate from the concrete waste is due to its high cost of treatment and lack of space around the plant. Therefore, this paper puts forth a scheme of economical considerations in recycling over-ordered concrete by concrete reclaimer. A comparative study on costs and benefits between the current practices and the proposed recycling plan is examined. The study shows that the costs of the current practices in dumping over-ordered fresh concrete waste to landfill areas are double that of the proposed aggregate recycling plan. Therefore, the adoption of concrete reclaimer in recycling the over-ordered fresh concrete can provide a cost-effective method for the construction industry and help saving the environment.     

Utilization of waste foundry sand (WFS) in concrete manufacturing

Due to ever increasing quantities of waste materials and industrial by-products, solid waste management is the prime concern in the world. Scarcity of land-filling space and because of its ever increasing cost, recycling and utilization of industrial by-products and waste materials has become an attractive proposition to disposal. There are several types of industrial by-products and waste materials. The utilization of such materials in concrete not only makes it economical, but also helps in reducing disposal concerns. One such industrial by-product is waste foundry sand (SFS). Waste foundry sand is a by-product of ferrous and nonferrous metal casting industries. Foundries successfully recycle and reuse the sand many times in a foundry. When the sand can no longer be reused in the foundry, it is removed from the foundry and is termed as waste foundry sand.Published literature has shown that WFS could be used in manufacturing Controlled Low-Strength Materials (CLSM) and concrete. This paper presents an overview of some of the research published on the use of WFS in concrete. Effect of WFS on concrete properties such as compressive strength, splitting tensile strength, modulus of elasticity, freezing-thawing resistance, and shrinkage are presented.     

利用土聚技术固化处理重金属的研究进展

土聚物是一种新型的无机聚合物,它具有类沸石似的网络结构,其分子链由Si、0、Al等以共价键连接而成。由于它的渗滤性低,对重金属元素不仅予以物理束缚也能进行化学束缚,因此利用它来固化重金属污染物的效果很好。同时,土聚物的强度又比由硅酸盐水泥制成的混凝土要高许多,因此其固化物还可被应用于道路或其他建设领域。但遗憾的是目前利用含重金属污泥制成土聚水泥的研究还基本属于空白阶段,建议加强这方面的研究。     

Management and recycling of waste glass in concrete products: Current situations in Hong Kong

Disposal of more than 300 tonnes waste glass daily derived from post-consumer beverage bottles is one of the major environmental challenges for Hong Kong, and this challenge continues to escalate as limited recycling channels can be identified and the capacity of valuable landfill space is going to be saturated at an alarming rate. For this reason, in the past ten years, a major research effort has been carried out at The Hong Kong Polytechnic University to find practical ways to recycle waste glass for the production of different concrete products such as concrete blocks, self-compacting concrete and architectural mortar. Some of these specialty glass-concrete products have been successfully commercialized and are gaining wider acceptance. This paper gives an overview of the current management and recycling situation of waste glass and the experience of using recycled waste glass in concrete products in Hong Kong.     

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.     

The effect of Na and Ca salts on MSWI bottom ash activation for reuse as a pozzolanic admixture

In this study the possibility of both chemical and combined chemical + thermal activation of municipal solid waste incinerator bottom ash was investigated. A number of chemical activators including Na₂SiO₃·9H₂O, NaOH, Na₂SO₄ and CaCl₂·2H₂O were individually added at varying concentrations to bottom ash/Portland cement mixtures having different bottom ash contents. The effect of the selected compounds was evaluated in terms of macroscopic properties including mechanical strength and composition of cementitious materials/water slurries. The results showed that Na-based activators were not capable of improving the characteristics of the cementitious products if compared to Portland cement under both normal and accelerated curing. Conversely, the use of calcium chloride at 40 °C-curing did promote the pozzolanic properties of bottom ash, leading to UCS values of 45.5 and 60.0 MPa after 10 and 20 days, respectively, as opposed to a value of 43.6 MPa obtained after 28 days for Portland cement under normal curing conditions.     

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.     

Mechanical recycling of EOL concrete into high-grade aggregates

Recycling End of Life (EOL) concrete into high-grade aggregate for new concrete is a challenging prospect for the building sector because of the competing constraints of low recycling process cost and high aggregate product quality. A further complicating factor is that, from the perspective of the environment, there is a strong societal drive to reduce bulk transport of building materials in urban environments, and to apply more in situ recycling technologies for Construction & Demolition Waste. The European C2CA project investigates a combination of smart demolition, grinding of the crushed concrete in an autogenous mill to increase the liberation of cement mortar from the surface of aggregates and a novel dry classification technology called ADR to remove the fines. The feasibility of this recycling process was examined in a demonstration project involving 20,000 tons of EOL concrete from two office towers in Groningen, the Netherlands. Results show that the +4 mm recycled aggregate compares favorably with natural aggregate in terms of workability and the compressive strength of the new concrete, showing 30% higher strength after 7 days.     

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.     

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.     

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.     

垃圾焚烧飞灰处置与资源化利用研究进展

随着生活垃圾焚烧处理方式的不断推广,焚烧飞灰的产生量也不断增加。按照我国固体废物分类方法,焚烧飞灰属于危险废物,必须进一步处置才能进入填埋场或资源化利用。本文分析了飞灰物理化学特性,论述了常规处置技术（水泥固化、化学药剂稳定化、酸溶剂提取和熔融固化等）存在的问题。将原始飞灰直接应用于水泥、混凝土或路基材料,飞灰中高含量的重金属和盐类会产生新的环境问题。飞灰水洗可以高效去除其中的可溶性盐类,水洗飞灰在焙烧后重金属的浸出浓度远低于原始飞灰烧结后的相应浓度,飞灰水洗-焙烧技术具有很好的应用前景。