Recycling phosphogypsum as a sole calcium oxide source in calcium sulfoaluminate cement and its environmental effects

Effect of phosphogypsum adding on setting kinetics and mechanical strength of geopolymers based on metakaolin or fly ash matrices

Our study aims to highlight the effects of the addition of phosphogypsum on certain fresh and hardened characteristics of geopolymer matrices based on metakaolin or fly ash. In the fresh state, workability and setting were studied by rheology and by the electrical conductivity measurement. The hardened state was characterized by XRD, DTA, SEM, and compressive strength measurement. Workability investigations reveal that the addition of phosphogypsum increases the viscosity, which limited the phosphogypsum addition rate to 15 wt% for metakaolin-based matrices and 12 wt% for fly ash-based matrices, with a setting retarding effect in both cases. Analyses of the matrices show dissolution of gypsum along with formation of sodium sulfate and calcium silicate hydrate. Moreover, the introduction of phosphogypsum to these matrices up to a mass rate of 6% has no significant effect on the mechanical strength. Beyond that rate, the compressive strength drops from a value of 55 MPa for the matrices without addition down to 35 MPa and 25 MPa when the addition rate is 12 wt% for the metakaolin-based and fly ash-based matrix, respectively. This degradation seems to be due to the increase in porosity created by addition of phosphogypsum.

Effect of recycled phosphogypsum and calcium aluminate cement on the strength behavior optimization of cement-treated dredged soil: A co-utilization of solid wastes

Dredged soil and phosphogypsum (PG) are waste materials that must be treated to reduce their negative environmental effects. Guided by the concept of waste treatment, this study proposed the use of PG as a supplementary cementitious material to stabilize waste-dredged soil, and calcium aluminate cement (CAC) was selected to further improve the strength of the cement-treated dredged soil. Several laboratory tests were conducted to investigate the pH, unconfined compressive strength (UCS), and failure strain of the cement-treated soils in different proportions. Microstructural and mineralogical tests were performed to reveal the mechanisms underlying the strength improvement of PG and CAC. The results showed that both PG and CAC enhanced the strength of cement-treated dredged soil. PG provided SO2- 4 to promote the formation of ettringite (aluminum ferrite trisulfate (AFt)), whereas CAC neutralized the acidity of PG and provided reactants to the reaction system, leading to an increase in the pH and strength with an increase in the relative CAC content. Meanwhile, an exponential relationship was obtained between pH and qu. Mineralogical changes demonstrated that the major hydration products of cementitious materials, such as calcium silicate (aluminate) hydrate (C-(A)-S-H), AFt, and calcium aluminate hydrate (C-A-H), enhanced the strength by filling pores between particles and bridging soil particles. However, excess CAC content may not be favorable for the later strength formation, the relative CAC content is recommended to be in the range of 40%-60%. Compared to using sand, the construction of a square kilometer of reclamation consumed 3.5 million tons of PG, and saved 1.54 billion USD by using dredged soil as raw material. Hence, the use of PG to treat dredged soils will have great environmental sustainability, economic benefits, and engineering value.

Continuous and simultaneous conversion of phosphogypsum waste to sodium sulfate and potassium sulfate using quaternary phase diagram

In this present work, the transformation of the Moroccan phosphogypsum (PG) waste, considered a potential source of sulfate, into potassium sulfate compound could help reduce environmental impact and create a new value chain for the phosphate industry. Generally, solid-liquid equilibria are frequently applied in chemical industries. They are a valuable aid in visualizing the precipitation, separation, and purification of a solid phase and the pathways by which crystallization can occur. This process aims to produce potassium sulfate (K₂SO₄), a high-value fertilizer, from sulfate solutions obtained after dissolving PG in a NaOH medium. The quaternary phase diagram Na⁺, K⁺//Cl^-, SO₄^2--H₂O at 25 °C was especially used to determine the operating conditions and the design of a crystallization process during the PG conversion into K₂SO₄. The Jänecke representation of this system enables the determination of the optimal trajectory in the phase diagram for the double decomposition reaction. X-ray fluorescent (XRF) and X-ray diffraction (XRD) techniques were conducted to identify the crystalline phases formed during our process. In summary, the results of this study could contribute to the development of a sustainable valorization PG. Furthermore, K₂SO₄ represents a good alternative to potassium chloride for chloride-sensitive crops.

Thermal co-treatment of aluminum dross and municipal solid waste incineration fly ash: Mineral transformation, crusting prevention, detoxification, and low-carbon cementitious material preparation

Harmless disposal and resource utilization of hazardous industrial wastes has become an important issue with the green development of human society. However, resource utilization of hazardous solid wastes, such as the production of cementitious materials, is usually accompanied by a pretreatment process to remove adverse impurities that contaminate the final product. In this study, aluminum dross (AD) was thermally co-treated with another hazardous waste, municipal solid incineration fly ash (MSWI-FA), to synergistically solidify F and Na, control leaching of heavy metals, and remove chloride impurities. Significant crusting was observed when AD was thermally treated by itself, but not when AD and MSWI-FA were thermally co-treated. In the process of co-thermal treatment, the remaining Cl, Na, and K contents were reduced to as low as 0.3%, 1.8%, and 0.6%, respectively. CaO and SiO₂ in MSWI-FA reacted with Na₃AlF₆ and Al₂O₃ in AD, and formed CaF₂ and Na₆(AlSiO₄)₆, which contributed to the prevention of crusting and limited the leaching concentrations of F and Na to below detection thresholds and 270.6 mg/L, respectively. In addition, heavy metals were well solidified, and dioxins were fully decomposed during thermal treatment. Finally, a sulfoaluminate cementitious material (SACM) with high early- and later-age strengths was successfully created via synergetic complementarity using thermally co-treated AD and MSWI-FA together with other solid wastes. Collectively, this study outlines a promising method for the efficient and sustainable utilization of AD and MSWI-FA.

Utilization path of bulk industrial solid waste: A review on the multi-directional resource utilization path of phosphogypsum

Phosphogypsum is one of the hottest issues in the field of environmental solid waste treatment, with complex and changeable composition. Meanwhile, phosphogypsum contains a large number of impurities, thus leading to the low resource utilization rate, and it can only be stockpiled in large quantities. Phosphogypsum occupies a lot of land and poses a serious pollution threat to the ecological environment. This paper mainly summarizes the existing pretreatment and resource utilization technology of phosphogypsum. The pretreatment mainly includes dry method and wet method. The resource utilization technology mainly includes building materials, chemical raw materials, agriculture, environmental functional materials, filling materials, carbon sequestration and rare and precious extraction. Although there are many aspects of resource utilization of phosphogypsum, the existing technology is far from being able to consume a large amount of accumulated and generated phosphogypsum. Through the analysis, the comparison and mechanism analysis of the existing multifaceted and multi-level resource treatment technologies of phosphogypsum, the four promising resource utilization directions of phosphogypsum are put forward, mainly including prefabricated building materials, eco-friendly materials and soil materials, and new green functional materials and chemical fillers. Moreover, this paper summarizes the research basis of multi field and all-round treatment and disposal of phosphogypsum, which reduces repeated researches and development, as well as the treatment cost of phosphogypsum. This paper could provide a feasible research direction for the resource treatment technology of phosphogypsum in the future, so as to improve the consumption of phosphogypsum and reduce environmental risks.

Determination of utilization strategies for hemihydrate phosphogypsum in cemented paste backfill: Used as cementitious material or aggregate

Due to the prominent advantages of low cost and efficient utilization, cemented hemihydrate phosphogypsum (HPG) backfill is becoming popular in mine goaf treatments in China as a new promising branch of cemented paste backfill (CPB). The HPG gelling activity time dependence determines its role in CPB, that is, whether it is used as a cementitious material or aggregate. Laboratory and field experiments showed that the HPG gelling activity decreases with an increasing aging time due to the gradual HPG conversion from the hemihydrate to the dihydrate form. The HPG conversion can be described by the Avrami equation, and further divided into acceleratory and slow reaction periods. Soluble P₂O₅ formed insoluble brushite coatings, significantly inhibiting the HPG conversion. Increasing the Al₂O₃ content and reducing temperature further retarded the HPG conversion. Reducing the temperature inside the stacks by lowering their stacking height delayed the HPG gelling activity decay. At a stacking height of 1.5 m, HPG can be prepared into cementitious materials for common CPB methods within the first 137 h of aging, thereafter it can only be used as an inactive aggregate. Finally, an application case is presented to illustrate the effectiveness of the utilization strategies in guiding the use of HPG in CPB.

Recycling phosphogypsum as the sole calcium oxide source in calcium sulfoaluminate cement production and solidification of phosphorus

Because the disposal of phosphogypsum (PG) can lead to serious contamination of the air, soil, and water, recycling of PG has attracted wide attention. This study investigated the effect and solidification of phosphorus in the production of calcium sulfoaluminate (CSA) cement using PG as the sole CaO source. The effects of three phosphorus impurities (Ca₃(PO₄)₂, CaHPO₄, Ca(H₂PO₄)₂) on the decomposition of CaSO₄, formation of minerals, microstructure of the clinker, and the hydration and mechanical properties of the cement were studied. Experimental results show that Ca₃(PO₄)₂ and Ca(H₂PO₄)₂ promoted the decomposition of CaSO₄ and the formation of clinker minerals with the increase in P₂O₅ content, whereas CaHPO₄ showed a promoting effect only when the P₂O₅ content was more than 1.5 wt%. The increase in phosphorus incorporation in Ca₂SiO₄ leads to the transformation of β-Ca₂SiO₄ to α'-Ca₂SiO₄ and then to Ca₇Si₂P₂O₁₆. The presence of three phosphates in the clinker enhanced the growth of crystal grains and the generation of a liquid phase. Compared with Ca₄Al₆SO₁₆ without phosphorus, the hydration reaction of phosphorus-bearing Ca₄Al₆SO₁₆ started later and ended earlier, and the reaction time was shorter. The presence of phosphorus impurities reduces the 1-day strength of CSA cement but does not affect the development of the 3-day and 28-day strengths. Considering environmental aspects, the solidification of phosphorus in the production of CSA clinker were quantified by measuring the distribution of elements. The results indicated that phosphorus is solidified by Ca₄Al₆SO₁₆, Ca₂SiO₄, and Ca₄Al₂Fe₂O₁₀, and Ca₂SiO₄ has a stronger ability to solidify phosphorus than the other two minerals. Ca₃(PO₄)₂ is more difficult to solidify than CaHPO₄ and Ca(H₂PO₄)₂. This study is of great significant to guide the large-scale clean utilization of PG in the production of CSA cement.

Effect of phosphogypsum on the properties of magnesium phosphate cement paste with low magnesium-to-phosphate ratio

The incorporation of phosphogypsum (PG) in magnesium potassium phosphate cement (MPPC) can promote the utilization of PG not only by utilising the phosphate impurity in PG, but also by immobilising the heavy metals with MPPC. This paper investigates the feasibility of the incorporation of PG in preparing MPPC. Both early age properties, including workability and setting time, and hardened properties of compressive strength and microstructure, of PG-incorporated MPPC paste were investigated, and the hydration mechanism was explored. The results indicated that the addition of PG increased the workability of MPPC and extended the setting time of MPPC. However, incorporation of 20% PG slightly reduced the compressive strength because higher PG content led to the loose microstructure. Moreover, the addition of PG did not change the formation of hydration product, while it only reduced the hydration heat. Finally, compared to PG, the concentration of leached heavy metals of MPPC with PG was significantly reduced after 28 days curing.

Preparation and Properties of a Sulphoaluminate Magnesium-Potassium Phosphate Green Cementitious Composite Material from Industrial Solid Wastes

The preparation of high-performance green cementitious material from industrial solid waste is a feasible large-scale utilization approach for industrial solid waste. This work investigates the feasibility of using industrial solid wastes in a sulphoaluminate–magnesium–potassium–phosphate cementitious composite material (SAC-MKPC) clinker preparation and the influence of the calcination temperature and clinker ingredients on the hydration behavior and mechanisms of the SAC-MKPC with a Mg/P ratio of 5. The results show that the novel SAC-MKPC that was prepared from aluminum slag, carbide slag, coal gangue, and magnesium desulfurization slag was composed mainly of mineral MgO, C4A3S¯, and C₂S and the calcination temperature of the main mineral phases was 1250–1350 °C. The solid-waste-based SAC-MKPC had better mechanical properties and excellent water resistance compared with the MKPC. The optimal compressive strength reached 35.2, 70.9, 84.1, 87.7, and 101.6 MPa at 2 h, 1 d, 3 d, 7 d, and 28 d of hydration, respectively. The X-ray diffraction spectra and scanning electron micrographs of the hydration products of the SAC-MKPC clinker showed that AFt and K-struvite crystals coexisted and adhered to form a dense structure. This work provides an innovative idea to produce green cementitious material using industrial solid wastes and may promote the sustainable development of the power and mining industries.

Phosphorus Substitution Preference in Ye'elimite: Experiments and Density Functional Theory Simulations

Density functional theory (DFT) simulation has been recently introduced to understand the doping behavior of impurities in clinker phases. P-doped ye'elimite, a typical doping clinker phase, tends to form when phosphogypsum is used to manufacture calcium sulfoaluminate cement (CSA) clinkers. However, the substitution mechanism of P has not been uncovered yet. In this study, the influence of different doping amounts of P on the crystalline and electronic structure of ye'elimite was investigated using backscattered scanning electron microscopy-energy X-ray dispersive spectroscopy, X-ray diffraction tests, Rietveld quantitative phase analysis, and DFT simulations. Furthermore, the substitution preference of P in ye'elimite was revealed. Our results showed that increasing the doping amount of P increased the impurity contents in CSA clinkers, transforming the ye'elimite crystal system from the orthorhombic to the cubic system and decreasing the interplanar spacing of ye'elimite. Based on the calculation results of the defect formation energies, additional energies were required for P atoms to substitute Ca/Al atoms compared with those required for P atoms to substitute S atoms in both orthorhombic and cubic systems of ye'elimite. Combined calculation results of the bond length-bond order and partial density of states showed that the doped P atoms preferably substituted S atoms; the second possible substituted atoms were Al atoms, while there was only a slight possibility for substitution of Ca atoms. The substitution of P atoms for S atoms can be verified based on the elemental distribution in P-doped ye'elimite and the increasing residual CaSO₄ contents. The transition of the crystal system and a decrease in the interplanar spacing for ye'elimite can also prove that the substitution of P atoms for Al atoms occurred substantially.

Experimental study on static and dynamic mechanical properties of phosphogypsum

Phosphogypsum (PG) is a solid waste product of the wet-process phosphoric acid industry that accumulates in large amounts on the ground, forming PG ponds. In recent years, the amount of PG produced and discharged into ponds has increased significantly with the increase in the market demand for phosphate fertilizers. To enrich the basic knowledge of PG properties and provide basic data for the stability analysis of PG dams, a series of laboratory geotechnical tests, including permeability tests, compressibility tests, triaxial shear tests, and dynamic triaxial tests, were conducted in this study. During the preparation of the test samples, solubility and high-temperature dehydration of PG were considered. The results indicated that PG exhibits medium compressibility and medium to weak permeability characteristics. The stress-strain curves of the triaxial shear tests were divided into three typical stages: initial deformation stage, strain hardening stage, and destruction stage. With increasing dry density and consolidation confining pressure, both the shear strength and deformation modulus significantly increased. The relationship between the deformation modulus and confining pressure gradually changed from linear to logarithmic with increasing density. The liquefaction resistance curves (CSR-N_L curves) of PG were expressed by power functions. With increasing dry density, the curves shifted higher and became steeper. Compared with the Hardin-Drnevich model, the Davidenkov model was found to be more suitable for describing the relationship between the dynamic shear modulus ratio and damping ratio of PG and the dynamic shear strain. Furthermore, compared with those of tailings and natural soils, the engineering mechanical properties of PG were relatively poor, which may be related to its uniform particle distribution and neat particle stacking structure.