Utilization of blended fluidized bed combustion (FBC) ash and pulverized coal combustion (PCC) fly ash in geopolymer

Use of Fluidized Bed Combustion Fly Ash as a Partial Substitute for Cement in Underwater Concrete Mixes

Despite limitations to coal combustion energy production, many countries face the still-unresolved problem of utilising the wastes from fluidised bed coal combustion. One direction of rational utilisation can be using these wastes in the building materials industry. The study aimed to analyse the possibility of using fluidised bed combustion fly ashes as a partial substitute for cement in the underwater concrete (UWC). Two groups of concrete mixes were tested, containing 20 to 50% of fluidised bed combustion fly ashes. Investigations of the rheological properties of the concrete mixes and the mechanical performance of the hardened concrete confirmed the possibility of replacing cement in UWC with fluidised bed combustion fly ash up to 30% of the cement mass. The higher content of the fly ashes significantly worsens the UWC strength as well as the consistency and wash-out loss of the concrete mixes, excluding its use in underwater concreting.

Synthesis of Zeolite from Circulated Fluidized Bed Coal Fly Ash

Circulating fluidized bed combustion (CFBC) is known for its ability to significantly reduce the emission NOx and SO2 from coal combustion, the fly ash produced from CFBC (CFBFA), however, is...

The Effect of Circulating Fluidised Bed Bottom Ash Content on the Mechanical Properties and Drying Shrinkage of Cement-Stabilised Soil

This study aimed to determine the effect of circulating fluidised bed bottom ash (CFB-BA) content on the mechanical properties and drying shrinkage of cement-stabilised soil. Experiments were performed to study the changes in unconfined compressive strength and expansibility of cement-stabilised soil with different CFB-BA contents and the underlying mechanisms based on microscopic properties. The results show that CFB-BA can effectively increase the unconfined compressive strength of the specimen and reduce the amount of cement in the soil. When the combined content of CFB-BA and cement in the soil was 30%, the unconfined compressive strength of the specimen with C/CFB = 2 after 60 days of curing was 10.138 MPa, which is 1.4 times that of the pure cement specimen. However, the CFB-BA does not significantly improve the strength of the soil and cannot be added alone as a cementing material to the soil. Additionally, swelling tests showed that the addition of CFB-BA to cement-stabilised soil can significantly reduce the drying shrinkage. This research project provides reference values for the application of CFB-BA in cement–soil mixing piles, including compressive strength and the reduction in the shrinkage deformation of specimens.

Synthesis and Characterization of Biochar-Based Geopolymer Materials

The aim of this research is to evaluate the possibility to realize alkali-activated materials exploiting biochar, a secondary raw material coming from pyrolysis/gasification processes, for environmental benefits, such as improvement of soil fertility and reduction of CO2 emissions into the atmosphere thanks to the carbon sink process where carbon dioxide is subtracted from the cycle of carbon. For the matrix of the geopolymers, a waste material derived from incinerator bottom ash was used and compared to pure metakaolin matrix. The materials obtained are lightweight and porous, with high water absorption capacity and moisture adsorption/desorption. BET analysis shows an increase in specific surface by increasing the biochar content and the biochar acts as a filler in the pores. From porosimetry analysis it is possible to follow the evolution of the curing process of the geopolymer prepared: specimens containing 70 wt% biochar after 28 and 90 days showed an increase in total Hg intrusion volume, pore area and total porosity but a decrease in the dimensions of pores. Due to the technical properties of materials containing biochar, they can be used in the future for a cleaner design of products in the field of sustainable construction for insulating panels or lightweight materials for houses and gardens in terraces and balconies.

Fly Ash as an Eco-Friendly Filler for Rigid Polyurethane Foams Modification

There is currently a growing demand for more effective thermal insulation materials with the best performance properties. This research paper presents the investigation results on the influence of two types of filler on the structure and properties of rigid polyurethane foam composites. Fly ash as a product of coal combustion in power plants and microspheres of 5, 10, 15, and 20 wt.%, were used as rigid polyurethane foams modifiers. The results of thermal analysis, mechanical properties testing, and cellular structure investigation performed for polyurethane composites show that the addition of fly ash, up to 10 wt.%, significantly improved the majority of the tested parameters. The use of up to 20 wt.% of microspheres improves the mechanical and thermal properties and thermal stability of rigid polyurethane foams.

Influence of the Composition and Curing Time on Mechanical Properties of Fluidized Bed Combustion Fly Ash-Based Geopolymer

This paper presents novel research on a fluidized bed combustion (FBC) fly ash-based geopolymer as a contribution to the problem of FBC fly ash disposal, and a proposal for a new geopolymer composition-an environmentally friendly material that is possible to use in construction. Geopolymer samples of various composition (containing FBC fly ash as the main raw material, metakaolin and CRT glass as additional components, and sodium silicate and sodium hydroxide as activators) were subjected to flexural and compressive strength tests. An investigation on the effect of the demolding time was carried out on one selected mixture. The test showed that both the composition and the demolding time have a decisive influence on the basic mechanical properties. A mixture containing FBC fly ash to metakaolin in a mass ratio of 3:1, removed from the mold after 14 days, was found to be the best in terms of the mechanical parameters expected from a material that could be used in construction, e.g., for the production of precast elements. According to the results obtained, FBC fly ash is a promising and environmentally friendly raw material for the production of geopolymer, with good mechanical properties and low density. Moreover, a high compressive strength can be obtained by curing the geopolymer at ambient temperature.

Extending the Life Cycle of Cement Binders by Partially Replacing Portland Cement with Different Types Fluidized Bed Combustion Fly Ash

A significant reduction in the CO2 emission associated with cement production is obtained by partially replacing Portland cement with supplementary cementing materials (SCM’s): e.g., siliceous fly ash or granulated blast furnace slag. In the near future, the limited availability of these materials will do more attractive to use ashes from combustion in fluidized bed boilers, which currently are mainly deposited in various landfills. Paper identifies the effect of Fluidized Bed Combustion (FBC) fly ash from both hard and brown coal combustion on the durability of mortars exposed to sodium and magnesium sulfate solution at different curing temperature: 20 and 5 °C. The evaluation was based on the results of long-term linear changes of mortar samples made with Portland cement and different amounts of FBC fly ash addition stored in a corrosive environment, as well as the evaluation of the type of formed corrosion products using XRD and microstructural studies (SEM/EDS). It has been shown that amount of FBC fly ashes used in binders significantly determines sulfate resistance of prepared cements as well as its chemical composition. By using fluidized ashes, the sulfate resistance of cement binders can be achieved with their content even of 15%.

Preparation of Synthetic Zeolites from Coal Fly Ash by Hydrothermal Synthesis

Large amounts of coal combustion products (as solid products of thermal power plants) with different chemical and physical properties cause serious environmental problems. Even though coal fly ash is a coal combustion product, it has a wide range of applications (e.g., in construction, metallurgy, chemical production, reclamation etc.). One of its potential uses is in zeolitization to obtain a higher added value of the product. The aim of this paper is to produce a material with sufficient textural properties used, for example, for environmental purposes (an adsorbent) and/or storage material. In practice, the coal fly ash (No. 1 and No. 2) from Czech power plants was firstly characterized in detail (X-ray diffraction (XRD), X-ray fluorescence (XRF), scanning electron microscopy with energy dispersive X-ray analysis (SEM-EDX), particle size measurement, and textural analysis), and then it was hydrothermally treated to synthetize zeolites. Different concentrations of NaOH, LiCl, Al₂O₃, and aqueous glass; different temperature effects (90–120 °C); and different process lengths (6–48 h) were studied. Furthermore, most of the experiments were supplemented with a crystallization phase that was run for 16 h at 50 °C. After qualitative product analysis (SEM-EDX, XRD, and textural analytics), quantitative XRD evaluation with an internal standard was used for zeolitization process evaluation. Sodalite (SOD), phillipsite (PHI), chabazite (CHA), faujasite-Na (FAU-Na), and faujasite-Ca (FAU-Ca) were obtained as the zeolite phases. The content of these zeolite phases ranged from 2.09 to 43.79%. The best conditions for the zeolite phase formation were as follows: 4 M NaOH, 4 mL 10% LiCl, liquid/solid ratio of 30:1, silica/alumina ratio change from 2:1 to 1:1, temperature of 120 °C, process time of 24 h, and a crystallization phase for 16 h at 50 °C.

Utilization of Fly Ashes from Fluidized Bed Combustion: A Review

Traditionally fly ash is thought to be glassy, spherical particle originating from pulverized coal combustion (PCC) at temperature up to 1700 °C. However, nowadays fluidized bed combustion (FBC) technology is spreading quickly around the world as it is an efficient and environmentally friendly method. FBC is also able to utilize mixtures of low-grade solid fuels (e.g., coal, lignite, biomass, and waste) that have fluctuating quality, composition, and moisture contents. However, this leads to a high variation in the produced fly ash quality, unlike PCC fly ash, and hence challenges when attempting to utilize this fly ash. In this study, the utilization of fluidized bed combustion fly ash (FBCFA) was reviewed using the Scopus database. The most promising utilization target for FBCFA from biomass combustion is as a fertilizer and soil amendment. In construction, the FBCFA from various fuels is utilized as cement replacement material, in non-cement binders, as lightweight aggregates and cast-concrete products. Other types of construction applications include mine backfilling material, soil stabilizer, and road construction material. There are also other promising applications for FBCFA utilization, such as catalysts support material and utilization in waste stabilization.

Effects of High CaO Fly Ash and Sulfate Activator as a Finer Binder for Cementless Grouting Material

The effects or high CaO fly ash and sulfate activator on cementless grouting material were investigated through Labiles Waterglass (LW) grouting applied at an actual construction field. Circulating fluidized bed combustion ash was used as CaO fly ash, and petro cokes desulfurization gypsum was used as sulfate activator. Cementless grouting material (CGM) could decrease the gel time by about 16.7% compared with ordinary Portland cement (OPC). This characteristic improved the average daily workload and construction period per meter by about 13.5% with CGM. Furthermore, when constructing 1000 holes of LW grouting, the construction time could be reduced by 19 days (20% of the total construction period of LW grouting). Meanwhile, CGM could increase the homogel strength by about 48.4% after 28 days compared with OPC. After X-ray diffraction analysis and scanning electron microscope analysis, CGM was found to produce cement hydrate by chemical reaction mechanism of high CaO fly ash and sulfate activator, even though cement was not used. The matrix structure properties of CGM and OPC specimens were similar, but CGM, with 134.3% fineness, exhibited higher compressive strength and lower air permeability than OPC. As a result, CGM could reduce the leakage length per square meter by 74.4% compared with OPC. Using CGM as a substitute for OPC in LW grouting in actual sites could be beneficial in terms of securing construction speed and durability, as well as reducing CO₂ emissions due to reduction of OPC usage.

Fluidized bed combustion fly ash as filler in composite polyurethane materials

Fly ash (FA) is a waste material having great potential as modifier of mechanical and thermal properties in polyurethane (PUR) technology. There are very few reporting the use of fluidized bed combustion (FBC) FA in the production of PUR foams. In this work, authors have used the as received FBC FA as an additive to PUR rigid foams. The composite materials containing 5, 10, 15, and 20 wt% of FA were obtained by hand mixing and casting method. Microscopic observations of both unmodified and composite foams showed a well formed, cellular structure of the rigid foam. The cell structure was uniform; most of the cells were closed, which was an important parameter influencing thermal insulation properties of PUR materials. FA was uniformly distributed within PUR matrix and placed between cells. When the content of FA in composite foams increased, cells' dimensions decreased, which suggested that FA particles acted as nucleation sites during the foam formation process. The absorption bands presented in IR spectrum of PUR foam confirmed the presence of urethane bonds in the unmodified foam material. The IR spectrum of as-received FA reconfirmed the crystalline phases recognized by XRD analysis, which were anhydrite, quartz, lime, calcite and aluminosilicate. No additional bands were observed which suggested that no chemical bonding between PUR matrix and FA particles occurred in the composite foam. The incorporation of FA into the PUR matrix, up to 10 wt%, improved the mechanical performance of the composite materials, when compared to unmodified PUR foam. Such a tendency suggested the occurrence of interfacial interactions between polymer matrix and FA particles, as well as the uniform distribution of the filler within PUR material. For all the materials analyzed, the addition of FA to PUR foam reduced both carbon content and the gross calorific value. The addition of FA improved the thermal stability of the PUR foam material (barrier effect of the FA prevented the release of gases from the foam structure).

Contaminated biomass fly ashes--Characterization and treatment optimization for reuse as building materials

The incineration of treated waste wood generates more contaminated fly ashes than when forestry or agricultural waste is used as fuel. The characteristics of these biomass fly ashes depend on the type of waste wood and incineration process parameters, and their reuse is restricted by their physical, chemical and environmental properties. In this study, four different fly ash types produced by two different incineration plants were analysed and compared to Dutch and European standards on building materials. A combined treatment was designed for lowering the leaching of contaminants and the effect of each treatment step was quantified. A pilot test was performed in order to scale up the treatment. It was found that chlorides (which are the main contaminant in all studied cases) are partly related to the amount of unburnt carbon and can be successfully removed. Other contaminants (such as sulphates and chromium) could be lowered to non-hazardous levels. Other properties (such as particle size, LOI, oxide and mineralogical compositions) are also quantified before and after treatment.

Trace element partitioning behavior of coal gangue-fired CFB plant: experimental and equilibrium calculation

Energy recovery is a promising method for coal gangue utilization, during which the prevention of secondary pollution, especially toxic metal emission, is a significant issue in the development of coal gangue utilization. In the present study, investigation into trace element partitioning behavior from a coal gangue-fired power plant in Shanxi province, China, has been conducted. Besides the experimental analysis, thermodynamic equilibrium calculation was also conducted to help the further understanding on the effect of different parameters. Results showed that Hg, As, Be, and Cd were highly volatile elements in the combustion of coal gangue, which were notably enriched in fly ash and may be emitted into the environment via the gas phase. Cr and Mn were mostly non-volatile and were enriched in the bottom ash. Pb, Co, Zn, Cu, and Ni were semi-volatile elements and were enriched in the fly ash to varying degrees. Equilibrium calculations show that the air/fuel ratio and the presence of Cl highly affect the element volatility. The presence of mineral phases, such as aluminosilicates, depresses the volatility of elements by chemical immobilization and competition in Cl. The coal gangue, fly ash, and bottom ash all passed the toxicity characteristic leaching procedure (TCLP), and their alkalinity buffers the acidity of the solution and contributes to the low solubility of the trace elements.

Alkali activation of recovered fuel-biofuel fly ash from fluidised-bed combustion: Stabilisation/solidification of heavy metals

Recovered fuel-biofuel fly ash from a fluidized bed boiler was alkali-activated and granulated with a sodium-silicate solution in order to immobilise the heavy metals it contains. The effect of blast-furnace slag and metakaolin as co-binders were studied. Leaching standard EN 12457-3 was applied to evaluate the immobilisation potential. The results showed that Ba, Pb and Zn were effectively immobilised. However, there was increased leaching after alkali activation for As, Cu, Mo, Sb and V. The co-binders had minimal or even negative effect on the immobilisation. One exception was found for Cr, in which the slag decreased leaching, and one was found for Cu, in which the slag increased leaching. A sequential leaching procedure was utilized to gain a deeper understanding of the immobilisation mechanism. By using a sequential leaching procedure it is possible fractionate elements into watersoluble, acid-soluble, easily-reduced and oxidisable fractions, yielding a total 'bioavailable' amount that is potentially hazardous for the environment. It was found that the total bioavailable amount was lower following alkali activation for all heavy metals, although the water-soluble fraction was higher for some metals. Evidence from leaching tests suggests the immobilisation mechanism was chemical retention, or trapping inside the alkali activation reaction products, rather than physical retention, adsorption or precipitation as hydroxides.

Alkali activation processes for incinerator residues management

Incinerator bottom ash (BA) is produced in large amount worldwide and in Italy, where 5.1 millionstons of municipal solid residues have been incinerated in 2010, corresponding to 1.2-1.5 millionstons of produced bottom ash. This residue has been used in the present study for producing dense geopolymers containing high percentage (50-70 wt%) of ash. The amount of potentially reactive aluminosilicate fraction in the ash has been determined by means of test in NaOH. The final properties of geopolymers prepared with or without taking into account this reactive fraction have been compared. The results showed that due to the presence of both amorphous and crystalline fractions with a different degree of reactivity, the incinerator BA geopolymers exhibit significant differences in terms of Si/Al ratio and microstructure when reactive fraction is considered.