Recycling of ladle slag in cement composites: Environmental impacts

Generation, utilization, and environmental impact of ladle furnace slag: A minor review

More than 20 million tons of ladle furnace slag are produced annually. This slag is mainly treated by stockpiling; however, stacking results in dust and heavy metal pollution. Utilizing this slag as a resource can reduce primary resource consumption and eliminate pollution. In this review, existing studies and practices related to slag are discussed, and applications for different slag types are analyzed. The findings reveal that under alkali- or gypsum-activated conditions, CaO-SiO2-MgO, CaO-Al2O3-MgO, and CaO-SiO2-Al2O3-MgO slags may act as a low-strength binder, a garnet- or ettringite-based binder, and a high-strength cementitious material, respectively. Partial replacement of cement with CaO-Al2O3-MgO or CaO-SiO2-Al2O3-MgO slag can adjust the settling time. Meanwhile, CaO-SiO2-Al2O3-FeO-MgO slag combined with fly ash can be used to prepare a high-strength geopolymer, and CaO-Al2O3-MgO and CaO-SiO2-MgO slags may yield high carbon dioxide sequestration percentages. However, the aforementioned applications could lead to secondary pollution because these slags contain heavy metals and sulfur. Removing them or suppressing their dissolution is therefore of significant interest. Reusing hot slag in a ladle furnace could be an efficient utilization strategy because it can recover heat energy while utilizing the components of the hot slag. However, adopting this approach necessitates the further development of an efficient method for removing sulfur from hot slag. Overall, this review elucidates the relationship between the utilization method and slag type and identifies future research directions, thereby providing references and guidance for future research on slag utilization.

Simultaneous speciation of chromate, molybdate and arsenate in lysimetric water from geotechnical composites installed in field lysimeters

Anion-exchange high performance liquid chromatography inductively coupled plasma mass spectrometry (HPLC-ICP-MS) was used for simultaneous speciation of chromate, molybdate and arsenate. The repeatability of measurement tested for multielemental standard solution of chromate, molybdate and arsenate (50 ng mL⁻¹ of Cr, Mo and As, pH 12) was ± 0.9%, ± 4.9% and ± 4.1%, respectively. Limits of quantification (LOQs) were low (0.53 ng mL⁻¹ for chromate and arsenate and 1.03 ng mL⁻¹ for molybdate, expressed as elemental concentrations). A wide linear concentration range (from LOQs to 500 ng mL⁻¹) was obtained. The performances of this method enabled simultaneous speciation analysis in samples of water from lysimeters, in which three geotechnical composites, made of recycled waste, were installed in parallel in compacted and uncompacted, 20 times less dense form. The release of toxic chemical species of elements into lysimetric waters from each composite was studied. The results revealed that the degree of compaction and the composition of composites both have a significant influence on leaching of chromate, molybdate and arsenate. The study proved that multielemental speciation analysis is fast and cost-effective method for investigations of environmental impacts of materials, made from recycled waste, and can be used in other similar applications.

Porous Fire-Resistant Materials Made from Alkali-Activated Electric Arc Furnace Ladle Slag

The application of electric arc furnace ladle slag (EAF ladle slag) in cement products might be limited due to the volume expansion and volume instability created by late hydration. Proper control technique should be developed before the reuse of ladle slag (LS). With the addition of aluminum powder in alkali-activated slag pastes, porous materials were produced. By adjusting the activator modulus between 1.25 and 2.00, fine pores were produced in the foamed pastes, and the material densities were controlled between 594 and 1184 kg/m3. The compressive strengths increased from 0.95 to 9.04 MPa with the increase in density. Direct firing tests showed that the produced porous materials could resist fire damage. With low thermal conductivities range from 0.532 to 1.435 W/m·K, the temperatures in the back panel of the materials were below 100 °C, even under flames of 800 °C for 1 h, which were better than marketing rock wool. The alkali-activated technique was proven to be applicable for the manufacturing of porous fire-resistant materials from ladle slag in this research.

Treatment of ladle furnace slag by carbonation: Carbon dioxide sequestration, heavy metal immobilization, and strength enhancement

Ladle furnace slag (LFS) is a by-product of the steel industry and is difficult to be reused due to its weak cementitious property, low strength, and potential leaching of heavy metals. The emission of carbon dioxide (CO₂) is also a concern for the steel industry. Therefore, the aim of this study was to use CO₂ to immobilize heavy metals in LFS and enhance its strength. The LFS specimens were carbonated with different initial water contents, CO₂ pressures, and carbonation periods. The carbonated LFS were then studied by leaching test, unconfined compressive strength (UCS), X-ray diffraction (XRD), thermogravimetric analysis (TGA), fourier transform infrared spectroscopy (FTIR), and field emission scanning electron microscopy (FESEM) with energy dispersive X-ray spectroscopy (EDX). The results showed that LFS had carbonation reactivity and could sequester CO₂ up to 9.6% of its own mass. The carbonation also effectively reduced the leaching of heavy metals from LFS, especially Pb and Zn. The concentrations of leached Pb and Zn of carbonated LFS were significantly reduced from 2760 and 1460 μg/L to 0.11 and 0.56 μg/L, respectively, being one order of magnitude (Pb) or three orders of magnitude (Zn) lower than limits of inert waste and three drinking water regulations. The strength of the carbonated LFS also remarkably increased and was two orders of magnitude higher than that of the uncarbonated LFS. Following the carbonation, calcium carbonate, nesquehonite, and hydromagnesite were produced; these carbonates filled pores and bound LFS particles, which enhanced the strength of LFS.

Feasibility study on the utilization of coal mining waste for Portland clinker production

CMWs (coal mine wastes) as the waste products of coal exploitation or washing plants are a source of pollution that generates waste management problems, especially those that are very old and without a known owner. CMW chemical composition indicates that it contains SiO₂-Al₂O₃-Fe₂O₃ in such percentages that it can be used in the production of Portland cement clinker, which can lead to potential savings in clinker production, not only in raw material but also in fuels if the CMW has a minimum calorific value and has not suffered self-combustion. After characterization of different CMWs from mining sites located in the north of Spain, six types of CMW have been selected and different raw meal formulations have been designed by software, maximizing the substitution rate of CMW and ensuring a correct raw meal chemical parameters. Along with a reference raw meal, all CMW clinkers were sintered, ground with gypsum, and tested determining the setting time, compressive strength, and soundness. The results of the physico-mechanical tests show that the mechanical performance of the CMW cements was consistent with the European requirements for a CEM Type I cement. CMW, especially those with a residual energetic content, can be utilized in clinker raw meal due to its availability in large quantities at low cost with the further significant benefits for waste management and environmental practices in mining and in cement production processes.

Application of washed MSWI fly ash in cement composites: long-term environmental impacts

In the present study, long-term environmental impacts of compact and ground cement composites, in which 30 wt.% of cement was replaced by washed municipal solid wastes incineration (MSWI) fly ash, were investigated for use in building industry. Consecutive leaching tests over a time span of 180 days were performed in acid water, deionized water, and saline water, respectively, with the accumulative concentration of different elements determined in the leachate. Different leaching behaviors are observed among different potential toxic elements (PTEs). For instance, higher concentrations of V in the leachate were observed from the compact cement composites than those from the ground ones. The concentration of Ba in the leachate increased with the decrease of particle size of the cement composites, and an initial increase in the leaching efficiency of Sn was followed by a clear decline with the leaching time. In addition, kinetic study revealed that the leaching behaviors of potential toxic elements follow a second-order model. The results demonstrated that the addition of washed MSWI fly ash into cement can contribute to the attrition resistance, indicating that the washed MSWI fly ash could be a promising alternative for cement as supplementary building materials.

Long-term leaching behaviours of cement composites prepared by hazardous wastes

In order to evaluate the long-term environmental impact of Eco-Ordinary Portland Cement (EOPC) prepared by municipal solid wastes (MSS) and hazardous wastes (HW), consecutive leaching tests with a time span of 180 days were conducted on the EOPC composites in the compact and ground forms under deionized and saline water conditions. The results show that the heavy metals investigated can be classified into three groups according to their leaching behaviours. The concentrations of V, Pb, Ni, Ba, Cd and Zn in the leachate increase with the leaching time, which can be classified into the first group. Cu and Sn are in the second group, and their concentrations increase initially, and decline afterward. Cr and As are in the third group, and their concentrations decline firstly, followed by a clear increase. Besides, a kinetic study was also conducted in the present study, revealing that the leaching behaviours of heavy metals follow a second-order model. Furthermore, our results suggest that the EOPC is resistant to the saline water, but the application of such materials in marine conditions should be paid attention to due to the pollution of arsenic.

In order to evaluate the long-term environmental impact of Eco-Ordinary Portland Cement (EOPC) prepared by hazardous wastes, long-term leaching tests were conducted on the EOPC composites under deionized and saline water conditions.

Long-term environmental impacts of building composites containing waste materials: Evaluation of the leaching protocols

The NEN 7375 test has been proposed for evaluating the long-term environmental impacts caused by the release of contaminants from monolithic building and waste materials. Over a period of 64days, at specific points in time, the leaching solution (demineralised water) is replenished. By applying the NEN 7375 test, leaching of contaminants that is based mainly on diffusion is followed. In the present work, the results from modified leaching protocols were evaluated against those obtained by NEN 7375 test. In modified protocols, synthetic sea, surface and MilliQ water were used for the leaching of selected elements and chromate, molybdate and vanadate from compact and ground building composites (98% mixture of fly ash (80%) and cement (20%), and 2% of electric arc furnace (EAF) dust) over 6months. The leaching solutions were not replenished, imitating both the diffusion and the dissolution of contaminants. The data revealed larger extent of leaching when the leaching solution was not replenished. More extensive was also leaching from ground composites, which simulated the disintegration of the material over time. The composition of the leaching solution influenced the release of the matrix constituents from the composites and, consequently, the amount of elements and their chemical species. Synthetic sea and surface water used as leaching solutions, without replenishing, were found to be suitable to simulate the conditions when the building material is immersed in stagnant environmental waters.

Chemical characterisation of dredged sediments in relation to their potential use in civil engineering

During capital and/or maintenance dredging operations, large amounts of material are produced. Instead of their discharge, dredged sediments may be a valuable natural resource if not contaminated. One of the possible areas of application is civil engineering. In the present work, the environmental status of seaport dredged sediment was evaluated in order to investigate its potential applicability as a secondary raw material. Sediments were analysed for element concentrations in digested samples, aqueous extracts and fractions from sequential extraction; for fluoride, chloride and sulphate concentrations in aqueous extracts; and for tributyltin (TBT). Granulometric and mineralogical compositions were also analysed. The elemental impact was evaluated by calculation of the enrichment factors. The total element concentrations determined showed moderate contamination of the dredged sediments as was confirmed also by their moderate enrichment factors, presumably as a result of industrial and port activities. Elemental concentrations in the aqueous extract were very low and therefore do not represent any hazard for the environment. The water-soluble element concentrations were under the threshold levels set by the EU Directive on the landfill of waste, on the basis of which the applicability of dredged sediments in civil engineering is evaluated, while the content of chloride and sulphate were above the threshold levels. It was found out that due to the large amounts of sediment available, civil engineering applications such as the construction of embankments and backfilling is the most beneficial recycling solution at present.