Geopolymers as a material suitable for immobilization of fly ash from municipal waste incineration plants

Preparation and Hydration Properties of Sodium Silicate-Activated Municipal Solid Waste Incineration Bottom Ash Composite Ground-Granulated Blast Furnace Slag Cementitious Materials

The production of municipal solid waste incineration bottom ash (MSWIBA) is substantial and has the potential to replace cement, despite challenges such as complex composition, uneven particle size distribution, and low reactivity. This paper employs sodium silicate activation of MSWIBA composite Ground-granulated Blast Furnace slag (GGBS) to improve the reactivity in preparing composite cementitious materials. It explores the hydration performance of the composite cementitious materials using isothermal calorimetric analysis, Fourier-transform infrared (FTIR) spectroscopy, XRD physical diffraction analysis, and SEM tests. SEM tests were used to explore the hydration properties of the composite gelling. The results show that with an increase in MSWIBA doping, the porosity between the materials increased, the degree of hydration decreased, and the compressive strength decreased. When the sodium silicate concentration increased from 25% to 35%, excessive alkaline material occurred, impacting the alkaline effect. This inhibited particle hydration, leading to a decrease in the degree of hydration and, consequently, the compressive strength. The exothermic process of hydration can be divided into five main stages; quartz and calcite did not fully participate in the hydration reaction, while aluminum did. The vibrational peaks of Si-O-Ti (T = Si and Al) were present in the material. The vibrational peaks of XRD, FTIR, and SEM all indicate the presence of alumosilicate network structures in the hydration products, mainly N-A-S-H and C-A-S-H gels.

Application of Industrial Waste Materials by Alkaline Activation for Use as Geopolymer Binders

The purpose of this study is to synthesize geopolymer binders as an environmentally friendly alternative to conventional cement using available local raw materials. Waste materials such as chalcedonite (Ch), amphibolite (A), fly ash from lignite combustion (PB), and diatomite dust (D) calcined at 900 °C were used to produce geopolymer binders. Metakaolin (M) was used as an additional modifier for binders based on waste materials. The base materials were subjected to fluorescence X-ray fluorescence (XRF) analysis and X-ray diffractometry (XRD) to determine chemical and phase composition. A laser particle size analysis was also performed. The various mixtures of raw materials were activated with a 10 M solution of NaOH and sodium water glass and then annealed for 24 h at 60 °C. The produced geopolymer binders were conditioned for 28 days under laboratory conditions and then subjected to microstructural analysis (SEM) and flexural and compressive strength tests. The best compressive strength results were obtained by the Ch + PB samples-more than 57 MPa, while the lowest results were obtained by the Ch + D+A + M samples-more than 20 MPa. On the other hand, as a result of the flexural strength tests, the highest flexural results were obtained by D + A + M + PB binders-more than 12 MPa, and the lowest values were obtained by binders based on Ch + D+A + M-about 4.8 MPa.

Recovery of Phosphorus and Metals from the Ash of Sewage Sludge, Municipal Solid Waste, or Wood Biomass: A Review and Proposals for Further Use

This review provides an overview of methods to extract valuable resources from the ash fractions of sewage sludge, municipal solid waste, and wood biomass combustion. The resources addressed here include critical raw materials, such as phosphorus, base and precious metals, and rare earth elements for which it is increasingly important to tap into secondary sources in addition to the mining of primary raw materials. The extraction technologies prioritized in this review are based on recycled acids or excess renewable energy to achieve an optimum environmental profile for the extracted resources and provide benefits in the form of local industrial symbioses. The extraction methods cover all scarce and valuable chemical elements contained in the ashes above certain concentration limits. Another important part of this review is defining potential applications for the mineral residues remaining after extraction. Therefore, the aim of this review is to combine the knowledge of resource extraction technology from ashes with possible applications of mineral residues in construction and related sectors to fully close material cycle loops.

Solidification/stabilization of chromite ore processing residue via co-sintering with hazardous waste incineration residue

In order to realize the harmless and resource disposal of hazardous waste incineration residue (HWIR) and chromite ore processing residue (COPR), this paper prepares glass-ceramics by HWIR. The COPR was co-sintered with the base glass of HWIR to realize the solidification and stabilization of COPR. The results shown that the single-stage sintering method has a simple process and low energy consumption, while the two-stage sintering method has better mechanical properties. Chromium in COPR may be solidified/stabilized by physical encapsulation and chemical fixation. When the content of COPR reaches 50%, the leaching concentration of Cr and Cr(VI) in the solidified body of HWIR solidified COPR (IRSC) is less than 5 mg/L, which satisfies the US EPA and CN GB5085.3 standard limits. This study achieves waste control by waste and prepares solidified bodies (IRSC) with good mechanical properties, chemical corrosion resistance, and low leaching concentration of heavy metals, which provides feasibility for its engineering application.

Heavy metal removal using an advanced removal method to obtain recyclable paper incineration ash

Various agents, including ethylenediaminetetraacetic acid, oxalic acid, citric acid, and HCl, were applied to remove heavy metals from raw paper incineration ash and render the ash recyclable. Among these prepared agent solutions, ethylenediaminetetraacetic acid showed the highest efficiency for Pb removal, while oxalic acid showed the highest efficiencies for Cu, Cd, and As removal. Additionally, three modes of an advanced removal method, which involved the use of both ethylenediaminetetraacetic acid and oxalic acid, were considered for use at the end of the rendering process. Among these three modes of the advanced removal method, that which involved the simultaneous use of ethylenediaminetetraacetic acid and oxalic acid, i.e., a mixture of both solutions, showed the best heavy metal removal efficiencies. In detail, 11.9% of Cd, 10% of Hg, 28.42% of As, 31.29% of Cu, and 49.19% of Pb were removed when this method was used. Furthermore, the application of these three modes of the advanced removal method resulted in a decrease in the amounts of heavy metals eluted and brought about an increase in the CaO content of the treated incineration ash, while decreasing its Cl content. These combined results enhanced the solidification effect of the treated incineration ash. Thus, it was confirmed that the advanced removal method is a promising strategy by which recyclable paper incineration ash can be obtained.

Effect of Municipal Solid Waste Incineration Ash on Microstructure and Hydration Mechanism of Geopolymer Composites

The geopolymerization process is an appropriate way of disposing of municipal solid waste incineration fly ash (MSWIFA), and possesses the advantages of immobilizing the heavy metals and making full use of its pozzolanic properties in manufacturing green, cementitious materials. In this study, coal fly ash (FA) and metakaolin (MK) were used to prepare a geopolymer composite, with MK partially replaced by different proportions of MSWIFA through the alkali-activation method. The microstructure and hydration mechanism of the geopolymer composites containing MSWIFA were investigated through mercury intrusion porosimetry (MIP), scanning electron microscopy (SEM), and Fourier transform-infrared spectroscopy (FT-IR) tests; and the immobilization effect of the geopolymer paste on heavy metal ions was explored through inductively coupled plasma-atomic emission spectrometry (ICP-AES). The MIP analysis showed that the addition of MFARR had an overall degrading effect on the pore structure of the matrix. When the content of MSWIFA reached the maximum of 35%, the porosity and average pore diameter increased by 25% and 16%, respectively, corresponding to the case without MSWIFA. However, the pore size distribution exhibited an improving trend when the MFARR was increased from 15% to 25%. The SEM images revealed that the integrity of the micromorphology of the geopolymer mortar became weaker after adding MSWIFA. When the MSWIFA content was increased to 35%, the microstructural compactness decreased and more pores and microcracks appeared in the matrix. The FT-IR pattern study suggested that all the geopolymer composites had a similar internal structure, consisting of O-H, C-O, Si-O-Si, and Si-O-Al. The main component of the geopolymer paste hydrated at 28 d remained dominated by calcium silica-aluminate (C-A-S-H), when the MSWIFA ranged from 0% to 35%. Finally, the ICP-AES results showed that the leaching concentrations of the geopolymer paste of J-40 at 28 d for Cd, Cr, Cu, Pb, and Zn met the requirements of Chinese standards.

Development of Geopolymers Based on Fly Ashes from Different Combustion Processes

The main aim of this research is to assess different fly ashes as raw materials for the manufacturing of geopolymers. Three different fly ashes have been investigated. First, a conventional fly ash from the Skawina coal power plant (Poland), obtained at a temperature of 900–1100 °C. Second, ultra-fine fly ash from a power plant in China; the side product received at 1300 °C. The third fly ash was waste was obtained after combustion in incineration plants. To predict the properties and suitability of materials in the geopolymerization process, methods based on X-ray analysis were used. The applied precursors were tested for elemental and chemical compounds. The investigations of geopolymer materials based on these three fly ashes are also presented. The materials produced on the basis of applied precursors were subjected to strength evaluation. The following research methods were applied for this study: density, X-ray fluorescence (XRF), X-ray diffraction analysis (XRD), Scanning Electron Microscopy (SEM), flexural and compressive strength. The obtained results show that materials based on fly ashes had a similar compressive strength (about 60 MPa), while significant differences were observed during the bending test from 0.1 to 5.3 MPa. Ultra-fine fly ash had a lower flexural strength compared to conventional fly ash. This study revealed the need for process optimization for materials based on a precursor from a waste incineration plant.

Hybrid Materials Based on Fly Ash, Metakaolin, and Cement for 3D Printing

Nowadays, one very dynamic development of 3D printing technology is required in the construction industry. However, the full implementation of this technology requires the optimization of the entire process, starting from the design of printing ideas, and ending with the development and implementation of new materials. The article presents, for the first time, the development of hybrid materials based on a geopolymer or ordinary Portland cement matrix that can be used for various 3D concrete-printing methods. Raw materials used in the research were defined by particle size distribution, specific surface area, morphology by scanning electron microscopy, X-ray diffraction, thermal analysis, radioactivity tests, X-ray fluorescence, Fourier transform infrared spectroscopy and leaching. The geopolymers, concrete, and hybrid samples were described according to compressive strength, flexural strength, and abrasion resistance. The study also evaluates the influence of the liquid-to-solid ratio on the properties of geopolymers, based on fly ash (FA) and metakaolin (MK). Printing tests of the analyzed mixtures were also carried out and their suitability for various applications related to 3D printing technology was assessed. Geopolymers and hybrids based on a geopolymer matrix with the addition of 5% cement resulted in the final materials behaving similarly to a non-Newtonian fluid. Without additional treatments, this type of material can be successfully used to fill the molds. The hybrid materials based on cement with a 5% addition of geopolymer, based on both FA and MK, enabled precise detail printing.

Recycling of Mechanically Ground Wind Turbine Blades as Filler in Geopolymer Composite

This paper concerns the recycling of waste material from wind turbine blades. The aim of the research was to determine the possibility of using ground waste material derived from the exploited structures of wind turbines as a filler in geopolymer composites. In order to determine the potential of such a solution, tests were carried out on three different fractions originating from the ground blades of wind turbines, including an analysis of the morphology and chemical composition of particles using SEM and an EDS detector, the analysis of organic and inorganic matter content and tests for multivariate geopolymer composites with the addition of waste material. The compression and flexural strength, density and absorbability tests, among others, were carried out. The composite material made of the geopolymer matrix contained the filler at the level of 5%, 15% and 30% of dry mass. The addition of the filler showed a tendency to decrease the properties of the obtained geopolymer composite. However, it was possible to obtain materials that did not significantly differ in properties from the re-reference sample for the filler content of 5% and 15% of dry mass. As a result of the research, it was found that waste materials from the utilization of used wind power plants can become fillers in geopolymer composites. It was also found that it is possible to increase the strength of the obtained material by lowering the porosity.

Geopolymer Foams-Will They Ever Become a Viable Alternative to Popular Insulation Materials?-A Critical Opinion

Over the last several years, there has been a large increase in interest in geopolymer materials, which are usually produced from waste materials, and their applications. The possibilities of application of geopolymers seem to be unlimited, and they are used in almost all fields of technology. Their use as insulation materials appears promising due to their complete nonflammability and excellent strength. However, one limitation is their complex manufacturing process and lack of stability of the obtained geopolymer foams as well as difficulties in achieving such good insulation properties possessed by polyurethane foams, polystyrene, and wool. Hundreds of studies have already been performed on insulating geopolymer foams and various types of foaming agents, and their authors reported that foamed insulating geopolymers had a density starting from 200 kg/m³ and thermal conductivity from 0.04 W/mK. However, the repeatability of the obtained results on an industrial scale is questionable. It is still a challenge to obtain a geopolymer material with comparable properties as conventional insulation materials and to overcome the barriers associated with the successful implementation of geopolymer material as insulation in buildings and other applications on a mass scale. This paper provides a comprehensive review of the methods used for the production of foamed geopolymers and the best parameters obtained, as well as a summary of the most important information reported in the scientific literature. It also presents the results of a critical analysis of the feasibility of implementing this technology for mass deployment. In addition, the problems and limitations that are most often encountered with the implementation of geopolymer technology are discussed.

Process Design for a Production of Sustainable Materials from Post-Production Clay

Alkali activated cement (AAC) can be manufactured from industrial by-products to achieve goals of "zero-waste" production. We discuss in detail the AAC production process from (waste) post-production clay, which serves as the calcium-rich material. The effect of different parameters on the changes in properties of the final product, including morphology, phase formation, compressive strength, resistance to the high temperature, and long-term curing is presented. The drying and grinding of clay are required, even if both processes are energy-intensive; the reduction of particle size and the increase of specific surface area is crucial. Furthermore, calcination at 750 °C ensure approximately 20% higher compressive strength of final AAC in comparison to calcination performed at 700 °C. It resulted from the different ratio of phases: Calcite, mullite, quartz, gehlenite, and wollastonite in the final AAC. The type of activators (NaOH, NaOH:KOH mixtures, KOH) affected AAC mechanical properties, significantly. Sodium activators enabled obtaining higher values of strength. However, if KOH is required, the supplementation of initial materials with fly ash or metakaolin could improve the mechanical properties and durability of AAC, even c.a. 28%. The presented results confirm the possibility of recycling post-production clay from the Raciszyn II Jurassic limestone deposit.

Eco-Friendly Fired Brick Produced from Industrial Ash and Natural Clay: A Study of Waste Reuse

Bottom ash (BA) is an industrial solid waste formed by the burning of coal. The environmental problems and storage costs caused by this waste increase with every passing day. In this study, the use of BA as an additive (clay substitute) in fired brick production was investigated. The study consisted of two stages. In the first stage, cylinder blocks were produced from clay used in brick production. The second stage was the examination of the experimental substitution of clay with 10, 20, 30 and 40% BA. Samples were fired at 900, 1000, 1100 and 1150 °C to produce fired brick samples. The unit weight, compressive strength (before and after freeze-thawing) and water absorption were analyzed for the samples. The unit weight values decreased in the samples containing BA. The mechanical properties met the conditions prescribed in the relevant standards; i.e., all of the samples fired at 1100 and 1150 °C had a sufficient compressive strength over 20 MPa. The high potential of fired bricks for the construction industry was proved. BA can be used as a clay substitute, while the developed protocol can be used to effectively produce fired bricks.

Incorporation of Alkali-Activated Municipal Solid Waste Incinerator Bottom Ash in Mortar and Concrete: A Critical Review

In the light of one of the most common waste management issues in urban areas, namely the elimination of municipal solid waste (MSW; about 486 kg of the waste per capita were generated in the EU in 2017), this study discusses one technique as an outlet in the construction industry for the by-product of the waste’s incineration in energy recovery facilities (i.e., MSW incinerator bottom ash—MIBA). There have been some investigations on the use of MIBA as partial replacement of cement to be used in cementitious composites, such as concrete and mortars. However, the waste’s incorporation ratio is limited since further products of hydration may not be produced after a given replacement level and can lead to an unsustainable decline in performance. In order to maximize the incorporation of MIBA, some research studies have been conducted on the alkali activation of the waste as precursor. Thus, this study presents an extensive literature review of the most relevant investigations on the matter to understand the material’s applicability in construction. It analyses the performance of the alkali-activated MIBA as paste, mortar, and concrete from different perspectives. This literature review was made using search engines of several databases. In each database, the same search options were repeated using combinations of various representative keywords. Furthermore, several boundaries were made to find the most relevant studies for further inspection. The main findings of this review have shown that the chemical composition and reactivity of MIBA vary considerably, which may compromise performance comparison, standardization and commercialization. There are several factors that affect the performance of the material that need to be considered, e.g., type and content of precursor, alkaline activator, curing temperature and time, liquid to solid ratio, among others. MIBA-based alkali-activated materials (AAM) can be produced with a very wide range of compressive strength (0.3–160 MPa). The main factor affecting the performance of this precursor is the existence of metallic aluminum (Al), which leads to damaging expansive reactions and an increase in porosity due to hydrogen gas generation stemming from the reaction with the alkaline activator. Several approaches have been proposed to eliminate this issue. The most effective solution was found to be the removal of Al by means of eddy current electromagnetic separation.

Stabilization of lead contaminated soil with traditional and alternative binders

The application of an innovative solidification/stabilization (S/S) process was investigated for the remediation of Pb contaminated soil. The performance of Pb stabilization was evaluated by comparing the use of calcium aluminate cement (CAC) and an alkali activated metakaolin binder vs the Ordinary Portland Cement (OPC). The phase composition of the stabilized products was investigated by XRD and correlated to the internal microstructure obtained by SEM-EDX imaging. Leaching tests were performed to ascertain the effectiveness of the proposed binders in the S/S of the contaminated soil, and Pb release was evaluated for each binding system. The overall results proved that multiple mechanisms are involved in Pb retention and that key parameters regulating the stabilization performance are strongly dependent on the type of applied binder system. Pb was found to be associated to C-S-H in the case of OPC, whereas ettringite played a key role in the retention of this contaminant using the CAC binder. The use of a NaOH activated metakaolin resulted in almost total retention of Pb, despite a lack of solidification, highlighting the importance of pH in the regulation of the leaching behavior.

Optimal Design of Ph-Neutral Geopolymer Foams for Their Use in Ecological Plant Cultivation Systems

We have calculated that with the world population projected to increase from 7.5 billion in 2017 to 9.8 in 2050, the next generation (within 33 years) will produce 12,000-13,000 Mt of plastic, and that the yearly consumption will reach 37-40 kilos of plastic per person worldwide. One of the branches of the plastics industry is the production of plastics for agriculture e.g., seed trays and pots. In this paper, novel metakaolin-based geopolymer composites reinforced with cellulosic fibres are presented as an alternative to plastic pots. Materials can be dedicated to agricultural applications, provided they have neutral properties, however, geopolymer paste and its final products have high pH. Therefore, a two-step protocol of neutralisation of the geopolymer foam pots was optimised and implemented. The strength of the geopolymer samples was lower when foams were neutralised. The reinforcement of geopolymers with cellulose clearly prevented the reduction of mechanical properties after neutralisation, which was correlated with the lower volume of pores in the foam and with the cellulose chemical properties. Both, neutralisation and reinforcement with cellulose can also eliminate an efflorescence. Significantly increased plant growth was found in geopolymer pots in comparison to plastic pots. The cellulose in geopolymers resulted in better adsorption and slower desorption of minerals during fertilisation. This effect could also be associated with a lower number of large pores in the presence of cellulose fibres in pots, and thus more stable pore filling and better protection of internal surface interactions.

Calcined Post-Production Waste as Materials Suitable for the Hydrothermal Synthesis of Zeolites

The zeolite production process is currently being very intensively researched. Due to environmental protection, as well as issues related to the guidelines of a zero-waste economy, all activities aimed at obtaining such materials from post-processed waste are extremely important. This article presents an innovative method of utilising calcined carboniferous shale in order to produce synthetic zeolites. The raw material for testing came from two Polish hard coal mines. Both the chemical and phase composition of the coal shale were characterised. Based on the recorded thermal analysis results coupled with the mass spectrometer, the processes occurring during the heating of raw materials were interpreted and the calcination temperatures were determined. The changes in the phase composition of raw materials resulting from the calcination process used were also analysed. The heat-treated raw materials were subjected to the synthesis of zeolites in an aqueous solution of sodium hydroxide by means of the hydrothermal method at a concentration of 2.75 M. The results of water leaching and structural parameters are presented for both raw materials, as well as the produced synthesis. The conducted research confirmed that after the application of the synthetic process on coal shale, a zeolite with a surface area of S_BET equal to 172 m²/g can be obtained.