Reuse potential of low-calcium bottom ash as aggregate through pelletization

Coal combustion residues which include fly ash, bottom ash and boiler slag is one of the major pollutants as these residues require large land area for their disposal. Among these residues, utilization of bottom ash in the construction industry is very low. This paper explains the use of bottom ash through pelletization. Raw bottom ash could not be pelletized as such due to its coarseness. Though pulverized bottom ash could be pelletized, the pelletization efficiency was low, and the aggregates were too weak to withstand the handling stresses. To improve the pelletization efficiency, different clay and cementitious binders were used with bottom ash. The influence of different factors and their interaction effects were studied on the duration of pelletization process and the pelletization efficiency through fractional factorial design. Addition of binders facilitated conversion of low-calcium bottom ash into aggregates. To achieve maximum pelletization efficiency, the binder content and moisture requirements vary with type of binder. Addition of Ca(OH)₂ improved the (i) pelletization efficiency, (ii) reduced the duration of pelletization process from an average of 14–7 min, and (iii) reduced the binder dosage for a given pelletization efficiency. For aggregate with clay binders and cementitious binder, Ca(OH)₂ and binder dosage have significant effect in reducing the duration of pelletization process.     

改性粉煤灰混凝剂处理工业混合废水的试验研究

通过混合酸、氯化钠制备改性粉煤灰混凝剂,探讨粉煤灰粒度、酸用量、加热时间、反应温度等对废水处理效果的影响,得出制备混凝剂最佳工艺方案。通过正交试验,用最佳混凝剂处理工业混合废水,找出混凝剂投量、废水pH值、搅拌时间及静置时间等最佳参数,探索一条以废治废的可行方法。     

双掺粉煤灰再生骨料对混凝土强度影响研究

通过试验研究再生骨料混凝土中粉煤灰和再生骨料对混凝土强度的影响。采用粉煤灰替代部分水泥、再生骨料替代部分天然粗骨料的方法,通过正交试验测定混凝土立方体抗压强度的方法,来研究粉煤灰对再生骨料混凝土强度的影响。试验得出:当再生骨料掺量为20%~30%时,粉煤灰的最佳掺量为20%左右;当再生骨料掺量高于40%、粉煤灰掺量高于20%时,其混凝土拌合物搅拌时间不小于240 s,且当粉煤灰在20%~30%时,可获得较理想的混凝土抗压强度;当粉煤灰的掺入量分布在20%~30%、再生骨料的最佳掺量为50%时,可获得较理想的混凝土抗压强度。由此得出,合理的再生骨料、粉煤灰掺量对混凝土的抗压强度影响并不明显且有提高的趋势,对降低混凝土成本,提高建筑垃圾的再生利用,有一定的经济效益和社会效益。     

The influence of fly ash load and particle size on the formation of PCDD,PCDF, PCBz and PCB in a pilot incinerator

A laboratory-scale, fluidized bed reactor fuelled by a synthetic fuel was used to study the influence of fly ash load, particle size, temperature and residence time on the low-temperature formation of chlorinated aromatic compounds. Large fly ash particles were removed from the flue gases by means of a cyclone at the entrance to the cooling section of the reactor. The experimental variables were varied according to an experimental plan of full factorial design. Polychlorinated dibenzo-p-dioxins, dibenzo-furans, polychlorinated benzenes and biphenyls were analysed in the collected flue gas samples. Despite the fact that most of the fly ash load was removed by the cyclone, formation of chlorinated aromatics occurred to the same extent as in earlier experiments, without the cyclone. These results demonstrate the importance of small fly ash particles in the post-combustion formation of chlorinated aromatics.     

The effect of the addition of fly ash to municipal digested sludge on its electroosmotic dewatering

Effective handling of municipal digested sludge requires that the product cake have low water content. To this end, we investigated the change in sludge dewaterability after the addition of fly ash to municipal digested sludge, dewatering of which is difficult because of its high organic content. The performance of the dewatering is compared with that of electroosmotic dewatering (EDW) and conventional mechanical dewatering (CMD). Fly ash classified by sieving to the size of 25–75 μm and >75 μm is added to the municipal digested sludge by 10, 20, and 50 wt% by wet base. When adding fly ash particles to municipal digested sludge, dewatering efficiency improved with smaller fly ash particle size and with increase in the amount. When sludge was dewatered using an electroosmotic dewatering method, the dewatering efficiency is improved about 40% by adding fly ash of 25–75 μm particle size with 20 wt% when compared with conventional mechanical dewatering method without adding the fly ash. It is concluded that fly ash particles rich in inorganic material are helpful in the dewatering process when added to municipal digested sludge and EDW is more effective than CDW.     

Characterization of bottom ash in municipal solid waste incinerators for its use in road base

Incineration of municipal solid wastes (MSWs) produces by-products which can be broadly classified as bottom and fly ashes. Since MSW incineration started, possibilities other than landfilling the incineration residues have been sought; most initiatives in this sense tend to use these residues as aggregate substitute in pavements and other road construction elements. The main goal of the present work is the physical and chemical characterization of the local incineration bottom ash towards its eventual re-utilization. The study includes not only the specific aspects regarding its role as pavement element, but also the assessment of the environmental effects. Therefore, together with the determination of physical (moisture content, apparent and bulk densities, crystallinity, etc.) and engineering properties (particle size distribution, abrasion and impact resistance, etc.), full chemical characterization of the bottom ash and the study of leaching as a function of aging time have been undertaken. The results obtained indicate that the metal content of both the raw bottom ash and its leachates fulfill the environmental regulations provided that the bottom ash is stored for at least one month. Engineering properties of the bottom ash are close to those of natural aggregates and, thus, road-construction use of these residues seems to be feasible.     

Possibility of using waste tire rubber and fly ash with Portland cement as construction materials

The growing amount of waste rubber produced from used tires has resulted in an environmental problem. Recycling waste tires has been widely studied for the last 20 years in applications such as asphalt pavement, waterproofing systems and membrane liners. The aim of this study is to evaluate the feasibility of utilizing fly ash and rubber waste with Portland cement as a composite material for masonry applications. Class C fly ash and waste automobile tires in three different sizes were used with Portland cement. Compressive and flexural strength, dry unit weight and water absorption tests were performed on the composite specimens containing waste tire rubber. The compressive strength decreased by increasing the rubber content while increased by increasing the fly ash content for all curing periods. This trend is slightly influenced by particle size. For flexural strength, the specimens with waste tire rubber showed higher values than the control mix probably due to the effect of rubber fibers. The dry unit weight of all specimens decreased with increasing rubber content, which can be explained by the low specific gravity of rubber particles. Water absorption decreased slightly with the increase in rubber particles size. These composite materials containing 10% Portland cement, 70% and 60% fly ash and 20% and 30% tire rubber particles have sufficient strength for masonry applications.     

燃煤飞灰颗粒物中元素分布规律的研究

利用ICP-AES光谱仪和TOC总碳分析仪对不同粒级下的飞灰颗粒进行了元素测定,对元素分布规律的形成原因进行了分析.分析结果表明:煤经旋流燃烧器燃烧而未经过除尘设备的飞灰中300目以下小颗粒含量较高.随着燃烧温度的升高,大颗粒的含碳量增加,小颗粒的含碳量减少,元素Al、Mg、Cr在各个粒级中含量变化不大,Ti、Ba、V在大于280目的小颗粒中含量有下降趋势,其他大部分痕量元素在大于300目的小颗粒中得到富集.     

Improvement of electrical resistivity tomography for leachate injection monitoring

Leachate recirculation is a key process in the scope of operating municipal waste landfills as bioreactors, which aims to increase the moisture content to optimize the biodegradation in landfills. Given that liquid flows exhibit a complex behaviour in very heterogeneous porous media, in situ monitoring methods are required. Surface time-lapse electrical resistivity tomography (ERT) is usually proposed. Using numerical modelling with typical 2D and 3D injection plume patterns and 2D and 3D inversion codes, we show that wrong changes of resistivity can be calculated at depth if standard parameters are used for time-lapse ERT inversion. Major artefacts typically exhibit significant increases of resistivity (more than +30%) which can be misinterpreted as gas migration within the waste. In order to eliminate these artefacts, we tested an advanced time-lapse ERT procedure that includes (i) two advanced inversion tools and (ii) two alternative array geometries. The first advanced tool uses invariant regions in the model. The second advanced tool uses an inversion with a “minimum length” constraint. The alternative arrays focus on (i) a pole–dipole array (2D case), and (ii) a star array (3D case). The results show that these two advanced inversion tools and the two alternative arrays remove almost completely the artefacts within +/?5% both for 2D and 3D situations. As a field application, time-lapse ERT is applied using the star array during a 3D leachate injection in a non-hazardous municipal waste landfill. To evaluate the robustness of the two advanced tools, a synthetic model including both true decrease and increase of resistivity is built. The advanced time-lapse ERT procedure eliminates unwanted artefacts, while keeping a satisfactory image of true resistivity variations. This study demonstrates that significant and robust improvements can be obtained for time-lapse ERT monitoring of leachate recirculation in waste landfills.     

Removal of unburned carbon from municipal solid waste fly ash by column flotation

Unburned carbon (UC) is the major source of organic contaminants in municipal solid waste (MSW) fly ash. So most organic contaminants can be removed by the removal of the UC from the MSW fly ash. In this paper, we first used a technique of column flotation to remove UC from MSW fly ash. The influences of column flotation parameters on the recovery efficiency of UC were systematically studied. It was found that the UC recovery efficiency was greatly influenced by the gas flow rate, pH value, collector kerosene's concentration and the types of fly ash. By optimizing the above parameters, we have successfully removed 61.2% of the UC from MSW fly ash having 5.24% UC content. The removal mechanism was well accounted for the kinetic theory of column flotation and surface-chemistry theory. The results indicate that the column flotation technique is effective in removing the UC from MSW fly ash, and show that there is a strong possibility for practical application of this technique in removing the organic contaminants from MSW fly ash.     

Performance evaluation of cement stabilized fly ash-GBFS mixes as a highway construction material

Fly ash and granulated blast furnace slag (GBFS) are major by-products of thermal and steel plants, respectively. These materials often cause disposal problems and environmental pollution. Detailed laboratory investigations were carried out on cement stabilized fly ash-(GBFS) mixes in order to find out its suitability for road embankments, and for base and sub-base courses of highway pavements. Proctor compaction test, unconfined compressive strength (UCS) test and California Bearing Ratio (CBR) test were conducted on cement stabilized fly ash-GBFS mixes as per the Indian Standard Code of Practice. Cement content in the mix was varied from 0% to 8% at 2% intervals, whereas the slag content was varied as 0%, 10%, 20%, 30% and 40%. Test results show that an increase of either cement or GBFS content in the mixture, results in increase of maximum dry density (MDD) and decrease of optimum moisture content (OMC) of the compacted mixture. The MDD of the cement stabilized fly ash-GBFS mixture is comparably lower than that of similarly graded natural inorganic soil of sand to silt size. This is advantageous in constructing lightweight embankments over soft, compressible soils. An increase in percentage of cement in the fly ash-GBFS mix increases enormously the CBR value. Also an increase of the amount of GBFS in the fly ash sample with fixed cement content improves the CBR value of the stabilized mix. In the present study, the maximum CBR value of compacted fly ash-GBFS-cement (52:40:8) mixture obtained was 105%, indicating its suitability for use in base and sub-base courses in highway pavements with proper combinations of raw materials.     

Evaluation of bioaccessible arsenic in fly ash by an in vitro method and influence of particle-size fraction on arsenic distribution

A huge amount of fly ash is produced by coal-fired power plants every year in China and leads to increasing environmental problems associated with disposal and treatment. It will be very helpful for the study of management and disposal of solid waste to understand the bioaccessibility and environmental behaviors of arsenic in fly ash. In this paper, an in vitro physiologically-based extraction test was applied to estimate the solubility and bioaccessibility of arsenic in fly ash in the human gastrointestinal tract. The fly ash samples were sieved into different fractions with different particle sizes (100–60, 60–10, 10–2.5, <2.5 μm). The influence of particle size on both total and bioaccessible arsenic was also investigated. The results demonstrated that arsenic concentrations in fly ash were significantly correlated with particle size. The proportion of bioaccessible arsenic (gastric and intestinal arsenic) accounting for the total arsenic was in the range of 36–67 %. The statistic analysis indicated that total arsenic in fly ash was linearly correlated with bioaccessible arsenic. The results illustrated that bioaccessible arsenic was dominated by total arsenic.     

Removal of Cr6 + and Ni2+ from aqueous solution using bagasse and fly ash

Raw bagasse and fly ash, the waste generated in sugar mills and boilers respectively have been used as low-cost potential adsorbents. Raw bagasse was pretreated with 0.1N NaOH followed by 0.1N CH3COOH before its application. These low-cost adsorbents were used for the removal of chromium and nickel from an aqueous solution. The kinetics of adsorption and extent of adsorption at equilibrium are dependent on the physical and chemical characteristics of the adsorbent, adsorbate and experimental system. The effect of hydrogen ion concentration, contact time, sorbent dose, initial concentrations of adsorbate and adsorbent and particle size on the uptake of chromium and nickel were studied in batch experiments. The Sorption data has been correlated with Langmuir, Freundlich and Bhattacharya and Venkobachar adsorption models. The efficiencies of adsorbent materials for the removal of Cr(VI) and Ni(II) were found to be between 56.2 and 96.2% and 83.6 and 100%, respectively. These results were obtained at the optimized conditions of pH, contact time, sorbent dose, sorbate concentration of 100 mg/l and with the variation of adsorbent particles size between 0.075 and 4.75 mm. The order of selectivity is powdered activated carbon > bagasse > fly ash for Cr(VI) removal and powdered activated carbon > fly ash > bagasse for Ni(II) removal.     

Recycling of municipal solid waste incinerator fly ash by using hydrocyclone separation

The municipal solid waste incinerators (MSWIs) in Taiwan generate about 300,000 tons of fly ash annually, which is mainly composed of calcium and silicon compounds, and has the potential for recycling. However, some heavy metals are present in the MSWI fly ash, and before recycling, they need to be removed or reduced to make the fly ash non-hazardous. Accordingly, the purpose of this study was to use a hydrocyclone for the separation of the components of the MSWI fly ash in order to obtain the recyclable portion. The results show that chloride salts can be removed from the fly ash during the hydrocyclone separation process. The presence of a dense medium (quartz sand in this study) is not only helpful for the removal of the salts, but also for the separation of the fly ash particles. After the dense-medium hydrocyclone separation process, heavy metals including Pb and Zn were concentrated in the fine particles so that the rest of the fly ash contained less heavy metal and became both non-hazardous and recyclable.     

Fly ash scrubbing in a novel dual flow scrubber

Scrubbers are used as particulate emission control devices with the increase in stringency of old regulations or promulgation of new regulations. Scrubbing of fly ash in a novel dual flow scrubber, i.e., one water filled bubble section and one section with water-spray, is reported in this article. The presented system included a tapered section in order to achieve the bubble regime. On the other hand, a two-phase critical flow atomizer was used for the generation of spray regime with high degree of spray uniformity. Experiments were carried out for studying the behavior of the system in terms of various pertinent variables. The fly ash removal mechanism was explained in terms of various physical interactions. Electrostatic effect was found to have an insignificant influence on the collection efficiency of fly ash. The removal efficiency was found to decrease with the increase in inlet fly ash loading in the bubble section while it was increased in the spray section. A compromise must, therefore, be struck while operating the scrubber for achieving the desired performance. The effects of other operating variables studied on the removal efficiency remained similar in the regimes under investigation. The combined effect was, however, that the spray regime was dominating. Experimentation also revealed that the bubble section collected particles down to 20 microm size. Detailed experimentation revealed that almost 100% removal efficiency (zero penetration) of fly ash could be achieved in the dual flow scrubber at a QL/QG ratio of 3.0 m3/1000 ACM (actual cubic meter). Almost zero penetration of fly ash particles, clearly demonstrated that the dual flow scrubber with its staging operations met with the stricter emission regulations for particulate matter. Selection of any particulate control device is intrinsically related to the performance as a function of various pertinent variables of the system. Correlations were, therefore, put forward for the prediction of the performances of the bubble and the spray sections in terms of various pertinent variables of the system. The overall removal efficiency achievable in the dual flow scrubber was predicted with the help of these correlations. The predicted values were in excellent agreement with the experimental values (well within +/-5.0% deviation). Comparison of the performance of the present system with the existing systems indicated that the bubble and spray sections either alone or in combination (as in a dual flow scrubber), was energy and efficiency-wise much better than the existing systems. The novelty of the system is also described.     

Heavy metal speciation in various types of fly ash from municipal solid waste incinerator

Fly ash (FA) from municipal solid waste incinerators has been known as hazardous waste, which is mostly because of the high content of heavy metal and dioxins. Besides the content, the form of the heavy metals in fly ash is also very important, because it is tightly related with the leaching behavior of fly ash in diverse circumstances. To evaluate the environment potential risk of fly ash, the Tessier chemical extraction method was adopted. In this study, four kinds of fly ash were examined, one sample from China (CFA) and the other three from Japan (RFA, CaFA and NaFA). Five metal elements were detected and they were Ni, Cr, Cd, Pb, and Cu. The result of total heavy metals’ concentration showed CFA has the lowest content. As to the Tessier chemical extraction experiments, the results show that Cd, Pb, and Cu have higher leaching risk in the environment than other heavy metals. The result of leaching test experiment showed that the more exchangeable speciation of Cd, Cr and Pb in FA, the more it could leach out in natural environment.     

Aggregate material formulated with MSWI bottom ash and APC fly ash for use as secondary building material

The main goal of this paper is to obtain a granular material formulated with Municipal Solid Waste Incineration (MSWI) bottom ash (BA) and air pollution control (APC) fly ash to be used as secondary building material. Previously, an optimum concrete mixture using both MSWI residues as aggregates was formulated. A compromise between the environmental behavior whilst maximizing the reuse of APC fly ash was considered and assessed. Unconfined compressive strength and abrasion resistance values were measured in order to evaluate the mechanical properties. From these results, the granular mixture was not suited for certain applications owing to the high BA/APC fly ash content and low cement percentages used to reduce the costs of the final product. Nevertheless, the leaching test performed showed that the concentrations of all heavy metals were below the limits established by the current Catalan legislation for their reutilization. Therefore, the material studied might be mainly used in embankments, where high mechanical properties are not needed and environmental safety is assured.     

Evaluation of concrete incorporating bottom ash as a natural aggregates replacement

A study on the incorporation of coal bottom ash from thermoelectric power stations as a substitute material for natural sand in the production of concrete is here presented. The normally coarse, fused, glassy texture of bottom ash makes it an ideal substitute for natural aggregates. The use of bottom ash in concrete presents several technical challenges: the physical and mineralogical characteristics of the bottom ash; the effect on water demand and the participation on cements hydratation. In the production of the concrete, substitutions in volume were used. Two different ways to employ bottom ash were used to make up the mix proportions: one considering the natural humidity present in the porous particles and the other not considering it, seeking to maintain the same strength. These considerations are fundamental given that the process of bottom ash extraction is carried out through moisture. Mechanical tests by compressive strength were performed and the elastic modulus was determined. An analysis of the influence of bottom ash in the formation of pores was carried out through tests for the water loss by air drying and water uptake by capillary absorption. The results show that the higher the bottom ash contents in the concrete, the worse the performance regarding moisture transport. However, for one bottom ash concrete type, the mechanical properties were maintained.     

Investigation of hydrogen generation from municipal solid waste incineration fly ash

Hydrogen generation from municipal solid waste incineration fly ash was investigated to understand the influences of contacting method, kinds of contact solution, liquid to solid ratio, and particle size distribution of materials. Redox properties of materials and hydrogen generation were also studied. The largest quantity of gas generated in contact with water was 29.1 ml/g-ash, most of which was hydrogen. Fluidized bed fly ash generated more gas than stoker fly ash. In order to calculate the hydrogen generation potential (the maximum quantity of gas generated in contact with water), a novel system using a Y-shaped test tube and NaOH was utilized. This method gives values which are related to the quantity of generated gas in contact with water. A relationship between the aluminum content and hydrogen generation potential was observed, especially for fluidized bed fly ash. The reducing potential of fluidized bed fly ash was higher than that of stoker fly ash. Only fluidized bed fly ash showed a positive correlation between aluminum content and reducing potential, and between reducing potential and hydrogen generation potential. These results suggest that fluidized bed fly ash contains more Al⁰ than stoker fly ash. Received: September 11, 1998 / Accepted: March 19, 1999     

New technology and application of brick making with coal fly ash

China has ranked first in the coal fly ash emission in the world. The multipurpose use of the fly ash from power plant waste is always an important topic for the Chinese environmental protection, which has drawn the concern of the government, scientific research departments, manufacturing enterprises and industry experts. This paper introduces an experimental research on how to recycle fly ash effectively, a kind of new technology of making bricks by which fly ash content could be amounted to 50–80 %. The article introduces raw materials of fly ash brick, production process and key control points. It introduces how to change the technical parameters of the existing brick-making mechanical device, optimize the parameters combination and improve the device performance. High-content fly ash bricks are manufactured, which selects wet fly ash from power plants, adding aggregate with reasonable ratio and additives with reasonable dosage, and do the experimental research on manufactured products for properties, production technology and selection about technology parameters of production equipment. All indexes of strength grade, freezing-thawing resisting, and other standards of the studied bricks reached the national standards for building materials industry.