Selected Strength Properties of Coal Bottom Ash (CBA) Concrete Containing Fly Ash under Different Curing and Drying Conditions

This study aims to evaluate the effect of curing and drying conditions on the strength properties of concrete containing coal bottom ash (CBA) and fly ash as substitutes for fine aggregates and cement, respectively. The strength properties of the concrete including CBA and fly ash were evaluated under two different curing and drying conditions: saturated surface-dry (SSD) conditions and oven-dried conditions at curing ages of 28 and 91 days. The natural fine aggregates of the mixtures were replaced by CBA fine aggregates at 25%, 50%, 75%, and 100% by volume. In addition, the cement in the mixtures was partly replaced with fly ash at 20% and 40%. The experimental program included the measurement of the unit weight, compressive strength, splitting tensile strength, flexural strength, and ultrasonic pulse velocity of the concrete. The test results showed that the compressive strength, splitting tensile strength, and flexural strength decreased as the CBA content increased under both SSD and oven-dried conditions. The curing and drying conditions of the concrete with CBA and fly ash considerably influenced the reduction in the compressive, splitting, and flexural tensile strengths of the concrete. Additionally, the experimental results showed that fly ash insignificantly contributed to the reduction in the strength properties under both SSD and oven-dried conditions. Finally, the relationships between ultrasonic pulse velocity and the splitting tensile strength, flexural tensile strength, and compressive strength were investigated.     

Strength and Microstructure of Geopolymer Based on Fly Ash and Metakaolin

The production of Portland cement is widely regarded as a major source of greenhouse gas emissions. This contributes to 6–7% of total CO₂ emissions, according to the International Energy Agency. As a result, several efforts have been made in recent decades to limit or eliminate the usage of Portland cement in concrete. Geopolymer has garnered a lot of attention among the numerous alternatives due to its early compressive strength, low permeability, high chemical resistance, and great fire-resistant behaviour. This study looks at the strength and microstructure of geopolymer based on fly ash and a combination of metakaolin and fly ash. Compressive strengths were measured at 7, 14, and 28 days, and microstructure was examined using SEM and XRD.     

Chemical Distributions of Different Sodium Hydroxide Molarities on Fly Ash/Dolomite-Based Geopolymer

Geopolymers are an inorganic material in an alkaline environment that is synthesized with alumina–silica gel. The structure of geopolymers consists of an inorganic chain of material and a covalent-bound molecular system. Currently, Ordinary Portland Cement (OPC) has caused carbon dioxide (CO₂) emissions which causes greenhouse effects. This analysis investigates the impact on fly ash/dolomite-based-geopolymer with various molarities of sodium hydroxide solutions which are 6 M, 8 M, 10 M, 12 M and 14 M. The samples of fly ash/dolomite-based-geopolymer were prepared with the usage of solid to liquid of 2.0, by mass and alkaline activator ratio of 2.5, by mass. After that, the geopolymer was cast in 50 × 50 × 50 mm molds before testing after 7 days of curing. The samples were tested on compressive strength, density, water absorption, morphology, elemental distributions and phase analysis. From the results, the usage of 8 M of NaOH gave the optimum properties for the fly ash/dolomite-based geopolymer. The elemental distribution analysis exposes the Al, Si, Ca, Fe and Mg chemical distribution of the samples from the selected area. The distribution of the elements is related to the compressive strength and compared with the chemical composition of the fly ash and dolomite.     

Recycling of Pre-Washed Municipal Solid Waste Incinerator Fly Ash in the Manufacturing of Low Temperature Setting Geopolymer Materials

In this work, three samples of municipal solid waste incinerators fly ash (MSWI-FA) have been stabilized in systems containing coal fly ash to create geopolymers through a polycondensation reaction. Monolithic products have been obtained with both MSWI fly ash as received and after the partial removal of chloride and sulfate by water washing. The polycondensation products have been characterized qualitatively by means of Fourier transform infrared spectroscopy, X-ray diffraction and scanning electron microscopy and quantitatively, through the determination of the volume of reacted water and silicate. Furthermore, the heavy metals and chloride releases together with the physico-mechanical properties have been evaluated on the hardened products. In conclusion, considering the technological and environmental performances of the obtained geopolymers, they could be suitable for many non-structural applications, such as backfilling of abandoned quarries, decorative materials or brick fireplaces, hearths, patios, etc.     

Kinetics Study of Al Extraction from Desilicated Coal Fly Ash by NaOH at Atmospheric Pressure

The most promising source of alumina in the 21st century is the coal fly ash (CFA) waste of coal-fired thermal plants. The methods of alumina extraction from CFA are often based on the pressure alkaline or acid leaching or preliminary roasting with different additives followed by water leaching. The efficiency of the alumina extraction from CFA under atmospheric pressure leaching is low due to the high content of acid-insoluble alumina phase mullite (3Al₂O₃·2SiO₂). This research for the first time shows the possibility of mullite leaching under atmospheric pressure after preliminary desilication using high liquid to solid ratios (L:S ratio) and Na₂O concentration. The analysis of the desilicated CFA (DCFA) chemical and phase composition before and after leaching has been carried out by inductively coupled plasma optical emission spectrometry (ICP-OES) and X-ray diffraction (XRD). The morphology and elemental composition of solid product particles has been carried out by scanning electron microscopy with energy-dispersive X-ray spectroscopy (SEM-EDX). An automated neural network and a shrinking core model (SCM) were used to evaluate experimental data. The Al extraction efficiency from DCFA has been more than 84% at T = 120 °C, leaching time 60 min, the L/S ratio > 20, and concentration of Na₂O—400 g L⁻¹. The kinetics analysis by SCM has shown that the surface chemical reaction controls the leaching process rate at T < 110 °C, and, at T > 110 °C after 15 min of leaching, the process is limited by diffusion through the product layer, which can be represented by titanium compounds. According to the SEM-EDX analysis of the solid residue, the magnetite spheres and mullite acicular particles were the main phases that remained after NaOH leaching. The spheric agglomerates of mullite particles with non-porous surface have also been found.     

The Influence of Cement Substitution by Biomass Fly Ash on the Polymer–Cement Composites Properties

The generation of energy for the needs of the population is currently a problem. In consideration of that, the biomass combustion process has started to be implemented as a new source of energy. The dynamic increase in the use of biomass for energy generation also resulted in the formation of waste in the form of fly ash. This paper presents an efficient way to manage this troublesome material in the polymer–cement composites (PCC), which have investigated to a lesser extent. The research outlined in this article consists of the characterization of biomass fly ash (BFA) as well as PCC containing this waste. The characteristics of PCC with BFA after 3, 7, 14, and 28 days of curing were analyzed. Our main findings are that biomass fly ash is suitable as a mineral additive in polymer–cement composites. The most interesting result is that the addition of biomass fly ash did not affect the rheological properties of the polymer–cement mortars, but it especially influenced its compressive strength. Most importantly, our findings can help prevent this byproduct from being placed in landfills, prevent the mining of new raw materials, and promote the manufacture of durable building materials.     

Predicting the Compressive Strength of Concrete Containing Fly Ash and Rice Husk Ash Using ANN and GEP Models

Climate change has become trending news due to its serious impacts on Earth. Initiatives are being taken to lessen the impact of climate change and mitigate it. Among the different initiatives, researchers are aiming to find suitable alternatives for cement. This study is a humble effort to effectively utilize industrial- and agricultural-waste-based pozzolanic materials in concrete to make it economical and environmentally friendly. For this purpose, a ternary blend of binders (i.e., cement, fly ash, and rice husk ash) was employed in concrete. Different variables such as the quantity of different binders, fine and coarse aggregates, water, superplasticizer, and the age of the samples were considered to study their influence on the compressive strength of the ternary blended concrete using gene expression programming (GEP) and artificial neural networking (ANN). The performance of these two models was evaluated using R², RMSE, and a comparison of regression slopes. It was observed that the GEP model with 100 chromosomes, a head size of 10, and five genes resulted in an optimum GEP model, as apparent from its high R² value of 0.80 and 0.70 in the TR and TS phase, respectively. However, the ANN model performed better than the GEP model, as evident from its higher R² value of 0.94 and 0.88 in the TR and TS phase, respectively. Similarly, lower values of RMSE and MAE were observed for the ANN model in comparison to the GEP model. The regression slope analysis revealed that the predicted values obtained from the ANN model were in good agreement with the experimental values, as shown by its higher R² value (0.89) compared with that of the GEP model (R² = 0.80). Subsequently, parametric analysis of the ANN model revealed that the addition of pozzolanic materials enhanced the compressive strength of the ternary blended concrete samples. Additionally, we observed that the compressive strength of the ternary blended concrete samples increased rapidly within the first 28 days of casting.     

Morphology and Chemical Composition of Magnetic Particles Separated from Coal Fly Ash

Iron and other metal compounds are the materials that often appear in coal seams, because they also appear as a component of former organic matter in coal rocks. Although iron is the dominant element in coal rocks, other metals such as titanium, lead, cobalt, nickel, and copper are also present. In this study, the properties of magnetic particles of a size between 1 and 20 µm of globular structure and iron containing, were separated from coal fly ash, and studied using a scanning electron microscopy, energy disperse spectroscopy, and X-ray diffraction spectroscopy. The investigations were comprised of micrographs of the structure of these particles, their elemental composition, and phase analysis.     

Mechanical and Durability Analysis of Fly Ash Based Geopolymer with Various Compositions for Rigid Pavement Applications

Ordinary Portland cement (OPC) is a conventional material used to construct rigid pavement that emits large amounts of carbon dioxide (CO₂) during its manufacturing process, which is bad for the environment. It is also claimed that OPC is susceptible to acid attack, which increases the maintenance cost of rigid pavement. Therefore, a fly ash based geopolymer is proposed as a material for rigid pavement application as it releases lesser amounts of CO₂ during the synthesis process and has higher acid resistance compared to OPC. This current study optimizes the formulation to produce fly ash based geopolymer with the highest compressive strength. In addition, the durability of fly ash based geopolymer concrete and OPC concrete in an acidic environment is also determined and compared. The results show that the optimum value of sodium hydroxide concentration, the ratio of sodium silicate to sodium hydroxide, and the ratio of solid-to-liquid for fly ash based geopolymer are 10 M, 2.0, and 2.5, respectively, with a maximum compressive strength of 47 MPa. The results also highlight that the durability of fly ash based geopolymer is higher than that of OPC concrete, indicating that fly ash based geopolymer is a better material for rigid pavement applications, with a percentage of compressive strength loss of 7.38% to 21.94% for OPC concrete. This current study contributes to the field of knowledge by providing a reference for future development of fly ash based geopolymer for rigid pavement applications.     

A Study on the Utilization of Coal Fly Ash Derived Grog in Clay Ceramics

Grog is an additive material that plays important roles in ceramic making. It improves the fabrication process of green bodies as well as the physical properties of fired bodies. Few low-cost materials and wastes have found their application as grog in recent years, thus encouraging the replacement of commercial grogs with cost-saving materials. Coal fly ash, a combustion waste produced by coal-fired power plant, has the potential to be converted into grog owing to its small particle sizes and high content of silica and alumina. In this study, grog was derived from coal fly ash and mixed with kaolin clay to produce ceramics. Effects of the grog addition on the resultant ceramics were investigated. It was found that, to a certain extent, the grog addition reduced the firing shrinkage and increased the total porosity of the ceramics. The dimensional stability of the ceramics at a firing temperature of 1200 °C was also not noticeably affected by the grog. However, the grog addition in general had negative effects on the biaxial flexural strength and refractoriness of the ceramics.     

Foam Glass Lightened Sorel’s Cement Composites Doped with Coal Fly Ash

Lightweight Sorel’s cement composites doped with coal fly ash were produced and tested. Commercially available foam granulate was used as lightening aggregate. For comparison, reference composites made of magnesium oxychloride cement (MOC) and quartz sand were tested as well. The performed experiments included X-ray diffraction, X-ray fluorescence, scanning electron microscopy, light microscopy, and energy dispersive spectroscopy analyses. The macro- and microstructural parameters, mechanical resistance, stiffness, hygric, and thermal parameters of the 28-days matured composites were also researched. The combined use of foam glass and fly ash enabled to get a material of low weight, high porosity, sufficient strength and stiffness, low water imbibition, and greatly improved thermal insulation performance. The developed lightweight composites can be considered as further step in the design and production of alternative and sustainable materials for construction industry.     

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.     

Effect of Fly Ash on Strength and Stiffness Characteristics of Controlled Low-Strength Material in Shear Wave Monitoring

Fly ash, the main component for controlled low-strength material (CLSM), has physical and chemical characteristics according to the resources used in the thermal power plant, and thus fly ash type can influence the physical and strength properties of CLSM. This study investigates the effect of fly ash type on the engineering properties of CLSM and establishes relationships between mechanical properties of CLSM and shear wave velocity (SWV) for long curing times. Six fly ashes with different physical properties and chemical components are used for preparing the CLSM mixtures. The air content, unit weight, flowability, and setting time of CLSM are measured. Unconfined compressive strength (UCS) and elastic modulus (E) are obtained from unconfined compressive tests, and SWV (V_s) is determined using a bender element-based wave measurement system. Experimental results show that the stiffness and strength characteristics of CLSM are relevant to the contents of two oxides (SiO₂ and Al₂O₃) and the fineness of fly ash. Because the evolution of SWV is influenced by the fly ash type, the relationships UCS-V_s and E-V_s are well established. Thus, considering the fly ash type, shear wave monitoring may be effectively used for estimating strength and stiffness characteristics of CLSM.     

Opportunities for Recycling PV Glass and Coal Fly Ash into Zeolite Materials Used for Removal of Heavy Metals (Cd,Cu, Pb) from Wastewater

This work shows the development and characterization of two zeolite structures by recycling PV glass and coal fly ash for the removal of cadmium, copper, and lead from synthetic solutions containing one or three cations. The materials were characterized in terms of crystalline structure (XRD), morphology (SEM, AFM), and specific surface. For increasing the heavy-metals removal efficiency, the adsorption conditions, such as substrate dosage, preliminary concentration, and contact time, were optimized. The pseudo-second-order kinetic model adsorption kinetics fit well to describe the activity of the zeolites ZFAGPV-A and ZFAGPV-S. The zeolite adsorption equilibrium data were expressed using Langmuir and Freundlich models. The highest adsorption capacities of the ZFAGPV-A zeolite are q_maxCd = 55.56 mg/g, q_maxCu = 60.11 mg/g, q_maxPb = 175.44 mg/g, and of ZFAGPV-S, are q_maxCd = 33.45 mg/g, q_maxCu = 54.95 mg/g, q_maxPb = 158.73 mg/g, respectively. This study demonstrated a new opportunity for waste recycling for applications in removing toxic heavy metals from wastewater.     

Preparation and Properties of Foam Concrete Incorporating Fly Ash

Foam concrete is fire resistant and durable and has broad applicability as a building insulation material. However, cement has high energy consumption and causes pollution, necessitating an environment-friendly cementitious material to replace the cement used to prepare foam concrete. In this study, foam concrete was prepared through chemical foaming. The influence of the foaming agent material, foam stabiliser, and fly ash on the basic properties of the foam concrete, including the dry bulk density, compressive strength, and thermal conductivity, was studied, and the pore structure was characterised. The results show that with an increase in the hydrogen peroxide (H₂O₂) content, the dry bulk density, compressive strength, and thermal conductivity of foam concrete decreases, whereas the pore diameter increases (0.495 to 0.746 mm). When the calcium stearate content is within 1.8%, the pore size tends to increase (0.547 to 0.631 mm). With increase in the fly ash content, the strength of foam concrete gradually decreases, and the dry bulk density first decreases and then increases. When the blending ratio of fly ash is 10–40%, the thermal conductivity gradually decreases; an extreme thermal conductivity of 0.0824 W/(m·K) appears at the blending ratio of 40%, and the dry bulk density is 336 kg/m³.     

The Triaxial Test of Polypropylene Fiber Reinforced Fly Ash Soil

Recently, soil reinforcement using arranged or randomly distributed fibers has attracted increasing attention in geotechnical engineering. In this study, polypropylene (PP) fibers with three lengths (6, 12, and 24 mm) and three mass percentages (0.5%, 1%, and 1.5%) were used to reinforce a coal fly ash soil (FAS) mixture. Unconsolidated, undrained triaxial tests were carried out in order to study the mechanical properties of the polypropylene fiber-reinforced FAS mixture and evaluate the impact of fiber on the shear strength of the FAS mixture. It is found that the fiber length of 12 mm could significantly improve the shear strength of the polypropylene fiber reinforced FAS mixture, and little effect is shown on the shear strength while using a fiber length of 24 mm. Additional fibers enhance the energy absorption capacity of the FAS specimens and therefore the highest energy absorption capacity occurs when the fiber content is 1% and the fiber length is 12 mm. The peak deviator stress enhances impressively with the addition of polypropylene fiber. The impact of fiber on the peak deviator stress is the largest when fiber content is within 1.0%. The fiber length has little effect on the peak deviator stress when it exceeds 12 mm.     

Study on the Overall Reaction Pathways and Structural Transformations during Decomposition of Coal Fly Ash in the Process of Alkali-Calcination

In this research, phase transformation and the role of NaOH on the structure of coal fly ash (CFA) during an alkali-calcination process were identified by a combination of X-ray powder diffraction (XRD), Fourier transform infrared (FTIR) and deconvolution analysis. The variation in the different functional groups and structural parameters of the raw and post-alkali calcinated CFA were analysed by deconvolution of the FTIR results, conducted with a Gaussian approach. The results, firstly, provide a deep insight into the functional groups in CFA. In CFA systems, the vibration signals of Q⁰, Q¹, Q² and Q³ were detected and the dominant structural units associated with Si tetrahedron groups were isolated to Q³ and Q². Deconvolution analysis of the band from 400 to 1400 cm⁻¹ showed that the added NaOH resulted in an increase in Q¹ at the cost of Q³ and Q² and the degree of reaction of the CFA was, therefore, decreased. Concurrently, it was established that the changes in the Gaussian peak component were related to the calcination temperature and time that allowed us to tailor the model of the structural decomposition of CFA.     

Recycling of Waste Solution after Hydrothermal Conversion of Fly Ash on a Semi-Technical Scale for Zeolite Synthesis

Nowadays, using fly ash for zeolites production has become a well-known strategy aimed on sustainable development. During zeolite synthesis in a hydrothermal conversion large amount of post-reaction solution is generated. In this work, the solution was used as a substrate for Na-A and Na-X zeolites synthesis at laboratory and technical scale. Obtained materials were characterized using particle size analysis, X-ray diffraction (XRD), X-ray fluorescence spectroscopy (XRF), transmission electron microscopy (TEM), Fourier transformed infrared spectroscopy (FTIR), and nitrogen adsorption/desorption isotherm. Produced zeolites revealed high purity (>98%) and monomineral zeolitic phase composition. The SiO₂ content was in the range 39–42% and 40–38%, whereas Al₂O₃ content was 23–22% and 25–26% for Na-X and Na-A, respectively. TEM and BET analyses revealed Na-X zeolite pores were almost identical to commercial 13X with S_BET in the range 671–734 m²/g. FTIR indicated slight differences between materials obtained at laboratory and technical scale in Si-O-(Si/Al) bridges of the zeolitic skeleton. The results showed good replicability of the laboratory process in the larger scale. The proposed method allows for waste solution reusability with a view to highly pure zeolites production in line with circular economy assumptions.     

Potential of Soil Stabilization Using Ground Granulated Blast Furnace Slag (GGBFS) and Fly Ash via Geopolymerization Method: A Review

Geopolymers, or also known as alkali-activated binders, have recently emerged as a viable alternative to conventional binders (cement) for soil stabilization. Geopolymers employ alkaline activation of industrial waste to create cementitious products inside treated soils, increasing the clayey soils’ mechanical and physical qualities. This paper aims to review the utilization of fly ash and ground granulated blast furnace slag (GGBFS)-based geopolymers for soil stabilization by enhancing strength. Previous research only used one type of precursor: fly ash or GGBFS, but the strength value obtained did not meet the ASTM D 4609 (<0.8 Mpa) standard required for soil-stabilizing criteria of road construction applications. This current research focused on the combination of two types of precursors, which are fly ash and GGBFS. The findings of an unconfined compressive strength (UCS) test on stabilized soil samples were discussed. Finally, the paper concludes that GGBFS and fly-ash-based geo-polymers for soil stabilization techniques can be successfully used as a binder for soil stabilization. However, additional research is required to meet the requirement of ASTM D 4609 standard in road construction applications, particularly in subgrade layers.     

Resistance of Soda Residue–Fly Ash Based Geopolymer Mortar to Acid and Sulfate Environments

The early mechanical performances of low-calcium fly ash (FFA)-based geopolymer (FFA–GEO) mortar can be enhanced by soda residue (SR). However, the resistance of SR–FFA–GEO mortar to acid or sulfate environments is unclear, owing to the various inorganic calcium salts in SR. The aim of this study was to investigate the long-term mechanical strengths of up to 360 d and evaluate the resistance of SR–FFA–GEO mortar to 5% HCl and 5% Na₂SO₄ environments through the losses in compressive strength and mass. Scanning Electron Microscopy (SEM), Energy-Dispersive Spectroscopy (EDS) and Fourier Transform Infrared Spectrometer (FTIR) experiments were conducted for the SR–FFA–GEO mortars, both before and after chemical attack, to clarify the attack mechanism. The results show that the resistances of the SR–FFA–GEO mortar with 20% SR (namely M10) to 5% HCl and 5% Na₂SO₄ environments are superior to those of cement mortar. The environmental HCl reacts with the calcites in SR to produce CaCl₂, CO₂ and H₂O to form more pores under HCl attack, and the environmental Na⁺ cations from Na₂SO₄ go into Si-O-Al network structure, to further enhance the strength of mortar under Na₂SO₄ attack. These results provide the experimental basis for the durability optimization of SR–FFA–GEO mortars.