Search Results (11)

The increase in industrial waste generation presents a global problem that is a consequence of the needs of modern society. To achieve the goals of the EU Green Deal and to promote the concept of circular economy (CE), the valorization of industrial residues as secondary raw materials offers a pathway to economic, environmental, energetic, and social sustainability. In this respect, Al-containing industrial residues from alumina processing (red mud), thermal power plants (fly ash and bottom ash), and metallurgy (slag), as well as other industries, present a valuable mineral resource which can be considered as secondary raw materials (SRMs) with the potential to be used in construction, supporting the concept of circular economy. This paper focuses on the characterization of 19 secondary raw materials from the East South-East Europe (ESEE) region regarding their physical, chemical, mineralogical, and radiological characteristics. The goal is to provide a foundation for future innovations based on secondary raw materials, in alignment with the EU Green Deal and the principles of circular economy. The results showed that fly ash has the potential to be the best material among those analyzed to be used in the cement industry, mainly due to its favorable radiological and mineralogical properties. However, it is important to control the amount of free lime in the mixture, ensuring it remains below 10%. After evaluating secondary mineral raw materials for metal recovery, the results indicate that these materials are not viable sources for base metals or other technology-critical metals, such as REEs. Full article

The advanced quality control of the raw mix remains a priority for the cement industry, particularly in recent years, where large quantities of alternative fuels and raw materials are used in clinker production, aiming to reduce the CO₂ footprint. This study presents an adaptive control system with a variable sampling period for regulating raw mix quality in the raw mill (RM) output in a process with four independent inputs and four outputs: the lime saturation factor (LSF), silica modulus (SM), alumina modulus (AM), and SO₃. The three pillars of the system are (1) mill dynamics calculation using exclusively industrial data, (2) the design of the controllers to meet robustness criteria, and (3) performance enhancement through simulators. Our technique periodically adjusts the gains of the controllers based on the mill’s dynamic parameters, which are computed from raw mix laboratory analyses. The presented results correspond to more than 14,000 h of mill operation. The standard deviation of the LSF at the mill outlet ranged from 1.5 to 3, which is equivalent to 1 to 2 standard deviations of LSF reproducibility. The standard deviation of the other moduli was close to the corresponding reproducibility of each. The presented adaptive gain-scheduling controller for LSF can be applicable to a broad range of raw meal grinding systems. Full article

In this paper, ground granulated blast furnace slag, steel slag, red mud, waste ceramic powder, and desulfurization gypsum were used as raw materials to develop a kind of multi-source solid-waste-based soft soil solidification material. Three ratios and the strength activity index were used to determine the fractions of different solid wastes. The mineralogical and microstructural characterization was analyzed by X-ray diffraction (XRD), scanning electron microscope (SEM), and thermogravimetric analysis–differential scanning calorimetry (TG&DSC) tests. The results showed that the unconfined compressive strength of the three types of soft soil increases with an increase in the content of the solidifying agent. The failure strain of the stabilized soil decreases from 1.0–1.3% to 0.75–1.0%, and the failure mode gradually changes from plastic failure to brittle failure. The optimum content of the solidifying agent was determined to be 17% (the lime saturation factor (KH), silica modulus (SM), and alumina modulus (IM) of the solidifying agent were set to 0.68, 1.74, and 1.70, respectively), and the unconfined compressive strength (28 d) of the solidified soil (sandy soil, silty clay, and organic clay) was 3.16 MPa, 2.05 MPa, 1.04 MPa, respectively. Both measurements can satisfy the technical requirements for a cement–soil mixing pile, suggesting the possibility of using various types of solid waste as a substitute for cement. Full article

The advent of industrialization has produced an enormous amount of industrial waste slag, which drastically pollutes environmental resources. This study examines the production, stability, and microstructure of a novel backfill geopolymer paste derived from multiple industrial waste slags, including silica-alumina precursors (low-calcium composition) and waste slags (high-calcium composition), as well as two additives. The characteristics of self-hardening were discovered. The effects of low-calcium fly ash, granulated blast furnace slag, red mud, and lime powder on fluidity and compressive strength were then evaluated. To assess the stability, the resistances to drying shrinkage, permeability, and chemical attack by an optimized geopolymer backfill paste were investigated. Furthermore, SEM-EDS, XRD, FTIR, and TG-DSC tests were employed to reveal the microstructures, products, and thermal stability. The results show that the backfill paste hardens well and has no impact on alkalinity dissolution for adjacent soils and water. The optimum sample, P1, had a water-binder ratio of 0.70, resulting in 201 mm fluidity and 2.1 MPa 28-d compressive strength. In terms of drying shrinkage, permeability, and Na₂SO₄ and NaCl solution attack, sample P1 outperformed the conventional Ordinary Portland cement paste (OPC) for 90 days. The paste P1 containing about 46.0 wt% waste slags meets the fresh and hardened property requirements for goaf backfill, and the chemical binding of P1 is acquired from the mixture of (N,C)-A-S-H, C-S-H, and C-A-S-H gel products. These findings lay the groundwork for the scientific application of a wide range of waste slags in backfill engineering. Full article

Industrialization has resulted in a large number of industrial waste slags being produced, which severely pollute the environment. This urgently needs resourceful treatment. The objective of this paper is to investigate the preparation, performance, and cementation mechanism of a novel geopolymer backfill paste for goaf. We reused diverse industrial waste slags based on low-calcium silica–alumina precursors (two fly ashes FAI, FAII, and red mud RM), high-calcium-based slags (carbide slag CS, soda residue SR, briquette residue slag BRS, and granulated blast furnace slag GBFS), and two additives (gypsum powder GP and lime powder LP). The hardening of backfill pastes was investigated by analyzing the effects of FAI, GBFS, RM, and LP on physical and chemical performance. The cementation mechanism of the prepared backfill paste was revealed through morphology, mineralogy, and chemical products through the use of X-ray diffraction (XRD), scanning electron microscopy (SEM), energy dispersive spectroscopy (EDS), and Fourier transform infrared spectroscopy (FTIR). The results show that the prepared backfill paste incorporating various solid wastes (FAI, FAII, RM, CS, SR, GBFS, RBS, etc.) yields a 28-d compressive strength of 2.1 MPa (higher than the required value of 0.6 MPa) and a fluidity of 201 mm. Geopolymer gels (N,C)-A-S-H, calcium silicate hydrated C-S-H, and calcium aluminosilicate hydrated C-A-S-H gels serve as chemical cementers, whereas unreacted particles serve as physical filler skeletons. These findings provide an experimental and theoretical basis for the interchangeable use of various identical component solid wastes in backfill engineering materials. Full article

Alkali-activated binders have the potential to consume various types of waste materials. Low initial molar ratios of SiO₂/Al₂O₃ geopolymer mortars were considered in this article. Here we studied alkali-activated binders produced with photovoltaic glass powder in 5%; kaolin clay in 15%; ground granulated blast furnace slag in 30%; alumina-lime cement in 30%; and, interchangeably, fly ash from coal combustion in 5%, fly ash from biomass combustion in 5%, or granulated autoclaved cellular concrete in 5%. The influence of clay dehydroxylation, curing conditions, glass presence, and a kind of waste material was investigated. According to the experimental results, strength (compressive and tensile) gradually increased with increasing time and with the use of calcined clay. Significant improvement in compressive strength was seen with the additional 3 days curing time in 105 °C when non-sintered clay was used. The presence of photovoltaic glass in alkali-activated mortars immobilised mercury and arsenic but released zinc, chromium, and sulphates. The microscopic observations confirmed the greater densification of the microstructure of the binder made of calcined clay due to its greater surface development and dehydroxylation. The binder of non-calcined clay was granular, and the interfacial transitional zone was more porous. The C–A–S–H gel seemed to be the main phase. XRD examination confirmed the presence of C–A–S–H, C–S–H, zeolites, and many other phases in minor amount. The presented research was a pilot study, and its main goal was to develop it further. Full article

The utilization of red mud waste discharged from the Bayer production process used for extracting alumina from bauxite presents a pressing demand in the aluminum industry. This study aims to adopt a chemical modifier to solidify the Bayer red mud for its application in highway subgrade. The mechanism and properties of the modified red mud using a modifier composed of cement, phosphogypsum and organic polymer, were analyzed and investigated. It was found that the optimal modifier dosage of the solidified modifier was 8%. The three-day unconfined compressive strength of the modified Bayer red mud could reach up to 3 MPa and its strength loss when immersed in water at 7 days and 28 days measured less than 20%. For its real application as subgrade, its road performance could be achieved with good bearing capacity, including a resilient modulus value greater than 90 MPa, a dynamic deformation modulus reaching up to 140 MPa and the Falling Weight Deflectometer (FWD) value measuring less than 100 (0.01 mm). Compared with traditional lime or cement stabilized soil, using locally modified Bayer red mud for subgrade filling can reduce the project cost, minimize the consumption of non-renewable resources and reduce the emission of environmental hazards, thus providing an engineering reference for large-scale and resource-based road applications. Full article

In order to avoid potential environmental pollution from geopolymer-based material wastes, this work investigated the feasibility of using these materials as alternative raw materials in the preparation of cement clinker. The geopolymer binders and mortars were used as substitutes for natural mineral clays since they are rich in silica and alumina. Simulated geopolymer wastes were prepared by the activation of metakaolin or fly ash by an alkaline silicate solution. The cement-clinkers fired at 1450 °C for 1h were characterized by XRD, XRF, SEM-EDS, and a free lime (CaO_f) content test. The anhydrous clinker mineral phases C₃S (Ca₃SiO₅), C₂S (Ca₂SiO₄), C₃A (Ca₃Al₂O₆), and C₄AF (Ca₄Al₂Fe₂O₁₀) were well-crystallized in all investigated formulations. The free lime was lower than 1.3 wt% in all elaborated clinkers, which indicates a high degree of clinkerization. The results demonstrate that geopolymer binder and mortar materials are suitable substitutes for natural mineral clay incement clinker preparation. Full article

Low bearing capacity soils may pose serious construction concerns such as reduced bearing capacity and excessive hydro-associated volume changes. Proper soil remediation techniques must be planned and implemented before commencing any construction on low bearing capacity soils. Environmentally friendly soil stabilizers are gradually replacing traditional soil stabilizers with high carbon dioxide emissions such as lime and cement. This study investigated the use of an alternative pozzolanic mix of nano-additives (i.e., nano-silica and nano-alumina) and cement to reduce the usage of cement for achieving competent soil stabilization outcomes. A series of unconfined compressive strength (UCS), direct shear, and durability tests were conducted on marl specimens cured for 1, 7, and 28 days stabilized with nano-additives (0.1~1.5%), 3% cement, and combined 3% cement and nano-additives. The UCS and shear strength of stabilized marl increased with nano-additives up to a threshold nano-additive content of 1% which was further intensified with curing time. Nano-additive treated cemented marl specimens showed long durability under the water, while the cemented marl decomposed early. The microfabric inspection of stabilized marl specimens showed significant growth of calcium silicate hydrate (CSH) products within the micro fabric of nano-silica treated marl with reduced pore-spaces within aggregated particles. The results confirmed that nano-additives can replace cement partially to achieve multi-fold improvement in the strength characteristics of the marl. Full article

This work analyses the influence of fine concrete fractions (<5 mm) of different natures —calcareous (HcG) and siliceous (HsT)—obtained from construction and demolition waste (C&DW) on the behaviour of blended cement pastes with partial replacements between 5 and 10%. The two C&DW fractions were characterised by different instrumental techniques. Subsequently, their lime-fixing capacity and the physico-mechanical properties of the blended cement pastes were analysed. Lastly, the environmental benefits of reusing these fine wastes in the manufacture of future eco-efficient cement pastes were examined. The results show that HsT and HcG exhibit weak pozzolanic activity, owing to their low reactive silica and alumina content. Despite this, the new cement pastes meet the physical and mechanical requirements of the existing regulations for common cements. It should be highlighted that the blended cement pastes initially showed a coarser pore network, but then they underwent a refinement process between 2 and 28 days, along with a gain in compressive strength, possibly due to the double pozzolanic and filler effect of the wastes. The environmental viability of the blended cements was evaluated in a Life Cycle Assessment (LCA) concluding that the overall environmental impact could be reduced in the same proportion of the replacement rate. This is in line with the Circular Economy goals and the 2030 Agenda for Sustainable Development. Full article

Expansive sulfate-bearing soils are frequently encountered in transportation and construction practices. These soils are often treated with a lime or cement stabilizer to improve the relevant qualities. However, the reaction between sulfate and alumina in soils and calcium of lime or cement can lead to the formation of ettringite, an expansive sulfate mineral resulting in soil swelling or heaving. The underlying mechanisms often involve intricate interactions between chemical processes and mechanical responses. The present study explores a chemo–mechanical approach in an attempt to quantify several mechanisms potentially responsible for the volume expansion, including the geochemical formation of ettringite, crystallization pressure, and osmosis-induced swelling. The geochemical reaction leading to ettringite formation is examined with a specific focus on the circumstances under which it may lead to volume change. The crystallization pressure developed during the ettringite formation may also play a significant role in the soil expansion and is investigated in the present study based on thermodynamic formulations, and the resulting volume expansion is simulated. The osmosis-induced swelling is studied within the context of the chemo–mechanical framework, and its kinetics is also explored. Numerical simulations are performed in the present study to examine different scenarios driven by distinct predominant mechanisms. In particular, the interplay between ettringite formation and osmosis swelling as interpreted from some recently-reported experimental studies shows that these mechanisms can all contribute to the observed expansion processes, and overall, the modeling results are consistent with the experimental findings. Full article