Search Results (260)

Geopolymers are an environmentally sustainable class of low-calcium alkali-activated materials (AAMs), distinct from high-calcium C–A–S–H gel systems. Synthesized from aluminosilicate-rich precursors such as fly ash, metakaolin, slag, waste glass, and coal gasification fly ash (CGFA), geopolymers offer a significantly lower carbon footprint, valorize industrial by-products, and demonstrate superior durability in aggressive environments compared to Ordinary Portland Cement (OPC). Recent advances in thermodynamic modeling and phase chemistry, particularly in CaO–SiO₂–Al₂O₃ systems, are improving precursor selection and mix design optimization, while Artificial Neural Network (ANN) and hybrid ML-thermodynamic approaches show promise for predictive performance assessment. This review critically evaluates geopolymer chemistry and composition, emphasizing precursor reactivity, Si/Al and other molar ratios, activator chemistry, curing regimes, and reaction mechanisms in relation to microstructure and performance. Comparative insights into alkali aluminosilicate (AAS) and aluminosilicate phosphate (ASP) systems, supported by SEM and XRD evidence, are discussed alongside durability challenges, including alkali–silica reaction (ASR) and shrinkage. Emerging applications ranging from advanced pavements and offshore scour protection to slow-release fertilizers and biomedical implants are reviewed within the framework of the United Nations Sustainable Development Goals (SDGs). Identified knowledge gaps include standardization of mix design, LCA-based evaluation of novel precursors, and variability management. Aligning geopolymer technology with circular economy principles, this review consolidates recent progress to guide sustainable construction, waste valorization, and infrastructure resilience. Full article

Excellent mechanical properties are a prerequisite for the widespread application of different types of concrete in practical engineering. However, when coal gangue (CG) is used as coarse aggregate (CA) and geopolymer cement is used as auxiliary cementitious material, while reducing the demand for ordinary cement and industrial waste emissions, it has a negative impact on mechanical performance. Therefore, in response to the data gap in the study of mechanical properties of coal gangue coarse aggregate-fly ash geopolymer concrete (CG-FA-GPC), inspired by a large number of research results on fiber-reinforced concrete, this study uses basalt fiber (BF) as a reinforcing material to investigate the enhancing effect of BF on the mechanical properties of CG-FA-GPC. We selected compressive strength, flexural strength, splitting tensile strength, and stress–strain curve as evaluation indicators to compare and analyze the mechanical properties of ordinary concrete, CG-FA-GPC, and basalt fiber-reinforced coal gangue coarse aggregate-fly ash geopolymer concrete (BF-CG-FA-GPC), and to explore the reinforcement effect of BF. The results showed that with the increase in CG substitution rate, the compressive strength, flexural strength, and splitting tensile strength of CG-FA-GPC significantly decreased. A 100% CG substitution reduced the compressive strength, flexural strength, and splitting tensile strength of CG-FA-GPC by 34.5%, 43.4%, and 31.8%, respectively. The stress–strain curve reveals the dual effects of BF on the strength enhancement and deformation modification of CG-FA-GPC. With the increase in BF content, the three mechanical strengths of CG-FA-GPC show a pattern of first increasing and then decreasing, and the optimal BF content is 0.4% (volume fraction). This experiment lays the foundation for promoting research on the mechanical properties and durability of different fiber-reinforced CG-FA-GPC, advancing the feasibility of its large-scale engineering applications. Full article

Light-emitting diodes (LEDs) are made up of precious metals, e.g., gallium. These elements can be recovered and reused, reducing the need for new raw materials. Proper recycling prevents harmful substances in LEDs, such as lead and arsenic, from contaminating the environment. Recycling LEDs uses less energy compared to producing new ones, leading to lower carbon emissions. The valuable metal gallium faces the challenge of supply and demand due to the surge in its demand, the difficulty of separating it from minerals, and processing issues during extraction. In this review, we describe the methods for recycling gallium from LEDs by using different techniques such as pyrolysis (95% recovery), oxalic acid leaching (83.2% recovery), HCL acid leaching of coal fly ash (90–95% recovery), subcritical water treatment (80.5% recovery), supercritical ethanol (93.10% recovery), oxidation and subsequent leaching (91.4% recovery), and vacuum metallurgy separation (90% recovery). Based on our analysis, hydrometallurgy is the best approach for recovering gallium. It is reported that approximately 5% of the waste from LEDs is adequately recycled, whereas the total gallium potential wasted throughout production is over 93%. By recycling LEDs, we can minimize waste, conserve resources, and promote sustainable practices. Thus, recycling LEDs is essential for strengthening a circular economy. Full article

To address the environmental risks associated with large-scale stockpiling of red mud (RM) and coal gangue (CG) and the demand for their high-value utilization, this study proposes a ternary concrete system incorporating RM, fly ash (FA), and CG aggregate. The effects of RM content, FA content, CG aggregate replacement rate, and water-to-binder ratio on workability, mechanical properties, and frost resistance durability were systematically investigated through orthogonal experiments, with the underlying micro-mechanisms revealed by scanning electron microscopy (SEM) and energy dispersive spectroscopy (EDS). The results indicate that workability is predominantly governed by the water-to-binder ratio, while the micro-aggregate effect of FA significantly enhances fluidity. Mechanical properties are most significantly influenced by RM content; under a 20% CG aggregate replacement rate and a 0.45 water-to-binder ratio, an optimal compressive strength was achieved with a low content combination of RM and FA. Frost resistance deteriorated markedly with increasing RM and FA content, with the high-content group approaching the failure threshold after only 25 freeze–thaw cycles, occurring 50 and 125 cycles earlier than the medium- and low-content groups, respectively. Macro-micro results indicate a synergistic threshold at 20% red mud and 45% fly ash, yielding a compressive strength of 24.96 MPa. This value exceeds the 24.87 MPa of the 10% red mud + 45% fly ash group and the 21.90 MPa of the 10% red mud + 55% fly ash group. Microstructurally, this group also exhibits superior C-S-H gel uniformity and narrower crack widths compared to the others. Excessive incorporation of red mud and fly ash leads to agglomeration of unhydrated particles and increased porosity, aligning with the observed macroscopic strength degradation. This research identifies and quantifies the synergistic threshold governing RFCTSWC performance evolution, providing theoretical support for engineering applications of solid waste concrete. Full article

In this study, we report the development of a novel magnetized coal fly ash-supported nano-silver composite (AgNPs/MCFA) for dual-functional applications in wastewater treatment: the efficient degradation of methyl orange (MO) dye and broad-spectrum antibacterial activity. The composite was synthesized via a facile impregnation–reduction–sintering route, utilizing sodium citrate as both a reducing and stabilizing agent. The AgNPs/MCFA composite was systematically characterized through multiple analytical techniques, including Fourier transform infrared spectroscopy (FTIR), scanning electron microscopy (SEM), transmission electron microscopy (TEM), X-ray diffraction (XRD), and vibrating sample magnetometry (VSM). The results confirmed the uniform dispersion of AgNPs (average size: 13.97 nm) on the MCFA matrix, where the formation of chemical bonds (Ag-O-Si) contributed to the enhanced stability of the material. Under optimized conditions (0.5 g·L⁻¹ AgNO₃, 250 °C sintering temperature, and 2 h sintering time), AgNPs/MCFA exhibited an exceptional catalytic performance, achieving 99.89% MO degradation within 15 min (pseudo-first-order rate constant k_a = 0.3133 min⁻¹) in the presence of NaBH₄. The composite also demonstrated potent antibacterial efficacy against Escherichia coli (MIC = 0.5 mg·mL⁻¹) and Staphylococcus aureus (MIC = 2 mg·mL⁻¹), attributed to membrane disruption, intracellular content leakage, and reactive oxygen species generation. Remarkably, AgNPs/MCFA retained >90% catalytic and antibacterial efficiency after five reuse cycles, enabled by its magnetic recoverability. By repurposing industrial waste (coal fly ash) as a low-cost carrier, this work provides a sustainable strategy to mitigate nanoparticle aggregation and environmental risks while enhancing multifunctional performance in water remediation. Full article

In the process of the work of a coal power station is formed ash and slag, which, along with process water, are deposited in the dumps. Coal ash waste dumps significantly degrade the surrounding environment due to their unprotected surfaces, which are highly susceptible to wind and water erosion. This results in the dispersion of contaminants into adjacent ecosystems. Pollutants migrate into terrestrial and aquatic systems, compromising soil quality and water resources, and posing documented risks to the environment and human health. Primary succession on the coal ash dumps of the Apatity thermal power plant (Murmansk Region, NW Russia) was initiated by cyanobacterial colonization. We studied cyanobacterial communities inhabiting three spoil sites that varied in time since decommissioning. These sites are characterized by exceptionally high concentrations of calcium and magnesium oxides—levels approximately double those found in the region’s natural soils. A total of 18 cyanobacterial taxa were identified in disposal sites. Morphological analysis of visible surface crusts revealed 16 distinct species. Furthermore, 24 cyanobacterial strains representing 11 species were successfully isolated into unialgal culture and tested with a molecular genetic approach to confirm their identification from 16S rRNA. Three species were determined with molecular evidence. Cyanobacterial colonization of coal fly ash disposal sites begins immediately after deposition. Primary communities initially exhibit low species diversity (four taxa) and do not form a continuous ground cover in the early years. However, as succession progresses—illustrated by observations from a 30-year-old deposit—spontaneous surface revegetation occurs, accompanied by a marked increase in cyanobacterial diversity, reaching 12 species. Full article

To address the limitations of traditional hardened concrete road surfaces in coal mine tunnels, which are prone to damage and entail high maintenance costs, this study proposes using modular concrete blocks composed of fly ash and coal gangue as an alternative to conventional materials. These blocks offer advantages including ease of construction and rapid, straightforward maintenance, while also facilitating the reuse of substantial quantities of solid waste, thereby mitigating resource wastage and environmental pollution. Initially, the mineral composition of the raw materials was analyzed, confirming that although the physical and chemical properties of Liangshui Well coal gangue are slightly inferior to those of natural crushed stone, they still meet the criteria for use as concrete aggregate. For concrete blocks incorporating 20% fly ash, the steam curing process was optimized with a recommended static curing period of 16–24 h, a temperature ramp-up rate of 20 °C/h, and a constant temperature of 50 °C maintained for 24 h to ensure optimal performance. Orthogonal experimental analysis revealed that fly ash content exerted the greatest influence on the compressive strength of concrete, followed by the additional water content, whereas the aggregate particle size had a comparatively minor effect. The optimal mix proportion was identified as 20% fly ash content, a maximum aggregate size of 20 mm, and an additional water content of 70%. Performance testing indicated that the fabricated blocks exhibited a compressive strength of 32.1 MPa and a tensile strength of 2.93 MPa, with strong resistance to hydrolysis and sulfate attack, rendering them suitable for deployment in weakly alkaline underground environments. Considering the site-specific conditions of the Liangshuijing coal mine, ANSYS 2020 was employed to simulate and analyze the mechanical behavior of the blocks under varying loads, thicknesses, and dynamic conditions. The findings suggest that hexagonal coal gangue blocks with a side length of 20 cm and a thickness of 16 cm meet the structural requirements of most underground mine tunnels, offering a reference model for cost-effective paving and efficient roadway maintenance in coal mines. Full article

To reveal the long-term deformation behavior of high-volume fly ash-based backfill under continuous mining and backfilling, a fly ash–cement backfill material with 73.0% fly ash content was developed, and creep characteristic tests considering initial damage were conducted. The results demonstrate that: (1) A calculation method for the initial damage of backfill based on stress–strain hysteresis loop cycles is proposed, with cumulative characteristics of initial damage across mining phases analyzed; (2) Creep behaviors of backfill affected by initial damage are investigated, revealing the weakening effect of initial damage on long-term bearing capacity; (3) An enhanced, nonlinear plastic damage element is developed, enabling the construction of an HKBN constitutive model capable of characterizing the complete creep behavior of backfill materials. The research establishes a theoretical framework for engineering applications of backfill materials with early-age strength below 5 MPa, while significantly enhancing the utilization efficiency of coal-based solid wastes. Full article

Nowadays, there is wide advocacy for a transition to circular economic models. Fly Ash (FA) in particular is a major by-product of coal combustion and its annual waste has reached one million tonnes. Cenospheres (CSs) are considered as possibly the most valuable element within FA. Thus, in this research, polymeric foam replication was employed to fabricate ceramic foams based on a CS matrix, for potential biomedical applications. For the fabrication of foams, four types of natural marine sponges were used as templates along with a binder agent. The specimens were sintered at 1200 °C for 1 h. The results were encouraging as the specimens obtained retained the given shape and geometry. Further research will enhance the potential of such materials for future use in biomedical engineering. Full article

To reduce the cost of coal mine filling materials, a novel composite cementitious material was developed by utilizing coal-based solid waste materials, including fly ash, desulfurized gypsum, and carbide slag, along with cement and water as raw materials. Initially, a comprehensive analysis of the physical and chemical properties of each raw material was conducted. Subsequently, proportioning tests were systematically carried out using the single-variable method. During these tests, multiple crucial performance indicators were measured. Specifically, the fluidity and bleeding rate of the slurry were evaluated to assess its workability, while the compressive strength and chemically bound water content of the hardened sample were tested to determine its mechanical properties and hydration degree. Through in-depth analysis of the test results, the optimal formulation of the composite cementitious material was determined. In the basic group, the mass ratio of fly ash to desulfurized gypsum was set at 70:30. In the additional group, the carbide slag addition amount accounted for 20% of the total mass, the cement addition amount was 15%, and the water–cement ratio was fixed at 0.65. Under these optimal proportioning conditions, the composite cementitious material exhibited excellent performance: its fluidity ranged from 180 to 220 mm, the bleeding rate within 6 h was less than 5%, and the 28-day compressive strength reached 17.69 MPa. The newly developed composite cementitious material features good fluidity and high strength of the hardened sample, fully meeting the requirements for mine filling materials. Full article

In the present study, a programme of experimental investigations was carried out to examine the direct uniaxial tensile (and pull-out) behaviour of plain and fibre-reinforced lightweight aggregate concrete. The lightweight aggregates were recycled from fly ash waste, also known as Pulverised Fuel Ash (PFA), which is a by-product of coal-fired electricity power stations. Steel fibres were used with different aspect ratios and hooked ends with single, double and triple bends corresponding to 3D, 4D and 5D types of DRAMIX steel fibres, respectively. Key parameters such as the concrete compressive strength f_lck, fibre volume fraction V_f, number of bends n_b, embedded length L_E and inclination angle ϴ_f were considered. The fibres were added at volume fractions V_f of 1% and 2% to cover the practical range, and a direct tensile test was carried out using a purpose-built pull-out test developed as part of the present study. Thus, the tensile mechanical properties were established, and a generic constitutive tensile stress–crack width σ-ω model for both plain and fibrous lightweight concrete was created and validated against experimental data from the present study and from previous research found in the literature (including RILEM uniaxial tests) involving different types of lightweight aggregates, concrete strengths and steel fibres. It was concluded that the higher the number of bends n_b and the higher the volume fraction V_f and concrete strength f_lck, the stronger the fibre–matrix interfacial bond and thus the more pronounced the enhancement provided by the fibres to the uniaxial tensile residual strength and ductility in the form of work and fracture energy. A fibre optimisation study was also carried out, and design recommendations are provided. Full article

Developing resource-efficient technologies for producing ceramic materials with specific properties and performance characteristics is one of the most important tasks in modern materials science. As natural resources face depletion, the use of anthropogenic wastes, including fly ash from coal combustion, for the development of new compositions and the production of ceramics with an improved microstructure is of particular significance. The use of PM₁₀ fly ash microspheres in ceramic production will help to reduce particulate matter emissions. In this study, fine narrow fractions of PM₁₀ microspheres were successfully separated from coal fly ash using aerodynamic and magnetic separation. Glass–ceramic materials with a homogeneous microstructure, an open porosity of 0.4–37%, a compressive strength of 5–159 MPa, and acid resistance of up to 99.9% were obtained using narrow fractions. The materials obtained are promising for application as highly porous ceramics, effective microfiltration membranes, and fine-structured technical ceramics, which can be used in installations operating in aggressive media and/or at high temperatures. The ceramic membranes were characterised by high liquid permeability values up to 1194 L·m⁻²·h⁻¹·bar⁻¹. Filtration tests showed that the retention coefficient for dispersed microsilica particles with d_av = 1.9 μm is 0.99. Full article

The combustion of hard coal and lignite in power and combined heat and power plants generates significant amounts of coal fly ash (CFA), a waste material with variable properties. CFA naturally contains radionuclides, specifically naturally occurring radioactive materials (NORMs), which pose potential radiological risks to the environment and human health during their storage and utilization, including their incorporation into building materials. Although global research on the radionuclide content in CFA is available, there is a clear gap in detailed and current data specific to Central and Eastern Europe and notably, a lack of a systematic analysis investigating the influence of installed power plant capacity on the concentration profile of these radionuclides in the generated ash. This study aimed to fill this gap and provide crucial data for the Polish energy and environmental context. The objective was to evaluate the concentrations of selected radionuclides (²³²Th, ²²⁶Ra, and ⁴⁰K) in coal fly ash samples collected between 2020 and 2023 from 19 Polish power and combined heat and power plants with varying capacities (categorized into four groups: S1–S4) and to assess the associated radiological risk. Radionuclide concentrations were determined using gamma spectrometry, and differences between groups were analyzed using non-parametric statistical methods, including PERMANOVA. The results demonstrated that plant capacity has a statistically significant influence on the concentration profiles of thorium and potassium but not radium. Calculated radiological hazard assessment factors (Ra_eq, H_ex, H_in, IAED) revealed that although most samples fall near regulatory limits (e.g., 370 Bq kg⁻¹ for Ra_eq), some exceed these limits, particularly in groups S1 (plants with a capacity less than 300 MW) and S4 (plants with a capacity higher than 300 MW). It was also found that the frequency of exceeding the annual effective dose limits (IAEDs) showed an increasing trend with the increasing installed capacity of the facility. These findings underscore the importance of plant capacity as a key factor to consider in the radiological risk assessment associated with coal fly ash. This study’s outcomes are crucial for informing environmental risk management strategies, guiding safe waste processing practices, and shaping environmental policies within the energy sector in Central and Eastern European countries, including Poland. Full article

Fly ash (FA) is a porous solid waste produced by coal-fired power plants that can be used as a carrier for solid–liquid phase change materials (PCM). Due to the disadvantages of FA, including small adsorption capacity and poor thermal performance, its application range is limited. Therefore, FA modification methods have received increasing attention. Two modification methods were used to improve the adsorption capacity of FA. After the modification experiments, the surface structure of modified fly ash (MFA) was eroded, revealing a three-dimensional porous structure. The Al/Si mass ratio of the alkali-modified sample increased from 0.67 to 1.28, and the specific surface area and pore volume increased from 3.82 m²/g and 0.008 cm³/g to 40.86 m²/g and 0.026 cm³/g, respectively. The shape-stable phase change material (SSPCM) prepared using the hybrid sintering method of Al-12Si alloy and alkali-modified fly ash (MFA-OH) exhibits excellent thermal properties and thermal cycling stability. The results showed that the heat storage density and thermal conductivity of SSPCM increased with an increase in PCM content. The thermal conductivity and latent heat of phase change in the composite with the highest latent heat of phase change in the sample were 18.24 W/(m·K) and 124.10 J/g, respectively. The optimum loading rate for the alloy is 65 wt%. After 100 thermal cycles, the latent heat and thermal conductivity of the phase change at SSPCM were 93.3% and 94.6% of the initial values, respectively. The research findings provide a feasible process for FA as a phase change carrier, and the application scope is extended. Full article

It is of strategic significance to extract germanium (Ge) in an ecological way for sustainable development. Adsorbents that already adsorb Ge have disadvantages such as poor selectivity and low adsorption capacity. In this study, a novel adsorbent material based on rice husk functionalized with tannic acid was developed for the efficient extraction of Ge from simulated coal fly ash leachate. The adsorption capacity of tannic acid-functionalized rice husk (TA-EPI-ORH) for Ge was 19.9 times higher than that of untreated rice husk, demonstrating significantly improved performance. The results showed that the adsorption process of Ge by TA-EPI-ORH is consistent with pseudo-second-order kinetic and Freundlich isotherm model. TA-EPI-ORH had excellent selective adsorption properties, with adsorption of 1.40 mg L⁻¹ Ge exceeding 95% and solid-liquid partition coefficients of 4380 mL g⁻¹, even in the presence of nine impurity metal ions (average concentration: 479.08 mg L⁻¹). When compared with the two main coexistence ions—aluminum (Al) and calcium (Ca)—both of which have the relatively highest concentrations (Al: 1594.20 mg L⁻¹, Ca: 1740.13 mg L⁻¹), the separation factors for Ge still maintain relatively high level with SF(Ge/Al) = 42.57 and SF(Ge/Ca) = 39.93. Compared to existing studies, TA-EPI-ORH exhibits superior selective adsorption performance even with the presence of more interfering ions. After elution of the adsorbed Ge from TA-EPI-ORH, the extraction rate of Ge with low initial concentration (1.40 mg L⁻¹) reached 85.17%, while the extraction rates of Al and Ca were only 1.02% and 1.18%, respectively. Further research revealed that the catechol groups on the surface of TA-EPI-ORH formed stable complexes with Ge, whereas the complexes with coexisting ions (e.g., Ca and Al) were unstable, thereby ensuring high selectivity for Ge. This green chemistry-based functionalization of rice husk not only enables high-value utilization of agricultural waste but also provides a sustainable and eco-friendly strategy for efficient Ge separation and recovery. Full article