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Related Experiment Video

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Two-way Valorization of Blast Furnace Slag: Synthesis of Precipitated Calcium Carbonate and Zeolitic Heavy Metal Adsorbent

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Artificial lightweight aggregates as utilization for future ashes - A case study.

Angelo Sarabèr¹, Robert Overhof, Terry Green

¹KEMA, P.O. Box 9035, 6800 ET Arnhem, The Netherlands. asaraber@vliegasunie.nl

Waste Management (New York, N.Y.)

|October 4, 2011

Summary

This study explored using coal fly ash to create lightweight aggregates for concrete. The resulting concrete demonstrated good strength and met environmental standards, though production costs remain a challenge.

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Area of Science:

Materials Science
Environmental Engineering
Civil Engineering

Background:

Increased coal co-combustion in the Netherlands will raise fly ash volumes.
Fly ash utilization is crucial, with lightweight aggregates (LWA) being a promising option.
This study assesses fly ash potential for LWA production.

Purpose of the Study:

To evaluate the feasibility of producing LWA from Dutch class F fly ash.
To investigate the properties of LWA and its performance in concrete.
To analyze the environmental and economic viability of this utilization method.

Main Methods:

Laboratory-scale rotary kiln production of LWA using class F fly ash and 8% clay.
Characterization of LWA properties.
Testing of concrete incorporating the produced LWA, including compressive strength and leaching behavior.
Life cycle assessment considering carbon footprint and operational costs.

Main Results:

Lightweight aggregates were successfully produced from high-lime class F fly ash.
Concrete with LWA exhibited good compressive strength and met stringent Dutch environmental leaching regulations.
While LWA has benefits in reduced weight (design, transport, insulation), its production costs currently exceed potential selling prices in the Netherlands, resulting in a negative gate fee for fly ash.

Conclusions:

Fly ash can be effectively utilized to produce LWA for concrete applications.
The environmental regulations for leaching are met, but economic feasibility requires further consideration or subsidies.
The negative gate fee suggests a need for economic incentives to promote this sustainable waste valorization pathway.