Innovative Synergistic Valorization of Lignite Fly Ash and Steel Industry Scrap-Soil as Secondary Resources for Compacted Ceramics

Abstract:

In the present research, the combined utilization of fly ash (FA), derived from a lignite-fed power station, along with scrap-soil (SS), a steel industry by-product, is investigated, for the development of eco-friendly ceramics, thus enhancing innovation and sustainability. The valorization of these low price and largely available industrial secondary resources as 100% the raw materials mixture in ceramic industry arises interesting technological, environmental and economical benefits. FA and SS were mixed in various proportions (0-70%wt. in SS), cold compacted at 20 tn load using an automated hydraulic press to form a series of 5 cm diameter disc-shaped specimens, and finally sintered at three different peak temperatures (1000oC, 1100oC and 1140oC) for 3h. Then, the specimen microstructure and physico-mechanical properties were characterized. According to the experimental results, a sintering temperature increase from 1000°C up to 1140oC significantly improves specimen densification, thus sharply enhancing the diametral tensile strength (DTS), from 0.5 MPa up to 12.8 MPa respectively for a 50-50%wt. FA-SS mixture. Mechanical strength also varies with the SS percentage in the raw materials. Physico-mechanical properties seem to be constant for specimens containing SS up to 60% at 1140oC.

• Periodical: Key Engineering Materials (Volume 660)
• Pages: 268-272
• DOI: https://doi.org/10.4028/www.scientific.net/KEM.660.268
• Online since: August 2015
• Authors: V. Karayannis, G. Papapolymerou, S. Zaoutsos, S. Lamprakopoulos, K. Ntampegliotis, X. Spiliotis
• Keywords: Ceramic, Compaction, Diametral Tensile Strength, Lignite Fly Ash, Scrap-Soil, Sintering, Thermal Conductivity

References

[1] L. Tsikritzis, G. Pekridis, R. Tsikritzi, E. Amanatidou, Dispersion and bioaccumulation of trace pollutants emitted by Coal-fired power plants in West Macedonia, Greece, Fresenius Environ. Bull., 22, 2, 343-350 (2013).

[2] V.G. Karayannis, A.K. Moutsatsou, E.L. Katsika, Recycling of lignite highly-calcareous fly ash into nickel-based composites, Fresenius Environ. Bull., 21, 8b, 2375-2380 (2012).

[3] A. Badanoiu, G. Voicu, Influence of raw materials characteristics and processing parameters on the strength of geopolymer cements based on fly ash, Environ. Eng. Manag. J., 10, 5, 673-681 (2011).

DOI: 10.30638/eemj.2011.091

[4] L. Zhang, Production of bricks from waste materials – a review, Constr. Build. Mater. 47 (2013) 643-655.

[5] V.G. Karayannis, A.K. Moutsatsou, E.L. Katsika, Synthesis of microwave-sintered ceramics from lignite fly and bottom ashes, J. Ceram. Process. Res., 14, 1, 45-50 (2013).

[6] N.U. Kockal, Utilisation of different types of coal fly ash in the production of ceramic tiles, Bol. Soc. Esp. Ceram. Vidr., 51, 5, 297-304 (2012).

DOI: 10.3989/cyv.412012

[7] K. Komnitsas, D. Zaharaki, V. Perdikatsis, Effect of synthesis parameters on the compressive strength of low-calcium ferronickel slag inorganic polymers, J. Hazard. Mat., 161, 2-3, 760-768 (2009).

DOI: 10.1016/j.jhazmat.2008.04.055

[8] J.H. Kim, K.G. Lee, Y. Kim, S.K. Kang, Efflorescence and leaching behavior of metal ions for EAF dust-clay based bricks, Mat. Sci. Forum, 449-452 (2004) 241-244.

DOI: 10.4028/www.scientific.net/msf.449-452.241

[9] A.T. Machado, F.R. Valenzuela-Diaz, C.A.C. De Souza, L.R.P. De Andrade Lima, Structural ceramics made with clay and steel dust pollutants, Appl. Clay Sci., 51 (2011) 503-506.

DOI: 10.1016/j.clay.2011.01.004

[10] X. Spiliotis, K. Ntampegliotis, D. Kasiteropoulou, S. Lamprakopoulos, K. Lolos, V. Karayannis, G. Papapolymerou, Valorization of mill scale waste by its incorporation in fired clay bricks, Key Eng. Mater., 608 (2014) 8-13.

DOI: 10.4028/www.scientific.net/kem.608.8

[11] V. Mymrin, R.A.C. Ribeiro, K. Alekseev, E. Zelinskaya, N. Tolmacheva, R. Catai, Environment friendly ceramics from hazardous industrial wastes, Ceram. Int. 40 (2014) 9427-9437.

DOI: 10.1016/j.ceramint.2014.02.014

[12] P. Porreca, E. Furlani, L. Fedrizzi, S. Bruckner, D. Minichelli, F. Tubaro, A. Bachiorrini, F. Andreatta, S. Maschio, Sintered ceramics from special waste incinerator ashes and steelmaking slag, Ind. Ceram., 27 (2007) 197-203.

[13] S. Kumar, R. Kumar, A. Bandopadhyay, Innovative methodologies for the utilization of wastes from metallurgical and allied industries, Res. Conserv. Recycl., 48 (2006) 301-314.

DOI: 10.1016/j.resconrec.2006.03.003

[14] V. Karayannis, X. Spiliotis, E. Papastergiadis, K. Ntampegliotis, G. Papapolymerou, P. Samaras, Contribution to the sustainable management of resources by novel combination of industrial solid residues into red ceramics, Bull. Environ. Contam. Toxicol., 94, 3, 345-351 (2015).

DOI: 10.1007/s00128-014-1446-8

[15] T. Sofilić, B. Bertić, V. Šimunić-Mežnarić, I. Brnardić, Soil pollution as a result of temporary steel scrap storage at the melt shop, Ecol. Balc., 5 (2013) 21-30.

[16] Information on http: /www. aeiforos. gr.