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Cement & Concrete Composites 46 (2014) 26–31

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Cement & Concrete Composites


journal homepage: www.elsevier.com/locate/cemconcomp

Durability and microstructure of CSA cement-based materials


from MSWI fly ash
Xiaolu Guo a,b,⇑, Huisheng Shi a,b, Wenpei Hu b, Kai Wu b
a
Key Laboratory of Advanced Civil Engineering Materials, Tongji University, Ministry of Education, Shanghai 201804, China
b
Institute of Environmental Materials, School of Materials Science and Engineering, Tongji University, Shanghai 201804, China

a r t i c l e i n f o a b s t r a c t

Article history: The decontamination and disposal of municipal solid waste incineration (MSWI) fly ash has great signif-
Received 28 December 2012 icance in the world. In this work, MSWI fly ash was successfully used as a raw material in sintering and
Received in revised form 17 October 2013 preparing calcium sulphoaluminate (CSA) cement in the laboratory. Compressive strength, durability and
Accepted 30 October 2013
microstructure of the prepared CSA cement-based materials were studied. The results show that com-
Available online 8 November 2013
pressive strength of the CSA cement has a developing trend similar to that of the Control Cement I which
develops strength quickly at an early curing age, but after 7 d, strength increases more slowly. The pre-
Keywords:
pared CSA cement-based materials perform well with respect to resistance to drying shrinkage, carbon-
Municipal solid waste incineration (MSWI)
fly ash
ation, and water permeation. The CSA cement mortar immersed in sulfate solution has a more compact
Calcium sulphoaluminate (CSA) cement microstructure and has the potential to be used in engineering constructions which require high resis-
Compressive strength tance to sulfate corrosion. Parts of the chloride ion from the MSWI fly ash could be sintered within the
Durability cement clinker and subsequently stabilized in hydration products. The leaching values of heavy metals
Microstructure from these systems are all within the current threshold limits.
Ó 2013 Elsevier Ltd. All rights reserved.

1. Introduction as HW18 for containing different types of heavy metals, chlori-


nated organic compounds, sulfur compounds, dioxins, etc. There-
At present, the growth rate of China’s municipal solid waste fore, it is very important to dispose of MSWI fly ash using proper
has reached more than 10% and it is 1.6% higher than the world and safe methods.
average. China is one of many countries that are facing serious The decontamination and disposal of MSWI fly ash has great
problems regarding landfills and pollution associated with muni- significance to the promotion and application of MSWI technol-
cipal solid wastes. The rapid growth of municipal solid waste has ogy in China [3]. At present, the disposal of MSWI fly ash mainly
become one of the problems that plague China’s future sustain- focuses on landfill disposal after pretreatment, but few studies
able development. Municipal solid waste incineration (MSWI) focus on its utilization. The published reports [4–8] have shown
technology has been developing quickly by virtue of its excellent that MSWI fly ash has cementitious properties and its main
effectiveness in volume reduction, weight reduction, and toxicity chemical components belong to the system of CaO–SiO2–SO3–
reduction, as well as energy and resource conservation [1]. How- Al2O3. Therefore, it has been studied for its potential in resource
ever, at the same time, the MSWI technology produces a large recycling and environmental protection, e.g. in cement pastes
quantity of MSWI fly ash which is equivalent to 2–5% of the ori- and mortars [9]. In the current study [10–12], most of the raw
ginal waste. It is predicted that the daily output of MSWI fly ash materials of calcium sulphoaluminate (CSA) cement are natural
will be more than 1500 tons; the annual output is up to 0.45– minerals, and industrial wastes such as blast furnace slag, and
0.5 million tons in major Chinese cities in 2012. Just in the city red mud. There are few research studies focusing on production
of Shanghai, the annual output of MSWI fly ash will increase to and application of CSA cement from MSWI fly ash. Our previous
70,000 tons over the next five years [2]. Even worse, MSWI fly study [13–16] has successfully prepared and sintered the CSA ce-
ash has been listed in the National Hazardous Waste Inventory ment from MSWI fly ash, partially replacing some of the cement
raw materials. Following up on this basis, the performance mea-
sures of compressive strength, durability, and microstructure of
⇑ Corresponding author. Address: School of Materials Science and Engineering, the CSA cement-based materials were studied in this work.
Tongji University, 4800 Caoan Road, Shanghai 201804, China. Tel.: +86 21
69582144.
E-mail address: guoxiaolu@tongji.edu.cn (X. Guo).

0958-9465/$ - see front matter Ó 2013 Elsevier Ltd. All rights reserved.
http://dx.doi.org/10.1016/j.cemconcomp.2013.10.015
X. Guo et al. / Cement & Concrete Composites 46 (2014) 26–31 27

2. Materials and experimental program Table 2


Chemical composition (by mass) of the chemical reagents/(wt.%).

2.1. Materials Chemical reagents CaO Al2O3 SO3 LOI Total


CaCO3 55.59 0.00 0.00 43.99 99.98
The MSWI fly ash used in this work was obtained from the Suz- CaSO4 39.61 0.00 56.53 3.85 99.99
hou Wastes Incineration Plant in China, which utilizes a Belgium Al2O3 0.00 94.39 0.00 5.61 100.00
Seghers-Keppel furnace (with a capacity of 350 tons per day).
MSWI fly ash produced in this plant was a hybrid waste including
household waste, paper, plastic, and so on. The ash was collected in Table 3
the air pollution control system. The main composition of this ash Mix ratios of raw materials for the CSA cement from the MSWI fly ash/(wt.%).
is shown in Table 1. The main compositions of chemical reagents of Raw materials of the CSA cement MSWI fly ash CaCO3 CaSO4 Al2O3
calcium carbonate, aluminum oxide, etc. are given in Table 2. These
Percentage 31.14 29.71 14.23 24.92
chemical reagents were used to adjust the cement modulus (see
Tables 3 and 4).
In order to compare the performances between the prepared
CSA cement and the purchased cements, a series of comparison 2.2.2. Performances of the CSA cement-based materials from the MSWI
tests were designed and conducted. Two types of the purchased ce- fly ash
ments were Control Cement I (Marked as Cem I, a rapid hardening Three batches of paste samples were made from the prepared
CSA cement (the compressive strength could reach 30 MPa after CSA cement, Control Cem I, and Control Cem II, respectively. The
curing for 1 d) produced by the Shanghai Shuanghe Special Cement ratio of water to cement (W/C) is 0.3 by mass and the sample size
Co. Ltd., Shanghai, China) and Control Cement II (Marked as Cem II, is 10 mm  10 mm  10 mm. The compressive strength was tested
a rapid hardening cement of Composite Portland Cement PC32.5R after curing in water at room temperature at each age. All the val-
produced by the Haibao Cement Co. Ltd., Shanghai, China), respec- ues are the averages of six separate sample tests. Data that devi-
tively. The main chemical compositions of the Cem I and Cem II are ated from the mean by more than 10% were eliminated, but this
shown in Table 5. occurred only rarely.
According to the Chinese Standard for Test Methods of Long-Term
Performance and Durability of Ordinary Concrete (GB/T50082-2009),
2.2. Experimental program mortar samples with a size of 40 mm  40 mm  160 mm were
molded to test drying shrinkage and carbonation. The mass ratio
2.2.1. Preparation of the CSA cement from the MSWI fly ash of water/cement/sand is 0.5/1.0/3.0. For resistance to water perme-
Based on our previous studies [13–16], the optimum mix ratio ation, a conical frustum of mortar sample which was 70 mm (up)
of raw materials and the proper cement modulus of the CSA ce- and 80 mm (down) in diameter, and 30 mm in height was tested
ment from the MSWI fly ash were confirmed (Tables 3 and 4). after curing for 28 d. Each value is obtained using six conical
The raw mixtures were prepared as follows: 30 g of the raw mate- frustum of mortar samples, each tested by the water perme-
rials in predetermined proportions were taken and then mixed ation instrument. The six samples were tested under water pres-
thoroughly. After a thorough homogenization, the raw mixtures sure of 0.2 MPa for 2 h, then under an increasing water pressure
were pressed and molded into cylindrical samples of 30 mm in at a rate of 0.1 MPa/h. The value of the resistance to water perme-
diameter and 5 mm in height. The cylinders were dried in an oven ation was the maximum water pressure under which one-third
at 105 °C for 6 h and then fired in a Nabertherm furnace. An aver- of the six samples presented extruded water. According to the
age heating rate of about 30 °C/min was employed and the furnace Test Method for Determining the Capability of Resisting Sul-
was then kept at a proper firing temperature of 1200 °C for up to fate Corrosion of Cement (GB/T 749-2008), cement mortar bars
120 min. The CSA cement clinkers so prepared were cooled at (40 mm  40 mm  160 mm) were immersed in a 3 wt.% sulfate
ambient temperature and then ground to a fineness of about solution, while the control samples were immersed in water. Flex-
400 m2/kg Blaine surface. The chemical composition and mineral ural strengths of both were measured and the resistance modulus
composition of the CSA clinker powder were tested by X-Ray Fluo- of flexural strength was calculated as follows:
rescence (XRF) and X-Ray Diffraction (XRD), respectively. The K ¼ RSulfate solution =RWater  100% ð1Þ
chemical composition of the CSA clinker powder is given in Table 6.
XRD showed that the main minerals of this CSA cement are a cal- where K is the resistance modulus of flexural strength, RSulfate solution
cium sulphoaluminate phase (C 4 A3 S i.e. 3CaO  3A12O3  CaSO4) the flexural strength of the samples immersed in sulfate solution,
and a belite phase (C2S i.e. 2CaO  SiO2). MPa, RWater the flexural strength of the samples immersed in water,
Then, 5% calcium sulfate dihydrate (gypsum, DG) was ground MPa.
and sieved through a 0.08 mm mesh sieve until the residue is no Hydration products of the cement paste sample CSA95DG05
more than 10%. After that, it was mixed with the prepared CSA ce- were examined using XRD and an Environmental Scanning Elec-
ment clinker powder. Thus, the CSA cement from the MSWI fly ash tron Microscopy (ESEM). Soluble chloride ion content from cement
was created in the laboratory (Marked as CSA95DG05). paste CSA95DG05 at different hydration ages were tested using
precipitation titration. Leaching concentration of heavy metal ions
from cement paste CSA95DG05 cured for various setting ages were
conducted according to the Toxic Characteristic Leaching Proce-
Table 1 dure (TCLP).
Chemical composition (by mass) of the MSWI fly ash/(wt.%).

Composition CaO SiO2 Cl SO3 Al2O3 K2O Na2O Fe2O3 3. Results and discussion
Percentage 39.1 15.9 11.9 7.24 4.35 3.68 3.43 1.91
Composition MgO P2O5 TiO2 ZnO PbO BaO CuO MnO 3.1. Compressive strength
Percentage 1.64 1.08 0.61 0.54 0.23 0.14 0.13 0.10
Composition SrO NiO ZrO2 – – – – –
The compressive strengths of hardened cement pastes are
Percentage 0.04 0.02 0.01 – – – – –
shown in Fig. 1. Compared with Control Cem I and Cem II, the
28 X. Guo et al. / Cement & Concrete Composites 46 (2014) 26–31

Table 4
Cement modulus of the CSA cement from the MSWI fly ash/(wt.%).

Cement modulusa Alkalinity modulus (Cm) Alumina–sulfur ratio (P) Alumina–silica ratio (N)
CSA Cement 1.050 2.500 3.000

Alkalinity modulus (Cm) = CaO/(1.87SiO2 + 0.73Al2O3 + 0.93Fe2O3) = 1.050.


Alumina–sulfur ratio (P) = Al2O3/SO3 = 2.500.
Alumina–silica ratio (N) = Al2O3/SiO2 = 3.000.
a
Cement modulus.

Table 5
Chemical compositions (by mass) of Control Cement I (Cem I) and Control Cement II (Cem II)/(wt.%).

Control cements CaO SiO2 Al2O3 SO3 MgO Fe2O3 K2O Na2O LOI Total
Cem I 42.0 11.6 32.0 8.96 1.27 3.86 – – 0.39 100.1
Cem II 49.5 25.5 9.33 1.88 4.78 2.49 0.54 0.24 2.21 96.47

Table 6
Chemical composition (by mass) of the prepared CSA cement clinker/(wt.%). CSA95DG05
0.05 Cem I
CaO SiO2 Al2O3 Cl SO3 MgO Fe2O3 TiO2 Total
Cem II

Drying shrinkage rate /%


43.4 9.08 28.8 1.08 12.8 2.12 1.02 0.24 98.30
0.04

0.03
140

0.02
120
Compressive strength /MPa

0.01

100
0.00

80 0 7 14 21 28
CSA95DG05 Curing ages /d
Cem I
60 Cem II Fig. 2. Drying shrinkage rate at each curing age.

40
of Cem II. However, comparing cement mortar Cem I with
CSA95DG05, Cem I has a better resistance to drying shrinkage. This
20 may be due to the fact that in CSA95DG05 prepared from MSWI,
0 5 10 15 20 25 30 the presence of chloride, heavy metals, and other hazardous com-
Curing ages /d ponents in MSWI may have some effect on the shrinkage observed
in this study.
Fig. 1. Compressive strength at each curing age.

3.3. Resistance to carbonation


compressive strength of the CSA cement paste CSA95DG05 from
It was observed that the initial carbonation depths of mortar
the MSWI fly ash was significantly higher than that of Cem II, while
samples CSA95DG05 and Cem I were much lower than that of
being a bit lower than that of Cem I. The compressive strength of
Cem II. With the increase of time, the carbonation depths of sam-
the hardened CSA cement paste had a developing trend similar
ples CSA95DG05 and Cem I increased significantly, while the
to that of Control Cem I which developed strength quickly at an
growth rate of Cem II was a little bit smaller (Fig. 3). As seen in
early age, but more slowly after 7 d.
other tests, the reason for this may be that both CSA95DG05 and
Cem I are CSA cements, but Cem II is Composite Portland Cement.
3.2. Drying shrinkage rate The alkalinity of CSA cements is generally lower than that of Com-
posite Portland Cement [18]. For Cem II, the hydration products,
With the increase of curing age, the drying shrinkage rate of all such as Ca(OH)2, and C–S–H gel, generated during the hydration
three batches of mortar samples increased. At 28 d, the drying process, could react with CO2 etc. acid substances, resulting in car-
shrinkage rate of Control Cem I and CSA95DG05 tended to be sta- bonation. However, the main mineral compositions of CSA cements
ble while that of Cem II kept increasing. The drying shrinkage rates (i.e. CSA95DG05 and Control Cem I) are a calcium sulphoaluminate
of hardened cement pastes, from smallest to largest was Cem I, phase (C 4 A3 Si.e. 3CaO  3A12O3  CaSO4) and a belite phase (C2S i.e.
CSA95DG05, and Cem II (Fig. 2). This ranking is because both 2CaO  SiO2). Thus, the resistance to carbonation of CSA cement
CSA95DG05 and Cem I are CSA cements but Cem II is a Composite mortars (i.e. CSA95DG05 and Control Cem I) is better than that of
Portland Cement. Generally, CSA cements show a reduced drying Composite Portland Cement (i.e. Control Cem II).
shrinkage [17]. Thus, the resistance to drying shrinkage of hard- Among the CSA cement mortars of CSA95DG05 and Cem I, Cem I
ened cement paste CSA95DG05 and Cem I was better than that had a better carbonation resistance than that of CSA95DG05.
X. Guo et al. / Cement & Concrete Composites 46 (2014) 26–31 29

CSA95DG05 study the resistance to sulfate attack (corrosion) of our CSA cement
14 Cem I produced from the MSWI fly ash.
Cem II In Fig. 4, all three cement mortars have a good resistance to sul-
Carbonation depth / mm

fate corrosion, i.e. all the resistance data were above 100% versus
12 corrosion time. With the growth of the immersion time, the resis-
tance modulus of sample CSA95DG05 and Control Cem I did not
decrease, but increased, while that of Cem II began to decrease. It
10 indicated that the CSA cement-based materials from the MSWI
fly ash perform well in resistance to sulfate corrosion, which could
be useful in engineering constructions that require a high resis-
8 tance to sulfate corrosion.
In Fig. 5, hydration products and intensity of the characteristic
peak of AFt (peak intensity at d = 9.76 Å, d = 5.63 Å and
6
d = 3.88 Å) of sample CSA95DG05 immersed in water and in sulfate
solution (with the sample immersed in water for a period of 60 d)
0 7 14 21 28 were compared. The peak intensities of AFt of the sample im-
carbonation time / d mersed in sulfate solution were higher than that immersed in
water, indicating that the sulfate solution could improve hydration
Fig. 3. Carbonation depth versus time.
of the CSA cement and that the hardened CSA cement from the
During carbonation, the diffusion rate of CO2 depends on the den- MSWI fly ash performs well in resistance to sulfate corrosion.
sity of the cement mortar itself [18]. Compared with CSA95DG05, The hydration products of CSA95DG05 that has been immersed
Control Cem I has about 20 wt.% cement admixtures of lime pow- in sodium sulfate solution for different times are shown in Fig. 6.
der and slag powder. On one side, during hydration progress, ex- With the growth of immersion time, the calcium sulphoaluminate
cept for the gypsum reacting with the calcium sulphoaluminate phase (C 4 A3 S i.e. 4CaO  3A12O3  CaSO4) was hydrated and con-
phase to form AFt, the surplus gypsum has a role of sulfate activa- sumed, while the AFt peak intensity was increased gradually.
tor for cement admixtures. On the other side, hydration of C2S and The CSA cement immersed in sulfate solution has a more com-
lime powder in this system could generate Ca(OH)2 which has a pact microstructure (Fig. 7). The hydration products of the CSA ce-
role of alkali activator. Under the dual role of these two motives, ment immersed in sodium sulfate solution showed that the main
A12O3 from slag powder reacts with Ca(OH)2 and CaSO4 rapidly product was quantities of a gelatinous substance which may be
to form AFt. Meanwhile, surplus Ca(OH)2 reacts with SiO2 of slag an alumina gel produced by hydration.
powder to form C–S–H. Thus, the density of the cement mortar is
increased and its resistance to carbonation is improved. Hydration 3.6. Soluble chloride
products (AFt and C–S–H, etc.) of cement admixtures fill in the
interspaces of the cement mortar. The higher compacted micro- During the hydration of the CSA cement, soluble chloride ion
structure of the hardened cement pastes, the better their resistance content from cement paste sample CSA95DG05 was about 0.042–
to carbonation. 0.065% (Fig. 8). The content of soluble chloride ion was decreased
sharply versus curing age. From 14 d to 28 d, the curve tends to
be stable. As a result, in the laboratory experiments, it indicated
3.4. Resistance to water permeation that some chloride ion was sintered within the cement clinker
and subsequently stabilized in hydration products. With the deep-
Table 7 showed that all cement mortars of CSA95DG05, Cem I, ening of the hydration, some of the free chloride ions could also be
and Cem II had good water impermeability. Their impermeability fixed in new hydration products.
grades were all 14. The permeation height of samples CSA95DG05
and Cem I were a litter bit lower than that of Cem II. The perme- 3.7. Leaching concentration of heavy metals
ation heights of the samples CSA95DG05 and Cem I were
15.4 mm and 16.8 mm, respectively. The permeation height of Leaching concentration of heavy metal ions from the hardened
the sample Cem II was 18.2 mm. This illustrates that the prepared cement paste sample CSA95DG05 cured for various setting ages by
CSA95DG05 could also form a compact system that has a similar
water impermeability as Control Cem I and Cem II. Additionally,
Maneesh et al. [11] have found that water impermeability is asso- 116
ciated with pore volume (porosities), pore size distribution, pore
Resistance modulus of

size, and pore interconnectivity.


flexural strength /%

CSA95DG05
112 Cem I
3.5. Resistance to sulfate attack (corrosion) Cem II

As is well known, CSA cement has been shown to exhibit a high


108
resistance to sulfates. This also makes it particularly necessary to

Table 7 104
Water permeation depth of different cement mortars.

Sample Impermeability grade Permeation height (/103 m)


30 45 60 75 90
CSA95DG05 14 15.4
Cem I 14 16.8
Corrosion time /d
Cem II 14 18.2
Fig. 4. Resistance modulus of flexural strength versus corrosion time.
30 X. Guo et al. / Cement & Concrete Composites 46 (2014) 26–31

2
1

3 2 CSA95PG05-Water-60d
3 3 3 3
2

2 CSA95PG05-Na2SO4-60d

10 20 30 40 50 60 70

1 C2S 2 C4 A3 S 3 AF t
(a) XRD pattern

CSA95PG05-Water-60d
Intensity of characteristic peaks of AFt / cps

2T=9.06 CSA95PG05-Na2SO4-60d

2T=22.9

2T=15.76

6 8 10 12 14 16 18 20 22 24 26

(b) Intensity of characteristic peak of AFt Fig. 7. ESEM graphs of the CSA95DG05 immersed in water/sulfate solution for 60 d.

Fig. 5. XRD analyses of the CSA95DG05 immersed in water/sulfate solution for 60 d.

2 0.065
1 2
CSA95PG05
0.060
2 2
3 3 3 CSA95PG05-Na2SO4-30d
0.055
Cl /%
-

CSA95PG05-Na2SO4-60d
0.050

CSA95PG05-Na2SO4-90d 0.045

10 20 30 40 50 60 70
0.040
0 5 10 15 20 25 30
1 C2S 2 C4 A3 S 3 AF t Curing ages /d

Fig. 6. XRD patterns of the CSA cement paste immersed in sulfate solution. Fig. 8. Soluble chloride ion content from the sample of CSA95DG05.
X. Guo et al. / Cement & Concrete Composites 46 (2014) 26–31 31

Table 8 (4) This study deals with performance characteristics and dura-
Leaching concentration of heavy metal ions from the sample of CSA95DG05 harden bility of the CSA cement-based materials, but does not pro-
paste/(mg L1).
vide sufficient details on their environmental impact,
Element Threshold limits CSA95DG05 cement paste which would definitively need to be assessed further before
Test Ia Test IIb 1d 3d 28 d 60 d 120 d considering any engineering application, as certainly a lot of
Zn – 100 0.340 0.296 0.046 Nc N
work would still be necessary in order to ensure that neither
Cu – 100 0.056 0.048 0.038 N N the process, nor the produced material present any hazards.
Cr 5 15 0.775 0.120 0.210 0.200 0.190
Ni – 5 0.117 0.070 0.033 N N
Pb 5 5 0.120 0.060 0.029 N N
Acknowledgements
Cd 1 1 0.034 0.010 N N N
Co – – 0.082 0.030 N N N
Mn – – 0.517 0.012 0.012 0.012 0.012 The authors acknowledge and appreciate support received from
a the Research Fund for the National High-tech R&D Program (863
Threshold limits in Test I: USEPA guideline in TCLP, maximum concentration of
contaminants for the toxicity characteristic. Program) (2006AA06Z363) of China, the National Natural Science
b
Threshold limits in Test II: National Standard in China GB 5085.3-2007, iden- Foundation of China (51172164 and 51208370), and the Funda-
tification standards for hazardous wastes-Identification for extraction toxicity. mental Research Funds for the Central Universities (0500219170).
c
N: not detected (<0.005 mg/L).

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