Manufacture and characterization of carbonated lightweight aggregates from waste paper fly ash.

The combustion of biomass and waste paper sludge in a fluidized bed is ecologically profitable. However, a large amount of by-product with high hydraulic reactivity is produced and is considered as wastes. Most of the time the waste paper fly ash (WPFA) goes to landfills, therefore new utilization methods are necessary. In some countries, the high content of metallic and metalloids trace elements (MMTE) in WPFA, more specifically Barium (Ba) and Lead (Pb) makes its valorization difficult. In this paper, the Lightweight Aggregates (LWA) was produced from WPFA by granulating with water in high-intensity granulator. Since WPFA is rich in CaO, the addition of water promotes rapid setting and hydration compared to other types of ash. In this study, different granulation parameters were investigated, such as the rotation modes between the steel pan and the impeller, the rotation speed of the steel pan, the granulation time, in order to improve the mass percentage of the targeted LWA (2–16 mm). In order to evolve the immobilization potential of Ba and Pb, a carbonation process was performed, exposing the manufactured LWA to pure carbon dioxide (CO 2) gas at laboratory scale. The physical, morphological, thermal and mechanical characterizations were performed on LWA for use in mortars, concretes or civil engineering constructions. Results have demonstrated the influence of the rotation mode between the steel pan and the on the distribution of WPFA inside the steel pan and the change in the growth rate of the granules can be observed. Increased density and improved compressive strength with low porosity and water absorption were also found in LWA after carbonation. This was due to the occurrence of both a carbonation reaction and a hydration reaction. Furthermore, the results of thermogravimetry and SEM-EDS confirmed the formation of hydrated phases (ettringite, carboaluminates), also the formation of calcite in the pores and the external surface of the LWA. Regarding environmental aspects, the results have revealed that Ba and Pb were well immobilized in the solid matrix after carbonation. [Display omitted] • LWA was manufactured from WPA without any agglomerating agents. • The physical-chemical properties of LWA were improved after carbonation. • The resulted LWA meet the requirements of NF EN -13,055-1. • The microstructure of LWA was studied before and after carbonation. • Influence of time, mode and rotation speed on the size of the manufactured LWA. [ABSTRACT FROM AUTHOR]