Complementary vitrification of municipal solid waste incineration fly ash from grate furnaces and fluidised bed incinerators via a co-reduction process.

[Display omitted] • G-FA and F-FA were vitrified together based on their compositional complementarity. • Clean vitrified slag was obtained at 1300 °C without water-washing and any additives. • Cr, Ni, Cu could be recovered as Fe-Cr-Ni-Cu alloy. • FA was efficiently reutilized as three separated phases. The increasing application of municipal solid waste incineration (MSWI) emphasises the need for MSWI fly ash (FA) safe treatment. Based on the compositional complementarity of FA from grate furnaces (G-FA) and fluidised bed incinerators (F-FA), we proposed a co-reduction process to treat G-FA and F-FA together for producing vitrified slag and ferroalloys. The clean vitrified slag and Fe-Cr-Ni-Cu alloy were obtained with the mass ratios of 1:9 ∼ 6:4 (G-FA:F-FA) at 1300℃, which is about 300℃ lower than the conventional G-FA vitrification. The metals Zn, Cd, and Pb were mostly volatilised into the flue gas for potential recovery from the secondary FA. The thermodynamic SiO 2 -Al 2 O 3 -CaO ternary system demonstrated that an optimal mass ratio of the two complementary FA types contributes to the system shifting to the low-temperature melting zone. The co-reduction process of G-FA and F-FA could be a promising option for FA beneficial reutilization with environmental advantages. [ABSTRACT FROM AUTHOR]