Dissertations / Theses on the topic 'Pulverised fuel ash concrete'

Pulverised fuel ash (PFA) is a reactive silica source used in the manufacture of autoclaved aerated concrete (AAC). Experiments studied the hydrothermal reactions of PFA samples from two UK power stations with calcium hydroxide at 457 K, for periods up to 21 h. These conditions are comparable to those used in the manufacture of AAC. The process is characterised by the rapid consumption of ash particles. Associated with this is the solubilisation of large amounts of silica, alumina and alkalis. The formation of a semi-crystalline calcium silicate hydrate and a hydrogarnet phase occurs during the early stages of autoclaving. The hydrogarnet phase persists under the conditions studied, but conversion of the calcium silicate hydrate into tobermorite occurs with prolonged autoclaving. Differences in the hydrothermal performance of the two PFA samples are evident, which cannot be explained by the bulk elemental composition. Ash fractions obtained from a centrifugal air classifier have different reactivities during autoclaving and can result in specimens with different compressive strengths. Quantitative x-ray diffractometry showed that high levels of aluminosilicate glass are associated with the fine ash fractions, whereas most quartz, haematite and magnetite is associated with the coarse fractions. Significant differences exist in the mineralogical analyses of the two sets of ash fractions obtained from the bulk ash samples. The coarse ash fractions have the most varied morphology and composition.

Preplaced aggregate concrete (PAC) is produced by grouting high workability cement based grouts among the voids of compacted coarse aggregate mass. Because of its low shrinkage, PAC has been used for many repair jobs like; tunnel lines, dams and bridge piers. Moreover, it has been used for underwater construction. Grout has a major effect on the properties of produced PAC and well defined grout controls the properties of resulted PAC. The effect of types and amount of powder materials, admixtures, sand and water content on the properties of fresh and hardened grout for the production of PAC have been investigated. Tests on hardened grout and PAC properties have also been carried out to investigate the most important effects. A correlation between hardened properties of grout and PAC has also been analyzed. Grout rheology using four different gradation sands at two different cement-sand and at different w/c ratios ratios has been identified experimentally; no added chemical admixtures or mineral additives had first employed, then superplasticizer (SP) was added at 2% and 1%, and finally a combination of 1% SP and pulverized fuel ash (Pfa) at 20% of the cement weight was employed for all mixes. Grout tests have included two point workability tests by the Viskomat NT, flow time funnel test, Colcrete flow meter test, and water bleeding test. After that, eighteen grout mixes with high workability were produced using three different sands at three w/c ratios and two c/s ratios with 1% SP and Pfa at 20% of the cement weight were designed. Eighteen hardened grout and PAC then produced and their compressive strength and sorptivity were tested. Grout rheology can be defined by the rheology of cement paste employed and the internal distance between sand particles. The effect of sand surface texture on grout rheology is important at very low internal distances. Fresh grout yield stress is the most important property which gives the same degree of sensitivity for all grouts regardless the material type and content used in the mix. There are strong relations between compressive strength of grout and PAC, but less correlation between them in sorptivity test because of the effect high quantity of coarse aggregate of PAC. Sorptivity of PAC is low comparing with different kinds of concrete suggesting its advantage for underwater construction.

Coal combustion by-products generated from coal-fired power plant and cause enormous problems for disposal unless a way can be found to utilize these by-products through resource recovery programs. The implementation of air act regulations to reduce NOx emission have resulted millions of tonnes of pulverised fuel ash (PFA) accumulated with high percentage of unburned carbon made it un-saleable for the cement industry. Moreover, alternative fuels such as biomass and import coals were suggested to reduce gas emissions but on the other hand PFA marketability was reduced. The main objective of this study was thus to utilise high carbon PFA into value added products. Through this work, the relationships beside the factors that could influence the carbon content in the PFA and reduce it in terms of producing raw material useful for different applications were explored. These factors were extensively investigated through thermogravimetric analyses, surface area measurements, microscopy and optical studies, and particle size distribution analyses. Five high unburned carbon PFAs were selected as feedstocks for PFA beneficiation, cement tests, and carbon activation. In order to beneficiate a high carbon PFA, incipient fluidisation was selected as the preferred route being a dry separation method which does not expose the carbon to potential contaminants that may alter its reactivity or physical properties. Enriched PFAs (i.e. depleted carbon) were separated and then cement tests were conducted in different mixture ratios (PFA/cement) throughout different time scales. These tests were demonstrated by using samples derived from biomass co-firing and import coals. The PFA/cement mixtures achieved good strength and workability via standard values. Unburned carbon (i.e. enriched carbon) streams were activated using steam at temperature 850 C and time from 60-300 minutes. For all unburned carbons investigated in this project, the surface areas of their activated counterparts increased to reach maximum level after three hours and four hours compared with other works. But this increase dropped back according to the reduction of the pore widening. Consequently, the surface area exhibited a high level of low carbon burn-out for the carbon sourced from biomass co-firing (1435 m2/g and 38 wt.%, respectively). This was revealed due to the carbon gasification and pore widening level. In addition, optical studies showed that the carbon types changed in a different manner during the activation.

Bibliography: pages 92-101.
The generation of electricity by the combustion of pulverised coal produces large quantities of coal ash (PF A). The disposal of this ash lias become a matter of concern due to the unsightly and hazardous nature of the PF A, and it has been the subject of intense investigations into its suitability as a raw material. Many uses have been proposed for the PF A. When used as landfill or mining backfill, the attraction is the low cost of the material. Other uses, as in the concrete industry, use PF A because of the improvements in quality of the resultant product. PF A has been suggested as a raw material for the production of wear resistant materials. The PF A is composed in the main of SiO₂ and AI₂O₃, and is a suitable material for the production of alumino-silicate ceramic materials, which are known to be tough and wear resistant. To establish the suitability of PF A from the Lethabo Power Station as a raw material, a project to prepare glass ceramic materials from the PF A was started. The conversion of the PF A to a glass ceramic material is a complex process involving many stages, and the processing at each stage will affects the final properties of the material. It is not possible in a short project such as this to examine all the factors which exert some control on the process, and so a small subset of these parameters was selected for study, namely the effect of added oxides on the crystallisation behaviour. Glass items which crystallise on holding at high temperatures commonly do so by growth of crystals from the surface of the item. This results in a material that is mechanically weak, due to the highly oriented microstructure that results. Nucleating agents can be used to obviate this. By providing sites for crystal growth in the bulk of the sample, they induce the crystallisation of fine grained ceramics with good mechanical properties. This study examines the effect of TiO₂, P₂O₅, and a mixture of iron and chrome oxides on the crystallisation of the glass prepared using PF A. The effect of these oxides was evaluated by examination of the microstructure of the crystalline specimens, and the kinetics of crystallisation were analysed by fitting data obtained by isothermal crystallisation of the specimens to the Avrami equation. Finally, the mechanical properties of the materials were tested by solid particle erosion, and the materials ranked against a selection of other materials used for their wear resistance.

Bibliography: pages 161-166.
The chemical and mineral compositions are presented for 63 pulverized fuel ash (PFA) and 16 input coal samples collected from Lethabo, Duvha and Matla power stations over the period 1987-1988. Bulk chemical composition was determined by X-ray fluorescence spectrometry. The mineral concentrations were determined by semi-quantitative X-ray diffraction based on integrated counts over peak areas, with silicon used as an internal standard. The particle size distributions were determined for two sample sets from each power station with a Malvern Instruments Particle Sizer. The major phases present in the ash are glass ( 45-75% ), mullite (16-39%) and quartz (1.5-16% ). The quartz concentration decreases in PF A from fields 1 to 4 in all the stations, and is positively correlated with the SiO₂ concentration. The concentrations of glass, mullite and quartz in PFA generally vary within well defined limits which remain constant with time. An exception is the glass concentration in Duvha PFA. Spinel concentration generally decreases in concentration in PFA from fields 1 to 4, and is positively correlated with the Fe₂O₃ concentration. Of the trace elements determined, Zr, Rb and Mn generally have no or very low enrichment in concentration in PFA from fields 1 to 4. The highest enrichment factors ( > 5) were found for As, Ge and Se in Duvha PF A. The composition of the glass and ferrite spinel phases were determined by electron microprobe analysis. The glass consists of SiO₂ (21-100%) and Al₂ O₃ (0.1-49%), with significant proportions of CaO, TiO₂, Fe₂O₃ and MgO. Al₂O₃ , MgO and TiO₂ substitute for FeO in the spinel structure, with MgO substitution dominant in Duvha spinels. Chemical mass balance calculations suggest that of the elements determined for Lethabo PFA, the only one released in a significant proportion to the atmosphere is S(92% ).

Building rammed earth structures provides a sustainable alternative to concrete. As a building material, rammed earth exhibits very varied physical and material properties depending on the proportion of constituting soil types. When very sandy soil is used in rammed earth production, the properties are different from when a clayey soil is used. This variability can be seen as a very great advantage in the use of rammed earth as a building material. Builders are able to adjust specific properties by changing mix proportions to obtain a desirable balance in the characteristics of the resulting rammed earth structure. This research work looks at selected mechanical and physical properties of different mixes of rammed earth. It describes typical range of values in density, thermal conductivity, ultrasonic pulse velocity, water ingress and compressive strength. It examines how these factors interrelate in the same soil mixes. Samples were prepared by blending various soil types in specific proportions to ensure that each definition of soil grade is as specific as possible. Unstabilised rammed earth was tested as was cement stabilised rammed earth. Rammed earth was tested at various levels of stabilisation and it was discovered that higher rates of stabilisation was not always beneficial to every material property. The research also looked into the potential disposal of waste materials in rammed earth. As rammed earth is a monolithic material that largely remains undisturbed throughout its life span, it was suggested that waste materials could be stored in an inert form inside of rammed earth rather than dumping it in otherwise agricultural landmass. Pulverised Fuel Ash and Palm Kernel Shells were identified as wastes to be disposed in rammed earth. Pulverised Fuel Ash, a by-product of industrial furnace is found in abundance in developed countries that burn carbonaceous materials in power plants. Disposals have been seen as a problem as only a small proportion of high loss on ignition (LOI) Pulverised Fuel Ash has found application. Palm Kernel Shell is a by-product of the oil palm industry and is currently a menace in many developing countries that need to dispose large quantities of the shell in landfills. At an early stage of the research, experimental trial runs quickly showed that these supposedly waste materials had a positive effect on some of the material properties of the rammed earth walls they were made into. This research effort evolved to look into exploiting these materials to improve the physical and material property of rammed earth and to suggest their effect on stabilised and unstabilised rammed earth. The extent to which these materials could be useful and the level at which diminishing returns set in was also investigated. It was discovered that soil mixes that would otherwise not be considered suitable for use in rammed earth wall production can now be utilised as their characteristics can be improved on simply by adding Pulverised Fuel Ash or Palm Kernel shell in the right proportion. Incorporating Pulverised Fuel Ash in rammed earth resulted in increased compressive strength. Palm Kernel shell improved thermal properties without compromising compressive strength.

This report describes a 3 year study carried out to determine the effects of modern coal power generation technologies on the properties of fly ash and how these may affect the use of the material in concrete. A total of 18 fly ashes, from 11 different sources, produced under a range of conditions and technologies were investigated. These primarily included co-combustion, low NOx, supercritical and oxy-fuel technologies, although other available materials (run-of-station, air-classified, processed and stockpiled fly ashes) were included for comparison. The initial experimental work involved physical and chemical characterization of the fly ash samples. Thereafter, tests covering fresh properties, strength development and durability were carried out on selected concretes. A fly ash level of 30% was used with w/c ratios covering the practical range considered (0.35 to 0.65). Equal strength comparisons were also made where appropriate. Finally, granular (unbound fly ash) and monolithic (fly ash concrete) leaching tests were carried out to assess the environmental implications of using the fly ashes. The results from the physical and chemical characterization tests suggest that modern technologies used for coal fired power generation can have an influence on the properties of fly ash produced. The co-combustion, oxy-fuel and in-combustion low NOx fly ashes had reduced fineness and greater LOI, which had a negative effect on foam index and water requirement of the materials. However reactivity was largely unaffected. The post-combustion low NOx and supercritical fly ashes appeared to be unaffected by their production methods compared to that produced by conventional/establish means. Tests on fresh concrete properties showed that fly ashes with high LOI and low fineness required higher SP doses than the reference PC concrete. However, fly ashes with high fineness and low surface area were found to require a lower SP dose than the PC concrete. The concrete compressive strength tests indicate that, in general, finer fly ash concretes tended to have higher strengths than those containing coarser material. However, there did not appear to be any significant difference in performance between fly ash concretes, which suggests that, although modern technologies can have an impact on fly ash properties, if account is taken of these they should not have any significant influence on strength development. Comparison with an earlier study from the 1990s considering BS EN 450-1 fly ashes showed general agreement between the data. The durability study showed that finer, low LOI fly ashes had higher chloride resistance and at equal strength fly ash concretes performed better than those with PC. Equal strength fly ash concretes covering the modern technologies were found to have similar levels of durability for sulfate attack, abrasion and carbonation. High alkali concrete (following the BS 812-123 method) gave similar expansion levels and good resistance with respect to AAR. With air-entrainment, it was found that the fly ash concretes required high doses of AEA (relative to the PC concrete), with high LOI/BET fly ashes requiring greatest quantities. At equal strength, the fly ash concretes had poorer freeze-thaw scaling resistance than PC concrete. However, the majority of the fly ashes did manage to achieve acceptable scaling resistance according to the Swedish criteria. In general, the findings of the durability study are in agreement with the earlier study from the 1990s. Overall, no effect of production technology on the durability of concrete was observed. The leaching studies showed that, in general, in both granular and concrete form, modern fly ashes met the non-hazardous waste requirements in the WAC for all components tested except chromium. For the granular test, there were instances where elevated chromium levels were observed. Similarly, the fly ash concretes failed to meet the non-hazardous limit for chromium. However, chromium from the cement may have contributed to this, since the PC reference also failed to meet this requirement. Based on the results, there is no effect of production technology on the leaching characteristics of fly ash or concrete and the materials do not appear to pose a significant environmental risk. The practical implications of the study have been considered and overall, it has been shown that modern fly ashes behave in much the same way as traditional materials, and therefore, if these materials meet the requirements of BS EN 450-1, and their properties are taken into account in the proportioning of concrete, they should give satisfactory performance.

Degree: PhD Department: Engineering
1997, South African’s major power utility, recognised the need to improve the understanding of fly ash formation and slag deposition of South African coals. This requirement is due to the predicted quality changes of power station feedstocks and the limited research into the slagging propensity of South African coals. This research seeks to develop an analytical technique and a fly ash formation model for predicting the slagging propensity of coals. The research will establish if the models based on Carboniferous coals can be applied to South African Permian coals. A water-cooled suction pyrometer with a custom designed slag probe was used to obtain samples of fly ash and slag from within a 200 MWe pulverised fuel boiler. Simultaneously, samples of pulverised fuel feedstock were collected. The mineral attributes in the pulverised fuel and the phases in fly ash and slag deposit were quantified by CCSEM. The analytical procedure, CCSEM, has been developed with a novel procedure for identifying minerals and C-bearing phases. The new fly ash formation model assumes that the mineral attributes of the combusting pulverised fuel particle controls the size and elemental signature of the resultant fly ash particle(s). The new model has shown that the inherent mineral attributes controls the physical and chemical characteristics of the initial fly ash phases. Thereafter, conditions (stoichiometric, temperature and turbulence) within the combustion chamber promote the physical and/or chemical interaction of the initial fly ash particles. Slag deposits are enriched in Ca- and Fe-bearing alumino-silicates. The new slagging propensity index is based on either predicting or measuring the proportion of Ca- and Fe-bearing alumino-silicates. iv The numerous fly ash formation models, based on Carboniferous coals are not necessarily valid for South African coals. It is not the integrity of the actual fly ash formation mechanisms that is questioned, but rather the experimental scale on which the models are based. This research has produced an analytical technique and a fly ash formation model to predict the slagging propensity of coals. This forms a platform for further research into the role that organically bound cations, combustion conditions and boiler configuration has on the formation of Ca- and Fe-bearing alumino-silicates.