Preparation of ceramsite by coupling sintering MSW incineration fly ash with construction waste micro-powder and municipal sludge

doi:10.16085/j.issn.1000-6613.2024-2011

Abstract

Abstract:

The optimization experiment of raw material ratio and sintering parameters was carried out for the preparation of ceramsite by coupling construction waste micro-powder and municipal sludge with municipal solid waste (MSW) incineration fly ash. The properties of sintered ceramsite, mineral phase changes and migration characteristics of chlorine and heavy metals during sintering process were evaluated. The results indicated that with the incorporation of fly ash, micro-powder, and sludge at 30%, 65% and 10% respectively, under the conditions of preheating temperature at 500℃, preheating time of 20min, sintering temperature at 1150℃ and sintering time of 25min, it was possible to produce high-strength lightweight ceramic pellets with a mineral framework of diopside [Ca(Mg,Al)(Si,Al)₂O₆] and quartz (SiO₂), which complied with the GB/T 17431.1—2010 standard. Their bucket compression strength, bulk density and 1h water absorption rate were 13.01MPa, 1087kg/m³ and 0.43%, respectively. The sludge dosage, sintering temperature and preheating temperature had a significant impact on the key properties such as the cylinder compression strength, apparent density and 1h water absorption rate of ceramsite. The direct addition of raw fly ash into sintering can lead to high burn loss rates of Cl and Cd, Cu, Zn and Pb, which was not conducive to stable control of flue gas during sintering. It was recommended to perform necessary dechlorination pretreatment. The research results can provide scientific basis and theoretical reference for the resource utilization of high-strength and lightweight ceramsite prepared by coupling dechlorination and upgrading fly ash with multi-source solid waste sintering, as well as the optimization of sintering parameters and the control of heavy metal pollution during sintering process.

Key words: ceramsite, MSW incineration fly ash, construction waste micro-powder, municipal sludge, flue gas pollution control

摘要：

以生活垃圾（MSW）焚烧飞灰耦合建筑垃圾微粉-市政污泥烧结制备陶粒为目的，进行了原料配比及烧结参数的优化实验研究，并评价了烧结陶粒性能、烧结过程矿物相变化及氯、重金属迁移特征。结果表明：飞灰、微粉和污泥掺入量分别为30%、65%和10%，预热温度、预热时间、烧结温度和烧结时间分别为500℃、20min、1150℃和25min条件下，可烧制出以透辉石[Ca(Mg,Al)(Si,Al)₂O₆]和石英（SiO₂）为矿物骨架、符合GB/T 17431.1—2010规范的高强轻质陶粒，其筒压强度、堆积密度和1h吸水率分别为13.01MPa、1087kg/m³和0.43%。污泥掺量和烧结温度、预热温度对陶粒的筒压强度、表观密度和1h吸水率等关键性能影响较大。飞灰原灰的直接掺入烧结会导致Cl和Cd、Cu、Zn、Pb较高的烧失率，不利于烧结过程烟气的稳定控制，宜进行必要的脱氯预处理。研究结果可为脱氯提质飞灰耦合多源固废烧结制备高强轻质陶粒资源化利用研究以及烧结参数优化、烧结过程重金属污染控制等提供科学依据和理论参考。

关键词: 陶粒, 垃圾焚烧飞灰, 建筑垃圾微粉, 市政污泥, 烟气污染控制

CLC Number:

X705

NIE Yanqi, LI Yizhang, HE Xuyang, ZHANG Dingyuan, LI Weihua, GAO Weijie, ZHAO Changxia, SUN Yingjie, SUN Haoran, WANG Yufeng, ZHU Jinlin, BIAN Rongxing, LU Chenggang. Preparation of ceramsite by coupling sintering MSW incineration fly ash with construction waste micro-powder and municipal sludge[J]. Chemical Industry and Engineering Progress, 2025, 44(12): 7281-7289.

聂彦琪, 李祎璋, 何旭阳, 张丁元, 李卫华, 高伟杰, 赵长霞, 孙英杰, 孙浩然, 王玉凤, 朱金林, 卞荣星, 路成刚. 垃圾焚烧飞灰耦合建筑垃圾微粉-市政污泥烧结制备陶粒[J]. 化工进展, 2025, 44(12): 7281-7289.

Figures/Tables 15

References 31

[1]	中华人民共和国国家统计局. 中国统计年鉴2023 [M]. 北京: 中国统计出版社, 2023.
	National Bureau of Statistics of the People’s Republic of China. China Statistical Yearbook 2023[M]. Beijing: China Statistics Press, 2023.
[2]	LI Xue, SUN Yingjie, LI Weihua, et al. Solidification/stabilization pre-treatment coupled with landfill disposal of heavy metals in MSWI fly ash in China: A systematic review[J]. Journal of Hazardous Materials, 2024, 478: 135479.
[3]	孔祥蕊, 董玥岑, 张蒙雨, 等. 生活垃圾焚烧飞灰处理技术研究进展[J]. 化工进展, 2024, 43(7): 4102-4117.
	KONG Xiangrui, DONG Yuecen, ZHANG Mengyu, et al. Treatment technologies of fly ash from municipal solid waste incineration[J]. Chemical Industry and Engineering Progress, 2024, 43(7): 4102-4117.
[4]	尹俊权, 吴寅凯, 李卫华, 等. 垃圾焚烧典型工段灰/渣理化特性及环境风险性[J]. 化工进展, 2024, 43(8): 4714-4725.
	YIN Junquan, WU Yinkai, LI Weihua, et al. Physicochemical characteristics and environmental risk of ash/slag in typical sections of MSW incineration[J]. Chemical Industry and Engineering Progress, 2024, 43(8): 4714-4725.
[5]	LONG Yuyang, PU Kai, YANG Yuqiang, et al. Preparation of high-strength ceramsite from municipal solid waste incineration fly ash and clay based on CaO-SiO₂-A_l2O₃ system[J]. Construction and Building Materials, 2023, 368: 130492.
[6]	吴海仁, 郭辉东, 翟凌阁. 建筑垃圾资源化处理及掺烧技术研究[J]. 中国资源综合利用, 2024, 42(10): 126-129.
	WU Hairen, GUO Huidong, ZHAI Lingge. Research on resource utilization and co-incineration technology of construction waste[J]. China Resources Comprehensive Utilization, 2024, 42(10): 126-129.
[7]	王玉, 余广炜, 林佳佳, 等. 沼渣、飞灰和污泥生物炭制备建筑陶粒[J]. 化工进展, 2023, 42(2): 1039-1050.
	WANG Yu, YU Guangwei, LIN Jiajia, et al. Preparation of building ceramsite from food waste digestate residues, incineration fly ash and sludge biochar[J]. Chemical Industry and Engineering Progress, 2023, 42(2): 1039-1050.
[8]	方伟成, 程星星, 孙常荣. 响应曲面法优化污泥/粉煤灰复合陶粒滤料的制备[J]. 无机盐工业, 2022, 54(9): 119-125, 142.
	FANG Weicheng, CHENG Xingxing, SUN Changrong. Optimization of preparation of sludge/fly ash composite ceramsite filler materials by response surface methodology[J]. Inorganic Chemicals Industry, 2022, 54(9): 119-125, 142.
[9]	裴军军, 苑博文, 高敏, 等. 再生微粉多元复合胶凝体系的性能研究[J]. 硅酸盐通报, 2024, 43(5): 1812-1821.
	PEI Junjun, YUAN Bowen, GAO Min, et al. Properties of multi-component composite cementitious system of regenerated micropowder[J]. Bulletin of the Chinese Ceramic Society, 2024, 43(5): 1812-1821.
[10]	高瑞晓, 荣辉, 王海良, 等. 800密度等级的渣土陶粒制备及性能研究[J]. 硅酸盐通报, 2017, 36(5): 1646-1650.
	GAO Ruixiao, RONG Hui, WANG Hailiang, et al. Preparation and performance of 800 density grades muck-ceramsite[J]. Bulletin of the Chinese Ceramic Society, 2017, 36(5): 1646-1650.
[11]	季维生. 700密度等级渣土陶粒制备及其性能研究[J]. 硅酸盐通报, 2017, 36(7): 2209-2214.
	JI Weisheng. Preparation and performance of 700 density grades muck-ceramsite[J]. Bulletin of the Chinese Ceramic Society, 2017, 36(7): 2209-2214.
[12]	FURLANI Erika, Sergio BRÜCKNER, MINICHELLI Dino, et al. Synthesis and characterization of ceramics from coal fly ash and incinerated paper mill sludge[J]. Ceramics International, 2008, 34(8): 2137-2142.
[13]	RILEY CHARLES M. Relation of chemical properties to the bloating of clays[J]. Journal of the American Ceramic Society, 1951, 34(4): 121-128.
[14]	MI Hongcheng, YI Longsheng, WU Qian, et al. Preparation of high-strength ceramsite from red mud, fly ash, and bentonite[J]. Ceramics International, 2021, 47(13): 18218-18229.
[15]	MORENO-MAROTO José Manuel, Manuel UCEDA-RODRÍGUEZ, COBO-CEACERO Carlos Javier, et al. Studying the feasibility of a selection of Southern European ceramic clays for the production of lightweight aggregates[J]. Construction and Building Materials, 2020, 237: 117583.
[16]	WANG Xuxu, QIN Yuhong, OKEKE Ikechukwu, et al. Revealing the intrinsic sintering mechanism of high-strength ceramsite from CFB fly ash: Focus on the role of CaO[J]. Ceramics International, 2024, 50(13): 24281-24292.
[17]	ZHU Ying, SHAO Yingying, TIAN Chao, et al. Preparation of municipal solid waste incineration fly ash/granite sawing mud ceramsite and the morphological transformation and migration properties of chlorine[J]. Waste Management, 2024, 173: 1-9.
[18]	LIU Shunbo, ZHANG Hengyun, XU Xiaobin. A study on the transient heat generation rate of lithium-ion battery based on full matrix orthogonal experimental design with mixed levels[J]. Journal of Energy Storage, 2021, 36: 102446.
[19]	XIONG Xin, CHEN Hu, JIANG Pengcheng, et al. Honeycombed pomegranate-like sludge ceramsite particles: Preparation with fly ash floating beads as the pore-forming template and performance optimization[J]. Construction and Building Materials, 2024, 453: 139017.
[20]	杨珊珊. 城市污水处理厂污泥固化及制备陶粒初探[D]. 北京: 北京工业大学, 2015.
	YANG Shanshan. Sewage sludge curing experiment and preparation of ceramsite[D]. Beijing: Beijing University of Technology, 2015.
[21]	LI Tianpeng, SUN Tingting, LI Dengxin. Preparation, sintering behavior, and expansion performance of ceramsite filter media from dewatered sewage sludge, coal fly ash, and river sediment[J]. Journal of Material Cycles and Waste Management, 2018, 20(1): 71-79.
[22]	WANG Dong, HUANG Jinlou, PENG Hongtao, et al. Sinterability and expansion property of ceramsite made with lead-zinc mine tailings[J]. Applied Mechanics and Materials, 2014, 551: 23-27.
[23]	LI Pengwei, LUO Shaohua, ZHANG Lin, et al. Study on preparation and performance of iron tailings-based porous ceramsite filter materials for water treatment[J]. Separation and Purification Technology, 2021, 276: 119380.
[24]	XIAO Tingting, FAN Xuyang, ZHOU Chenyu, et al. Preparation of ultra-lightweight ceramsite from waste materials: Using phosphate tailings as pore-forming agent[J]. Ceramics International, 2024, 50(9): 15218-15229.
[25]	FUERTES V, REINOSA J J, FERNÁNDEZ J F, et al. Engineered feldspar-based ceramics: A review of their potential in ceramic industry[J]. Journal of the European Ceramic Society, 2022, 42(2): 307-326.
[26]	CHEESEMAN C R, MAKINDE A, BETHANIS S. Properties of lightweight aggregate produced by rapid sintering of incinerator bottom ash[J]. Resources, Conservation and Recycling, 2005, 43(2): 147-162.
[27]	FENG Jinyang, WU Donghua, LONG Min, et al. Diopside glass-ceramics were fabricated by sintering the powder mixtures of waste glass and Kaolin[J]. Ceramics International, 2022, 48(18): 27088-27096.
[28]	MÉNARD Y, ASTHANA A, PATISSON F, et al. Thermodynamic study of heavy metals behaviour during municipal waste incineration[J]. Process Safety and Environmental Protection, 2006, 84(4): 290-296.
[29]	JIANG Jianguo, XU Xin, WANG Jun, et al. Investigation of basic properties of fly ash from urban waste incinerators in China[J]. Journal of Environmental Sciences, 2007, 19(4): 458-463.
[30]	严建华, 李建新, 池涌, 等. 垃圾焚烧飞灰重金属蒸发特性试验分析[J]. 环境科学, 2004, 25(2): 170-173.
	YAN Jianhua, LI Jianxin, CHI Yong, et al. Characteristic analysis of heavy metals’ evaporation of MSWI fly ash[J]. Environmental Science, 2004, 25(2): 170-173.
[31]	杨凤玲, 李鹏飞, 叶泽甫, 等. 城市生活垃圾焚烧飞灰组成特性及重金属熔融固化处理技术研究进展[J]. 洁净煤技术, 2021, 27(1):169-180.
	YANG Fengling, LI Pengfei, YE Zefu, et al. Study progress on the composition characteristics of fly ash from municipal solid waste incineration and treatment technology of heavy metal melting and solidification[J]. Clean Coal Technology, 2021, 27(1): 169-180.

类型	指标	仪器/方法
陶粒性能	颗粒强度	微机控制电子万能试验机（WDW-50）
陶粒性能	表观密度、堆积密度、1h吸水率、筒压强度、空隙率	《轻集料及其试验方法第2部分：轻集料试验方法》（GB/T 17431.2—2010）
材料特性	元素组成	X射线荧光光谱仪（XRF，Zetium）
	矿物组成	X射线衍射仪（XRD，Smartlab9）
	重金属含量	石墨炉消解+电感耦合等离子体发射光谱仪（ICP-OES，iCAP7000）
	热稳定性	热重分析仪（TG-DTG，STA 449 F3）

类型	指标	仪器/方法
陶粒性能	颗粒强度	微机控制电子万能试验机（WDW-50）
陶粒性能	表观密度、堆积密度、1h吸水率、筒压强度、空隙率	《轻集料及其试验方法第2部分：轻集料试验方法》（GB/T 17431.2—2010）
材料特性	元素组成	X射线荧光光谱仪（XRF，Zetium）
	矿物组成	X射线衍射仪（XRD，Smartlab9）
	重金属含量	石墨炉消解+电感耦合等离子体发射光谱仪（ICP-OES，iCAP7000）
	热稳定性	热重分析仪（TG-DTG，STA 449 F3）

实验组别	CW掺量变化	MS掺量变化	FA掺量变化
实验组别	FA∶CW∶MS	FA∶CW∶MS	FA∶CW∶MS
G1	15∶65∶20	10∶60∶30	25∶60∶15
G2	20∶60∶20	15∶60∶25	30∶60∶15
G3	25∶55∶20	20∶60∶20	35∶60∶15
G4	30∶50∶20	25∶60∶15	40∶60∶15
G5	35∶45∶20	30∶60∶10	45∶60∶15

实验组别	CW掺量变化	MS掺量变化	FA掺量变化
实验组别	FA∶CW∶MS	FA∶CW∶MS	FA∶CW∶MS
G1	15∶65∶20	10∶60∶30	25∶60∶15
G2	20∶60∶20	15∶60∶25	30∶60∶15
G3	25∶55∶20	20∶60∶20	35∶60∶15
G4	30∶50∶20	25∶60∶15	40∶60∶15
G5	35∶45∶20	30∶60∶10	45∶60∶15

序号	因素			陶粒性能
序号	FA	CW	MS	筒压强度/MPa	表观密度/g·cm^-3	1h吸水率/%
1	20	55	10	10.80	2.06	1.00
2	20	60	15	12.00	2.22	2.33
3	20	65	20	11.20	2.22	1.52
4	25	55	15	10.10	2.30	1.93
5	25	60	20	11.50	2.28	1.04
6	25	65	10	12.20	2.22	1.15
7	30	55	20	12.30	2.30	1.38
8	30	60	15	8.10	2.34	1.55
9	30	65	10	13.10	2.17	0.35