Angeliki Moutsatsou

Removal of heavy metals from wastewater using CFB-coal fly ash zeolitic materials.

Polish bituminous (PB) and South African (SA) coal fly ash (FA) samples, derived from pilot-scale circulated fluidized bed (CFB) combustion facilities, were utilized as raw materials for the synthesis of zeolitic products. The two FAs underwent a hydrothermal activation with 1M NaOH solution. Two different FA/NaOH solution/ratios (50, 100g/L) were applied for each sample and several zeolitic materials were formed. The experimental products were characterized by means of X-ray diffraction (XRD) and energy dispersive X-ray coupled-scanning electron microscope (EDX/SEM), while X-ray fluorescence (XRF) was applied for the determination of their chemical composition. The zeolitic products were also evaluated in terms of their cation exchange capacity (CEC), specific surface area (SSA), specific gravity (SG), particle size distribution (PSD), pH and the range of their micro- and macroporosity. Afterwards the hybrid materials were tested for their ability of adsorbing Cr, Pb, Ni, Cu, Cd and Zn from contaminated liquids. Main parameters for the precipitation of the heavy metals, as it was concluded from the experimental results, are the mineralogical composition of the initial fly ashes, as well as the type and the amount of the produced zeolite and specifically the mechanism by which the metals ions are hold on the substrate.

Comparative uptake study of toxic elements from aqueous media by the different particle-size-fractions of fly ash

The purpose of the study described in this paper was to determine the removal of Cr (total), Cr (VI), Cu, Ni, Pb, Zn and Cd from wastewater using different particle-size-fractions of highly calcareous and highly siliceous fly ashes (FAs). Three different Hellenic FAs (two calcareous and one siliceous) were tested for their capability of precipitating heavy metals from aqueous solutions. Each FA sample was separated into six different size-fractions with a grain diameter range of: [(0-25) (25-40) (40-90) (90-150) (150-400) and (>400)] μm. The different FA grain-fractions were evaluated in terms of their chemical composition, pH, Loss on Ignition (LOI) and CaO(f) (%). Batch adsorption experiments were then carried out, indicating that the various grain-fractions of the highly siliceous FA were more efficient in precipitating Cr (VI) but less capable of retaining Cd, Cu, Ni, Pb and Zn. On the other hand, the high-Ca fly ashes were proven to be more efficient in uptaking Cd, Cu, Ni, Pb and Zn, but less in hexavalent chromium. This particular tendency was also confirmed in the case of the different particle-size-fractions of same fly ashes. It was actually verified that FAs can be more effective in the field of industrial wastewater-remediation when separated into their size-fractions.

Synthesis of A356 Al–high-Ca fly ash composites by pressure infiltration technique and their characterization

Eight types of A356 Al–fly ash composites were produced by pressure infiltration of high-Ca lignite fly ash. This type of ash was used for the first time in Al-composites synthesis, and particularly by liquid metal infiltration techniques. After examining mineralogy and chemistry, specific, narrow ash size fractions were used for the synthesis of composites, and properties linked to microstructure and wear strength of the materials. The effect of using ground ash particles on the microstructure and tribological performance of the composites was also investigated. It was concluded that using fine, high-Ca ash particles can improve the properties of composites, and that using ash particles in a ground form can better facilitate the production process of MMCs.

Influence of raw materials and distillation equipment on the heavy metal content of waste from an alcoholic anis-type beverage

This study focused on the heavy metal content waste resulting from the production of an anis-type beverage. Although natural ingredients were used in the production process, the waste contains heavy metals and is considered hazardous. Several metals were found in the waste (Fe, Cu, Ni, Zn, Cr and Cd), with concentrations of Fe to 157.5, Cu to 82.5, Zn to 31 and Ni to 8.5mg/l. To collect information on the source of these metals, the residues of the herbs used for flavoring were examined for processes employing metallic and non-metallic pot stills. Herbs distillation residues were found to contain metals in non-metallic stills, e.g. aniseed residues from glass stills contained Cu up to 1.02 and Ni up to 0.9 mg/l. Fennel residues contained Ni up to 1.2 and Zn up to 6.6mg/l. The main source for the metals was the bronze pot stills. The metals were in complexed form in the solution. The existence of metals in the amorphous phase as shown by a SEM micrograph indicates forming of metal-organic complexes, also verified by HPLC. Complexation data can be used for selecting the proper wash treatment method. The formation of large molecules favors precipitation and chemi-sorption treatment methods.

Synthesis and Characterization of Nickel-Alumina Composites from Recycled Nickel Powder

The recycling of metallic waste to create more valuable materials and their valorization into upgraded metal-based composites constitutes an important field of study. The composite industry nowadays considers environmental improvements as important as other properties of the materials. In the present paper, nickel powder was recycled from ferrous scrap, a low-cost and largely available material, by an effective hydrometallurgical recovery process. Then, this recycled powder was successfully used along with particulate α-alumina to prepare oblong nickel-based composite specimens with ceramic reinforcement loadings ranging from 0 to 30 wt.% by applying powder processing manufacturing techniques including cold isostatic pressing (CIP) and sintering. The microstructures obtained were characterized, the specimens were subjected to three-point bend tests, and their fracture behaviour was evaluated. By increasing the % ceramic reinforcement content, density clearly decreases while strengthening is achieved, thus leading to development of lightweight and enhanced oblong nickel-alumina composites. The composite microstructure, and particularly the metal-ceramic interface bonding, has a strong impact on fracture behaviour upon external loading.

By-products: oil sorbents as a potential energy source

The present study investigated the utilization of an industrial by-product, lignite fly ash, in oil pollution treatment, with the further potential profit of energy production. The properties of lignite fly ash, such as fine particle size, porosity, hydrophobic character, combined with the properties, such as high porosity and low specific gravity, of an agricultural by-product, namely sawdust, resulted in an effective oil-sorbent material. The materials were mixed either in the dry state or in aqueous solution. The oil sorption behaviour of the fly ash–sawdust mixtures was investigated in both marine and dry environments. Mixtures containing fly ash and 15–25% w/w sawdust performed better than each material alone when added to oil spills in a marine environment, as they formed a cohesive semi-solid phase, adsorbing almost no water, floating on the water surface and allowing total oil removal. For the clean-up of an oil spill 0.5 mm thick with surface area 1000 m2, 225–255 kg of lignite fly ash can be utilized with the addition of 15–25% w/w sawdust. Fly ash–sawdust mixtures have also proved efficient for oil spill clean-up on land, since their oil sorption capacity in dry conditions was at least 0.6–1.4 g oil g−1 mixture. The higher calorific value of the resultant oil–fly ash–sawdust mixtures increased up to that of bituminous coal and oil and exceeded that of lignite, thereby encouraging their utilization as alternative fuels especially in the cement industry, suggesting that the remaining ash can contribute in clinker production.

Compaction of High-Ca Fly Ash-Al- and Al-Alloy-Composites: Evaluation of their Microstructure and Tribological Performance

In this study, highly calcareous and siliceous fly ash particles were utilized for the fabrication of Aland Al-alloy-based MetalMatrix Composites (MMCs) by means of powder metallurgy. After compacting and sintering Al and Al/Si powders containing 10, 15, and 20wt. % ash particles, the homogenous (and with minimal amount of voids) microstructure of the produced composites was verified by means of Scanning Electron Microscopy (SEM). The composites were tested for their dry sliding wear behavior using a pin-on-disc machine against spheres of alumina. The worn surfaces of composites were then examined by using SEM and Energy Dispersive X-Ray Spectroscopy (EDS). It was shown that the addition of both types of FA enhanced the tribo-performance of Al, with the optimum metal powder replacement determined to the point of 15% wt., in the case of high-Si and 10% wt., in the case of high-Ca ash particles. Regarding alloy-matrix composites, although they generally presented worse tribological performance than pure Al/Si products, the additions of ashes up to 15% wt. resulted in only slight deterioration of the wear performance of composites. f 2011 The University of Kentucky Center for Applied Energy Research and the American Coal Ash Association All rights reserved. A R T I C L E I N F O Article history: Received 23 May 2011; Received in revised form 14 August 2011; Accepted 26 October 2011

Ferrous scrap yields powders for PM & MMCs

Abstract The increasing environmental problem posed by the dumping of ferrous scrap material in Greece has inspired a programme at the National Technical University of Athens, investigating the recovery from scrap of metals in the form of powders. Prof. A.K. Moutsatsou and V.G. Karayannis of the Laboratory of Inorganic and Analytical Chemistry explain the basis of their hydrometallurgical recovery process and outline investigations to demonstrate the potential of the powders for use in PM and MMCs.

Synergistic Sintering of Lignite Fly Ash and Steelmaking Residues towards Sustainable Compacted Ceramics

The development of value-added ceramic materials deriving only from industrial by-products is particularly interesting from technological, economic, and environmental point of views. In this work, the synergistic sintering of ternary and binary mixtures of fly ash, steelmaking electric arc furnace dust, and ladle furnace slag for the synthesis of compacted ceramics is reported. The sintered specimens’ microstructure and mineralogical composition were characterized by SEM-EDS and XRD, respectively. Moreover, the shrinkage, apparent density, water absorption, and Vickers microhardness (HV) were investigated at different sintering temperatures and raw material compositions. The characterization of the sintered compacts revealed the successful consolidation of the ceramic microstructures. According to the experimental findings, the ceramics obtained from fly ash/steel dust mixtures exhibited enhanced properties compared to the other mixtures tested. Moreover, the processing temperature affected the final properties of the produced ceramics. Specifically, a 407% HV increase for EAFD and a 2221% increase for the FA-EAFD mixture were recorded, by increasing the sintering temperature from 1050 to 1150°C. Likewise, a 972% shrinkage increase for EAFD and a 577% shrinkage increase for the FA-EAFD mixture were recorded, by increasing the sintering temperature from 1050 to 1150°C. The research results aim at shedding more light on the development of sustainable sintered ceramics from secondary industrial resources towards circular economy.