Claudio Ferone

Recycling of Pre-Washed Municipal Solid Waste Incinerator Fly Ash in the Manufacturing of Low Temperature Setting Geopolymer Materials

In this work, three samples of municipal solid waste incinerators fly ash (MSWI-FA) have been stabilized in systems containing coal fly ash to create geopolymers through a polycondensation reaction. Monolithic products have been obtained with both MSWI fly ash as received and after the partial removal of chloride and sulfate by water washing. The polycondensation products have been characterized qualitatively by means of Fourier transform infrared spectroscopy, X-ray diffraction and scanning electron microscopy and quantitatively, through the determination of the volume of reacted water and silicate. Furthermore, the heavy metals and chloride releases together with the physico-mechanical properties have been evaluated on the hardened products. In conclusion, considering the technological and environmental performances of the obtained geopolymers, they could be suitable for many non-structural applications, such as backfilling of abandoned quarries, decorative materials or brick fireplaces, hearths, patios, etc.

FTIR study of the thermal transformation of barium-exchanged zeolite A to celsian

In this study room temperature X-ray diffraction patterns and FTIR spectra of zeolite A in its Na form, Ba-exchanged zeolite A, hexacelsian, monoclinic celsian and Ba-exchanged zeolite A samples thermally treated at temperatures ranging from 200 to 1000 °C are reported. The combined inspection of room temperature X-ray diffraction patterns and FTIR spectra reveals the following points. 1) The thermal collapse of the microporous zeolite structure goes to completion upon thermal treatment at 200–300 °C; in the resulting amorphous phase the presence of the secondary building units of the zeolite A structure may be detected. 2) Thermal treatment in the temperature range 200–400 °C results in a middle-range order which favours the crystallisation of small crystallites of monoclinic celsian at 500 °C. 3) The further evolution of the amorphous phase in the 500–800 °C temperature range of thermal treatment instead of promoting the crystalline growth of monoclinic celsian, creates a middle-range order favourable to the crystallisation of hexacelsian which occurs at 1000 °C.

Thermal transformation of Ba-exchanged A and X zeolites into monoclinic celsian

Abstract The thermal transformation of Ba- and (Ba+Li)-exchanged precursors of zeolites A and X into monoclinic celsian has been investigated by X-ray diffractometry, differential thermal analysis, and thermodilatometry. Upon the proper thermal treatment either Ba-exchanged zeolite A or X give rise to the following transformations: zeolite→amorphous phase→hexacelsian→monoclinic celsian. Zeolite A-based precursors are more reactive than zeolite X-based precursors allowing all the reported transformations to occur at far lower temperatures starting from Ba-exchanged zeolite A rather than from Ba-exchanged zeolite X. In particular, starting from zeolite X-based precursors, fully monoclinic celsian may be obtained after 24 h at 1550°C in the absence of Li and after 6 h at 1100°C in the presence of Li, whereas starting from zeolite A-based precursors it may be obtained after 6 h at 1100°C in the absence of Li and by slow heating (1°C/min) up to 900°C in the presence of Li.

Application-Oriented Chemical Optimization of a Metakaolin Based Geopolymer

In this study the development of a metakaolin based geopolymeric mortar to be used as bonding matrix for external strengthening of reinforced concrete beams is reported. Four geopolymer formulations have been obtained by varying the composition of the activating solution in terms of SiO2/Na2O ratio. The obtained samples have been characterized from a structural, microstructural and mechanical point of view. The differences in structure and microstructure have been correlated to the mechanical properties. A major issue of drying shrinkage has been encountered in the high Si/Al ratio samples. In the light of the characterization results, the optimal geopolymer composition was then applied to fasten steel fibers to reinforced concrete beams. The mechanical behavior of the strengthened reinforced beams was evaluated by four-points bending tests, which were performed also on reinforced concrete beams as they are for comparison. The preliminary results of the bending tests point out an excellent behavior of the geopolymeric mixture tested, with the failure load of the reinforced beams roughly twice that of the control beam.

Use of reservoir clay sediments as raw materials for geopolymer binders

Abstract Abstract Among low cost or readily available raw materials, reservoir clay sediments are of interest as potential precursors in geopolymer binder manufacture. These materials come from dredging of reservoirs because periodical sediment removal is necessary in order to keep a satisfactory level of functionality. In this paper, two sediments, coming from reservoirs located in Southern Italy, have undergone preliminary characterisation by X-ray diffraction, differential thermogravimetry and Fourier transformed infrared (FTIR) spectroscopy. Then, the sediments were submitted to 1 and 2 h calcination treatments at 650 and 750°C. The effects of calcination were evaluated by means of 27Al magic angle spinning nuclear magnetic resonance and FTIR. The calcined samples were mixed with 5M NaOH solution, and the obtained mixtures were studied for reactivity by means of differential scanning calorimetry. Finally, cylindrical samples were prepared with the same mixtures and cured for 3 days at 60°C plus 4 and 25 days at room temperature. The obtained samples were subjected to unconfined compressive strength determinations in order to verify the actual occurrence of geopolymerisation. The results show that the calcined clay sediments can be suitable precursors in polycondensation reactions.

Synthesis of SiO2 and CaO rich calcium silicate systems via sol-gel process: Bioactivity, biocompatibility, and drug delivery tests

Silica and calcium silicate amorphous materials, mixed with sodium ampicillin, a broad-spectrum antibiotic, have been synthesized by sol-gel method. The amorphous nature of the gels was ascertained by X-ray diffraction analysis. The bioactivity of the synthesized materials has been put into evidence by the appearance of a crystal of hydroxyapatite on the surface of the samples soaked in a fluid simulating the composition of the human blood plasma, as detected through FTIR measurements and SEM micrographs. The present work refers to a series of in-vitro biocompatibility tests, which has been performed on silicate and CaO rich calcium silicate gel-glasses, to study the cell behavior when seeded on 1 cm(2) material fragments, introduced into an in-vitro culture system. 3T3 cell lines have been used and the viability has been evaluated by WST-8 test. The composition of the adopted glasses can be expressed by the following general formula: x CaO• (1 - x) SiO2 with x = 0.00; 0.30; 0.40; 0.50; 0.60. Subsequently, release kinetics in a simulate body fluid (SBF) has been investigated. The amount of sodium ampicillin released has been detected by UV-Vis spectroscopy. The release kinetics has appeared to occur in more than one stage. All data have shown that those materials could be used as drug delivery bioactive systems.

Coal Combustion Wastes Reuse in Low Energy Artificial Aggregates Manufacturing

Sustainable building material design relies mostly on energy saving processes, decrease of raw materials consumption, and increase of waste and by-products recycling. Natural and lightweight artificial aggregates production implies relevant environmental impact. This paper addresses both the issues of residues recycling and energy optimization. Particularly, three coal combustion wastes (Weathered Fly Ash, WFA; Wastewater Treatment Sludge, WTS; Desulfurization Device Sludge, DDS) supplied by the Italian electric utility company (ENEL) have been employed in the manufacture of cold bonded artificial aggregates. Previously, the residues have been characterized in terms of chemical and mineralogical compositions, water content, particle size distribution, and heavy metal release behavior. These wastes have been used in the mix design of binding systems with the only addition of lime. Finally, the artificial aggregates have been submitted to physical, mechanical, and leaching testing, revealing that they are potentially suitable for many civil engineering applications.

Preparation and Characterization of New Geopolymer-Epoxy Resin Hybrid Mortars

The preparation and characterization of metakaolin-based geopolymer mortars containing an organic epoxy resin are presented here for the first time. The specimens have been prepared by means of an innovative in situ co-reticulation process, in mild conditions, of commercial epoxy based organic resins and geopolymeric slurry. In this way, geopolymer based hybrid mortars characterized by a different content of normalized sand (up to 66% in weight) and by a homogeneous dispersion of the organic resin have been obtained. Once hardened, these new materials show improved compressive strength and toughness in respect to both the neat geopolymer and the hybrid pastes since the organic polymer provides a more cohesive microstructure, with a reduced amount of microcracks. The microstructural characterization allows to point out the presence of an Interfacial Transition Zone similar to that observed in cement based mortars and concretes. A correlation between microstructural features and mechanical properties has been studied too.

Recycling of Clay Sediments for Geopolymer Binder Production. A New Perspective for Reservoir Management in the Framework of Italian Legislation: The Occhito Reservoir Case Study

Reservoir silting is an unavoidable issue. It is estimated that in Italy, the potential rate of silting-up in large reservoirs ranges from 0.1% to 1% in the presence of wooded river basins and intensive agricultural land use, respectively. In medium and small-sized reservoirs, these values vary between 0.3% and 2%. Considering both the types of reservoirs, the annual average loss of storage capacity would be of about 1.59%. In this paper, a management strategy aimed at sediment productive reuse is presented. Particularly, the main engineering outcomes of an extensive experimental program on geopolymer binder synthesis is reported. The case study deals with Occhito reservoir, located in Southern Italy. Clay sediments coming from this silted-up artificial lake were characterized, calcined and activated, by means of a wide set of alkaline activating solutions. The results showed the feasibility of this recovery process, optimizing a few chemical parameters. The possible reuse in building material production (binders, precast concrete, bricks, etc.) represents a relevant sustainable alternative to landfill and other more consolidated practices.

Synthesis and Characterization of Novel Epoxy Geopolymer Hybrid Composites

The preparation and the characterization of novel geopolymer-based hybrid composites are reported. These materials have been prepared through an innovative synthetic approach, based on a co-reticulation in mild conditions of commercial epoxy based organic resins and a metakaolin-based geopolymer inorganic matrix. This synthetic strategy allows the obtainment of a homogeneous dispersion of the organic particles in the inorganic matrix, up to 25% in weight of the resin. The materials obtained present significantly enhanced compressive strengths and toughness with respect to the neat geopolymer, suggesting their wide utilization for structural applications. A preliminary characterization of the porous materials obtained by removing the organic phase from the hybrid composites by means of heat treatments is also reported. Possible applications of these materials in the field of water purification, filtration, or as lightweight insulating materials are envisaged.