Management and valorization of phosphate beneficiation slime:a critical review

Abstract The valorization of phosphate mine waste (PMW) in different fields has recently become attractive to many researchers. This review paper examines the potential use of PMW as a raw material in different applications toward sustainable management strategies. Dewatering, recovery of phosphate and heavy metals, building materials and ceramics applications have been captured in this paper. Based on the origin of deposit and the treatment during ore beneficiation, the PMW shows different mineral compositions and various percentage of chemical elements which make it suitable for most of the studied applications. The objective of this paper is to show the potential of the phosphate mine waste valorization and to identify the knowledge gap

Mine wastes based geopolymers: A critical review

The quantities of waste rocks and tailings generated by the mining industry have been increased in the last decades. The accumulation and the surface storage of these mine wastes represents a real challenge in terms of environmental and health issues. Thus, the recycling and valorization of these mine wastes is one of the most effective ways of reducing their volume and mitigating their negative environmental impact. Among the recent and sustainable management strategies, geopolymerization technology offers many advantages, (i) the stabilization of polluted/inert mine wastes in the geopolymer matrix, (ii) valorization of a large volume of wastes in the construction sector and consequently minimization of environmental impacts, and finally (iii) the significant reduction of greenhouse gas emissions generated by the use of ordinary Portland cement (OPC) in the construction sector. This paper is intended to present an updated and critical review of the existing literature about mine wastes based geopolymers, by focusing mainly on the mechanical performances of each type of waste. The fundamentals of geopolymers synthesis and the effect of metakaolin substitution by mine wastes are investigated. The influence of the chemical composition of mine wastes was linked to the compressive strength. Results of recent studies showed that geopolymeric materials elaborated using mine wastes presented similar or better mechanical, physical, and durability properties compared to OPC

Recycling of precast concrete waste sludge with paper mill and biomass ashes for lightweight granulated aggregate production

Abstract The construction and demolition waste generation is increasingly evolving with the rapid urbanization, with more than a quarter of the produced waste being landfilled without further treatment or recycling strategy. Hence, sustainable management and valorization methods such as recycling in construction materials is becoming increasingly essential to tackle the economic and environmental burdens of landfilling waste. Construction and demolition waste recycling has been intensively studied. However, the present study proposes a promising solution for recycling construction and demolition wastes (CDWs) from the precast concrete waste sludge and ashes from paper mill sludge and biomass. Artificial lightweight aggregates were designed and produced by alkali activating a mixture of 50–90 wt% of dried and milled CDW with 3–25 wt% of ash and 5–35 wt% of blast furnace slag. The properties of the produced aggregates were assessed via density, water absorption, porosity, and crushing tests, in addition to microstructural characterizations using XRD and scanning electron microscopy SEM analysis. The optimum NaOH concentration was 8M with the highest mechanical properties and lowest efflorescence. The produced aggregates revealed a high crushing force of 82 N at 28 days with 50 wt% CDW, 15 wt% biomass ash, and 25 wt% blast furnace slag presenting a possible recycling pathway for such side-stream materials

Fusion of phosphate by-products and glass waste for preparation of alkali-activated binders

Landfilling of mine and industrial waste streams leads to environmental and economic issues. Sustainable management methods through valorization in manufacturing green construction materials are a current research interest. Here, a promising process for recycling mine tailings, such as phosphate sludge, is proposed. A mixture of phosphate sludge, kaolin clay (Al source), and glass waste (Si source) was prepared. Three fluxing agents were tested at 1000 °C (NaOH, NaCO, NaSO). NaCO was selected as the most cost-effective. The precursors were alkaline activated with NaOH solution (2, 6, and 8 M). At 28 days of curing (20 h room temperature + 6 h 85 °C + room temperature), the best compressive strength (of more than 45 MPa) was obtained with 8 M NaOH. The reaction products, characterized by XRD, FTIR, SEM, and MAS NMR, show that the main reaction products is a gel N–A–S–H/(N,C)–A–S–H together with some unreacted crystalline phases formed during the fusion

Utilization of calcite-rich Green Liquor Dregs (GLD) by-products from pulp and paper industry: Cement clinker production and life cycle analysis

The pulp and paper industry produces several calcite-rich by-products including Green Liquor Dregs (GLDs), lime mud, grits, sludges, etc. Presently, majority of these by-products are managed by landfilling. The GLD used in this study is mainly dominated by calcite (∼80 %) and Hydrotalcite like compounds (HTlc, ∼12 %). It is used to produced OPC clinkers by using them as 0 %, 5 %, 10 %, 15 %, and 20 % replacement of limestone used for clinker production. TGA-DSC analysis of the clinker raw meals up to 1350 ℃ indicates that increase in GLD leads to slight reduction in the decomposition temperature for the raw meals, and a slight change in the formation temperatures for C2S and C3S. The mineral phase compositions of all the clinkers are comparable with a slightly decreasing C3S and C2S with increasing GLD. Compared to the Bogue calculated compositions, C3S and C2S are slightly lower, while the C3A is significantly lower and C4AF is significantly higher. The environmental leaching of GLD and the clinkers are all within the limits set by EN-12457-2. The environmental impact of clinker production and effect of GLD is analyzed for cradle-to-gate scenario with system boundaries. This analysis shows that by using GLD as replacement for limestone can lower the impact on diversity as well as CO2 related to transportation can also be reduced

Investigation of different paper mill ashes as potential supplementary cementitious materials

Abstract Integrating supplementary cementitious materials (SCMs) in cement-based construction materials is a key strategy for reducing environmental burdens and the greenhouse gas emissions related to cement production. Supplies of commonly applied SCMs such as fly ash and blast furnace slag are becoming limited, and therefore the search for alternative SCMs is of high significance. The present research investigates the viability of four paper mill ashes collected at different stages from the same incineration process as SCMs at different cement substitution rates (5–30 wt%). The ashes were first classified depending on their mineralogical and chemical composition, and their contribution to strength development of the prepared mortars is examined. Furthermore, the effects of the ashes on the hydration kinetics and the fresh and hardened properties of the prepared mortars were studied. The obtained results showed that a high level of SCM replacement accelerates the early hydration reactions and decreases the setting time. In addition, the incorporation of paper mill ashes increased the bound water depending on the ash type and resulted in strength development of the mortars at low replacement per- centages (5–10 wt%). This study shows that the ashes belonging to type C medium acid based on bio ash classification could be incorporated as SCMs at a maximum level of 10 wt%, while those corresponding to type C low acid could be used up to 20–30 wt%

Enhancing the thermal stability of alkali-activated Fe-rich fayalite slag-based mortars by incorporating ladle and blast furnace slags:physical, mechanical and structural changes

Abstract A proper and detailed understanding of the thermal stability of Fe-rich fayalite slag-based alkali-activated materials (AAMs) is important due to their potential use in refractory and fire-resistant applications. Here, fayalite slag (FS) was used as the main precursor for AAMs. The effects of incorporating ladle slag (LS) or blast furnace slag (BFS) and different temperature exposures up to 1000 °C were investigated through visual observation, compressive strength, ultrasonic pulse velocity (UPV), thermal conductivity, x-ray diffraction (XRD), thermogravimetry and differential scanning calorimetry (TG/DSC), Fourier transform infrared spectroscopy (FTIR) and scanning electron microscope coupled with electron probe microanalyzer (SEM-EPMA). The experimental results indicated that the incorporation of LS or BFS as additional calcium and aluminum sources positively affected the high-temperature behavior of blended mortars, which exhibited a reduction in voids, cracks, and thermal shrinkage while having higher residual strength and thermal stability than solely FS-based AAMs. This was mainly due to the differences in mineralogical transformation and the phases formed. Interestingly, the joint effect of elevated temperature exposure and the addition of LS or BFS enhanced the formation of more stable crystalline phases and densified the structure of blended mortars at 1000 °C

Fusion of phosphate by-products and glass waste for preparation of alkali-activated binders

Abstract Landfilling of mine and industrial waste streams leads to environmental and economic issues. Sustainable management methods through valorization in manufacturing green construction materials are a current research interest. Here, a promising process for recycling mine tailings, such as phosphate sludge, is proposed. A mixture of phosphate sludge, kaolin clay (Al source), and glass waste (Si source) was prepared. Three fluxing agents were tested at 1000 °C (NaOH, Na2CO3, Na2SO4). Na2CO3 was selected as the most cost-effective. The precursors were alkaline activated with NaOH solution (2, 6, and 8 M). At 28 days of curing (20 h room temperature + 6 h 85 °C + room temperature), the best compressive strength (of more than 45 MPa) was obtained with 8 M NaOH. The reaction products, characterized by XRD, FTIR, SEM, and MAS NMR, show that the main reaction products is a gel N–A–S–H/(N,C)–A–S–H together with some unreacted crystalline phases formed during the fusion