Fly ash,

High calcium fly ash and granulated blast furnace slag are cementitious. Low calcium fly ash is termed a normal pozzolan. Condensed silica fume and rice husk ash are highly pozzolanic. Slowly cooled blast furnace slag, bottom ash, and field burnt rice husk ash are weak pozzolans. 

Fly ash contains about 15% crystalline material, the rest being an amorphous material and carbon. The major crystalline materials in fly ash are quartz, mullite, hematite, and magnetite. The reactivity of fly ash depends on the loss on ignition, fineness, and mineralogical and chemical composition. The pozzolanic activity also depends on the mineralogy of coal and on the glassy or non-crystalline structure of fly ash. 

Fly ash may be used as a replacement of cement or fine aggregate or as an additional component at the concrete mixing plant. Fly ash has been used up to 60% replacement of cement. Addition of fly ash reduces the water requirement for a particular consistency or flow. Low calcium fly ash acts largely as a fine aggregate initially, but with time will react to pozzolanic compounds. High calcium fly ash participates in the early cementing reactions. Partial replacement of fly ash results in the reduction in temperature rise in fresh concrete due to the reduction in the heat of hydration. 

Much of the mineral particulate matter in a polluted atmosphere is in the form of oxides and other compounds produced during the combustion of high-ash fossil fuel. Small particles in the exhaust from mineral-containing fossil fuels are called fly ash. Most fly ash enters furnace flues and is efficiently collected in a properly equipped stack system. However, some fly ash escapes through the 

Stack and enters the atmosphere. Unfortunately, the fly ash thus released tends to consist of smaller particles that do the most damage to human health, plants, and visibility. 

The composition of fly ash varies widely, depending upon the fuel. The predominant constituents are oxides of aluminum, calcium, iron, and silicon. Other elements that occur in fly ash are magnesium, sulfur, titanium, phosphorus, potassium, and sodium. Elemental carbon (soot, carbon black) is a significant fly ash constituent. 

The size of fly ash particles is a very important factor in determining their removal from stack gas and their ability to enter the body through the respiratory tract. Although only a small percentage of the total fly ash mass is in the smaller size fraction of around 0.1 pm size, it includes the vast majority of the total number of particles and particle surface area. Submicrometer particles probably result from a volatilization—condensation process during combustion, as reflected in a higher concentration of more volatile elements such as As, Sb, Hg, and Zn. In addition to their being relatively much more respirable and potentially toxic, the very small particles are the most difficult to remove by electrostatic precipitators and bag houses (see Chapter 8, Section 8.4). 

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Differential pulse polarography and stripping voltammetry have been applied to the analysis of trace metals in airborne particulates, incinerator fly ash, rocks. 

Control technology requirements vary according to the scale of operation and type of emission problem. For instance, electrostatic precipitator design requirements for fly-ash control from 1000-MW coal-fired power boilers differ from those for a chemical process operation. In the discussion that follows, priority is given to control technology for the CPI as opposed to the somewhat special needs of other industries. 

R. Dennis and co-workers, "Filtration Model for Coal Fly Ash with Glass Fabrics," EPA Rpt. EPA-600/7-77-095a, NTIS Pub. PB 276-489j MS, August 1977. 

The proposed mechanism by which chlorinated dioxins and furans form has shifted from one of incomplete destmction of the waste to one of low temperature, downstream formation on fly ash particles (33). Two mechanisms are proposed, a de novo synthesis, in which PCDD and PCDF are formed from organic carbon sources and Cl in the presence of metal catalysts, and a more direct synthesis from chlorinated organic precursors, again involving heterogeneous catalysis. Bench-scale tests suggest that the optimum temperature for PCDD and PCDF formation in the presence of fly ash is roughly 300°C. 

Both CI2 and HCl have been shown to chlorinate hydrocarbons on fly ash particles. Pilot-scale data involving the injection of fly ash from municipal waste combustion (33) show that intermediate oxygen concentrations (4—7%) produce the highest levels of PCDD and PCDF. These data also show significant reductions in PCDD and PCDF emissions with the upstream injection of Ca(OH)2 at about 800°C. 

T. R. Dobie, S. Y. Ng, md N. W. Henning, Eaboratoy Evaluation of Eignite Fly ash as a Stabilisyation Ndditivefor Soils and Aggregates, final report PB... 

E. Barenberg, "Lime-Fly Ash Aggregate Mixtures in Pavement Constmction," NationalMsh Mssociation Bulletin, 1972. 

The high temperatures in the MHD combustion system mean that no complex organic compounds should be present in the combustion products. Gas chromatograph/mass spectrometer analysis of radiant furnace slag and ESP/baghouse composite, down to the part per biUion level, confirms this behef (53). With respect to inorganic priority pollutants, except for mercury, concentrations in MHD-derived fly-ash are expected to be lower than from conventional coal-fired plants. More complete discussion of this topic can be found in References 53 and 63. 

The oxidant preheater, positioned in the convective section and designed to preheat the oxygen-enriched air for the MHD combustor to 922 K, is located after the finishing superheat and reheat sections. Seed is removed from the stack gas by electrostatic precipitation before the gas is emitted to the atmosphere. The recovered seed is recycled by use of the formate process. Alkali carbonates ate separated from potassium sulfate before conversion of potassium sulfate to potassium formate. Sodium carbonate and potassium carbonate are further separated to avoid buildup of sodium in the system by recycling of seed. The slag and fly-ash removed from the HRSR system is assumed to contain 15—17% of potassium as K2O, dissolved in ash and not recoverable. 

Spheres. HoUow spherical fillers have become extremely useflil for the plastics industry and others. A wide range of hoUow spherical fillers are currently available, including inorganic hoUow spheres made from glass, carbon, fly ash, alumina, and 2h conia and organic hoUow spheres made from epoxy, polystyrene, urea—formaldehyde, and phenol—formaldehyde. Although phenol—formaldehyde hoUow spheres are not the largest-volume product, they serve in some important appHcations and show potential for future use. 

The monoalkyl derivatives in salt form appear to have low toxicity. The monomethyl sulfate sodium salt has an approximate oral lethal dose greater than 5000 mg/kg of body weight for rats (129). Monododecyl sulfate sodium salt is widely marketed as a detergent and shampoo ingredient (oral LD q 1268 mg/kg for rats) (126). Both dimethyl sulfate and monomethyl sulfate occur in the environment in coal fly-ash and in airborne particulate matter (130). 

Acid Leaching. DHect acid leaching for vanadium recovery is used mainly for vanadium—uranium ores and less extensively for processing spent catalyst, fly ash, and boiler residues. Although 20 in spent catalysts dissolves readily in acid solutions, the dissolution of vanadium from ores and... 

The choice of selected raw materials is very wide, but they must provide calcium oxide (lime), iron oxide [1309-37-1/, siHca, and aluminum oxide (alumina). Examples of the calcereous (calcium oxide) sources are calcium carbonate minerals (aragonite [14791-73-2] calcite [13397-26-7] limestone [1317-65-3] or mad), seasheUs, or shale. Examples of argillaceous (siHca and alumina) sources are clays, fly ash, mad, shale, and sand. The iron oxide commonly comes from iron ore, clays, or mill scale. Some raw matedals supply more than one ingredient, and the mixture of raw matedals is a function of their chemical composition, as deterrnined by cost and availabiHty. 

Industrial by-products are becoming more widely used as raw materials for cement, eg, slags contain carbonate-free lime, as well as substantial levels of silica and alumina. Fly ash from utility boilers can often be a suitable feed component, because it is already finely dispersed and provides silica and alumina. Even vegetable wastes, such as rice hull ash, provide a source of silica. Probably 50% of all industrial by-products are potential raw materials for Pordand cement manufacture. 

Po22olans iaclude natural materials such as diatomaceous earths (see Diatomite), opaline cherts, and shales, tuffs, and volcanic ashes or pumicites, and calciaed materials such as some clays and shales. By-products such as fly ashes and siUca fume are also employed. In the United States the proportion of po22olan iaterground with clinker has varied from 15 to over 30%, whereas ia Italy, cements with a 30—40% po22olan content are produced. 

SNR s fluidized-bed cogeneiation system is an early example of the commercial development of AFBC technology. Foster Wheeler designed, fabricated, and erected the coal-fired AFBC/boHer, which generates 6.6 MWe and 37 MW thermal (also denoted as MWt) of heat energy. The thermal energy is transferred via medium-pressure hot water to satisfy the heat demand of the tank farm. The unit bums 6.4 t/h of coal and uses a calcium to sulfur mole ratio of 3 to set the limestone feed rate. The spent bed material may be reiajected iato the bed as needed to maintain or build bed iaventory. The fly ash, collected ia two multicyclone mechanical collectors, may also be transferred pneumatically back to the combustor to iacrease the carbon bumup efficiency from 93%, without fly ash reiajection, to 98%. 

In ECS s 1986 repowefing project Babcock and Wilcox (B W) constmcted a bubbling-bed section to ECS s existing 125 MWe pulverized-coal furnace to produce 31.3 t/h of lime, usiag cmshed coal as the source of heat to calciae limestone ia the fluidized bed. A portion of the lime is drawn from the bed as bottom ash and a portion is collected as fly ash. Both portions are transferred to a cement (qv) plant adjacent to the boiler. The hot flue gas from the EBC flows iato the existing main pulverized-coal furnace, ia which a B W LIMB system was also iastaHed to absorb sulfur dioxide dufing those times when the EBC is not operating. 

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