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Environ Chem Lett (2014) 12:153–175

DOI 10.1007/s10311-014-0454-6

REVIEW

Review of fly ash inertisation treatments and recycling


Annalisa Zacco • Laura Borgese • Alessandra Gianoncelli •

Rudolf P. W. J. Struis • Laura E. Depero •


Elza Bontempi

Received: 19 December 2013 / Accepted: 3 January 2014 / Published online: 24 January 2014
 Springer International Publishing Switzerland 2014

Abstract Fly ash (FA) is a by-product of power, and reduce the pressure on demand for primary raw materials,
incineration plants operated either on coal and biomass, or help to reuse valuable materials which would otherwise be
on municipal solid waste. FA can be divided into coal fly wasted and reduce energy consumption and greenhouse gas
ash, obtained from power plant burning coal, flue gas emissions from extraction and processing.
desulphurisation FA, that is, the by-product generated by
the air pollution control equipment in coal-fired power Keywords Fly ash  Heavy metals  Organic pollutants 
plants to reduce the release of SO2, biomass FA produced Recycling
in the plants for thermal conversion of biomass and
municipal solid waste incineration (MSWI) FA, that is, the List of abbreviations
finest residue obtained from the scrubber system in a AES Acid extraction sulphide stabilisation process
MSWI plant. Because of the large amount produced in the APC Air pollution control
world, fly ash is now considered the world’s fifth largest COSMOS Colloidal silica medium to obtain safe inert
material resource. The composition of FA is very variable, DC Direct current
depending on its origins; then, also pollutants can be very EDTA Ethylenediaminetetraacetate
different. In this frame, it is fundamental to exploit the FA Fly ash
chemical or physical potentials of FA constituents, thus FGD Flue gas desulphurisation
rendering them second-life functionality. This review paper LCA Life cycle assessments
is addressed to FA typology, composition, treatment, LOI Loss of ignition
recycling, functional reuse and metal and organic pollu- MSWI Municipal solid waste incineration
tants abatement. Because of the general growing of envi- PAH Polycyclic aromatic hydrocarbon
ronmental awareness and increasing energy and material PCB Polychlorinated bifenyl
demand, it is expected that increasing recycling rates will PCDD Polychlorodibenzo-p-dioxin
PCDF Polychlorodibenzo-p-furan
POP Persistent hazardous organic pollutants
A. Zacco  L. Borgese  A. Gianoncelli 
RHA Rice husk ash
L. E. Depero  E. Bontempi (&)
INSTM and Chemistry for Technologies Laboratory, Brescia S/S Solidification/stabilisation
University, Via Branze 38, 25023 Brescia, Italy TEQ Toxic equivalent
e-mail: elza.bontempi@ing.unibs.it

R. P. W. J. Struis
General Energy Research (ENE), Laboratory for Bioenergy and
Catalysis (LBK), Paul Scherrer Institute, 5232 Villigen, Introduction
Switzerland
This review would like to provide a comprehensive
R. P. W. J. Struis
École Polytechnique Fédérale de Lausanne (EPFL-ENAC-IIE), description of fly ash (FA) typologies, composition, recy-
1015 Lausanne, Switzerland cling, functional reuse and treatments, emphasising

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154 Environ Chem Lett (2014) 12:153–175

developments and trends in FGA treatments during the past found. Quartz and mullite are the major crystalline con-
four decades ([1976) with references to more than 220 stituents of low-calcium ash, whereas high-calcium FA
publications. Among the three considered FA sources, coal, consists of quartz, tricalcium aluminate, calcium silicate
biomass and municipal solid wastes (MSW), the use of coal and tetracalcium aluminosilicate (Ahmaruzzaman 2010).
is predominant. Recent surveys put global coal FA pro- The less predominant minerals include calcite, pyrite and
duction in the region of 750 million tons/year (Blissett and hematite. Because of this structural variety, coal FA is one
Rowson 2012), which means a rise about 50 % compared of the most complex anthropogenic materials that can be
to the last decade. This is likely due to the increasing characterised.
energy demand from economically developing countries Coal FA mineralogy also depends on the coal source.
such as India, China and Brazil. So far, European countries Coal can be generally divided into four typologies, which
put much effort in heat, energy and power generation from are anthracite, bituminous, sub-bituminous and lignite.
renewable biomass-based sources and by diversification of Therefore, final coal FA composition is also determined by
their energy supply from biomass (Rajamma et al. 2009; the type of coal burned to produce it. Generally, it is shown
Yin et al. 2008). The initial targets of FA treatments were that coal FA from sub-bituminous and lignite coals is
mainly devoted to MSW volume reduction, inhibition of characterised by higher CaO and MgO and lower Al2O3
metal leaching, inertisation, stabilisation and landfill or to with respect to the higher-grade fuels such as bituminous
obtain secondary ores and additives for building materials. and anthracite coals. On the contrary, bituminous coal FA
Then, the growth of environmental problem consciousness contains less than 10 % CaO (and usually does not contain
and the increasing demand for energy and materials have any crystalline compounds of Calcium) in total and often
changed the targets towards the exploitation of physical– mainly consist of aluminosilicate glass. Coal FA that
chemical potentialities of FA main constituents, to make contains more than 15 % CaO is composed of calcium
them secondary materials. The mineral composition of FA aluminosilicate glass in addition to substantial proportions
is mainly responsible for its following treatments and of crystalline calcium compounds including tricalcium
reuses. This has been made possible by the deepened aluminate, tetracalcium aluminosilicate, calcium silicate
knowledge of FA composition, morphology and modifi- and calcium oxide (Manz 1999).
cations due to their different sources. A brief classification Table 1 shows the normal range of chemical constitu-
of FA is reported below since it sets the framework for ents of bituminous coal FA with those of lignite coal FA
development and trends of FA treatments. and sub-bituminous and anthracite coal FA. Lignite and
This article is an abridged version of the chapter by sub-bituminous coal FA have lower loss of ignition (LOI
Gianoncelli et al. (2013) published in the book series that is an indication of the amount of carbon in FA) than
Environmental Chemistry for a Sustainable Word (http:// FA from bituminous coals. Lignite coal FA may have a
www.springer.com/series/11480). higher concentration of sulphite compounds than bitumi-
nous coal FA.
The major matrix elements of coal FA are Si, Al and Fe
Fly ash typologies together with significant percentages of Ca, K, Na and Ti
(Matti et al. 1990). FA contains essential macronutrients
Coal fly ash like P, K, Ca, Mg and S and micronutrients including Fe,

Coal FA is a predominantly inorganic residue obtained


from the flue gases of furnaces at pulverised coal power Table 1 Range of chemical compounds of FA produced from dif-
ferent coal types (Ahmaruzzaman 2010; Moreno et al. 2005)
plants. Coal FA is generally produced at 1,200–1,700 C
from the various inorganic and organic constituents of the Component Bituminous Sub-bituminous Lignite Anthracite
parent coal. (wt%)
The characteristics of produced FA differ depending on SiO2 20–60 40–60 15–45 28–57
the coal source, the method of combustion of power plants Al2O3 5–35 20–30 10–25 18–36
(Scheetz and Earle 1998; Helmuth 1987) and typologies of Fe2O3 10–40 4–10 4–15 3–16
emission control devices, storage and handling (Jala and CaO 1–12 5–30 15–40 1–27
Goyal 2006). Therefore, FA shows a wide variation in their MgO 0–5 1–6 3–10 1–4
physicochemical and mineralogical properties. About 300 SO3 0–4 0–2 0–10 0–9
individual minerals have been identified in different coal Na2O 0–4 0–2 0–6 0–1
FAs (Vassilev and vassileva 2005). The main detected
K2O 0–3 0–4 0–4 0–4
crystalline phases are mullite, quartz, magnetite, haematite
LOI 0–15 0–3 0–5 1–8
and anhydrite (Helmuth 1987; Wang 2008). Glass is also

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Environ Chem Lett (2014) 12:153–175 155

Mn, Zn, Cu, Co, B and Mo. The type of coal used for coal-fired power plants, to reduce sulphur amount in air.
combustion affects the sulphur content of FA. Coal FAs The term FGD generally refers to wet scrubbers that
contain many elements at concentrations greater than remove sulphur dioxide emissions from large electric
50 mg/kg. Some of these may produce environmental utility boilers (mainly based on coal combustion). These
concern (Izquierdo and Querol 2012). For example, coal systems are capable of removing approximately 70–90 %
FA is often rich in trace elements like mercury, cobalt and of the SO2 in the flue gas, depending on the operating
chromium (Izquierdo and Querol 2012), which are con- conditions.
centrated in smaller FA particles (Adriano et al. 1980). Al Since the end of the 1970s, more than 100 million tons
in FA is mostly bound in insoluble aluminosilicate struc- of FGD FA has been produced in hard coal and lignite
tures, and this considerably limits its biological toxicity. power plants in Europe (Leiva et al. 2010). In comparison
The ratio between Ca and S is strictly related to the pH of with coal FA, much less data are available on the properties
the water–ash system and so plays the dominant role in the of FGD FA. Kost et al. (2005) published a study reporting
leachability of most elements contained in FA (Izquierdo chemical physical properties of FGD samples collected
and Querol 2012). from 13 different locations. The composition of all samples
Moreno et al. (2005) reported that the following trace was dominated by Ca, S, Al, Fe and Si, and strong pref-
elements are present in 23 European coal FA: As, B, Ba, erential partitioning into the acid insoluble residue (i.e. coal
Be, Cd, Co, Cr, Cu, Ge, Hg, Li, Mo, Ni, Pb, Rb, Sb, Se, Sn, ash residue) was observed for Al, Ba, Be, Cr, Fe, Li, K, Pb,
Sr, Th, U, V and Z. Concentration values are in agreement Si and V. Specific surface area was related to particle size,
with the elemental composition found for coal FA from and it varied between 1.3 m2/g with bed ash and 9.5 m2/g
other areas (Jankowski et al. 2006). It is noticeable that with spray dryer material. Many of the chemical and
elements, such as As, Cr, Pb and Se, are present in coal FA. physical properties of FGD FA were associated with the
Moreover, coal FA generally shows a relatively low con- quality of the coal rather than the combustion and SO2
tent of environmentally available toxic metals, mainly in scrubbing processes used.
the leachable fraction. The leachability of toxic elements is
closely related to the phase with which they are associated Municipal solid waste incineration fly ash
and to leaching conditions such as pH (Jankowski et al.
2006). From the morphological point of view, coal FA Municipal solid waste incineration (MSWI) is a highly
consists of fine, glass-like particles, with dimensions that efficient technique for waste management, because it
fall in the range from 0.01 to 100 microns. The morphology reduces significantly the volume of waste. The main eco-
of coal FA particles is controlled primarily by the com- nomic advantage of this system is that the energy produced
bustion temperature and subsequent cooling rate. The during waste burning is recovered. However, MSWI causes
particles are predominantly spherical in shape. Scanning environmental problems, mainly related to the disposal of
electron microscopy analysis has revealed that coal FA produced FA. There are different types of ash residues that
samples consist of solid spheres, hollow spheres (ceno- result from cleaning emissions from MSW incinerators,
spheres) and irregular unburned carbon. Mineral aggre- and it is important to differentiate between FA and air
gates containing corundum, quartz and magnetite particles pollution control (APC) residues. FA is the finer fraction of
have also been observed (Benezet et al. 2008; Kutchko and the particulate (\200 lm) which is entrained in the flue gas
Kim 2006). and subsequently trapped in an electrostatic precipitator
filter before any further treatment of the gaseous effluents.
Flue gas desulphurisation fly ash FA can be recovered separately from the gas stream, or it
can be incorporated into the APC residues. APC residues
Coal burning can convert sulphur-bearing impurities to are produced from scrubber systems that involve the
gaseous SO2, an atmospheric pollutant and a precursor to injection of an alkaline material (for example lime) to
acid rain. In the past two decades, restrictions on the remove acid gases, particulates and flue gas condensation/
emission of sulphur dioxide from coal-fired power plants reaction products. FAs and APC residues are often con-
have been increasingly stringent. In response to these sidered together, as a unique output from the MSWI plants.
requirements, power plants have had to remove increasing This residue is often called MSWI FA (De Boom and
amounts of SO2 from the flue gases before releasing them Degrez 2012). The mineralogy of MSWI FA is a mixture of
to the atmosphere. This problem has spurred the develop- crystalline and amorphous phases [amorphous can be
ment of various types of scrubbing processes to convert higher than 50 % (Bontempi et al. 2010b)]. MSWI FA is
SO2 from flue gases into solid products for disposal or preferentially composed of sulphate and aluminosilicate
beneficial reuse. Flue gas desulphurisation (FGD) FA is the glass as well as silicate minerals (Enighmy et al. 1995;
by-product generated by air pollution control equipment in Forestier and Libourel 1998; Fermo et al. 1999, 2000), and

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it is also rich in soluble salts (as for example halite and Fly ash from biomass matter burning
sylvite). Toxic elements in MSWI FA are more concen-
trated in glassy phases rather than in crystalline ones Combustion of biomass is a common technique to generate
(Zevenbergen and Comans 1994). heat and power in both small- and large-scale grate fur-
Elemental chemical analysis of MSWI FA is reported in naces (domestic boilers, stoves, district heating plants). In
Table 2. High concentrations of heavy metals (i.e. As, Cd, recent years, pressures on global environment and sus-
Hg, Pb and Zn) (Forestier and Libourel 1998; Sabbas et al. tainability have led to an increasing interest on renewable
2003) are present as a result of volatilisation and following energy sources and diversification of Europe’s energy
condensation as well as due to concentration phenomena supply. Among the available resources, the biomass plays
occurring during combustion. Organic micropollutants may an important role, since it is considered a renewable and
be also present. CO2-neutral energy resource. Nowadays, biomass is ranked
Several studies (Spesier et al. 2000; Sabbas et al. 2003) as fourth after oil, gas and coal, providing approximately
demonstrated that a number of weathering reactions can 14 % of the world’s energy needs (Shen et al. 2009).
promote mineralogical changes in MSWI FA. For example, Moreover, one of the problems associated with biomass
because of natural carbonation, and several other factors combustion is related with the ash production, in the
such as pH, redox potential, temperature and humidity thermal conversion process itself (for example, slagging
conditions, some mineralogical changes can occur over and fouling phenomena) and also its environmental
time. The mineralogical changes in FA by ageing (both management.
hydrated and naturally aged fly ash) may include reactions The quantity and quality of ashes produced in a biomass
as oxidation, carbonation, neutralisation of pH, dissolution, power plant are strongly influenced by the characteristics
precipitation and absorption, towards formation of stable of the biomass source (Mukherjee et al. 2008; Burke 2007).
secondary minerals, such as ettringite, hydrocalumite and a For example, combustion of wood generates low amounts
C–S–H phase. In particular, the natural carbonation pro- of ashes to be managed; on the contrary, herbaceous bio-
duces a change in the mineralogy of FA and formation of mass, agriculture wastes and rice husk have higher ash
new phases that eventually impact FA leaching behaviour content. Agricultural residues are usually mainly composed
(Sabbas et al. 2003). Then, such structural changes may of cellulose, hemicelluloses and lignin. Other components
also be beneficial, leading to significant reductions in trace are extractives, lipids, proteins, simple sugars, starches,
elements for leaching (Meima and Comans 1999). water, hydrocarbons, ash and many more compounds that
contain a variety of functional groups present in the bind-
ing process (Sun 2010). The functional groups present in
biomass molecules include acetamido, carbonyl, phenolic,
Table 2 Ranges of chemical elements in MSWI fly ash (Hjelmar
1996) amido, amino, sulfhydryl carboxyl, ester and hydroxyl
groups (Beveridge and Murray 1980; Gupta and Ali 2000).
Element Fly ash (wt%) Element Fly ash (ppm)
These groups have the affinity for metal complexation. The
Si 9.5–19 Ag 31–95 characteristics of ashes from biomass combustion are
Al 4.9–7.8 As 49–320 influenced by biomass source (for example, herbaceous
Fe 1.8–3.5 Ba 920–1,800 material, wood or rice husk) and combustion technology
Ca 7.4–13 Be nd (for example, fixed bed or fluidised bed) (Obernberger
Mg 1.1–1.9 Cd 250–450 et al. 1997). The ashes from biomass burning are quite
K 2.3–4.7 Co 29–69 different also depending on the type of soil and harvesting
Na 2.2–5.7 Cr 140–530 (ASTM 2005).
Ti 0.75–1.2 Cu 860–1,400 Generally, the main inorganic elements in biomass ash
Si 0.11–0.32 Hg 0.8–7 are Ca, K, Na, Si and P, among which there are some
Cl 4.5–10.1 Mo 15–49 important nutrients (Masia et al. 2007). Moreover, some
P 0.48–0.96 Ni 92–240 biomass fuels have high silicon content (e.g. rice husk),
Mn 0.08–0.17 Pb 7,400–19,000 while some have high alkali metal content (e.g. wood).
Sc 6.1–33
Rice husk ash, in particular, is the main studied ash from
Sn 1,400–1,900
biomass. Rice is one of the major crops grown throughout
the world. Covering 1 % of the earth’s surface, rice is now
Sr \80–250
grown on every continent and is deeply embedded in cul-
V 32–150
tures and rituals. World rice production is approximately
W nd
645 million tons. Asian farmers produce rice about 90 %
Zn 19,000–41,000
of the world production of 100,000 tons or more. Two

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Environ Chem Lett (2014) 12:153–175 157

countries, China and India, grow more than half of the total Table 3 Quantification of ele-
Element Concentration
(Ruangtaweep et al. 2011). For every 4 tons of rice, 1 ton ments found in the FA mixture
(mg/l)
(Bontempi et al. 2010b)
of rice husk is produced. Rice husk is generally employed
S 62
as biomass for energy recovery. Rice husk has a chemical
Cl 309
composition that can differ upon the varieties of paddy
K 94
sown, geographical conditions, soil chemistry, proportion
Ca 1,846
of irrigated area, fertiliser used, climatic variation, timeli-
ness of crop production operations and agronomic practices Ti 21
in the paddy growth process (Chaudhary and Jollands Cr 1
2004; DSIRI 1992; Rao 1980; Patel et al. 1987). Rice Mn 2
husk’s major constituents are cellulose, hemicellulose, Fe 69
lignin and hydrated silica (Chandrasekhar et al. 2005). Cu 9
Silica is the major component of the external part of the Zn 47
rice husk (Mahin 1990; Ismail and Waliuddin 1996). After Br 7
combustion, 15–30 % of rice husk is turned into rice hush Sr 5
ash (RHA) (Mehdinia et al. 2011). RHA is collected by Pb 12
particulate entrapment equipment which is upstream to the
stacks of rice husk-fired boilers (Naiya et al. 2009). RHA
contains 80–95 % of silica and minor amounts of metallic to get complete combustion and minimise their formation.
elements (Chandrasekhar et al. 2005). Chemical composi- The temperature of the combustion reactor should be above
tion and crystallinity of RHA may differ considerably 1000 C, residence times should be greater than 1 s. Tur-
according to the burning technique, depending on the bulence in the chamber should be represented by a Rey-
temperature regime and gasification structures. nolds number greater than 50,000 and feed rate must be
controlled. In the end-of-pipe treatment systems, very rapid
gas cooling from 400 to 250 C should be achieved. Semi-
Fly ash treatments dry lime scrubbing and bag filtration coupled with acti-
vated carbon injection as end-of-pipe treatments can play a
Municipal solid waste incineration FAs are the most role in prevention or minimisation of dioxins content in the
problematic ashes due to the high content of possible final flue gas emitted in the atmosphere (McKay 2002).
dangerous substance. The composition of municipal solid There are two alternative ways of handling FA residues:
waste varies over time and from country to country, due to landfilling after adequate treatment or recycling as a sec-
the differences in lifestyle and waste recycling process ondary material after suitable inertisation. The proposed
seasons. Chemical and physical characteristics of ash inertisation technologies are devoted to heavy metals
depend on the compositions of the raw MSW, the opera- entrapment and organic pollutants abatement.
tional conditions, the type of incinerator and air pollution
control system design. The major common oxides present Heavy metal entrapment
in ash are SiO2, Al2O3, CaO, Fe2O3, Na2O and K2O. CaO
is the most abundant compound that exists in MSWI FA FA treatments devoted to the entrapment/removal of heavy
(Alba et al. 1997). The most abundant elements are Si, Al, metals can be grouped into three classes (IAWG 1997) (see
Fe, Ca, Mg, K, Na and Cl. Cd, Cr, Cu, Hg, Ni, Pb and Zn Fig. 1): (1) separation processes; (2) solidification/stabili-
are the most abundant heavy metals, with Zn and Pb sation (S/S) and (3) thermal methods. Each of them will be
generally found in the largest amounts (see Table 3) considered in the following paragraphs.
(Bontempi et al. 2010b). These metals may cause leaching
problems and are harmful to the environment without Separation processes
proper treatments.
Another problem of FA is the content of organic pol- Separation methods include all techniques that allow the
lutants like dioxins compounds. The international emission extraction of some species from the waste, aiming to
standard limit for dioxins content in flue gas is 0.1 ng improve the quality of the residue for further utilisation
I-TEQ/m3. In order to minimise it, dioxins are removed and/or to recover selected species.
from fine gasses by lime scrubbing and activated carbon
injection (Hinton and Lane 1991; Lee et al. 2008). There Washing The goal is, in general, to remove soluble salts
are many ways of reducing dioxin/furan compounds for- using water as leachant. In this way, chlorides can be
mation during MSW incineration, like the system designed extracted after solution evaporation and salts may be

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158 Environ Chem Lett (2014) 12:153–175

• Washing that of mineral acids and water. Hong et al. (2000) used
Separation • Leaching
processes
• Electrochemical chelating agents to recover Cr, Cu, Pb and Zn.
processes
• Thermal treatment It is clear that the efficiency of extraction depends
• Chemical stabilization greatly upon the heavy metal considered, extracting agent,
• The Ferrox® process
• Phosphate based stabilisation
pH and liquid/solid ratio used.
processes
Heavy • Mechanochemistry Leaching of heavy metals can be also improved through
metals • Acid extraction
bioleaching, i.e. using bacterial leaching processes. Krebs
S/S • Chemical fixation and
entrapment solidification with binders
et al. (2001) made an extraction with more than 80 %
treatments • Cement based processes
• Colloidal silica
• RHA
recovery for Cd, Cu and Zn through bioleaching by Thi-
• Carbonation
• Bitumen encapsulation
obacilli thiooxidans. However, there was a low efficiency
• Vitrification
• Conventional
• Aging
• Geopolymers
for Pb. Bosshard et al. (1996) have shown that the envi-
Thermal • Plasma ronmental quality of the residues, containing heavy metals,
treatments • Melting/Fusion
• Sintering can be improved with respect to reuse through bioleaching
• Microwave
by Aspergillus Niger.
Fig. 1 Classification of the main techniques for heavy metal Due to the mobility of water-leachable compounds, a
entrapment successful removal of metals is expected applying super-
critical fluid extraction with CO2 in which traces of water
and extractants are dissolved. Furthermore, CO2 can be
recovered (Francois and Criado 2007; Chimenos et al. easily recycled (Kersch et al. 2004).
2005; Mulder 1996; Nzihou and Sharrock 2002). Rani et al. Nam et al. (2005) explained the use of electron beam
(2008) explored several washing treatment. In particular irradiation on FA that significantly increased the leaching
for MSWI FA, they showed that it is possible to wash FA potential of heavy metals.
with water or with an acidic water solution. However,
previous studies have reported that washing methods, Electrochemical processes Electrochemical processes are
involving only water, are not very good for salt removal methodologies that involve reduction and oxidation reac-
since large quantities of heavy metals (e.g. Pb and Zn) are tions at the interface of electrode/electrolytes, induced by a
also released simultaneously (Quina et al. 2008). potential difference between the electrodes. During an
electrochemical process in water media, metals may be
Leaching Leaching can be defined as the dissolution of a deposited on the cathode surface and H2 may be generated
soluble constituent from a solid phase into a solvent, and it (due to reduction reaction) and oxygen may be released at
is usually the first important operation step of any FA the anode (through oxidation reaction). The main advan-
treatment process. tage of these methods is that they do not require the
In the literature, many studies reported about the use of addition of other chemicals, but removing metals when the
chemical agents for heavy metal leaching. Sabbas et al. concentration is low may be difficult (Yang and Tsai 1998).
(2003) showed the influence of pH on leaching. This is Variables that significantly affect this process are current
strongly related to the nature of contaminants to be density, temperature, mixing conditions, distance between
removed as well as their mineral phase(s). Three main the electrodes and the pH of the solution. Pedersen (2002)
typical leaching behaviours for solubility-controlled proposed a kind of electrochemical process called elec-
leaching have been identified: (1) cation-forming species trodialytic remediation. It is a remediation technique used
and non-amphoteric metal ions (e.g. Cd) that display fairly for the removal of heavy metals and chlorides from FAs,
constant high values at pH \ 4 and decreases strongly up introduced as a possible new ‘‘extraction’’ method.
to pH 8–9, remaining approximately constant or slightly It was demonstrated that electrodialytic remediation
increasing for higher pH values; (2) amphoteric metals method enhanced heavy metal extractability from MSWI
(including Al, Pb, Zn) increase solubility under both FA compared to more traditional extraction methods. Good
strongly acidic and strongly alkaline conditions and (3) results were observed for removal of Cd, Pb, Zn, Cu and Cr
oxyanion-forming elements (e.g. As, Cr, Mo, V, B, Sb) (Lima et al. 2012; Pedersen 2002; Pedersen et al. 2005).
whose solubility decreases in alkaline ranges (pH [ 10)
(Sabbas et al. 2003). Van der Bruggen et al. (1998) and Thermal treatment This method may be used for the
Katsuura et al. (1996) operated by the acid extraction removal of heavy metals through evaporation at tempera-
processes. Fedje et al. (2010), on the basis of the alkalinity tures lower than melting point, enabling metal recycling of
of FA, investigated some alternative leaching media such the metals. In general, heavy metals of interest are Zn, Pb,
as EDTA, ammonium nitrate, ammonium chloride and a Cu and Cd. Many promising studies have been reported in
number of organic acids, comparing their performance with the literature about the separation of heavy metals by

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Environ Chem Lett (2014) 12:153–175 159

thermal treatment (Auer et al. 1999; Jakob et al. 1995, metals (Pb and Cd) from FA residues (Lundtorp et al.
1996; Stucki and Jakob 1997; Lutz 2002; Zhao et al. 2004). 2002).
Analytical tools were improved to make a better quanti- Phosphate-based stabilisation processes Stabilisation
tative analysis of the evaporated heavy metals during by the addition of phosphates (i.e. phosphoric acid) is one
thermo(-chemical) treatments using TG-ICP (Ludwig et al. of the most promising and intensively investigated tech-
2007). It was also demonstrated that synchrotron-based niques. Insoluble phosphate are many, particularly cal-
X-ray absorption spectroscopy allowed gaining insights in cium phosphates and heavy metal phosphates, such as
the fate of Zn (Struis et al. 2004) and Pb (Struis et al. 2009) copper, lead and zinc phosphate. Since FA is rich in
by studying MSWI FA at room temperature, as a function calcium that is generally present as calcium carbonate,
of the treatment temperature and atmosphere (inert gas or most of the leachable metals are caught during the pre-
air). cipitation of calcium phosphates including traces of
metals. Above all, apatite is one of the most thermody-
Solidification/stabilisation treatments namically stable phosphates. Piantone et al. (2003) pro-
posed an approach for monitoring phosphation of MSWI
Solidification/stabilisation (S/S) treatments are the most FA. Neutrec is an industrialised phosphate-based process
used process for waste incineration residues. The principal developed by Solvay S.A., consisting in scrubbing flue
function of solidification/stabilisation is to produce a gases through a sodium bicarbonate solution, with the aim
material with physical (specific surface area, porosity, etc.), of obtaining a non-hazardous residue and minimising the
mechanical (durability, mechanical strength, etc.) and disposal of FA residues in hazardous landfills. This
chemical properties able to immobilise hazardous species treatment consists of four steps: (1) filtration of the flue
originally present in waste. The S/S processes use reactive gases producing mixtures of soluble and insoluble mineral
formulations, water and other components in sludges and particles; (2) ash washing at basic pH to remove salts; (3)
hazardous wastes, to form stable solids. Additives or phosphation of the solid residues to trap metals and (4)
binders, such as cements or pozzolanic materials, are used drying and calcination of the solid phosphate residues to
to immobilise hazardous components present in waste. The destroy organic compounds.
S/S procedure usually consists in mixing wastes with water Rani et al. (2008) reported about the VKI process,
and binders and sometimes with chemical additives such as developed by a consortium of Danish companies and
sodium silicate, soluble phosphates and carbonates. Even if explained by Hjelmar et al. (Hjelmar and Birch 1997;
S/S treatments are the most used methods, they are not Hjelmar et al. 1999; Hjelmar and Hansen 2006). This
completely efficient for the treatment of soluble salts. process improves the leaching characteristics of FA resi-
dues. It involves the removal of soluble salts by aqueous
Chemical stabilisation Chemical stabilisation processes extraction, chemical stabilisation of the washed product
basically involve chemical precipitation of heavy metal- with carbon dioxide (CO2) or phosphoric acid (H3PO4),
incorporating insoluble compounds and/or heavy metal washing and a final dehydratation. pH buffering capacities
substitution/adsorption into various mineral species. The of both carbon dioxide and phosphoric acid are very
principal forms of chemical agents used include sulphides important. Indeed, this mechanism reduces the residues pH
(IAWG 1997; Katsuura et al. 1996), soluble phosphates without removing totally the alkalinity which protects
(Derie 1996; Enighmy et al. 1995; Hjelmar et al. 1999; against future acidification. Wastewaters coming from this
Nzihou and Sharrock 2002), ferrous iron sulphate (Lund- process must be following treated, to reduce the content of
torp et al. 1999) and carbonates (Hjelmar et al. 1999). trace elements and heavy metals before being discharged.
The Ferrox process The Ferrox process was devel- In many aspects, VKI process is similar to Ferrox sta-
oped in Denmark as an on-site treatment for FA residues bilisation process with the exception of the nature of used
prior to landfill disposal (Lundtorp et al. 2002; Jensen et al. reagents.
2002). This process consists in mixing three major reagents Eichmy et al. (1997) developed the WES-PHix pro-
that are ferrous sulphate solution, recycled water and FA cess. It consists in FA stabilisation by means of 1.2 mol of
residues. The oxidation of ferrous iron takes place followed phosphoric acid/kg of residue and water at an L/S ratio of
by pH adjustment with either additional FeSO4 or H2SO4, 0.4. They found that the treatment of MSWI FA with
and finally, in a plate-and-frame filter press, the treated phosphate reduced the fraction of leachable divalent heavy
residue is dehydrated. The precipitated ferrohydroxide is metals, by 38 % for Cd, 58 % for Cu, 99 % for Pb and 28 %
oxidised by air ferrihydrite, and the suspension is then for Zn. Stabilisation occurs due to precipitation of metal
separated into treated residue and wastewater. It was phosphates rather than due to adsorption of metals onto
reported that this process is able to leach out large amounts phosphates. This process needs less water than Ferrox and
of salts (Cl, Na, K and Ca) but low concentrations of trace VKI for phosphate stabilisation and retains salts in the

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160 Environ Chem Lett (2014) 12:153–175

treated product. Therefore, salt leaching is expected to be (Landreth 1986). Shi and Kan (2009) showed that MSWI
higher than for other processes. FA was mainly composed of silica, calcium, alumina oxide
Mechanochemistry Mechanochemistry is based on the and iron oxide, which were quite similar to those of com-
transformation of substances caused by mechanical energy. plementary cementitious materials commonly used, such as
Nomura et al. (2006) showed that mechanochemical granulated blast furnace slag and coal FA. Moreover,
treatment and cementation completely inhibits Pb elution cement is the most frequently used and widely studied
from FA. A possible mechanism may be that Pb-containing binder. Solidification with cement is widely understood,
compounds are transformed into different species forms simple, easily available and results in a stable product (Roy
and stabilised during hydration. et al. 1991).
Lately, Nomura et al. (2008) used lead oxide (PbO), a Colloidal silica Bontempi et al. (2010a) have recently
typical Pb compound in FA, as a model substance to proposed a new method for MSWI FA inertisation mainly
explore Pb immobilisation in mechanochemical treatment based on the use of colloidal silica as metal stabiliser. FA
of FA. They showed that Pb leaching is inhibited at 93 %. from MSWI, flue gas desulphurisation (FGD) and coal FA
Mechanochemical process does not need heating and pro- were used in the process together with aqueous colloidal
duces insignificant gas emissions. Large plants with dispersions of SiO2 particles with high specific surface
sophisticated facilities are not needed, and simple closed- area. Experiments showed that metal leaching decreased
system designs more likely to be accepted by local resi- after this treatment. In particular, Zn and Pb contribution is
dents, may be adopted. For these reasons, immobilisation highly decreased in the treated materials with respect to the
of heavy metals in FA by mechanochemical treatment may MSWI FA. Table 4 shows the elemental content of
be a practical pretreatment technique for the recycling of leaching solutions of the different components used in the
FA in cement (Guo et al. 2010). proposed treatment. Results show that the procedure is
Acid extraction Acid extraction followed by sulphide effective in the inertisation of FA not only for Pb, but also
stabilisation (AES) has been used for treating incinerator for V, As and Se.
residues. In the AES process, FA is extracted by acid Moreover, high content of chlorine and bromine is
solution and then stabilised by NaHS to transform residual present (see Table 4) and their salts can be recovered by
heavy metals into insoluble heavy metal sulphides. FA is washing before obtaining the final material designated as
then discharged as stabilised cake for final landfill disposal, colloidal silica medium to obtain safe inert (COSMOS) by
and solid salt residue is recycled for soda production. Bontempi et al. (2010a). The structural characterisation of
Condensed water is also recycled and used for cooling; the FA and COSMOS by means of XRD shows that FA con-
plant does not discharge wastewater. In a recent research, tains a significant amount of portlandite that is not found
article Xue et al. (2010) showed that hydrochloric acid was with the COSMOS sample. Indeed, COSMOS shows the
an effective extractant. presence of a small number of crystalline phases, with
*25 % calcium carbonates as the main phase, together
Chemical fixation and solidification with binders Treat- with calcium sulphate, and silicon oxide. About *65 % of
ments with hydraulic or chemical binders generally yield the COSMOS material is amorphous, suggesting that only
good leaching properties at relatively low costs (Sabbas a small amount of silica crystallised. This may be because
et al. 2003). The aim is to incorporate the waste with the inertisation process is performed at room temperature.
binders and produce a monolithic solid with structural Considering that calcite is the predominant new phase
integrity and long-term stability. Solidification inhibits present in COSMOS with respect to FA, it may propose a
leaching by reducing waste/leachant contact and by form- carbonation reaction similar to that of portlandite with CO2
ing a stable pH environment in which many heavy metals [see reaction (1)]. According to a similar reaction [see
remain insoluble. reaction (2)], also the compound CaClOH may disappear
Cement-based processes S/S in cement-based materials due to carbonation. Moreover, it may also be supposed that
is the most frequently applied approach to minimise the carbonation may increase in the efficiency of inertisation
environmental impact of hazardous wastes, which provides by reducing metal mobility.
also the possibility of the final material reuse. This tech-
nology involves mixing FA with cement to form a solidi- Ca(OH)2 þ CO2 ! CaCO3 þ H2 O ð1Þ
fied monolithic material after hydration. Leaching of
CaClOH þ CO2 ! CaCl2 þ H2 O ð2Þ
hazardous components would become difficult under the
disposal conditions, thereby reducing the dangerousness of Bontempi et al. (2010a) concluded that MSWI FA could
the final material. American State Bureau of Environmental be considered a valuable resource for industrial applica-
Protection refers to cement immobilisation as the best tions and may represent an interesting alternative to other
technology to dispose poisonous and harmful wastes inert materials for building applications.

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Environ Chem Lett (2014) 12:153–175 161

Table 4 Results of the TXRF quantitative analysis performed with the leaching solution of MSWI FA, FGD FA, coal FA and the corresponding
inertised mixture before washing (Bontempi et al. 2010b)
Element MSWI fly ash (mg/l) FGD fly ash (mg/l) Coal fly ash (mg/l) Inertised mixture (mg/l)

P n.d. n.d. 0.3 ± 0.1 n.d.


S n.d. 1.1 ± 0.9 67 ± 6 98 ± 9
Cl 2,477 ± 234 980 ± 93 n.d. 3,522 ± 288
K 433 ± 46 6.6 ± 0.8 6.6 ± 0.6 479 ± 41
Ca 1,850 ± 171 794 ± 97 173 ± 14 2,318 ± 177
V n.d. n.d. 0.29 ± 0.02 n.d.
Cr n.d. n.d. 0.031 ± 0.004 n.d.
Fe 0.18 ± 0.08 n.d. 0.03 ± 0.01 1.1 ± 0.4
Zn 3.7 ± 0.3 0.03 ± 0.01 0.013 ± 0.002 1.6 ± 0.1
As n.d. n.d. 0.048 ± 0.004 n.d.
Se n.d. n.d. 0.96 ± 0.07 n.d.
Br 33 ± 2.8 4.4 ± 1 0.012 ± 0.001 71 ± 6
Rb n.d. n.d. 0.012 ± 0.002 n.d.
Sr n.d. 1.8 ± 0.1 2.4 ± 0.19 n.d.
Ba n.d. n.d. 0.19 ± 0.02 n.d.
W n.d. n.d. 0.053 ± 0.005 n.d.
Pb 13 ± 1 n.d. n.d. n.d.
n.d. Not detected

et al. 2013), mixed with MSWI FA, flue gas desulfurisation


residues (FGD) and coal FA.
As shown in Fig. 2, extracted silica contains also
sodium sulphate that is a product of the extraction process,
due to the employment of NaOH and H2SO4. Removal of
sodium sulphate is generally made in the literature using
distiled water, followed by vacuum filtration (Foletto and
Gratieri 2006). In case of COSMOS–RICE, sodium
removal is not necessary since the technology involves a
washing of the obtained material after metal stabilisation,
to remove soluble salts.
Metal concentrations in the leaching solutions decrease
exponentially as a function of silica content from RHA,
used in the inertisation procedure (Fig. 3). The point at
Fig. 2 XRD patterns of RHA and extracted silica zero abscissa corresponds to metal concentration in raw
MSWI FA leaching solution. These results show that heavy
RHA An evolution of COSMOS technology was very metal entrapment is directly related to the content of the
recently proposed: COSMOS–RICE where naturally silica employed to produce COSMOS–RICE.
occurring silicas, especially those found in agrowaste, Carbonation Emissions of CO2 from MSWI plants are a
provided an alternative source to commercial silica pre- significant source of greenhouse gas, so their production
cursors (Bosio et al. 2013). As previously reported, glob- must be controlled. Carbonation is an important step in the
ally, approximately 600 million tonnes of rice are produced weathering process that may change the mineralogical
each year. For every 1,000 kg of paddy milled, about characteristics of FA, and it may have some positive effects,
220 kg (22 %) of rice husk (RH) is produced. RHA con- such as decreasing heavy metal leaching. Carbonation
tains more than 90 % silica. Under controlled burning involves the dissolution of CO2 in water, with following pH
conditions, RH gives amorphous silica, which is highly decrease. Calcite precipitates, as the predominant mineral
reactive due to its ultra-fine size and high surface area. formed during FA maturation, until CO2 equilibrium is
Amorphous silica can be easily extracted from RHA, to be reached. Moreover, heavy metals can be entrapped in the
employed in the proposed inertisation procedure (Bosio newly formed minerals. The source of CO2 is the

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162 Environ Chem Lett (2014) 12:153–175

chemical activator, as for example aqueous alkali (Na, K or


Li) hydroxide. Geopolymers are formed at room or low
(40–90 C) temperatures (Duxson et al. 2005).The mecha-
nism of the geosynthetic reaction may be described by the
reaction steps shown in (3) and (4) (Davidovits 1994):

NaOH;KOH
ðSi2 O5 ; Al2 O2 Þn þ nH2 O ! n(OH)3  SiOAl
 ðOHÞ3 ð3Þ
NaOH;KOH
n(OH)3  SiOAl  ðOHÞ3 ! fNa; Kg  ðSiOO
Al OÞn  3nH2 O
ð4Þ
This technology has received increasing attention,
Fig. 3 Concentrations of metals in leaching solutions of COSMOS–
RICE obtained using different content of RHA. The point at zero because of its low cost, flexibility, low processing temper-
abscissa corresponds to concentration of metals in the MSWI fly ash ature and capability to immobilise and stabilise hazardous
leaching solution wastes. Geopolymers have a function similar to cement
binders in terms of metal encapsulation (Lancellotti et al.
atmosphere. However, natural carbonation can be acceler- 2010). The approach is the same as for S/S of hazardous
ated using other sources of CO2 and different methods. wastes by pozzolan-based binders, which also does not
Waste containing heavy metals has higher susceptibility remove heavy metals from the polluted waste, but binds
towards carbonation. Metal fixation may be also improved them physically and chemically in the solid matrix in order
incorporating waste species into a carbonate phase by a to reduce their mobility. Depending on the source material
mechanism involving solid solution reactions with calcite and the process conditions, geopolymers may improve
(Malviya and Chaudhary 2006). Li et al. (2007) proposed an chemical and physical properties, such as acid attack resis-
accelerated carbonation treatment for MSWI FA treatment. tance, fire resistance, structural integrity, low permeability,
Although Li et al. (2007) measured a decrease in ion levels high compressive strength and durability, low shrinkage,
with leachates due to carbonation, the decreased mobility of fast or slow setting, and low thermal conductivity.
chlorides was still higher than the acceptance value. Ecke
(2003) showed that carbonation of MSWI FA may reduce Pb
and Zn leachability of two orders of magnitude. However, it Thermal treatments
was reported that Cd leaching may increase one order of
magnitude, and in the case of cement, the leaching of metals Thermal treatments of FA are used extensively in some
as Cr, Ni and Sb may increase because of carbonation in the countries to reduce leaching from residues, reduce their
long term. volume and obtain a final material suitable for reuse. Ther-
Bitumen encapsulation A waste encapsulation process mal treatment techniques include vitrification, melting, sin-
using bitumen was developed in France in the 1960s for tering and the use of microwave. In most of the cases, thermal
radioactive waste disposal. Benefits of this encapsulation treatments create a more homogeneous, denser product with
process are due to its simplicity together with chemical improved leaching properties. Vitrification allows the
inertness, water impermeability and resistance to breaking. physical encapsulation of contaminants in the glass matrix,
Based on the asphalt manufacturing process (Rani et al. especially the mobilisation of volatile elements, such as Hg,
2008), a stabilisation technique for the treatment of FA Pb and Zn. A major drawback of these methods, however, is
residues was developed by Shell Bitumen in the early 1990s. that they require high amounts of energy (Sabbas et al. 2003).
The resultant material was put into steel beats or transferred
directly to a storage site for waste. Hard-grade bitumen was Vitrification Vitrification is a process where residues are
employed to guarantee that the stabilised waste preserved its mixed with glass precursor and then combined at high
structural integrity for a long time (Rani et al. 2008). temperatures into a single-phase amorphous, glassy prod-
uct. Typical vitrification temperatures are 1,000–1,500 C
Geopolymer Geopolymerisation technology has been and then the material is cooled to form a single solid phase
proposed to stabilise and solidify FA. Unlike glass, geo- (amorphous and homogeneous). The waste material is
polymers are obtained by the reaction between a solid melted with additives (glass precursors) in order to fix the
aluminosilicate, where Ca is absent or contained in low contaminants in the final matrix (alumino-silicates).
amount, and a highly concentrated alkaline solution, as the Retention mechanisms are chemical bonding of inorganic

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Environ Chem Lett (2014) 12:153–175 163

species in the residues with glass-forming materials, such While subgroups of B are as follows:
as silica, and encapsulation of residue constituents by a
• electric arc melting furnaces;
layer of glassy material (Sabbas et al. 2003). This tech-
• electric resistance melting furnaces;
nique has the advantage of stabilising hazardous waste,
• plasma melting furnaces; and
reducing the amount of waste to be landfilled and pro-
• induction melting furnace (high frequency, low frequency).
ducing potentially reusable materials. After vitrification,
there is a significant decomposition rate (99.95 %) of It is not possible to highlight the best technique. Indeed,
PCDD/Fs, considered as toxic equivalent (TEQ), in the the most appropriate one should be chosen according to the
produced slag. In fact, thermal methods are very efficient to specific conditions (Sakai and Hiraoka 2000). Sakai and
destroy dioxins, furans and other toxic organic compounds Hiraoka (2000) utilised melting technology for FA. They
(Bernardo et al. 2010; Ferreira et al. 2003; Izumikawa observed that inorganic elements were reorganised after
1996; Park and Heo 2002; Sabbas et al. 2003). There are melting treatment according to their boiling temperature. In
different technologies for heat supplying in vitrification particular, Si, Al, Ca, Fe, Mg, Mn, P, Cr and Sn, which have
such as the conventional electric furnaces and plasma arc high boiling points, were converted into slag, while elements
technology. such as Cd and Pb, which have a low boiling point, were
found in exhaust gases. Jung et al. (2005) concluded that the
Plasma Plasma arc treatment is a high-energy technology treatment performance depended on the volatility of metals
able to treat a range of scheduled wastes. In plasma arc present in FA. Nowak et al. (2012) tested different amounts
treatment, a thermal plasma field is created by directing an and types of chlorides (NaCl, MgCl2, CaCl2) on heavy metal
electric current through a low-pressure gas stream. The removal from MSWI FA by thermal treatments. Nowak
plasma system consists of a direct current (DC) hollow et al. (2012) concluded that MgCl2 may be the best reactant
graphite cathode installed through the top of a furnace and for the process due to high heavy metal removals, especially
supported by a vertical manipulator column. An inert gas, Zn, and low remaining chloride content, which is also nec-
in particular argon, is introduced down the centre of the essary for further use of the treated ash.
cathode to generate a stable plasma arc that is transferred to
the furnace melt. The process is able to manage different Sintering Sintering is an alternative method to recycle
particle size and chemical composition ashes. The furnace FA, and it is a viable method to produce glasses and glass–
operates under controlled reducing conditions and runs ceramics from incinerator residues. Sintering involves
approximately at temperatures between 1,500–1,600 C heating the residues to a point where particles bonding take
(Sakai and Hiraoka 2000; Rani et al. 2008). Sakai and place and chemical phases in the residues reorganise. A
Hiraoka (2000) demonstrated the recovery of Pb and Zn denser product with less porosity and a higher strength is
during the vitrification of FA. Also Mugica et al. (1995) obtained. Temperatures involved in this process are usually
analysed the vitrification process with plasma, and they in the range of 900–1,000 C. When MSW is incinerated, a
explained that this technology was adequate for FA from few sintering occur in the furnace (Sabbas et al. 2003). The
electrostatic precipitator filter. resulting material usually has lower metal leachability.
Some authors have used water washing as a pretreat-
ment to lower sintering temperatures (Mangialardi 2001).
Melting (or fusion) Melting is similar to vitrifying, but
Wey et al. (2006) investigated the sintering behaviour of
this process does not include the addition of glass materi-
FA with a rotary kiln and looked for a solution to reduce
als. The glass formed may not be homogeneous but a
heavy metal concentrations at acceptable levels by con-
multiple-phased product. It is possible to separate specific
sidering also heavy metal partitions in the process. Wang
metal phases from the melted product and recycle these
et al. (1998) studied the sintering process at different
metals after refinement. Process temperatures are similar to
conditions of pressure, temperature and time.
those used in vitrification (Sabbas et al. 2003).
Melting processes are divided into two technology
Microwave Microwave energy is a non-ionising electro-
groups: A—fuel-burning melting system and B—electric
magnetic radiation with frequencies in the range of
melting system; each one is subdivided into 5 subgroups.
300 MHz–300 GHz. The use of microwave heating in FA
Subgroups of A are as follows:
treatment is relatively new even if this technique was
• surface melting furnaces; developed over 50 years ago. Compared with other con-
• swirling-flow melting furnaces; ventional thermal treatment technologies, the microwave
• coke-bed melting furnaces; technique offers the advantage of selective, uniform and
• rotary kiln melting furnaces; and rapid heating, because of its characteristics of polar oscil-
• internal melting furnaces. lation and effect of dielectric losses.

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164 Environ Chem Lett (2014) 12:153–175

Rawlings et al. (2006) and Fukui et al. (2006) immo- Hydrothermal


Chemical
bilised coal FA into a glass–ceramic material by micro- reactions treatment

wave processing in a much shorter time, and they


Supercritical
compared the physical and mechanical properties to those Thermal • Vitrification water oxidation
treatment • Melting (SCWO)
obtained by conventional heating. Organics
In a second work, Fukui et al. (2007) compared the pollutants
Mechanochemistry
hydrothermal treatment with microwave heating and abatement Solidification/Stabilization
UV irradiation
conventional heating of coal FA with an aqueous solution (photolytic)
of NaOH and a mixture of rice husk ash, as the silica Non-thermal
plasma process
Biological
source at 100 C. They explained that the microwave removal

heating shortened the reaction time with respect to con-


ventional electric heater and that the added RHA changed Fig. 4 Classification of several techniques for organic pollutant
the crystalline phase of the obtained zeolite. Indeed, they abatement
found that the particle size of phillipsite obtained by
microwave was smaller than that obtained by conven- vitrification is one of the most satisfactory technology to
tional process. Chou et al. (2009) studied the sintering of treat organic pollutant contents in FA. Until now, various
MSWI FA by microwave heating. They investigated the types of melting furnaces have been developed over the last
effects of process time, ageing time, material and salt decade with good percentage conversion (Wang et al.
contents. They observed that MSWI FA could be sintered 2009; Kulkarni et al. 2008; Kuo et al. 2003).
under microwave processing to form a glass–ceramic Non-toxic materials can be obtained through melting
material. This process was able to immobilise heavy processes of FA, and slags obtained maybe used as a
metals. They also made ageing tests during 0–30 days and resource, since PCDD/PCDF compounds are decomposed
concluded that ageing did not increase the leaching of at the typical melting operating temperatures (Nishida
heavy metals, but increased the weights of the materials et al. 2001). Non-thermal plasma is a process more
obtained by sintering of MSWI FA by 40–60 % of water economical than those previously reported in principal
absorption from air. because of its lower maintenance costs (Zhou et al.
2003).
Organic pollutants abatement Another promising method for degradation of dioxins is
the photocatalytic reaction on semiconductor films, such as
Besides a high content of inorganic compounds, incinera- TiO2, ZnO, CdS and Fe2O3, under ultraviolet (UV) or solar
tion residues also contain abundant carbon-based com- light. This reaction takes place at room temperature and
pounds resulting from incomplete combustion of organic ambient pressure with low-energy photons. TiO2 has been
matter. Ashes often contain persistent hazardous organic used predominantly as the photocatalyst (Kim et al. 2006;
pollutants (POP), such as polycyclic aromatic hydrocar- Choi et al. 2000).
bons (PAH), polychlorinated biphenyl’s (PCB), methyl Catalytic dechlorination on noble metal and transition
sulphates, polychlorinated dibenzo dioxins (PCDD) and metal catalysts is a simple and efficient method. In recent
furans (PCDF). years, it has been developed including hydrogenation by
Polychlorinated dibenzo dioxins and PCDFs are syn- means of hydrogen donor species, such as metal hydrides,
thesised in MSWI after combustion by reactions between formic acid and its salts, and alcohols with water or
the resulting FA and flue gas at low temperature methanol as solvents (Hagenmaier et al. 1991; Zhijun et al.
(350–250 C). FA produced in well-controlled combustion 2007). They showed good dechlorination efficiencies in
of coal has been found to contain lower levels of PCDD water, especially for octa- and hepta-chlorinated congen-
dioxins and PCDF, together with low amounts of PAH. On ers. Regarding costs and safety of reagents, they concluded
the contrary, wood combustion may produce ashes with that this decomposition method was one of the most
higher amounts of PAH, PCDD and PCDF. environmentally and economically promising detoxifica-
Several different kinds of organic pollutant abatement tion methods for dioxins.
methods have been studied over the past three decades. The literature reports some works about the elimination
Although thermal treatment has produced the best results, of PCDDs and PCDFs under hydrothermal conditions. A
other approaches for degrading organochlorinated com- hydrothermal treatment is a physicochemical process based
pounds have been developed as well (Fig. 4). on temperature, relative humidity and time. Water and
Thermal technologies can be used for FA treatment to other solutions, such as NaOH (Ma and Brown 1997;
decompose dioxins under suitable conditions and may Yamaguchi et al. 1996), are mixed in a reactor at high
produce recyclable, fused-slag by-products. Thermal temperatures and pressures.

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Environ Chem Lett (2014) 12:153–175 165

Supercritical water oxidation is another way for an

Strenght Material
Controlled Low
effective removal of dioxins based on supercritical water
(Sako et al. 1997) and other oxidising agents such as pure
oxygen gas and hydrogen peroxide.
Mechanochemical treatments by planetary ball mill may
be another effective way of dioxin degradation directly in
Pozzolanic Nature
bare FA (Nomura et al. 2006) or FA mixed with other

Abundant Reserves
reactants such as CaO (Yan et al. 2007) and hybrid

Size Range
compound.
Bioremediation is an alternative waste management Fly Ash
Resourse
method that overcomes some disadvantages or other
existing methods. It is economical and has minimal impact
on the environment. Moreover, it is one of the most
Chemical Composition
important fields in environmental microbiology and bio-
technology. Several microbial species were found able to

Source of Silica,
Alumina, Iron
catabolise dibenzo-p-dioxin (PCDD) and dibenzofuran
(PCDF), and their congeners, which allow the removal
dioxin from FA (Nam et al. 2005).

Fly ash recycling Fig. 5 Possible uses of FA based on its properties (Wang and Wu
2006)

Most of the produced FA are not reused but landfilled.


However, this practice has recently become less attractive production. The adsorption performance of FA can be
because of environmental concerns. further improved by carbon activation (Ahmaruzzaman
The most reused FA is coal FA, about 39 % in the USA 2010).
and 47 % in Europe (ECOBA 2008; ACAA 2010). MSWI Sometimes, the unburned carbon may be also separated
FA are partially recovered in a few cases, but, in general, from FA to obtain a residue with above 50 % of carbon
they are still landfilled. In some cases, MSWI FA residues content, such as in the case of RHA (An et al. 2011).
are placed in salt mines where they are used as backfill. It is reported that the use of FA, alone or mixed with
The possible employment of MSWI FA is limited to some other reagents, for absorption of NOx and SOx was effec-
applications, as for example geopolymers (Galiano et al. tive (Rubel et al. 2005; Rubio et al. 2007; Davini 2002).
2011) or inert materials (Zacco et al. 2012), after the sta- It has also been observed that some coal FA can capture
bilisation of leachable metals. mercury. Although the role of inorganic components of FA
Disposal of FA may soon be too expensive due to in this capture remains unclear, several studies showed that
stricter legislative requirements. For this reason, consider- unburned carbon from FA shows certain capabilities of
able research had been conducted worldwide on the reuse adsorbing elemental mercury (López-Antón et al. 2007;
of FA materials. Figure 5 shows several possible uses of Suárez-Ruiz et al. 2007; Suárez-Ruiz and Parra 2007).
FA based on its properties (Wang and Wu 2006). Fly ash is also able to absorb organic gaseous com-
pounds such as toluene, other aromatic hydrocarbon and m-
Adsorbent xylene (Peloso et al. 1983; Rotenberg et al. 1991).
Fly ash has also a good absorption capacity towards
Thanks to its good adsorption capacities, activated carbon heavy metals. Among the investigated metals, Pb, As, Cu,
produced by carbonising organic materials is the most Cd, Ni, Cr and Hg are the most often studied. Coal FA was
widely used adsorbent (Gaikwad 2004). However, the high found to be good adsorbent for the removal of Pb, Zn
cost of the activation process limits its employment. Due to (Prabhu et al. 1981), and Cd (Gashi et al. 1988), from
their good adsorbent properties, FA (and in particular those effluents of battery and fertiliser industries. Removal effi-
from coal and rice husk) may be used as precursor for ciencies were greater than 70 %. Coal FA was also tested
activated carbons (Maroto-Valer et al. 1999). for removal of As (V) (Diamadopoulos et al. 1993), Cu
Unburned carbon content in coal FA is usually in the (Panday et al. 1985; Gashi et al. 1988) and Hg (Kapoor and
range of 2–12 %. However, it is increasing significantly Viraraghavan 1992) from aqueous solution. To improve
(up to 20 %) due to the low oxygen content and lower removal efficiencies and adsorption capacities, chemical
combustion temperature required to reduce NOx modifications of FA can be also done (Zhu et al. 2012).

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166 Environ Chem Lett (2014) 12:153–175

Apak et al. (1996) reported that coal FA is a good adsor- toxic organic compounds can also be associated with FA
bent also for radionuclides of 137Cs and 90Sr. particles including mutagens and carcinogen substances.
Several studies are focused on the use of FA for water However, many applications for the use of FA, mainly coal
depuration, principally from heavy metals. Coal FA and FA, in agriculture and soil remediation had been proposed
RHA are mainly employed for this application due to their and studied in the past decades.
higher absorption capacity. Fly ash is an alkaline waste material with high adsorp-
Fly ash emerges as a potential candidate to treat phos- tion capacity and high surface area available for element
phate-laden effluents and fluoride from water (Chaturvedi adsorption, which may render cationic metals less mobile
et al. 1990), thanks to its composition that is rich in silica, (Ciccu et al. 2003). For this reason, coal FA was used for
aluminium, iron and calcium oxides. The addition of coal metal-contaminated soil stabilisation. To solve problems
FA to wastewater with phosphate was found to produce related to metal solubility and acid mine drainage, Iyer and
insoluble or low-solubility salts, as for example calcium Scott (2001) and Xenidis et al. (2002) suggested the use of
phosphate (Cheung and Venkitachalam 2000). coal FA. According to the literature, FA used for metal
Only a few studies were reported on boron adsorption immobilisation represents an effective, eco-friendly man-
using coal FA (Hollis et al. 1988). agement option for remediation of metal-contaminated
In a recent study, rice husk was chosen as carbon source soils also compared to phytoextraction (Denuex-mustin
and settling for microorganisms devoted to the reduction of et al. 2003).
nitrogen compounds (Shao et al. 2009). It was shown that it Many studies are dedicated to the impact of coal FA on
is safe to use rice husk as substrate in wastewater denitri- soil properties (cf. Tejasvi and Kumar 2012), showing that
fication when compared with traditional liquid carbon FA may be also rich in many macro- and micronutrients for
sources, and a rapid increase in nitrate removal efficiency plants. So, FA can be considered a potential resource also
was found. for improving the characteristics of damaged soils (cf.
It was proved that coal FA has a good potential also for Pandey and Singh 2010). Recently, pot culture experiments
phenolic compound adsorption (Singh and Nayak 2004; were conducted to verify the effect of coal FA for soil
Mahvi et al. 2004). Rice husk ash was even more effective amendment to improve the fertility of soil, leading to
than rice husk for phenol removal. higher productivity of the test crop. Forty percentage of FA
The potential of coal FA for removal of dyes from was found suitable for growth and yield of test crop (Te-
wastewater was proved (Mohan et al. 2002; Janos et al. jasvi and Kumar 2012).
2003). Coal FA has also been employed for its potential for There are only few works about the effects of coal FA
use as a photocatalyst for the removal of dyes from water amendment on soil biological properties. Many short-term
under visible light (Bayat 2002; Chandrasekhar and Pra- laboratory incubation studies showed that the addition of
mada 2006). FA to soils can inhibit microbial respiration, numbers, size,
Despite the great potential in the absorption applications enzyme activity and soil nitrogen cycling processes, such
of FA, the effectiveness of adsorption process depends on as nitrification and nitrogen mineralisation (Cerevelli et al.
conditions and variables used in the process, such as tem- 1986; Pichtel and Hayes 1990; Garau et al. 1991).
perature, pH, ionic strength, existence of competing Other studies suggest that coal FA can find better
organic or inorganic compounds in solution, initial adsor- application in agriculture or improvement of degraded soils
bent concentration, contact time and others. Finally, there when combined with organic amendments, such as cow
is lack of data concerning the reproducibility of the manure, farmyard manure, sewage sludge, press mud,
adsorption properties and the equilibrium conditions. paper factory sludge, crop residues or organic compost
(Kumpiene et al. 2007; Sajwan et al. 2003; Shen et al.
Use in agriculture 2008). The toxicity of heavy metals from FA, such as Pb,
Ni, Cr, Zn, Cu and Cd, were reduced with the increase in
The use of FA in agriculture is limited mainly by the fact organic matter content in the FA dump by building com-
that they contain potentially toxic elements, such as Cd, Pb, plexes with the heavy metals (Juwarkar and Jambhulkar
Ni, As, Cu, Zn, Cr, Se and others, (Rautaray et al. 2003; 2008).
Lee et al. 2006; Tiwari et al. 2008; Adriano et al. 2002), Another possible use of coal FA in agriculture is like
which may contaminate soil and also groundwater after substrates for ornamental plant production (Chen and Li
percolation (Pandey and Singh 2010). FA may also contain 2006; Jayasinghe et al. 2009, 2010). Since these orna-
radioactive elements like 238U, 232Th, 40K, 226Ra, 210Pb, mental plants are grown only for aesthetic purposes, the
228
Ra, 222Ru and 220Ru (Mandal and Sengupta 2003; Pa- accumulation of toxic elements is generally not so relevant.
pastefanou 2008) and other radionuclides, such as uranium Several studies have revealed that coal FA can be used
(U) and thorium (Th). Moreover, a complex mixture of as insecticide in agricultural areas against a range of

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Environ Chem Lett (2014) 12:153–175 167

lepidopterous and coleopterous pests infesting rice, vege- 2010). To reduce CO2 emissions and improve cement
tables, greens and certain other field crops (Narayanasamy quality, reactive amorphous silica is often used as additive
and Gnanakumar 1989; Basu et al. 2009; Sankari and in modern cement production reducing also clinker con-
Narayanasamy 2007). sumption. Successful examples include silica fume pro-
In conclusion, the potential of coal FA as a resource duced by silicone industry. Reactive silica can also be
material in agriculture is now well established. However, produced from combustion of organic residues, and in this
the recommendation for a large FA application to agri- case, it is called biosilica. Plant by-products, as for
cultural soils cannot be made, unless extensive trials are example rice husk ash, can produce biosilica. If it is
done to establish a proper combination of FA with each blended with Portland cement, the final product is called
type of soil to find its quality and safety. biocement. The use of biocement has shown environ-
mental, economic and technical benefits (Hosseini et al.
Building materials 2011).
Biocement with interesting properties can also be made
Thanks to the presence of cementitious substances like with ash coming from biomass burning. The demand of
calcium compounds and reactive glass, coal FA is suitable renewable energy sources has increased the use of biomass
to be used in Portland cement. Indeed, the partial in the production of heat and electricity and the production
replacement of cement with FA had been studied exten- of relative FAs. FAs from biomass have a main inorganic
sively in the last decade, because of economical and fraction and a minor organic fraction (i.e. unburned car-
environmental reasons. bon). A variety of plant residues contains Si to generate
There are essentially three applications for coal FA in enough amorphous biosilica for biocement production
cement: (1) replacement of cement in Portland cement (Girón et al. 2013).
concrete; (2) use as pozzolanic material in the production Despite promising results, only few works have been
of pozzolanic cements and (3) use as retardant ingredient devoted to biocement production and additional experi-
with cement and replacement of gypsum (CaSO42H2O). ments are still necessary to set up its use. Combustion of
The first use in Portland cement concrete is mainly due other alternative fuels may also have effects on resulting
to beneficial effects, such as lower water demand for FA (Hosseini et al. 2011).
similar workability, reduced bleeding and lower evolution Fly ash containing heavy metals, like MSWI FA, can be
of heat. The second use is mainly due to the economical incorporated into cementitious mixtures to reduce heavy
advantage of cement replacing by FA in pozzolana. FA metal leachability from solidified products and without the
addition reduces the cost of construction and increases its risks of unacceptable delay of cement setting.
durability. Indeed, FA concrete provides much strong and
stable protective cover to the steel against natural weath- Synthesis of zeolite
ering action. FA can also improve the concrete workability
without compromising strength. For this reason, it was Zeolites are crystalline aluminosilicates. As a consequence
employed in fibre-reinforced concrete that is characterised of their structural properties, zeolites have a wide range of
by low workability. Chemical activation was demonstrated industrial applications (Breck 1984) mainly based on ion
to be a method to increase the use of FA in concrete. High- exchange, gas and water adsorption.
volume FA concrete has emerged as a construction mate- Zeolites exist as natural minerals, due to alkaline acti-
rial in its own right. This concrete can contain more than vation of glassy volcanic rocks, or they can be synthesised
50 % of FA by mass of total cementitious materials (Reiner from a wide variety of high-Si and Al starting materials.
and Rens 2006), and it exhibits excellent mechanical The similarity of the FA composition to some volcanic
properties (Volz 2012). material is the reason for which the synthesis of zeolites
The pozzolanic reaction, which is normally slow, can be may start from this waste product. The conversion of FA in
accelerated by using coal FA with reduced particle size zeolites is one of the most promising approaches to
(Ahmaruzzaman 2010). Concrete durability properties, improve its use. Zeolites can be obtained by hydrothermal
such as resistance to alkali sulphate reaction, sulphate treatment of FA (Querol et al. 1995). Zeolite synthesised
attack and corrosion, are also enhanced by ultra-fine FA, from FA was employed also in the removal of heavy metals
which generally replace 5–15 % of the cement weight. from wastewater (Wu et al. 2012). Although MSWI FA has
Coal FA can also be combined with other binder a low content of SiO2 and Al2O3 (15–30 %), different types
material(s) to obtain more sustainable, high-performance of zeolites had been synthesised also from MSWI FA by
concrete. Higher content of FA is sometimes used, in fusion or hydrothermal process (Yang and Yang 1998;
special situations where properties other than strength, as Miyake et al. 2002). The main limitation for this process is
for example control of heat, are important (Ahmaruzzaman the high reaction temperature (125–200 C).

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168 Environ Chem Lett (2014) 12:153–175

Geopolymers tiles, with the advantage of lighter weight and better fire
resistance, than cedar shake roofing.
Geopolymer synthesis by the reaction of aluminosilicate The manufacture of sintered lightweight aggregates
minerals in the presence of alkali solutions at low tem- from FA is a good way to use larger quantities. FA had
peratures was first developed in the 1970s (Davidovits been employed for roadway construction, embankment soil
1994). Due to their good physical, chemical and mechan- stabilisation, subgrade-based course material, aggregate
ical properties, geopolymers can be used in Portland filler, bituminous pavement additive and mineral filler for
cement as binders, for concrete applications. bituminous concrete (Kim et al. 2012). The use of coal FA
Several studies were made to use FA for geopolymer as aggregate in road works was estimated to reduce con-
synthesis (Mustafa Al Bakri et al. 2011). Moreover, geo- struction costs about 10–20 % (Ahmaruzzaman 2010).
polymer synthesis process was considered a valid tech- Mine backfilling was shown to be an attractive option
nology for MSWI FA inertisation, because of its strong for FA recycling for plants located near the coal mine,
fixing capacity for heavy metals (Jin et al. 2011; Lancellotti especially in those areas where sand is scarce (Mathur
et al. 2010). One disadvantage of geopolymerisation is that 2000).
inorganic salts, common in MSWI FA, affect the process The application of coal FA as heterogeneous catalyst
negatively and may be eliminated by a water-washing material was also carefully considered (Wang 2008). The
pretreatment. The use of geopolymer binders was proposed most used catalyst substrates are metal oxides, such as
for making pervious concrete (also known as porous con- Al2O3, SiO2, TiO2 and MgO (Wang and Lu 2007). Thanks
crete or water-permeable concrete). It is a special concrete to its composition, coal FA can be used for this purpose.
with high void volume to allow air or water to move Moreover, coal FA was also employed as the catalytically
through. Pervious concrete was also successfully prepared active component (Khatri et al. 2010; Khatri and Rani
from alkali-activated lignite with high-calcium FA binder 2008).
(Tho-in et al. 2012). Coal FA and RHA had been investigated for their
Although large-scale application of geopolymers is very potential as silica source for the manufacture of mesopor-
complex, mainly due to the variability of the employed FA ous silica to be used in many separation and catalytic
for synthesis, high-performance geopolymer concretes processes. In addition, nearly pure amorphous silica can be
have been commercialised (van Deventer et al. 2012). obtained from RHA (Kalapathy et al. 2000).
Different studies had been conducted to find suitable
Other applications applications of FA in polymer production (Yang et al.
2006; Chaowasakoo and Sombatsompop 2007). The main
Irrespective of their origin, FAs have a good potential for fillers used in polymers are carbon black, calcium car-
use in ceramic products and their use in this field had been bonate, talc, kaolin, mica and wollastonite, but the use of
extensively reported (Barbieri and Lancellotti 2004; Yil- highly dispersible silica can further improve mechanical
maz 2012; Andreola et al. 2008). performances of the composites. FA-filled polymer com-
For tile production, the addition of 20 wt% MSWI FA posites are becoming attractive, because of their wide
was shown to produce high compressive strength and low applications and low cost (Sreekanth et al. 2011). For
water absorption after sintering at T = 960 C (Haiying example, Bosio et al. (2012) and Besco et al. (2013)
et al. 2007). However, the amount of leachable toxic heavy showed that COSMOS material, which is inertised MSWI
metals reduced to one-tenth compared with bare FA. FA formed by silica, calcium carbonate and sulphate, has
As FA is generally composed of oxides, such as SiO2, an interesting composition for being used as polymer filler.
Al2O3, CaO and Fe2O3, it received attention also as a low- Rubbers have a high potential to englobe FA compared
cost material for the manufacture of glass–ceramics and with other rubber cheapeners. Indeed, FA does not show
glass materials (Chu et al. 2013). FA with silica content any property deterioration, even at high loading where
higher than 50 % by weight can be used as a substitute for conventional cheapeners fail (Arayapranee et al. 2005;
silica in the manufacturing process of silicate glass, and the Zeng et al. 2012).
glass product immobilises and stabilises heavy metals in
the matrix (Park et al. 2009).
Although FA is commonly used in cements, it has rarely Conclusion
been applied for bricks (Cicek and Tanriverdi 2007). It was
found that coal FA bricks are as durable as clay bricks, and It is evident that FA has a great potential in environmental
in certain aggressive environments, they have better per- applications. FA is an interesting alternative to replace
formances. Shulman (2007) included FA in the manufac- activated carbon, building materials, zeolites and so on.
ture of lightweight roofing products, such as rigid roofing However, despite the large number of published research

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Environ Chem Lett (2014) 12:153–175 169

FLY ASH
treatment, including several technologies (diffusely
GENERATION addressed in this review); FA utilisation, covering all the
utilisation options of FA after processing; and landfilling.
Recycling and reuse of FA have a number of environ-
COLLECTION mental benefits, including reduced landfilling disposal,
reduced utilisation of virgin resources and reduced
amounts of greenhouse gas emissions. FA may be con-
sidered a valuable resource. Possible applications need to
PROCESSING
be studied to facilitate its employment in all areas of
economic interest. To increase the acceptance and use of
SECONDARY
FA in all the available applications, a deeper analysis of
RECYCLING RAW
MATERIALS long-term economic and environmental impacts, by means
of life cycle assessments (LCAs), is needed. Indeed, the
knowledge of environmental impact of FA as a raw
FLY ASH TREATMENT
material is still poor (Blissett and Rowson 2012).
This paper reviews the main FA typologies, describing
their composition and characteristics in view of their pos-
LANDFILL UTILIZATION
sible reuses. Several application of FA have been identified
ranging from agriculture to building material.
WASTE Big attention is devoted to environmental problems that
may arise to use of fly ash, due to the presence of inorganic
and organic pollutants, and to the technologies, available
for fly ash inertisation. In particular, those based on sus-
EMISSION
tainable methods are extensively analysed.
Fig. 6 Environmentally and economically sustainable fly ash man- Despite FA is a by-product of wastes, it is shown that it
agement (Sabbas et al. 2003) may represent an important resource for Europe, in terms
of non-energy raw materials, which have been recognised a
fundamental need for European economy.
data, FA has not been applied at an industrial scale in Important challenges should be overcome to improve
Europe mainly for two reasons: (1) the variability in how Europe can increase the recovery of materials from
chemistry, mineralogy and morphology of different FA waste. Fly ash recovery may be a first example of recycling
hinders its direct use and (2) FA may create a problem of promotion.
secondary environmental pollution because of the content
of significant amounts of readily leachable materials. Acknowledgments The authors from the Brescia University (Italy)
acknowledge LIFE? financial instrument of the European Commu-
The current use of new resources and the disposal of nity (LIFE? 2011 project ENV/IT/ 256) and RPWJ Struis thanks
waste materials must be reconsidered in view of a sus- Prof. Chr. Ludwig (EPFL, Switzerland) for valuable discussions.
tainable development. In particular, the high amount of
waste generated is still far from being used in its totality,
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