Utilization of Yatagan Power Plant Fly Ash in Production of Building Bricks

Abstract

Fly ash is a by-product of coal combustion, which accumulates in large quantities near the coal-fired power plants as waste material. Fly ash causes serious operational and environmental problems. In this study, fly ash from Yatağgan thermal power plant was used to produce light-weight building bricks. The study aimed to reduce the problems related to fly ash by creating a new area for their use. The optimum process parameters were determined for the production of real size bricks to be used in construction industry. The commercial size bricks (200 × 200 × 90-110 mm) were manufactured using pilot size equipment. Mechanical properties, thermal conductivity coefficients, freezing and thawing strengths, water absorption rates, and unit volume weights of the bricks were determined. Etringite (Ca6Al2 (SO4)3 (OH)12 25(H2O)) and Calcium Silicate Hydrate (2CaO.SiO2.4H2O) were identified as the binding phases in the real size brick samples after 2 days of pre-curing and 28 days curing at 50° C and 95% relative moisture. The water absorption rate was found to be 27.7 % in terms of mass. The mechanical and bending strength of the brick samples with unit volume weight of 1.29 g.cm-3 were determined as 6.75 MPa and 1,56 MPa respectively. The thermal conductivity of the fly ash bricks was measured in average as 0,340 W m-1 K-1. The fly ash sample produced was subjected to toxic leaching tests (Toxic Property Leaching Procedure (EPA-TCLP 1311), Single-step BATCH Test and Method-A Disintegration Procedure (ASTM)). The results of these tests suggested that the materials could be classified as non-hazardous wastes / materials.