Circulating fluidized bed fly ash (CFA) is a waste emitted from coal combustion process in circulating fluidized bed boilers. The high SO3 and f-CaO content severely limits its application in building materials. The purpose of this study is to explore the possibility of large-scale application of CFA in autoclaved aerated concrete (AAC). The preparation parameters of AAC were discussed and the performance was optimized. Moreover, the workability and environmental properties of AAC were explored. The results indicated that AAC was well adapted to high CFA content, although a high CFA content caused a higher water demand as well as a reduction in the silicon content. The introduction of quartz sand and blast furnace slag effectively addressed the problems of insufficient active silica and high specific gravity. When the CFA doping was 50 %, H4 sample showed the best mechanical properties (3.82 MPa and 641 kg/m3), which meet the requests of A3.5, B06 in the Chinese national standard GB/T 11968–2020. Moreover, the toxicity leaching results showed that H4 sample was green and harmless. During the performance optimization process, more well-crystallized tobermorite was produced, whose crystal form changed from acicular to slat. Massive C-S-H gels and better crystallinity of tobermorite were observed, where were bonded and intercalated with each other, thus enhancing the properties. The paper may provide guidance for high dosing of CFA in AAC.
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