METHODS FOR PROCESSING INCINERATOR BOTTOM ASH

Abstract

A method for processing incinerator bottom ash (IBA) comprises the steps of carbonating IBA aggregate material by CO.sub.2 sequestration and providing a stabilizing additive for mixing with the carbonated IBA aggregate material, wherein the additive comprises one or more components from group (b1) and one or more components from group (b2), wherein group (b1) consists of aluminium chloride and at least one other metal chloride, and wherein group (b2) consists of silica, zeolite and apatite. When the carbonated IBA and additive is mixed a stabilized IBA composition is formed, the stabilized IBA composition being suitable for use as a substitute for traditional aggregates in the manufacture of concrete and concrete products.

Claims

1. A method for processing incinerator bottom ash (IBA) comprising the steps of: (i) carbonating IBA aggregate material by CO.sub.2 sequestration; and (ii) providing a stabilizing additive for mixing with the carbonated IBA aggregate material, wherein the additive comprises one or more components from group (b1) and one or more components from group (b2), wherein group (b1) consists of aluminium chloride and at least one other metal chloride, and wherein group (b2) consists of silica, zeolite and apatite.

2. The method for processing IBA as claimed in claim 1, comprising the further step of: (iii) adding the additive to the carbonated IBA material to form a stabilized IBA composition.

3. The method for processing IBA as claimed in claim 1 or claim 2, wherein the additive is mixed with the carbonated IBA material as an aqueous solution.

4. The method for processing IBA as claimed in any preceding claim, wherein step (i) comprises exposing the IBA aggregate material to atmospheric CO.sub.2 and/or non-atmospheric CO.sub.2.

5. The method for processing IBA as claimed in any preceding claim, wherein step (i) comprises windrowing the IBA aggregate material.

6. The method for processing IBA as claimed in any preceding claim, comprising the further step of (iv): combining the carbonated IBA aggregate material and the additive of steps (i) and (ii), or the stabilised carbonated IBA aggregate composition of step (iii), with cement to form a binder composition.

7. The method for processing IBA as claimed in any preceding claim, wherein the at least one other metal chloride in group (b1) is selected from: sodium chloride, potassium chloride, magnesium chloride, calcium chloride, barium chloride, ammonium chloride, strontium chloride, and combinations thereof.

8. The method for processing IBA as claimed in any preceding claim, wherein the one or more components from group (b1) make up 70.0-99.0 wt.% of the total weight of the components (b1) and (b2).

9. The method for processing IBA as claimed in any preceding claim, wherein the one or more components from group (b2) make up 1.0-30.0 wt.% of the total weight of the components (b1) and (b2).

10. The method for processing IBA as claimed in any preceding claim, wherein the additive comprises 1 to 10% by weight of aluminium chloride; 45 to 90% weight of the at least one other metal chloride from group (b1); and 1 to 10% by weight of the components from group (b2).

11. The method for processing IBA as claimed in any preceding claim, wherein the additive further comprises one or more components from a group (b3), wherein group (b3) consists of magnesium oxide, calcium oxide and a combination thereof.

12. The method for processing IBA as claimed in claim 11, wherein the one or more components from group (b3) make up 5-40 wt.% of the total weight of components (b1), (b2) and (b3).

13. The method for processing IBA as claimed in any preceding claim, wherein the additive comprises ImmoCem® , RoadCem ® , or a mixture thereof.

14. The method for processing IBA as claimed in any one of claims 6 to 13, wherein the binder composition comprises: carbonated IBA aggregate in an amount of 50.0 - 70.0 wt%, based on the total weight of the binder composition; additive in an amount of 0.1 - 5.0 wt%, based on the total weight of the binder composition; and cement in an amount of 25.0 - 69.9 wt %, based on the total weight of the binder composition.

15. The method for processing IBA as claimed in any one of claims 6 to 14, wherein the binder composition comprises carbonated IBA aggregate and cement in a 70% / 30% by weight and/or by volume ratio.

16. The method for processing IBA as claimed in any preceding claim, further comprising the precursor processing steps of: (a) grinding IBA to form IBA aggregate material; (b) separating ferrous and non-ferrous metals from the IBA aggregate material; and (c) grading the IBA aggregate material obtained from precursor step (a) or precursor step (b) into suitable size ranges for step (i).

17. The method for processing IBA as claimed in claim 16, wherein precursor step (b) (separating of ferrous and non-ferrous metals from the IBA aggregate material) includes the sub-step of transferring the separated metals for metal recycling.

18. The method for processing IBA as claimed in claim 16 or claim 17, wherein precursor step (c) (grading the IBA aggregate material) includes the substeps of grading the IBA aggregate material to separate particles of greater than 28 mm in size, and optionally returning said particles to precursor step (a) for further grinding.

19. The method for processing IBA as claimed in claim 18, wherein precursor step (c) (grading the IBA aggregate material) includes grading the IBA aggregate material to separate particles of less than 28 mm, and preferably less than 25 mm, for step (i).

20. A stabilized IBA aggregate formed in accordance with the method defined in any one of claims 2 to 19.

21. A binder composition comprising cement and the stabilised carbonated IBA aggregate material formed in accordance with the method defined in any one of claims 2 to 19.

22. A construction composition comprising a binder composition as claimed in claim 21.

23. A construction composition as claimed in claim 22, wherein said construction composition further includes an aggregate component in addition to the stabilised carbonated IBA aggregate.

Description

BRIEF DESCRIPTION OF THE DRAWING

[0057] FIG. 1 is an exemplary flow diagram showing an exemplary method of processing incinerator bottom ash in accordance with aspects of the invention.

DETAILED DESCRIPTION

[0058] With reference to FIG. 1, there is shown a flow diagram of exemplary methods and steps for processing incinerator bottom ash (IBA) in accordance with the invention.

[0059] In optional first (a) and optional second (b) precursor processing steps, dried bulk IBA obtained as a by-product from waste incineration is ground to form an IBA aggregate material, and ferrous and non-ferrous metal particles are separated from said IBA material for metal recycling. Suitable methods of grinding and for separating metal fractions from IBA materials, e.g. magnetic and non-magnetic separation techniques, are well known and therefore not discussed in further detail.

[0060] In a third optional precursor processing step (c), the ground IBA aggregate material obtained from precursor processing step (a) or precursor processing step (b) is graded into suitable particle size ranges for further processing. Optionally, step (c) includes the separation of IBA aggregate material having a particle size of 28 mm or greater, or more preferably still 25 mm or greater, from the remaining ground IBA aggregate material, which can be subsequently matured by carbonation in accordance with step (i). Optionally, the oversized IBA aggregate material particles that are separated from the ground IBA aggregate material are returned for re-grinding in accordance with precursor step (a). Suitable methods of grading the ground IBA aggregate material and separating oversize particles are well known and therefore not discussed in further detail.

[0061] Precursor processing steps (a), (b) and (c), and associated optional sub-steps, define an optional precursor phase of the IBA processing process in accordance with the invention.

[0062] In step (i), IBA aggregate material, optionally obtained from precursor step (c), is carbonated by CO.sub.2 sequestration. In this step, the IBA aggregate material is exposed to CO.sub.2. The CO.sub.2 may be atmospheric CO.sub.2, and/or non-atmospheric CO.sub.2 obtained from a separate source. Accordingly, carbonation may be natural, or accelerated, or a combination thereof. To maximise exposure to CO.sub.2 and speed up the carbonation process, the IBA material can be windrowed, or periodically turned over or moved. This step matures the IBA aggregate material, and carbonates are formed within said IBA aggregate material.

[0063] Carbonation results in a decrease of the IBA’s pH in contact with water from approximately pH 12 to pH 9-10.5, as well as a reduction in the leaching of trace metals from the IBA as previously discussed.

[0064] The carbonated IBA aggregate material formed according to step (i), and any optional precursor steps, provides a bulk aggregate material in accordance with an aspect of the invention.

[0065] Once the IBA aggregate material has carbonated (i.e. ‘matured’) to a desired extent, which may be determined based on measurements of pH value, for example a pH of approximately 8.5, in a further step (iii) an additive composition, optionally provided in an intermediate step (ii), is added to the carbonated IBA aggregate material to form a stabilized IBA aggregate composition. Optionally, the additive composition is mixed with the matured IBA aggregate material as an aqueous solution. The so-formed stabilized IBA aggregate composition provides a stabilized IBA product in accordance with the invention.

[0066] A shown in the Figure, step (iii) can be performed as a discrete step to produce a stabilized carbonated IBA aggregate composition. However, as shown in the Figure, the step of adding the additive composition to the carbonated IBA aggregate material obtained from step (i) may be carried out simultaneously with the addition of cement in a variation of subsequent step (iv) as described below. This way stabilizing of carbonated IBA aggregate by the additive composition occurs during the mixing with cement in step (iv), rather than in a discrete step (iii).

[0067] The additive composition comprises one or more components from group (b1) and one or more components from group (b2), wherein group (b1) consists of aluminium chloride and at least one other metal chloride, and wherein group (b2) consists of silica, zeolite and apatite.

[0068] In examples, the at least one other metal chloride in group (b1) is selected from: sodium chloride, potassium chloride, magnesium chloride, calcium chloride, barium chloride, ammonium chloride, strontium chloride, and combinations thereof.

[0069] In examples, the one or more components from group (b1) make up 70.0-99.0 wt.% of the total weight of the components (b1) and (b2).

[0070] In examples, the one or more components from group (b2) make up 1.0-30.0 wt.% of the total weight of the components (b1) and (b2).

[0071] In examples, the additive comprises 1 to 10% by weight of aluminium chloride; 45 to 90% weight of the at least one other metal chloride from group (b1); and 1 to 10% by weight of the components from group (b2).

[0072] Optionally, the additive further comprises one or more components from a group (b3), wherein group (b3) consists of magnesium oxide, calcium oxide and a combination thereof.

[0073] Optionally, the one or more components from group (b3) make up 5-40 wt.% of the total weight of components (b1), (b2) and (b3).

[0074] Further detail of examples of the additive are found in European Patent No. EP 1 349 819 B1, the contents of which is incorporated herein by reference.

[0075] In examples, the additive composition is ImmoCem ®, or RoadCem ®, or a combination thereof. (ImmoCem ® and RoadCem ® are registered trade marks of Mega-Tech Holding B.V. and are manufactured by PowerCem Technologies B.V.).

[0076] Advantageously, the addition of the additive composition further stabilises and immobilises any heavy metals in the carbonated IBA aggregate to form a stabilised IBA aggregate composition which further mitigates leaching of said heavy metals from said stabilised IBA aggregate composition.

[0077] Optionally, the method for processing incinerator bottom ash (IBA) comprises the further step of (iv): combining either the carbonated IBA aggregate material and the additive composition of steps (i) and (ii), or the stabilised IBA aggregate composition of step (iii), with cement to form a binder composition.

[0078] Optionally step (iv) includes combining the carbonated IBA aggregate material and the additive of steps (i) and (ii), or the stabilized carbonated IBA aggregate composition of step (iii), with cement in ratios, for example by weight and/or by volume, dependent upon the ultimately desired mechanical properties, for example but not limited to, tensile strength, compressive strength, or flexural strength of the intended construction composition, component or unit comprising said binder composition.

[0079] Optionally, the binder composition comprises: carbonated IBA aggregate in an amount of 50.0 - 70.0 wt%, based on the total weight of the binder composition; the additive in an amount of 0.1 - 5.0 wt%, based on the total weight of the binder composition; and cement in an amount of 25.0 - 69.9 wt%, based on the total weight of the binder composition.

[0080] Optionally the binder composition comprises stabilized carbonated IBA aggregate and cement in a 70% / 30% by weight and/or by volume ratio.

[0081] The so-formed binder compositions comprising cement, carbonated IBA aggregate material and additive composition provides a binder product in accordance with a third aspect of the invention.

[0082] In a further optional step (v), the binder composition(s) are formed into construction compositions, for example by the addition of water, and optionally by the addition of additional aggregate components, such as but not limited to sand or gravel.

[0083] In accordance with a fourth aspect of the invention there is provided a construction composition comprising the binder compositions in accordance with the third aspect of the invention. Optionally, the construction composition is concrete.

[0084] It will be understood that steps method steps (a) and (b) and (c) and associated optional sub-steps can be considered to define a precursor phase of an IBA processing process.

[0085] Method step (i) can be considered to define a first phase of the overall IBA processing process.

[0086] Step (iii) can be considered to define a second phase of the overall IBA processing process, this phase being an aspect of the invention when taken in isolation.

[0087] Step (iv) can be considered to define a third phase of the IBA processing process, this phase being a separate, further aspect of the invention when taken in isolation.

[0088] It will be understood that the various steps and phases of the overall IBA processing process can be conducted remotely and/or in isolation from one another.

[0089] When taken in isolation, the third phase defines a separate, further aspect of the invention.

[0090] When taken in isolation, the fourth phase defines a separate, further aspect of the invention.

[0091] Comparative tests performed 7 days after demoulding a series of moulded concrete sample cubes comprising: [a] water, traditional aggregate* and cement.sup.† only; [b] water, traditional aggregate*, cement.sup.† and stabilizing additive.sup.‡; [c] water, traditional aggregate*, cement.sup.† and carbonated IBA; and [d] water, traditional aggregate*, cement.sup.t, carbonated IBA and stabilizing additive.sup.‡; where the presence IBA replaced approximately 60% of the traditional aggregate content by volume, showed that the mean measured compressive strength of concrete [c] (26.4 N/mm.sup.2) and [d] (25.9 N/mm.sup.2) i.e. formed in accordance with aspects of the present invention, was essentially identical to that of a traditional concrete mix [a] (29.3 N/mm.sup.2) and a modified traditional mix [b] (29.0 N/mm.sup.2). (*Thames Valley Aggregates 540, 541, .sup.† Dragon Alfa CEM 1, .sup.‡PowerCem Technologies B.V.).

[0092] Thus IBA aggregates in accordance with the invention have been found to be viable substitutes for traditional aggregates in the production of concrete products.

[0093] Advantageously, using IBA to form stabilized IBA aggregates for use in binder compositions for use in the manufacture of construction compositions such as concrete, reduces the amount of IBA being placed into landfill or used as road sub-base material.

[0094] Furthermore, sequestration of CO.sub.2 by the IBA aggregate material from the atmosphere removes CO.sub.2 from the atmosphere and locks it into the IBA material.

[0095] Advantageously, the use of said binder compositions in the manufacture of concrete products provides a reduced-cost concrete relative to concrete made wholly from conventional prior-art aggregates such as sand, gravel and crushed rock. Furthermore, through the replacement of conventional aggregates with stabilized IBA aggregate material in accordance with aspects of present invention, the requirement for mining virgin aggregate and/or cement is reduced.