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Keywords = coal combustion waste

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26 pages, 4630 KB  
Article
Reaction Sequence Coordination in Ternary Solid-Waste Systems for Low-Carbon Cementitious Materials
by Youlin Ye, Guangyu Zhou, Yannian Zhang, Xin Wei and Ben Niu
Appl. Sci. 2026, 16(9), 4205; https://doi.org/10.3390/app16094205 - 24 Apr 2026
Viewed by 230
Abstract
Using solid waste as supplementary cementitious materials (SCMs) is an effective strategy for promoting low-carbon construction development. However, single or binary systems often exhibit mismatched reaction kinetics, thereby limiting their performance at high cement replacement rates. This study focuses on a novel low-carbon [...] Read more.
Using solid waste as supplementary cementitious materials (SCMs) is an effective strategy for promoting low-carbon construction development. However, single or binary systems often exhibit mismatched reaction kinetics, thereby limiting their performance at high cement replacement rates. This study focuses on a novel low-carbon concrete designed based on reaction sequence coordination, containing recycled brick powder (RBP), ground granulated blast-furnace slag (GGBS), and self-combusting coal gangue (SCCG). The effects of RBP, GGBS, and SCCG on the hydration process and microstructure of the novel low-carbon concrete with different replacement levels have been studied by testing compressive strength, workability, and durability and observing microstructural changes. The results showed that an optimized ternary composition with an RBP:GGBS:SCCG ratio of 4:3:1 achieves a cement replacement level of 30% while exhibiting a 28-day compressive strength of 38.26 MPa, representing a 14.2% increase compared with plain cement mortar. Microstructural analyses indicate that this enhanced performance results from a time-dependent reaction sequence, in which GGBS contributes predominantly at early ages by supplying calcium, whereas RBP and SCCG mainly participate through delayed pozzolanic reactions and pore refinement at later ages. Consequently, the optimized ternary mortar exhibits a water absorption of 11.12% and a 27.2% reduction in electrical flux. This study aims to provide practical strategies for enhancing the performance of low-carbon cementitious materials through a reaction sequence coordination design approach, thereby improving the utilization efficiency of solid waste in the production of low-carbon building materials. Full article
(This article belongs to the Section Civil Engineering)
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27 pages, 6049 KB  
Article
Impact of Coal-Fired Power Plant Activities on the Ecological Status of River Ecosystems: Case Study of Sokolitsa River, Bulgaria
by Vanina Mitseva, Tsvetelina Isheva, Mila Ihtimanska and Emilia Varadinova
Environments 2026, 13(4), 191; https://doi.org/10.3390/environments13040191 - 1 Apr 2026
Viewed by 1055
Abstract
Coal-fired power plants can adversely affect aquatic ecosystems through wastewater discharge, waste landfills, and the atmospheric deposition of toxic substances released during coal combustion. These processes degrade the water quality of nearby surface and underground water bodies. The study presents the impact of [...] Read more.
Coal-fired power plants can adversely affect aquatic ecosystems through wastewater discharge, waste landfills, and the atmospheric deposition of toxic substances released during coal combustion. These processes degrade the water quality of nearby surface and underground water bodies. The study presents the impact of the coal-fired power plant Contour Global Maritza East 3 on the ecological status of the Sokolitsa River, reflected by changes in the composition and structure of the sensitive phytobenthos and macrozoobenthos communities and supporting environmental variables, including water temperature, pH, dissolved oxygen, conductivity, nutrients, sulfates, calcium, and calcium carbonate hardness. Methods for monitoring and assessing the ecological status of surface water bodies compliant with European and national legislation were applied to the studied biological quality elements and key physicochemical variables. Historical monitoring data from a ten-year period, 2013–2022, together with data collected during the study in 2023 and 2024 were analyzed and evaluated. The results indicated a significant increase in most physicochemical variables downstream of the CFPP compared with the upstream site, including water temperature, conductivity, calcium carbonate hardness, calcium, sulfates and nitrogen (N) nutrients (ammonium N, nitrite N, nitrate N, total N). The ecological status of the river deteriorated, as indicated by the negatively affected aquatic habitats and the changes in the taxonomic richness and abundance of the studied organism groups. Full article
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15 pages, 2982 KB  
Article
Hydrodynamic Shielding and Oxidation Suppression in Merging Lazy Plumes
by Atsuyoshi Sato, Arata Kioka, Masami Nakagawa and Takeshi Tsuji
Fluids 2026, 11(4), 92; https://doi.org/10.3390/fluids11040092 - 30 Mar 2026
Viewed by 511
Abstract
This paper investigates the combustion dynamics of interacting lazy multi-component gas plumes (i.e., buoyancy-dominated gas releases with a low initial momentum flux), a configuration relevant to coal mining waste emissions. By coupling a three-dimensional large eddy simulation (mesh size of 10−2 m; [...] Read more.
This paper investigates the combustion dynamics of interacting lazy multi-component gas plumes (i.e., buoyancy-dominated gas releases with a low initial momentum flux), a configuration relevant to coal mining waste emissions. By coupling a three-dimensional large eddy simulation (mesh size of 10−2 m; paralleling with 2048 processors) with detailed chemical kinetics (GRI-Mech 3.0), we analyzed the sensitivity of the flow structure and plume stabilization to the vent spacing of twin hydrogen-rich multi-component gas plumes (H2-CO-CH4-air). The results identified a distinct topological transition. While gas plumes from vents spaced at δ/D=5 (δ and D are the spacing and width of gas vents, respectively) evolve independently, those at closely spaced sources (δ/D=5/4) exhibit rapid coalescence driven by hydrodynamic shielding. This hydrodynamic merging results in a unified column with an effective hydraulic diameter of Deff2D. This leads to a significant reduction in the surface-to-volume ratio available for ambient air entrainment, maintaining a coherent combustible-rich core to higher altitudes than isolated-source correlations would predict. However, despite this mass retention, the rapid vertical acceleration of buoyancy-dominated flows induces high strain rates, significantly disrupting the reaction zone structure. These findings establish that, for clustered emission sources, the dispersion hazard is governed by a coupling between hydrodynamic coalescence, which maintains reactant concentration, and finite-rate chemistry, restricting oxidation efficiency. This paper provides critical insights for designing gas capture infrastructure and assessing flammability limits in multi-vent systems. Full article
(This article belongs to the Special Issue 10th Anniversary of Fluids—Recent Advances in Fluid Mechanics)
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16 pages, 2890 KB  
Article
Occurrence of Organic Contaminants and Microbial Community Structure in River Sediments and Mollusks from an E-Waste Recycling Area in Southeast China
by Lingxi Zhan, Chaofeng Shen, Fei Li, Feng Zhang, Xia Ma, Chao Wu, Xin Xu, Jiang Zhang and Xiaodan Yang
Water 2026, 18(7), 773; https://doi.org/10.3390/w18070773 - 25 Mar 2026
Viewed by 472
Abstract
This study investigated the characteristics and interrelationships of polycyclic aromatic hydrocarbons (PAHs), phthalate esters (PAEs), and microbial communities in coastal river sediments and benthic mollusks collected from an e-waste recycling area in Taizhou, Zhejiang Province. In sediments, 16 PAHs and six PAEs were [...] Read more.
This study investigated the characteristics and interrelationships of polycyclic aromatic hydrocarbons (PAHs), phthalate esters (PAEs), and microbial communities in coastal river sediments and benthic mollusks collected from an e-waste recycling area in Taizhou, Zhejiang Province. In sediments, 16 PAHs and six PAEs were detected, with concentrations ranging from 2.66 to 379.99 μg/kg and 76.5 to 3426.57 μg/kg, respectively. Four-ring PAHs (particularly fluoranthene and pyrene) and Bis(2-ethylhexyl) phthalate (DEHP) were dominant, with DEHP posing a potential risk, especially at site 10, warranting further attention. In contrast, only eight PAHs and four PAEs were detected in mollusks, with concentrations of 60.14–523.10 μg/kg and 144.55–3005.71 μg/kg, respectively. Two-ring PAHs (particularly naphthalene) and Dibutyl phthalate (DBP) were dominant, likely derived directly from the overlying water. The PAHs in sediments primarily originated from fossil fuel combustion, biomass burning, and coal combustion, while PAEs were likely derived from the release of plastic waste from solid waste recycling. Lower concentrations and fewer PAH and PAE species were observed in the sediments near the ocean and at greater distances from the e-waste recycling sites. Significant differences were observed in microbial communities between sediment and mollusk samples. Dominant phyla shared by both sample types include proteobacteria, bacteroidetes, firmicutes, and acidobacteria. The concentration of low-ring PAHs was correlated with the microbial communities, particularly in mollusk samples. Relationships were also identified between microbial communities and DEHP concentrations in sediments or DBP concentrations in mollusks. Full article
(This article belongs to the Special Issue Fate and Transport of Contaminants in Soil and Water)
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16 pages, 1863 KB  
Article
Rare Earth Elements in Turkish Coal Fly Ashes: Enrichment Patterns and Secondary Resource Perspective
by Neslihan Ünal-Kartal
Sustainability 2026, 18(5), 2529; https://doi.org/10.3390/su18052529 - 5 Mar 2026
Viewed by 536
Abstract
In thermal power plants, fly ash produced from coal combustion is a solid waste that requires large storage areas and poses environmental risks. In addition, coal ash can contain significant amounts of critical elements, including rare earth elements and yttrium (REY). Despite high [...] Read more.
In thermal power plants, fly ash produced from coal combustion is a solid waste that requires large storage areas and poses environmental risks. In addition, coal ash can contain significant amounts of critical elements, including rare earth elements and yttrium (REY). Despite high supply risks, demand for REY is increasing in parallel with technological developments. Therefore, the recovery of REY from coal ash is becoming increasingly important for both solid waste disposal and as a raw material source. This study presents an integrated geochemical assessment of REY in fly ashes from coal-fired thermal power plants in Türkiye, based on systematically compiled and harmonised datasets. The REY concentration of fly ash varies between 134.00 and 429.48, with an average of 230.06 ppm. Light REY are predominant in all samples. The proportion of critical REY averages 34.75, with the highest value calculated at 42% in fly ash from the Yatağan thermal power plant. While most fly ashes show L-type enrichment, there are also samples showing M-type and H-type enrichment. According to initial national-scale estimates, coal fly ashes in Türkiye may contain approximately 3.7–5 kt of rare earth oxides per year. Despite their low REY content, Turkish fly ashes can be considered a potential source for REY recovery when considering the large waste volume, in conjunction with an integrated evaluation strategy. This study establishes a geochemical basis for future process-oriented and recovery-focused investigations. Full article
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15 pages, 1236 KB  
Review
Coal Gangue Recycling in Construction Materials: Strategies for Environmental Risk Mitigation via Heavy Metal Immobilization and Resource Utilization
by Yang Xue, Xiaoming Liu, Xuchao Wang and Wei Zhang
Materials 2026, 19(5), 949; https://doi.org/10.3390/ma19050949 - 28 Feb 2026
Cited by 1 | Viewed by 530
Abstract
Coal gangue represents the predominant solid waste in the coal industry and poses significant risks to both the ecological environment and human health. It has been demonstrated that recycling it in building materials effectively reduces stockpiling, mitigates environmental harm, and minimizes heavy metal [...] Read more.
Coal gangue represents the predominant solid waste in the coal industry and poses significant risks to both the ecological environment and human health. It has been demonstrated that recycling it in building materials effectively reduces stockpiling, mitigates environmental harm, and minimizes heavy metal leaching. However, a comprehensive review systematically focusing on the recycling of coal gangue and the behavior of its associated heavy metals in building materials is still lacking. This work introduces the physicochemical properties and environmental hazards of coal gangue, including spontaneous combustion, land occupation, and pollution risks. It also summarizes the leaching patterns, speciation, and immobilization mechanisms of heavy metals such as Cr, Cu, and Pb in gangue-based building materials, and reviews adsorption behaviors, solidification pathways, and microstructural interactions at the molecular scale. Despite ongoing efforts, over five billion tons of coal gangue remain accumulated in China, with secondary pollution from heavy metals continuing to pose serious concerns. To address these challenges, recommendations are proposed for establishing standardized leaching evaluation methods, and a novel approach for transitioning from heavy metal solidification to active utilization is introduced. This review aims to provide strategic direction for the green and sustainable recycling of coal gangue. Full article
(This article belongs to the Special Issue Testing of Materials and Elements in Civil Engineering (5th Edition))
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15 pages, 4702 KB  
Article
Alkaline Element Leaching from Fly Ash for Direct CO2 Fixation
by Lingjin Zhu, Yahu Yao, Chuncheng Cai, Rongqiang Qiao, Xilin Ji, Yazhou Zhang, Zhennan Niu, Shengqi Zhou, Yingshuang Zhang, Baiye Li and Zhiyi Zhang
Processes 2026, 14(2), 370; https://doi.org/10.3390/pr14020370 - 21 Jan 2026
Viewed by 570
Abstract
Fly ash (FA), a major by-product of coal combustion, has long been regarded as a challenging industrial solid waste. Its inherent abundance of alkaline-earth oxides positioned it as a promising candidate for CO2 sequestration through mineral carbonation. This study systematically investigated the [...] Read more.
Fly ash (FA), a major by-product of coal combustion, has long been regarded as a challenging industrial solid waste. Its inherent abundance of alkaline-earth oxides positioned it as a promising candidate for CO2 sequestration through mineral carbonation. This study systematically investigated the effects of key operational parameters, including time, stirring rate, ultrasonic treatment, and solid-to-liquid ratio, on the leaching efficiency of calcium ions and subsequent CO2 fixation. Ultrasonic treatment, a solid-to-liquid ratio of 1:7, a stirring speed of 600 rpm, and 7% monoethanolamine (MEA) collectively enhanced the calcium leaching efficiency (χe) to 16.7%, thereby supplying a substantial reservoir of calcium ions for CO2 fixation. Additionally, the CO2 injection into fly ash slurry and the slurry spraying into CO2 gas were investigated to optimize reactor configurations. The latter method demonstrated superior performance, attaining a CO2 fixation efficiency of 7.23%. This corresponds to a carbonation conversion efficiency (ηc) of approximately 44.5%, indicating that nearly half of the leached calcium ions were successfully converted into stable carbonates. Advanced characterization techniques (SEM-EDS, XRD, FTIR) confirmed the formation of stable carbonates and highlighted the role of additives in enhancing reactivity. The environmental benefit of this approach is addressing fly ash wastes and transforming fly ash into a CO2 fixation material. These findings provided critical insights for calcium leaching and CO2 fixation of fly ash. Full article
(This article belongs to the Section Petroleum and Low-Carbon Energy Process Engineering)
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26 pages, 4591 KB  
Article
Environmental Impact Assessment of New Cement Production Blending Calcareous Green Algae and Fly Ash
by Hafiz M. Irfan, Chi-Yun Wu, Muhammad Saddam Hussain and Wei Wu
Processes 2026, 14(2), 299; https://doi.org/10.3390/pr14020299 - 14 Jan 2026
Viewed by 534
Abstract
To improve traditional cement manufacturing, which generates a large amount of greenhouse gases, blending calcareous green algae and fly ash as cement replacement materials is expected to achieve nearly zero carbon emissions. As a calcareous green alga, Halimeda macroloba is a significant producer [...] Read more.
To improve traditional cement manufacturing, which generates a large amount of greenhouse gases, blending calcareous green algae and fly ash as cement replacement materials is expected to achieve nearly zero carbon emissions. As a calcareous green alga, Halimeda macroloba is a significant producer of biogenic calcium carbonate (CaCO3), sequestering approximately 440 kg of carbon dioxide (CO2) per 1000 kg of CaCO3, with CaCO3 production reported in relation to algal biomass. To assess the new low-carbon/low-waste cement production process, the proposed scenarios (2 and 3) are validated via Python-based modeling (Python 3.12) and Aspen Plus® simulation (Aspen V14). The core technology is the pre-calcination of algae-derived CaCO3 and fly ash from coal combustion, which are added to a rotary kiln to enhance the proportions of tricalcium silicate (C3S) and dicalcium silicate (C2S) for forming the desired silicate phases in clinker. Through the lifecycle assessment (LCA) of all scenarios using SimaPro® (SimaPro 10.2.0.3), the proposed Scenario 2 achieves the GWP at approximately 0.906 kg CO2-eq/kg clinker, lower than the conventional cement production process (Scenario 1) by 47%. If coal combustion is replaced by natural gas combustion, the fly ash additive is reduced by 74.5% in the cement replacement materials, but the proposed Scenario 3 achieves the GWP at approximately 0.753 kg CO2-eq/kg clinker, lower than Scenario 2 by 16.9%. Moreover, the LCA indicators show that Scenario 3 has lower environmental impacts on human health, ecosystem, and resources than Scenario 1 by 24.5%, 60.0% and 68.6%, respectively. Full article
(This article belongs to the Section Environmental and Green Processes)
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22 pages, 15048 KB  
Review
Catalytic Combustion of Low-Concentration Methane: From Mechanistic Insights to Industrial Applications
by Liang Shuai, Biaohua Chen and Ning Wang
Catalysts 2026, 16(1), 56; https://doi.org/10.3390/catal16010056 - 3 Jan 2026
Cited by 1 | Viewed by 1277
Abstract
Coal mining releases large amounts of low-concentration methane. Its global warming potential per unit mass is about 21 times that of carbon dioxide. Approximately 13.5 billion cubic meters are directly emitted each year without utilization. This results in both energy waste and environmental [...] Read more.
Coal mining releases large amounts of low-concentration methane. Its global warming potential per unit mass is about 21 times that of carbon dioxide. Approximately 13.5 billion cubic meters are directly emitted each year without utilization. This results in both energy waste and environmental issues. Technologies for utilizing methane with concentrations ≥8% are already mature. However, stable treatment of low-concentration methane remains challenging. Issues include unsustainable combustion and interference from impurities. This review provides a comprehensive overview of recent advances in the catalytic combustion of low-concentration methane, systematically examining reaction mechanisms, catalyst development (including noble metal catalysts, non-noble metal catalysts, and the role of supports), combustion methods, and numerical simulations. The analysis reveals that current research faces challenges such as mismatched catalyst performance under real conditions, insufficient combustion system stability, and gaps between numerical simulations and practice. Future work should focus on molecular-level catalyst design, integrated system innovation, and enhancing simulation predictive capabilities, thereby strengthening the link between basic research and engineering applications. This will promote the industrialization of efficient low-concentration methane utilization technologies, ultimately achieving both energy recovery and greenhouse gas emission reduction. Full article
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21 pages, 6406 KB  
Article
Sustainable Reclamation of Post-Mining Areas in Poland: The Long-Term Effects of Soil Substitute Covers and Phragmites australis Plantations
by Angelika Więckol-Ryk, Łukasz Pierzchała and Arkadiusz Bauerek
Sustainability 2025, 17(24), 11294; https://doi.org/10.3390/su172411294 - 17 Dec 2025
Viewed by 654
Abstract
Degraded post-mining landscapes require reclamation strategies that ensure soil stability, environmental safety and successful vegetation establishment. This study evaluated two soil cover systems applied between 2020 and 2025 on a mining spoil heap in Libiąż, Poland: a two-layer (TL) cover with a soil [...] Read more.
Degraded post-mining landscapes require reclamation strategies that ensure soil stability, environmental safety and successful vegetation establishment. This study evaluated two soil cover systems applied between 2020 and 2025 on a mining spoil heap in Libiąż, Poland: a two-layer (TL) cover with a soil substitute layer and a multilayer (ML) cover incorporating additional insulating materials. Both covers were non-saline and mildly alkaline. The applied methods supported favorable soil conditions after five years, with stable organic matter (24.48–28.26%), nitrogen (4.5–4.9 g/kg) and phosphorus (1.5–1.6 g/kg) contents, while potassium decreased markedly (from 17.1 to 6.44–6.83 g/kg), likely due to plant uptake or leaching. Leachate analyses showed low concentrations of toxic metals and salinity-related ions, confirming the environmental safety and inert properties of the soil substitute. Vegetation assessments revealed differences between reclamation systems, with Phragmites australis exhibiting greater stalk length, plant density and biomass in the TL cover. Establishment costs were also substantially lower for TL (EUR 1.65/m2) than for ML (EUR 6.14/m2). These results indicate that soil substitute covers provide a safe, cost-effective and functionally efficient reclamation option that supports circular economy principles by reusing mining waste and coal combustion by-products, while Phragmites australis enhances vegetation development and overall reclamation success. Full article
(This article belongs to the Section Sustainable Agriculture)
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17 pages, 2720 KB  
Article
Studying Natural Radioactivity of Coals and Ash and Slag Waste as Potential Raw Materials for Quality Assessment and Extraction of Rare Earth Elements
by Yuriy Pak, Dmitriy Pak, Pyotr Kropachev, Vladimir Matonin, Diana Ibragimova, Anar Tebayeva, Pavel Timoshenko, Natalya Tsoy and Yelena Tseshkovskaya
Geosciences 2025, 15(11), 420; https://doi.org/10.3390/geosciences15110420 - 4 Nov 2025
Cited by 3 | Viewed by 1219
Abstract
A significant portion of coal mined in Kazakhstan is mainly used for fuel energy and metallurgy. Approximately 60% of electricity is generated by coal-fired power engineering. About 19 million tons of ash and slag waste (ASW) are annually sent to dumps. After coal [...] Read more.
A significant portion of coal mined in Kazakhstan is mainly used for fuel energy and metallurgy. Approximately 60% of electricity is generated by coal-fired power engineering. About 19 million tons of ash and slag waste (ASW) are annually sent to dumps. After coal combustion, in ASW not only are natural radioactive nuclides NRN (U238, Th232, K40) concentrated, but also rare and rare earth elements (REE). In this regard, ASW that essentially turns into quasi-technogenic deposits of NRN and REE, requires systemic measures for their utilization. The possibilities of extracting REE from coal power-industry waste are estimated based on the analysis of the concentration of REE (Ce, La, Nd, Sm, etc.), NRN (U238, Th232 and their decay products, K40) and the established significant correlations between rare earth and radioactive elements. The purpose of this paper is to study the natural radioactivity of coals and ash and slag waste as potential raw materials for assessing the quality and extracting rare earth metals. The stated purpose involves solving the following problems: studying the features of the NRN and REE distribution in coals and ash and slag waste; assessing the possibility of using ash and slag waste as a promising source of REE extraction based on nuclear radiometric studies; and studying the spectrometry of natural gamma radiation for assessing the quality of coals. Full article
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28 pages, 9309 KB  
Review
Preparation, Properties and Chemical Modification Methods of the Fire-Fighting Foam for Coal Spontaneous Combustion
by Chenchen Feng, Ying Li, Hua Li, Mengmeng Bai and Zefeng Jing
Materials 2025, 18(21), 4888; https://doi.org/10.3390/ma18214888 - 25 Oct 2025
Viewed by 1657
Abstract
Coal spontaneous combustion causes both human casualties and environmental pollution. Owing to special flow behaviors, foam materials used in fire-fighting technology can effectively bring water and solid non-combustible substances into the fire-fighting area, greatly preventing spontaneous combustion. This paper systematically elucidates three foam [...] Read more.
Coal spontaneous combustion causes both human casualties and environmental pollution. Owing to special flow behaviors, foam materials used in fire-fighting technology can effectively bring water and solid non-combustible substances into the fire-fighting area, greatly preventing spontaneous combustion. This paper systematically elucidates three foam materials, three-phase foam, gel foam and curing foam, and analyzes their physical and chemical inhibition mechanisms on coal spontaneous combustion. In particular, the preparation, performance and latest chemical modification methods of the foam materials are summarized in detail. It is found that foam materials with environmental friendliness, economy and excellent anti-fire performance need to be consistently explored. The primary application areas for cement-based foamed materials remain the building materials and civil engineering industries, and their modification should be studied accordingly based on the specific application context. Furthermore, a new component of foam materials, coal gasification slag (a solid waste), is proposed. In addition, the seepage properties of fire-fighting foam in porous media should be fully studied to accurately grasp the dispersion of foam materials in mine goafs. This review provides new insights and guidance for the development of fire-fighting foam materials. Full article
(This article belongs to the Special Issue Foam Materials and Applications)
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25 pages, 2224 KB  
Article
Laboratory Quantification of Gaseous Emission from Alternative Fuel Combustion: Implications for Cement Industry Decarbonization
by Ofelia Rivera Sasso, Elias Ramirez Espinoza, Caleb Carreño Gallardo, Jose Ernesto Ledezma Sillas, Alberto Diaz Diaz, Omar Farid Ojeda Farias, Carolina Prieto Gomez and Jose Martin Herrera Ramirez
Materials 2025, 18(21), 4859; https://doi.org/10.3390/ma18214859 - 23 Oct 2025
Cited by 1 | Viewed by 1029
Abstract
The cement industry accounts for approximately 7% of global CO2 emissions, with fuel combustion contributing 40% of sectoral emissions. Alternative fuels from industrial and municipal waste offer emission reduction opportunities while addressing waste management challenges. This study quantifies real-time gaseous emissions (CO [...] Read more.
The cement industry accounts for approximately 7% of global CO2 emissions, with fuel combustion contributing 40% of sectoral emissions. Alternative fuels from industrial and municipal waste offer emission reduction opportunities while addressing waste management challenges. This study quantifies real-time gaseous emissions (CO2, CO, NOx, and SO2) from seven alternative fuels—sawdust (SD), pecan nutshell (PNS), wind blade waste (WBW), industrial hose waste (IHW), tire-derived fuel (TDF), plastic waste (PW), and automotive shredder residue (ASR)—during calcination at 850 °C. Bituminous coal served as the reference fuel. Gas concentrations were continuously monitored using the testo 350 portable gas analyzer. Emission factors were calculated on a mass basis (kg/kg fuel) and energy basis (kg/GJ) for standardized comparisons. Alternative fuels consistently produced lower CO2 emission factors than coal, with biomass-derived fuels (SD and PNS) showing reductions of 45% and 38%, respectively. Most alternative fuels generated lower CO and NOx emissions per unit energy due to their higher volatile matter content, promoting complete combustion. TDF was an exception, exhibiting 2.8 times higher CO emissions. SO2 emissions were negligible except in the case of TDF (0.14% sulfur content). The measured emission factors were 15–30% lower than theoretical IPCC values, confirming the environmental viability of alternative fuels as coal substitutes in cement production. Full article
(This article belongs to the Special Issue Eco-Friendly Materials for Sustainable Buildings)
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17 pages, 3615 KB  
Article
Increasing the Reactivity of Solid Fuel with Liquid Hydrocarbons from the Pyrolysis of Waste Tires
by Albina Misyukova, Askar Asilbekov, Aleksander Matveev, Kirill Larionov and Konstantin Slyusarskiy
Energies 2025, 18(20), 5494; https://doi.org/10.3390/en18205494 - 17 Oct 2025
Viewed by 736
Abstract
Utilization of waste tires via pyrolysis is a promising solution. The liquid hydrocarbons generated during this process could be used for enhancing low-reactivity coals for energy application. Current study investigates oxidation and combustion characteristics (including composition of gaseous combustion products) of low-reactivity coal [...] Read more.
Utilization of waste tires via pyrolysis is a promising solution. The liquid hydrocarbons generated during this process could be used for enhancing low-reactivity coals for energy application. Current study investigates oxidation and combustion characteristics (including composition of gaseous combustion products) of low-reactivity coal mixed with liquid hydrocarbons from pyrolysis of waste tires with a concentration up to 20%wt at 700 °C. The oxidation tests via TG-analyzer revealed that at heating rates up to 10 °C/min, the process had one stage, associated with combined oxidation of coal-liquid hydrocarbons mixture. Starting from 10 °C/min the second stage occurred at temperature ~400 °C due to evaporation of light components of the mixture. Combustion tests at experimental setup at 700 °C revealed almost linear increase in fuel reactivity, expressed into decline in ignition delay time of mixtures (up to 71.6%) with increasing concentration of liquid hydrocarbons, while flame and diffusion combustion times were, in contrast, increasing (by up to 69.5%). Increasing concentration of additives from 2.5 to 20%wt resulted not only in change in the form of obtained mixture but also changed the combustion mechanism from predominantly heterogeneous smoldering to majorly homogeneous gas-phase ignition and combustion. Gas-phase combustion products concentration curves generally complimented previously observed peculiarities of combustion. Increased CO and NOx concentrations in combustion products of coal mixed with liquid hydrocarbons revealed necessity in additional tailoring of burner characteristics for mitigating these effects. The compromise composition of mixture was found to include 10%wt of liquid hydrocarbons for enabling quick gas-phase ignition while maintaining moderate level of combustion products emissions. Full article
(This article belongs to the Section I2: Energy and Combustion Science)
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21 pages, 4678 KB  
Article
Evaluation of Co-Pelletization of Corn Stover and Plastic Waste as an Alternative Fuel Source for Cement Production
by Haley Stockham, Asmita Khanal, Sushil Adhikari and Ajay Shah
Energies 2025, 18(20), 5393; https://doi.org/10.3390/en18205393 - 13 Oct 2025
Viewed by 894
Abstract
Corn stover and plastic waste, severely underutilized feedstocks generated in the U.S., could be co-pelletized to produce fuel for cement production. High-density polyethylene bags (0–25% in 5% increments, dry basis) and corn stover were co-pelletized using a flat ring pellet mill with die [...] Read more.
Corn stover and plastic waste, severely underutilized feedstocks generated in the U.S., could be co-pelletized to produce fuel for cement production. High-density polyethylene bags (0–25% in 5% increments, dry basis) and corn stover were co-pelletized using a flat ring pellet mill with die diameters of 6 and 8 mm. Physical and chemical properties were assessed to determine pellet quality. These results informed techno-economic and life cycle greenhouse gas emissions (GHGe) analyses for a Midwestern plant producing 400,000 metric tons of pellets annually. The system boundary included feedstock acquisition at the pellet plant, size reduction, co-pelletization, and transportation of the pellets to the cement plant by rail. Total resource requirements in terms of raw materials, labor, fuel, equipment, the facility, and utilities were estimated. It was determined that the pellets would be delivered to the cement plant at USD 112.4–138.6/t pellets. The life cycle analysis estimated a total GHGe of 1621.1–1753.1 kg CO2e/t pellets associated with the pellet production, transportation, and combustion. The results suggest that substituting 25% of the thermal energy requirement of a cement plant with a 1.1 million t clinker annual production capacity with plastic–stover pellets would reduce the GHGe by 2.8% compared to 100% of the total energy requirement supplied by coal. Full article
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