填埋灰基少熟料水泥水化机理及其矿井功能性应用探索

Hydration mechanism of landfilled coal ash-based low-clinker cement and exploration of its functional application in coal mines

  • 摘要: 针对填埋灰长期堆存导致活性劣化、处置成本增加及潜在环境风险等问题,以高掺量(≥70%)填埋灰和低掺量(≤30%)熟料为前驱体,经机械化学粉磨活化后,配合硫酸钠与柠檬酸钠等弱碱性钠盐活化剂,在常温条件下制备了填埋灰基碱激发复合水泥(LHACs)。结合流动度、凝结时间及抗压强度测试,以及XRD、SEM-EDS、FT-IR、29Si MAS-NMR和水化量热等手段,系统评价其工作与力学性能、水化行为及动力学特征、水化机理以及经济环境效益。结果表明,在基本性能方面:柠檬酸钠/硫酸钠复合激发的SC-LHACs体系,其流动度约为99.8 mm,初/终凝时间分别为82和147 min,2 d早期/28 d终期强度分别达到了19.4和38.7 MPa,达到P.O. 32.5等级要求并接近P.O. 42.5水平;在水化产物与微观结构方面:C-LHACs体系以C−(A)−S−H凝胶为主,含硫酸钠的S-LHACs与SC-LHACs体系则以(N,C)−(A)−S−H凝胶为主,硫酸钠降低由熟料水化与填埋灰活化分别形成的链状/网状凝胶比例,促进填埋灰持续水化与产物结构致密化;在水化热量演化与动力学方面:弱碱性钠盐抬升首放热峰并提前主峰出现,诱导期明显缩短、早期放热占比提高,水化阶段界限趋于重叠,体系由典型NG-I-D模式演化为以界面反应/扩散为主导的I-D复合控制模式,Kondo模型可较好拟合其阶段演化规律;在水化机理方面:柠檬酸钠与硫酸钠分别通过络合与沉淀反应动态捕获熟料水化释放的Ca2+,缓解低熟料掺量造成的稀释效应,强化早期熟料水化并在孔隙溶液中构建“热−碱”协同激发环境,实现“熟料水化−填埋灰活化”协同反应与凝胶连续聚合;在经济与环境效益方面:与P.O. 42.5水泥相比,S-LHACs与SC-LHACs体系的生产成本分别为其29.1%和43.8%,碳排放仅为其34.2%和42.6%,实现高掺量填埋灰利用的同时兼具显著的减碳与降本优势。综上,LHACs兼具良好的工程适用性、结构稳定性与减碳降本优势,在高掺量填埋灰资源化利用及低碳矿井功能性材料领域具有应用潜力。

     

    Abstract: To address the activity deterioration, increased disposal costs, and potential environmental risks associated with long-term landfilling of coal ash, hybrid alkaline cements based on landfilled coal ash (LHACs) were prepared using high-replacement (≥70%) landfilled ash and low-replacement (≤30%) clinker as precursors. Mechanical-chemical grinding activation was employed, followed by the incorporation of weak-alkaline sodium salts (sodium sulfate and sodium citrate) to synthesize the binders under ambient curing conditions. The workability, mechanical performance, hydration behavior and kinetics, hydration mechanisms, as well as the associated economic and environmental benefits were systematically evaluated through flowability and setting-time tests, compressive strength measurements, X-ray diffraction (XRD), scanning electron microscopy with energy-dispersive spectroscopy (SEM-EDS), Fourier-transform infrared spectroscopy (FT-IR), 29Si MAS-NMR, and isothermal calorimetry. The results show that the SC-LHACs system activated by the sodium citrate/sodium sulfate combination exhibits favorable basic properties, with a flowability of 99.8 mm, initial and final setting times of 82 and 147 min, and compressive strengths of 19.4 MPa at 2 d and 38.7 MPa at 28 d, meeting the requirements of P.O. 32.5 cement and approaching those of P.O. 42.5 cement. Microstructural analyses reveal that C-LHACs mainly form C-(A)-S-H gels, whereas S-LHACs and SC-LHACs predominantly generate (N,C)-(A)-S-H gels. The incorporation of sodium sulfate decreases the proportion of chain-structured to network-structured gels derived from clinker hydration and ash activation, thereby promoting continuous ash hydration and matrix densification. In terms of hydration heat evolution and kinetics, weak-alkaline sodium salts elevate the first exothermic peak, advance the main hydration peak, shorten the induction period, and increase the fraction of early heat release. The hydration process evolves from the typical nucleation–growth/interfacial/diffusion (NG-I-D) regime of ordinary cement to an interface-reaction/diffusion (I-D) dominated combined kinetic mode, which is well described by the Kondo kinetic model. Mechanistically, sodium citrate complexes Ca2+ while sodium sulfate induces precipitation and ion exchange reactions, synergistically regulating the pore-solution chemistry, mitigating the dilution effect caused by low clinker content, and enabling coupled clinker hydration and ash activation with continuous gel polymerization. Economic and environmental assessments further indicate that, compared with P.O. 42.5 cement, the production costs of S-LHACs and SC-LHACs are reduced to 29.1% and 43.8%, while their carbon emissions decrease to 34.2% and 42.6%, respectively. Overall, LHACs demonstrate good engineering applicability together with significant cost and carbon reductions, showing strong potential for high-volume utilization of landfilled coal ash and low-carbon functional materials for underground coal mine applications.

     

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