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<p>Lignite-based power plants generate substantial volumes of fly ash (FA) and bottom ash (BA), posing long-term disposal and environmental concerns. Although prior studies have investigated FA or BA individually in brick production, limited attention has been given to their combined use at low dosages and under varied firing conditions. This study introduces a novel low-ash formulation by incorporating 2.5%, 5%, and 7.5% FA/BA into clay bricks fired at 900&#xa0;°C, 1000&#xa0;°C, and 1100&#xa0;°C. Results show that 2.5% FA/BA significantly enhances compressive strength (&gt; 25 MPa), surpassing ASTM C62-17 standards, while higher contents increase porosity and reduce mechanical integrity. SEM and XRD confirm the role of mullite formation at 1100&#xa0;°C in strengthening the matrix. Statistical and ANOVA analyses identify ash content as the dominant factor affecting strength and porosity. An economic assessment highlights 2.5% FA/BA at 900&#xa0;°C as optimal, offering a 43.7% fuel saving at 2.60 USD/m<sup>2</sup>. This work advances sustainable fired brick design through performance–cost optimization.</p>

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Transforming industrial waste by utilizing fly ash and bottom ash for sustainable clay bricks

  • 期刊论文

  • 发表日期：

    2025年6月29日

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  • Siwat Lawanwadeekul,
  • Prinya Chindaprasirt,
  • Anujit Phumiphan,
  • Anuwat Srisuwan,
  • Nonthaphong Phonphuak

摘要

Lignite-based power plants generate substantial volumes of fly ash (FA) and bottom ash (BA), posing long-term disposal and environmental concerns. Although prior studies have investigated FA or BA individually in brick production, limited attention has been given to their combined use at low dosages and under varied firing conditions. This study introduces a novel low-ash formulation by incorporating 2.5%, 5%, and 7.5% FA/BA into clay bricks fired at 900 °C, 1000 °C, and 1100 °C. Results show that 2.5% FA/BA significantly enhances compressive strength (> 25 MPa), surpassing ASTM C62-17 standards, while higher contents increase porosity and reduce mechanical integrity. SEM and XRD confirm the role of mullite formation at 1100 °C in strengthening the matrix. Statistical and ANOVA analyses identify ash content as the dominant factor affecting strength and porosity. An economic assessment highlights 2.5% FA/BA at 900 °C as optimal, offering a 43.7% fuel saving at 2.60 USD/m2. This work advances sustainable fired brick design through performance–cost optimization.