A novel way to upgrade the coarse part of a high calcium fly ash for reuse into cement systems

Reject fly ash (rFA) represents a significant portion of the fly ashes produced from coal-fired power plants. Due to the high carbon content and large particle mean diameter, rFA is not utilized in the construction sector (for example, as supplementary cementing material) and is currently dumped into landfills, thus representing an additional environmental burden. Recently, the feasibility of using rFA in a relatively small number of applications, like solidification/stabilization of other wastes, has been investigated by different researchers. However, as the overall amount of fly ash utilized in such applications is still limited, there is a need to investigate other possibilities for rFA utilization starting from a deeper understanding of its properties. In the work presented herein, mechanical and hydration properties of cementitious materials prepared by blending the coarse fraction of a lignite high-calcium fly ash with ordinary cement were monitored and compared with the respective ones of a good quality fly ash–cement mixture. The results of this work reveal that a relatively cheap, bilateral classification–grinding method is able to promote the pozzolanic behavior of the rFAs, so that the overall performances of rFA containing cements are drastically improved. The evaluation of these results supports the belief that appropriate utilization of non-standardized materials may lead to new environmental-friendly products of superior quality.