New Materials in Civil Engineering.

 Rice husk ash

Rice husks are the hard protective coverings of rice grains which are separated from the grains during milling process. Rice husk is an abundantly available waste material in all rice producing countries, and it contains about 30%–50% of organic carbon. In the course of a typical milling process, the husks are removed from the raw grain to reveal whole brown rice which upon further milling to remove the bran layer will yield white rice. Current rice production in the world is estimated to be 700 million tons. Rice husk constitutes about 20% of the weight of rice and its composition is as follows: cellulose (50%), lignin (25%–30%), silica (15%–20%), and moisture (10%–15%). Bulk density of rice husk is low and lies in the range 90–150 kg/m3.

Sources of rice husk ash (RHA) will be in the rice growing regions of the world, as for example China, India, and the far-East countries. RHA is the product of incineration of rice husk. Most of the evaporable components of rice husk are slowly lost during burning and the primary residues are the silicates. The characteristics of the ash are dependent on composition of the rice husks, burning temperature, and burning time. Every 100 kg of husks burnt in a boiler for example will yield about 25 kg of RHA. In certain areas, rice husk is used as a fuel for parboiling paddy in rice mills, whereas in some places it is field-burnt as a local fuel. However, the combustion of rice husks in such cases is far from complete and the partial burning also contributes to air pollution. The calorific value of rice husks is about 50% of that of coal, and assuming that husks have about 8%–10% of moisture content and zero bran, the calorific value is estimated to be 15 MJ/kg. Under controlled burning conditions, the volatile organic matter in the rice husk consisting of cellulose and lignin are removed and the residual ash is predominantly amorphous silica with a (microporous) cellular structure (Fig. 13.1). Due to its highly microporous structure, specific surface area of RHA as determined by the Brunauer–Emmett–Teller (BET) nitrogen adsorption method can range from 20 to as high as 270 m2/g, while that of silica fume, for example is in the range of 18–23 m2/g.

 

The chemical composition of RHA is significantly dependent on combustion conditions, and the burning temperature must be controlled to keep silica in an amorphous state. The ash obtained from uncontrolled combustion (as in open-field burning or in industrial furnaces at temperatures greater than 700°C–800°C) will contain significant amounts of cristobalite and tridymite which are nonreactive silica minerals. In order to develop pozzolanic activity, such ashes will be required to be ground to a very fine particle size which is likely to make their use financially unviable. Under controlled combustion (burning temperatures in the range of 500°C–700°C for a period of about 1 hour), amorphous silica is the major constituent of ash whose reactivity is attributed to the presence of this form of silica and to its very large surface area resulting from the microporous structure of ash particles. Although reactivity of a pozzolanic material improves upon increasing its fineness, Mehta and Monteiro (1997) reckon that grinding RHA to a high degree of fineness is not advisable since this material derives its pozzolanic activity from the internal surface area of its microporous particles which is already very high. When obtained from controlled combustion, the specific surface (as measured using nitrogen adsorption) of RHA can be as high as 50,000 m2/kg even though the particle size may be in the range of 10–75 μm, which is large when compared to that of silica fume for example. The average composition of well-burnt RHA is 90% amorphous silica, 5% carbon, and 2% K2O.

The applications of RHA include its use as a pozzolan in the construction industry, as a filler, additive, abrasive agent, oil adsorbent, sweeping component, and as a suspension agent for porcelain enamels. In the construction industry, RHA can be used as a partial replacement for cement. According to Chandrasekhar et al. (2006), each application requires specific properties such as reactivity for cement and concrete, chemical purity for synthesizing advanced materials, whiteness, and proper particle size for filler applications and high surface area and porosity for use as an adsorbent and catalyst. If used as a supplementary cementitious material in concrete, for example, RHA particles may have a high water demand due to their porous microstructure. This can be controlled by intergrinding the RHA particles with clinker during the process of cement manufacture so as to breakdown the porous structure and thereby reduce water demand. If intergrinding is not possible, then RHA may be used by blending it with cement at site. RHA in the blended cement will fix free lime released by clinker silicates during their hydration. The amorphous silica in the RHA can react with Ca(OH)2 in the secondary hydration reaction to form a kind of C-S-H gel, which has a floc-like morphology with a porous structure and large specific surface. The formation of the additional C-S-H contributes to both strength development and enhanced durability of concrete since in the secondary hydration reaction the free lime is converted into C-S-H gel which is insoluble in water. Fig. 13.2 presents a schematic illustration of the hydration mechanism proposed by Hwang and Chandra (1997) of cement paste containing RHA. RHA in blended cement is known to contribute to concrete strength from as early as 1–3 days of maturing. In addition to its contribution to strength, even at relatively small replacement dosages of 10% by weight of cement, RHA can produce a strong transition zone and very low permeability in hardened concrete in addition to significant reduction of bleeding in fresh concrete. Since Portland cement (PC) is typically the most expensive constituent of concrete, replacement of a part of it with RHA offers improved concrete affordability, particularly for developing countries.

 Utilization of industrial by-products and natural ashes in mortar and concrete development of sustainable construction materials

Physical properties

RHA is grayish-black in color due to unburned carbon. At burning temperatures of 550–800 °C, amorphous silica is formed, while crystalline silica is produced at higher temperatures. The specific gravity of RHA varies from 2.11 to 2.27; it is highly porous and light weight, with a very high specific surface area. Table 11.13 shows the physical properties of RHA reported by several researchers. shows images of RHA as received and after burning at 700 °C for 6 h (Della et al., 2002). Typically, RHA is used in the form of ground RHA, having typical particle sizes generally less than 10 ìm; natural RHA (NRHA) has larger sizes of approximately 100 ìm.

   

The properties of compressed earth-based (CEB) masonry blocks

Rice husk ash

Rice husk ash (RHA) is an abundantly available and renewable agriculture by-product from rice milling in the rice-producing countries. It has the highest proportion of silica content among all plant residues (Siddique, 2008; Xu, Lo, & Memon, 2012; Yalçin & Sevinç, 2001). A rice mill turns the paddy plant into 78% rice, 20% rice husk and 2% is lost in the process (Ash, 2010). The rice husk contains about 50% cellulose, 25–30% lignin and 15–20% silica (Ismail & Waliuddin, 1996). Hence, after the combustion, one-fifth to one-quarter of the rice husk will change into ash.

Rice husk is difficult to ignite and does not burn easily with an open flame, unless air is blown through the husk. Also, it has a high average calorific value of 3410 kcal/kg. Therefore, it is a good, renewable energy source. Rice husk can be used as an alternative energy source, i.e. as the fuel in the boiler of a rice-milling kiln to generate electricity where the heating value of the husk ranges from 12.6 MJ/kg (Xu et al., 2012) to 13.34–16.20 MJ/kg (Mansaray & Ghaly, 1997) to 15.7 MJ/kg, of which 18.8% is carbon, 62.8% is volatile materials, and 9.3% is moisture content (Ekasilp, Soponronnarit, & Therdyothin, 1995; Thorburn, 1982), and even up to 17 MJ/kg (Ferraro, Nanni, Vempati, & Matta, 2010).

The end product of RH in the boiler is RHA, which for the most part will end up as waste since it has little or no commercial value. Its disposal also evokes environmental problems because RHA does not biodegrade easily (Beagle, 1978) and it generates pollution, which has caused health problems to the inhabitants. In Uruguay, RHA was thrown into the river and brought about great contamination and ecological concern (Sensale, 2006).

CEB made of clay, calcium hydroxide (Ca(OH)2) and fine-grind uncontrolled burnt RHA can reach a maximum dry compression strength up to 20.7 MPa, with the best proportion of lime and RHA 1: (Muntohar, 2011). In another experiment (Riza, 2011), the best result in compressive strength was attained by a sample with a ratio of  RHA and lime equal to 0.25:0.75 in the fourteenth day, with 3.62 MPa, and its twenty-eighth-day strength was 3.48 MPa. Overall trends indicate that increasing RHA proportion in a mix ratio will consequently reduce the strength.

Porous concrete pavement containing nanosilica from black rice husk ash

Grinding procedure

Initially, the raw BRHA was sieved using a sieve size of 150 µm. The purpose of sieving the BRHA is to ensure the homogeneity of the BRHA size before the grinding process. Then, the BRHA passing through the 150 µm sieve was taken and ground for four different grinding periods. Each BRHA ground for four different grinding periods was designated as shown in Table 14.3. The BRHA was ground by a laboratory mill grinder, as shown in Fig. 14.4. The drum, balls, and rods used in this study were made from steel. Each drum contained one size of steel rods and four different sizes of steel balls. The milling speed used in this procedure was 60 rev/min. During the grinding process, each drum contained 500 g BRHA. The same amount of BRHA was placed in each drum for the following grinding process to ensure the consistency of the ground BRHA property. Fig. 14.5 shows the nanosized ground black RHA.

 

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