Orimulsion fly ash in clay bricks—part 3: chemical stability of ash-bearing products

The chemical stability of clay bricks containing Orimulsion ash (up to 6 wt.%) was assessed with a laboratory simulation of the brickmaking process. The development of efflorescence, the amount of water soluble salts and their elution, the fraction of S, V, Ni, Mg, Ca, Na and K immobilized in the ceramic matrix, and the amount of volatile elements potentially released during firing were determined by ICP–OES, XRPD, TGA, SEM and EMP analyses. The stabilizing mechanism acts through the capture of metals into the crystalline structure of silicates formed at high temperature. However, the firing conditions adopted in the brick industry (about 900 °C) do not permit the complete reaction of sulphates; there is considerable efflorescence and soluble salts are formed, even with 1.5% of ash added, producing a risk of sulphate attack to the mortars. On the other hand, the decompostion of sulphates during firing could bring about remarkable SOx emissions, particularly in carbonate-free bodies. In conclusion, the disposal of Orimulsion ash in clay bricks must be practiced with caution and an amount of ash below 1 wt.% weight is strongly recommended.