Flue gas desulfurization gypsum and coal fly ash as basic components of prefabricated building materials

► Use of industrial by-products in the manufacture of prefabricated building materials. ► Study on hydrothermal reactions of flue gas desulfurization gypsum, fly ash and lime. ► Both ettringite and calcium silicate hydrate formed as useful binding products. ► Within the investigated ranges 55–85°C and 2h–7d, ettringite formed at a higher rate. ► Conversion toward binding products was highest at 70°C and increased with curing time. The manufacture of prefabricated building materials containing binding products such as ettringite (6CaO·Al2O3·3SO3·32H2O) and calcium silicate hydrate (CSH) can give, in addition to other well-defined industrial activities, the opportunity of using wastes and by-products as raw materials, thus contributing to further saving of natural resources and protection of the environment. Two ternary mixtures, composed by 40% flue gas desulfurization (FGD) gypsum or natural gypsum (as a reference material), 35% calcium hydroxide and 25% coal fly ash, were submitted to laboratory hydrothermal treatments carried out within time and temperature ranges of 2h–7days and 55–85°C, respectively. The formation of (i) ettringite, by hydration of calcium sulfate given by FGD or natural gypsum, alumina of fly ash and part of calcium hydroxide, and (ii) CSH, by hydration of silica contained in fly ash and residual lime, was observed within both the reacting systems. For the FGD gypsum-based mixture, the conversion toward ettringite and CSH was highest at 70°C and increased with curing time. Some discrepancies in the hydration behavior between the mixtures were ascribed to differences in mineralogical composition between natural and FGD gypsum.