Sustainable Valorisation of Hazardous MSWI Air Pollution Control Fly Ash in Portland Composite Cement: Performance, Environmental Safety and Circular Economy Perspective

The management of hazardous municipal solid waste incineration (MSWI) residues represents a critical challenge for sustainable development due to their increasing generation and environmental risk. At the same time, the cement industry faces urgent pressure to reduce CO 2 emissions associated with clinker production, creating a demand for alternative supplementary cementitious materials. The aim of this study was to evaluate the feasibility of valorising hazardous municipal solid waste incineration (MSWI) air pollution control fly ash (EWC 19 01 07*) as a constituent of Portland composite cement, in line with circular economy principles and the need to reduce CO 2 emissions associated with clinker production. The investigated fly ash, originating from flue gas cleaning processes, is characterised by high alkalinity and elevated concentrations of heavy metals, which currently necessitate controlled landfilling. To enable its safe reuse, the ash was subjected to high-temperature thermal treatment following granulation and subsequently incorporated into cement formulations under semi-industrial conditions. Two Portland composite cements were produced with different ash contents, corresponding to CEM II/A-07 and CEM II/B-07, while a Portland cement manufactured from the same clinker was used as a reference material. The chemical and phase composition of the ash before and after thermal treatment was analysed using XRF and XRD, supported by SEM/EDS observations. The results demonstrate that thermal treatment at 1150 °C induces partial phase stabilisation of APC fly ash without full vitrification, allowing its integration into cement systems under semi-industrial conditions. The incorporation of ash significantly alters hydration behaviour through increased water demand governed by particle porosity, CaO-rich phase composition, and early ionic interactions in the pore solution, leading to reduced workability and mechanical performance. While immobilisation efficiencies exceeding 99.5% were achieved for most heavy metals due to precipitation and incorporation into hydration products, barium exhibited persistent leaching controlled by its solubility under highly alkaline conditions and limited incorporation into C–S–H phases. These findings define both the technological feasibility and the key environmental constraints of APC fly ash utilisation in Portland composite cement. From a sustainability perspective, the proposed approach contributes to the reduction in hazardous waste landfilling and supports clinker substitution in cement production. The results demonstrate the potential of integrating waste management and low-carbon material design within a circular economy framework while highlighting current environmental limitations related to barium leaching.