Municipal solid waste incineration fly ash (FA) can represent a sustainable supply of supplementary material to the construction industries if it is pre-treated to remove hazardous substances such as chloride, sulfate, and heavy metals. In this paper, the phenomenology associated with a water washing multi-cycle treatment of FA is investigated, focusing attention upon the mineral dissolution process. The efficacy of the treatment is assessed by leaching tests, according to the European Standard, and discussed in light of the occurring mineral phases. The water-to-solid (L/S) ratio is a crucial parameter, along with the number of washing cycles, for removing halite and sylvite, whereas quartz, calcite, anhydrite, and an amorphous phase remain in the solid residue. The sequential extraction method and dissolution kinetics modelling provide further elements to interpret leaching processes, and suggest that dissolution takes place through a two-step mechanism. Altogether, multi-step washing with L/S = 5 is effective in reducing contaminants under the legal limits for non-hazardous waste disposal, while the legal limits for non-reactive or reusable material cannot be completely reached, owing to sulfate and some heavy metals which still leached out from the residue.

Municipal solid waste (MSW) and refuse-derived fuel (RDF) incineration generate over 20 million tons of residues annually in the EU. These include bottom ash (IBA), fly ash (FA), and air pollution control residues (APCr), which pose significant environmental challenges due to their leaching potential and hazardous properties. While these residues contain valuable metals and reactive mineral phases suitable for carbonation or alkaline activation, chemical, techno-economic, and policy barriers have hindered the implementation of sustainable, full-scale management solutions. Accelerated carbonation technology (ACT) offers a promising approach to simultaneously sequester CO₂ and enhance residue stability. This review provides a comprehensive assessment of waste incineration residue carbonation, covering 227 documents ranging from laboratory studies to field applications. The analysis examines reactor designs and process layouts, with a detailed classification based on material characteristics, operating conditions, investigated parameters, and the resulting pollutant stabilization, CO₂ uptake, or product performance. In conclusion, carbonation-based approaches must be seamlessly integrated into broader waste management strategies, including metal recovery and material repurposing. Carbonation should be recognized not only as a CO₂ sequestration process, but also as a binding and stabilization strategy. The most critical barrier remains chemical: the persistent leaching of sulfates, chromium(VI), and antimony(V). We highlight what we refer to as the antimony problem, as this element can become mobilized by up to three orders of magnitude in leachate concentrations. The most pressing research gap hindering industrial deployment is the need to design stabilization approaches specifically tailored to critical anionic species, particularly Sb(V), Cr(VI), and SO₄²⁻.

Treatments to reduce the leaching of contaminants (chloride, sulfate, heavy metals) into the environment from bottom ash (BA) are investigated, as a function of the ash’s particle size (s). The aim is to make BA suitable for reuse as secondary raw material, in accordance with the legal requirements. Such treatments must be economically feasible and, possibly, have to use by-products of the plant (in this case, steam in excess from the turbine). For the sake of completeness and comparison, carbonation is performed on those BA particle size classes that are not positively responsive to steam washing. BA is partitioned into four different particle size classes (s ≥ 4.75, 4.75 > s ≥ 2, 2 > s ≥ 1 and s < 1 mm, corresponding to 36, 24, 13 and 27 wt%, respectively). In the case of s ≥ 2 mm (60 wt%), steam washing is effective in reducing to under the legal limits the leaching of chlorides, sulfate and heavy metals (Zn, Cu, Cd, Pb). It has been observed that steam washing causes both removal and dissolution of thin dust adherent to the BA’s surface. BA with 2 > s ≥ 1 (~13 wt% of total BA) requires a combination of steam washing and carbonation to achieve a leaching below the legal limits. The finest BA fraction, s < 1 mm (~27 wt% of total BA), is treated by carbonation, which reduces heavy metals leaching by 85%, but it fails to sufficiently curb chlorides and sulfates.