Use of ready-mixed concrete plant sludge water in concrete containing an additive or admixture

In this study, we investigated the feasibility of using sludge water from a ready-mixed concrete plant as mixing water in concrete containing either fly ash as an additive or a superplasticizer admixture based on sulfonated naphthalene-formaldehyde condensates (SNF). The chemical and physical properties of the sludge water and the dry sludge were investigated. Cement pastes were mixed using sludge water containing various levels of total solids content (0.5, 2.5, 5, 7.5, 10, 12.5, and 15%) in order to determine the optimum content in the sludge water. Increasing the total solids content beyond 5–6% tended to reduce the compressive strength and shorten the setting time. Concrete mixes were then prepared using sludge water containing 5–6% total solids content. The concrete samples were evaluated with regard to water required, setting time, slump, compressive strength, permeability, and resistance to acid attack. The use of sludge water in the concrete mix tended to reduce the effect of both fly ash and superplasticizer. Sludge water with a total solids content of less than 6% is suitable for use in the production of concrete with acceptable strength and durability.     

Effects of nano-SiO(2) and different ash particle sizes on sludge ash-cement mortar

The effects of nano-SiO₂ on three ash particle sizes in mortar were studied by replacing a portion of the cement with incinerated sewage sludge ash. Results indicate that the amount of water needed at standard consistency increased as more nano-SiO₂ was added. Moreover, a reduction in setting time became noticeable for smaller ash particle sizes. The compressive strength of the ash–cement mortar increased as more nano-SiO₂ was added. Additionally, with 2% nano-SiO₂ added and a cure length of 7 days, the compressive strength of the ash–cement mortar with 1 μm ash particle size was about 1.5 times better that of 75 μm particle size. Further, nano-SiO₂ functioned to fill pores for ash–cement mortar with different ash particle sizes. However, the effects of this pore-filling varied with ash particle size. Higher amounts of nano-SiO₂ better influenced the ash–cement mortar with larger ash particle sizes.     

Use of silicon and ferrosilicon industry by-products (silica fume) in cement paste and mortar

With increased environmental awareness, recycling/utilization of industrial byproducts is gaining ground. One such by-product is silica fume (SF), which is byproduct of the smelting process in the silicon and ferrosilicon industry. By-products of the production of silicon metal and the ferrosilicon alloys having silicon contents of 75% or more contain 85-95% non crystalline silica. Silica fume is very useful in the design and development of high quality cement paste/mortar and concrete.This paper presents comprehensive details of the physical, chemical, properties, and its reaction mechanism. It also covers the hydration characteristics, consistency, setting times, workability and compressive strength of cement paste and mortar.     

The reuse of municipal solid waste incinerator fly ash slag as a cement substitute

The results of the treatment of fly ash from a municipal solid waste incinerator (MSWI) by melting are described, and the safety and the effectiveness of using the slag produced by this melting treatment are studied. The properties of the MSWI fly ash slag were analyzed, to evaluate the feasibility of its reuse as a substitute for part of the cement required in mortar preparation. This MSWI fly ash slag was found to be comprised mainly of SiO₂ and CaO, which can be substituted for up to 20% of the cement content in mortar, without sacrificing the quality of the resultant concrete. In fact, the concrete thus produced has greater compressive strength, 10% higher than that without the substitution. The setting time of the fresh mortar becomes lengthens as increasing amounts of cement are replaced; while the spread flow value increases with the increasing percentage of cement substitution. X-ray diffraction analysis reveals that when the W/C=0.38 and the curing AGE=28 days, the crystal patterns in the mortar samples, prepared with different amounts of cement having been replaced by MSWI fly ash slag are similar. According to the results of the toxic characteristic leaching procedure analysis, MSWI fly ash slag should be classified as general non-hazardous industrial waste, that meets the effluent standard. Therefore, the reuse of MSWI fly ash slag is feasible, and will not result in pollution due to the leaching of heavy metals.     

Utilization of cement kiln dust (CKD) in cement mortar and concrete—an overview

Solid waste management is one of the major environmental concerns around the world. Cement kiln dust (KKD), also known as by-pass dust, is a by-product of cement manufacturing. The environmental concerns related to Portland cement production, emission and disposal of CKD is becoming progressively significant. CKD is fine-grained, particulate material chiefly composed of oxidized, anhydrous, micron-sized particles collected from electrostatic precipitators during the high temperature production of clinker. Cement kiln dust so generated is partly reused in cement plant and landfilled. The beneficial uses of CKD are in highway uses, soil stabilization, use in cement mortar/concrete, CLSM, etc.Studies have shown that CKD could be used in making paste/mortar/concrete. This paper presents an overview of some of the research published on the use of CKD in cement paste/mortar/concrete. Effect of CKD on the cement paste/mortar/concrete properties like compressive strength, tensile strength properties (splitting tensile strength, flexural strength and toughness), durability (Freeze–thaw), hydration, setting time, sorptivity, electrical conductivity are presented. Use of CKD in making controlled low-strength materials (CLSM), asphalt concrete, as soil stabilizer, and leachate analysis are also discussed in this paper.     

Utilization of cement kiln dust (CKD) in cement mortar and concrete—an overview

Solid waste management is one of the major environmental concerns around the world. Cement kiln dust (KKD), also known as by-pass dust, is a by-product of cement manufacturing. The environmental concerns related to Portland cement production, emission and disposal of CKD is becoming progressively significant. CKD is fine-grained, particulate material chiefly composed of oxidized, anhydrous, micron-sized particles collected from electrostatic precipitators during the high temperature production of clinker. Cement kiln dust so generated is partly reused in cement plant and landfilled. The beneficial uses of CKD are in highway uses, soil stabilization, use in cement mortar/concrete, CLSM, etc.Studies have shown that CKD could be used in making paste/mortar/concrete. This paper presents an overview of some of the research published on the use of CKD in cement paste/mortar/concrete. Effect of CKD on the cement paste/mortar/concrete properties like compressive strength, tensile strength properties (splitting tensile strength, flexural strength and toughness), durability (Freeze–thaw), hydration, setting time, sorptivity, electrical conductivity are presented. Use of CKD in making controlled low-strength materials (CLSM), asphalt concrete, as soil stabilizer, and leachate analysis are also discussed in this paper.     

Application of recycled paper sludge and biomass materials in manufacture of green composite pallet

Rice straw, rice husk and paper sludge are by-products and industrial waste, and are beneficial resources as raw biomass materials used for manufacturing value-added composite products. We investigated the effect on selected mechanical properties of adding rice straw, rice husk and paper sludge to wood composites to replace wood particles for manufacturing green pallets. Results showed that increasing the contents of rice straw and rice husk dramatically decreased the mechanical strength of the composites. This is because the wax and silicate coating of these materials obstructed the strong bonding with UF resin. When 10 wt.% of wood particle was replaced with 10 wt.% of paper sludge, the wood–paper sludge composites showed similar mechanical properties to those of wood particle. Wood particle can be replaced by 10 wt.% of dried paper sludge in accordance with the minimum requirement recommended by standards in green pallet manufacturing.     

Utilization of washed MSWI fly ash as partial cement substitute with the addition of dithiocarbamic chelate

The management of the big amount of fly ash as hazardous waste from the municipal solid waste incinerator (MSWI) has encountered many problems in China. In this study, a feasibility research on MSWI fly ash utilization as partial cement substitute in cement mortars was therefore carried out. MSWI fly ash was subjected to washing process to reduce its chlorine content (from 10.16% to 1.28%). Consequently, it was used in cement mortars. Ten percent and 20% replacement of cement by washed ash showed acceptable strength properties. In TCLP and 180-day monolithic tests, the mortars with washed ash presented a little stronger heavy metal leachability, but this fell to the blank level (mortar without washed ash) with the addition of 0.25% chelate. Therefore, this method is proposed as an environment-friendly technology to achieve a satisfactory solution for MSWI fly ash management.     

Strength and workability of masonry mortars manufactured with ladle furnace slag

Ladle furnace basic slag (LFS) is a by-product of the steelmaking process. It has rarely been recovered in the past and is usually disposed of in landfill sites. Despite containing stable chemical substances of great quality, some of which are potentially hydraulic, its practical applications have been limited. This paper discusses the attractive option of using LFS in the manufacture of masonry mortars for use in the construction industry, which requires an analysis of the principal characteristics of such mortars, i.e. workability and mechanical strength. It reports on a comparative study, using standard commercial admixtures, between conventional masonry mortars and mortars manufactured with LFS as a partial replacement for sand and cement, the results of which imply considerable economic savings in sand and cement, improvements in the properties of the mortars and in overall sustainability, by avoiding disposal and conserving natural resources.     

The implementation of wood waste ash as a partial cement replacement material in the production of structural grade concrete and mortar: An overview

The timber manufacturing and power generation industry is gradually shifting towards the use of biomass such as timber processing waste for fuel and energy production and to help supplement the electrical energy demand of national electric gridlines. Though timber processing waste is a sustainable and renewable source of fuel for energy production, the thermal process of converting the aforementioned biomass into heat energy produces significant amounts of fine wood waste ash as a by-product material which, if not managed properly, may result in serious environmental and health problems. Several current researches had been carried out to incorporate wood waste ash as a cement replacement material in the production of greener concrete material and also as a sustainable means of disposal for wood waste ash. Results of the researches have indicated that wood waste ash can be effectively used as a cement replacement material for the production of structural grade concrete of acceptable strength and durability performances. This paper presents an overview of the work carried out by the use of wood waste ash as a partial replacement of cement in mortar and concrete mixes. Several aspects such as the physical and chemical properties of wood waste ash, properties of wood waste ash/OPC blended cement pastes, rheological, mechanical and the durability properties of wood waste ash/OPC concrete mix are detailed in this paper.     

Properties of steel foundry electric arc furnace dust solidified/stabilized with Portland cement

Electric arc furnace dust from steel production is generated in considerable amounts worldwide and needs to be treated as hazardous waste. The aim of this study was to investigate the properties of electric arc furnace dust solidified/stabilized by using Portland cement. Mortar and paste samples were prepared with varying waste-to-binder ratios between 0% and 90%. A comprehensive experimental program was designed including XRF characterization, setting time, unconfined compressive strength, and toxicity characteristics leaching procedure (TCLP), synthetic precipitation leaching procedure (SPLP), and acid neutralization capacity (ANC) tests. The results were evaluated in order to determine if the solidified /stabilized product can be disposed of at a landfill site with domestic waste or at a segregated landfill. The effect of using sand on S/S performance was also investigated. The results indicated that the solidification /stabilization process using PC helps the heavy metals to be bound in the cement matrix, but the TCLP leaching results exceeded the EPA landfilling limits. The SPLP leaching results conformed to the limits implying that the waste or S/S products can be disposed of at a segregated landfill; however the low ANC of the S/S products reveals that there may be leaching in the long-term. The sand used in the mortar samples adversely affected the S/S performance, causing higher heavy metal leaching levels, and lower pH levels in the leachate after the TCLP extraction than those measured in the leachate of the paste samples.     

Laboratory stabilization/solidification of tank sludges: maximizing sludge loading

Highly radioactive, mixed-waste sludges that have been collected in tanks at Oak Ridge over several decades are being combined for treatment and disposal. Stabilization of the sludges in the different tank sets was tested prior to the proposed combination and treatment. This paper is the third one in a series on the laboratory stabilization/solidification of these tank sludges. It discusses efforts to maximize the sludge loading with no strength criterion for the grout formulation. Grout formulations were tested in the laboratory both with surrogates and with actual samples of tank sludge. Hydrogels eliminated free water generation, even at sludge loadings of >90wt%, albeit strong monoliths did not form at such high loadings. Correlations established the dependence of the chromium and mercury performance in the Toxicity Characteristic Leach Procedure for the surrogates on the slag content of the grout while the lead performance depended on the extract pH. The surrogate sludge loading was limited by the chromate content to about 90wt%, meeting Universal Treatment Standard limits. However, tests with actual sludges at such high loadings revealed problems with lead and silver stabilization that were not experienced with the surrogate testing.     

Waste high impact polystyrene (HIPS) microfiltration membranes for water treatment: A thorough experimental study

In our previous work, the prepared high-impact polystyrene (HIPS) membranes, synthesized using four concentrations (20, 25, 30, and 35 wt%) of waste HIPS, were proved to be promising for water purification by microfiltration process (MF). However, the fabricated membranes' mechanical properties and microfiltration process parameters were not investigated. Consequently, in this study, various parameters affecting the previously fabricated membranes' performance in the filtration process, such as membrane mechanical properties, feeding pressure, fouling behavior, and polymer concentration, were thoroughly investigated. With increasing polystyrene concentrations, the ultimate tensile strength of the fabricated membranes increased. When the concentration was increased from 20 to 25 wt percent, the elongation at break rose, but as the concentration was increased further, the membrane became brittle. Permeate flux and rejection both declined as polymer content was raised. Accordingly, the highest flux and humic acid (HA) rejection were shown by 20 wt% (14.18 L/m²h (LMH) and 98.95%, respectively). The antifouling properties declined when the polymer concentration was raised, and 20 wt% had the lowest total fouling resistance. Furthermore, the permeate flux was reduced while increasing the HA initial concentration.     

Evaluation of sulfate resistance of cement mortars containing black rice husk ash

In this paper, black rice husk ashes (BRHAs), which are agrowastes from an electricity generating power plant and a rice mill, were ground and used as a partial cement replacement. The durability of mortars under sulfate attack including expansion and compressive strength loss were investigated. For parametric study, BRHA were used as a Portland cement Type 1 replacement at the levels of 0%, 10%, 30%, and 50% by weight of binder. The water-to-binder ratios were 0.55 and 0.65. For the durability of mortar exposed to sulfate attack, 5% sodium sulfate (Na₂SO₄) and magnesium sulfate (MgSO₄) solutions were used. As a result, when increasing the percentage replacement of BRHA, the expansion and compressive strength loss of mortar decreased. At the replacement levels of 30% and 50% of BRHA, the expansion of the mortars was less than those mixed with sulfate-resistant cement. However, the expansion of the mortars exposed to Na₂SO₄ was more than those exposed to MgSO₄. Increasing the replacement level of BRHA tends to reduce the compressive strength loss of mortars exposed to Na₂SO₄ attack. In contrary, under MgSO₄ attack, when increasing the replacement level of BRHA, the compressive strength loss increases from 0% to 50% in comparison to Portland cement mortar. Results show that ground BRHA can be applied as a pozzolanic material to concrete and also improve resistance to sodium sulfate attack, but it can impair resistance to magnesium sulfate attack.     

The effects of recovering fibre and fine materials on sludge dewatering properties at a deinked pulp mill

The manufacture of deinked pulp generates large amounts of waste for disposal. The yield loss in the production of recycled paper can be up to 25%. The use of landfills for waste disposal is very expensive and will be prohibited in Europe in the next few years. Thus, there is a great pressure to improve the material efficiency and to reduce the amount of waste that is produced at deinked pulp mills. However, the issue is complex because an improvement of the material efficiency at one process unit may deteriorate the performance of other stages. For example, the attempts to increase the fibre yield in the deinking processes can lead to poor sludge dewatering properties, resulting in that there are no added advantages for the mill anymore.This work aims to determine the limitations between the sludge dewatering properties and the improvements in material efficiency at a deinked pulp mill by investigating the dewatering properties of sludge samples that contained variable amounts of fine screening and flotation froth rejects. The results show that the deinked pulp mill material efficiency can be increased without weakening the sludge dewatering properties if the fibre content is not reduced below a certain limit. The material efficiency can be increased either by (1) recovering fibres at an acceptable quantity where the fibre content does not decrease below the limiting point or by (2) recovering fine materials simultaneously with fibres in a way that maintains the fibre content above a limiting point. The first method provides an opportunity for deinking mills to increase the yield, even though the increase is less than 2 percentage units. With the simultaneous recovery of fibres and fine materials using the second method, it would be possible to improve the material efficiency at the deinked pulp mill by approximately 5 percentage units without affecting the dewatering of the combined sludge.     

Performance of lime-BHA solidified plating sludge in the presence of Na2SiO3 and Na2CO3

This research investigated the performance of lime-BHA (black rice husk ash) solidified plating sludge with 2 wt% NaO from Na(2)SiO(3) and Na(2)CO(3) at the level of 0, 30 and 50 wt%. The sludge was evaluated for strength development, leachability, solution chemistry and microstructure. The lime-BHA solidified plating sludge with Na(2)SiO(3) and Na(2)CO(3) had higher early strength when compared to the control. The addition of Na(2)SiO(3) and Na(2)CO(3) increased the OH(-) concentration and decreased the Ca(2+) and heavy metal ions in solution after the first minute. The XRD patterns showed that the addition of Na(2)SiO(3) resulted in the formation of calcium silicate hydrates, while the addition of Na(2)CO(3) resulted in CaCO(3). The heavy metals from the plating sludge, especially Zn, were immobilized in calcium zincate and calcium zinc silicate forms for the lime-BHA with and without Na(2)SiO(3) solidified wastes, while samples with Na(2)CO(3) contained Zn that was fixed in the form of CaZnCO(3). The cumulative leaching of Fe, Cr and Zn from the lime-BHA solidified plating sludge decreased significantly when activators were added, especially Na(2)CO(3).     

含油污泥特性分析与研究

含油污泥的性质决定其处理工艺及无害化、资源化利用的方式。通过对某油田原油处理系统和污水处理系统产生的含油污泥的理化性质及成分进行检测分析,探讨含油污泥的含油率、含水率、挥发固体、灰分、硫含量、pH值的测定方法,并从以上几个方面对含油污泥的理化性质进行了分析,为下一步含油污泥减量化、资源化、无害化处理提供技术选择的依据。     

Activated fly ash/slag blended cement

This paper presents the results of the preparation of an ecological cementing material from granulated blast-furnace slag (GBFS) and Class C fly ash (CCFA). The desulphurization gypsum, calcined at 600–800 °C for 0.5–1.5 h, works as the main ingredient of the activator in the cementing material. The optimized formulation of the cementing material was obtained with the aid of factorial design method: slag, 70%; CCFA, 18%; activator, 12%. The “partial super-fine grinding process” was adopted to improve the performance, i.e., 85% of the mixture is ground to Blaine fineness of 3500 cm²/g, 15% further ground to around 5000 cm²/g. The compressive strength of 28 days of the cement mortar is up to 49 MPa and flexural strength 8.4 MPa. The hydration products, investigated by SEM and X-ray diffraction, are mainly ettringite and C–S–H gel.     

Utilization of municipal solid waste (MSW) ash in cement and mortar

Solid waste management is gaining significant importance with the ever-increasing quantities of waste materials generated these days. With increased environmental awareness and its potential hazardous effects, recycling/utilization of these materials have become an attractive alternative to disposal. Some of these waste and hazardous materials could possible be used in cement-based materials. One of such waste is municipal solid waste. Ash is obtained after incineration of MSW.This paper presents comprehensive details of the physical, chemical, and mineralogical composition, elemental analysis of ash obtained from MSW. It also covers the effect of MSW ash on the hydration characteristics, setting times, compressive strength, sulfate resistance and mass loss of cement and mortar. It also deals with the leachate analysis of MSW ash.     

Manufacture of strand board made from construction scrap wood

The objective of this research was to evaluate the physical and mechanical properties of strand board made from construction scrap wood. The strand board was manufactured using Sugi (Cryptomeria japonica D. Don) and Douglas-fir (Pseudotsuga japonica) strands selected from construction scrap wood. The strands were oriented, and three-layer (face/core/face) strand board of three types was produced: one in which the strands of the face layer were oriented at a right angle to those of the core layer (R board), another in which the strands of the face layer were oriented parallel to those of the core layer (P board), and a third in which the strands of both layers were oriented at random (Ra board). The physical and mechanical properties of the boards were evaluated based on Japanese Industrial Standard (JIS). The main results obtained are as follows: the bending strength of the strand board with a density larger than 0.55 g/cm³ exceeded the standard value of type 18 particleboard of JIS A 5908. The bending strength of the strand board was affected by board density, strand orientation and resin content, and became larger with increased density as well as resin content. That of the parallel specimen of P board was the largest among the specimen-orientations and types. The internal bond strength of the strand board with a density larger than 0.55 g/cm³ exceeded the standard value of type 18 particleboard and type 24-10 particleboard of JIS A 5908. The internal bond strength was markedly affected by the resin content of the core layer, and became larger with increased density. The thickness swelling of the strand board decreased with increased resin content, and become larger with increased density.