Performance of industrial by-products in controlled low-strength materials (CLSM)

As the construction industry continues to recognise the importance of sustainable development, technologies such as controlled low-strength material (CLSM) have come to the forefront as viable means of safely and efficiently using by-product and waste materials in infrastructure applications. CLSM, also known as flowable fill, can be defined as an engineered backfill material containing fine aggregates, Portland cement, water and a by-product material. CLSM can provide an economically and technically feasible alternative to conventional fill materials because of potential cost savings related to its unique and often superior technical properties. In this present experimental study, three industrial by-products, namely fly ash (FA), rice husk ash (RHA) and quarry dust (QD), were used as constituent materials in CLSM. Mixture proportions were developed for CLSM containing these industrial by-products and were tested in the laboratory for various properties, such as flowability, unconfined compressive strength (UCS), stress-strain behaviour, density, water absorption and volume changes. Comparison between the two pozzolanic materials, namely FA and RHA, for their potential to produce an effective CLSM has been made. It can be observed from the results that by-product materials such as FA, RHA and QD can be successfully used in CLSM. This successful utilization of by-product materials is important to sustainable development and is the focus of this research.     

Utilization of high-volume mine tailing and by-products in composite binder production: hardened properties and sustainable development

Journal of Material Cycles and Waste Management - This study was designed to investigate the hardened performance of the paste specimens produced using a composite binder with high volumes of mine...     

Life-cycle impacts of the use of industrial by-products in road and earth construction

A two-stage study "Life cycle analysis of road construction and earthworks" was part of a more extensive Finnish research project "Assessment of the applicability of secondary products in earthworks". In the first stage of this work a life-cycle impact assessment procedure for the comparison and evaluation of alternative road and earth constructions was developed. Additionally, a database containing the environmental burdens of the most significant construction materials and unit operations was constructed. In order to evaluate the applicability of the procedure, the use of coal ash, crushed concrete waste and granulated blast-furnace slag in road construction was evaluated in case studies. The use of these secondary products was also compared with the use of natural materials in corresponding applications. The aim of the second stage was to transfer the assembled data for utilisation as a practical model by creating an inventory analysis program to calculate and compare the life cycle impacts of the most common road constructions and foundation engineering methods. The data obtained in the first stage was also augmented to the extent necessary for this purpose. The results of case studies indicate that the production and transport of the materials used in road constructions produce the most significant environmental burdens. Production of the bitumen and cement, crushing of materials and transport of materials are the most energy consuming single life-cycle stages of the construction. A large part of the emissions to atmosphere originates from energy production. In the expert assessment, consumption of natural materials and leaching behaviour were also regarded as being of great significance.     

Utilization (recycling) of iron and steel industry by-product (GGBS) in concrete: strength and durability properties

Due to exponential growing in urbanization and industrialization, byproducts from industries are becoming an increasing concern for recycling and waste management. Ground granulated blast furnace slag (GGBS) is by-product from the blast-furnaces of iron and steel industries. GGBS is very useful in the design and development of high-quality cement paste/mortar and concrete. This paper covers the properties of GGBS, reaction mechanism, and its effect on strength and durability properties of concrete. Properties covered are sorptivity, microstructure, compressive strength, splitting tensile strength, flexural strength, permeability, sulfate resistance, freezing and thawing resistance, corrosion of concrete.     

Utilization of coal gangue for the production of brick

Journal of Material Cycles and Waste Management - Coal gangue, an industrial solid waste discarded from coal mining and processing, was used as the sole raw material to prepare brick. The coal...     

A feasibility study of thermal hydrolysis by-products as barrier layer materials in the final cover system for a landfill

Most sludge has historically been disposed of in landfills and by ocean dumping but, because of its heavy metal content, this will be totally banned in Korea starting in 2012, based on the London Dumping Convention. Therefore, treatment and disposal methods that are environmentally friendlily are urgently required. The recycling of sewage sludge is a good treatment method for solving sludge problems in an environmentally friendly way. In this study, physical and environmental tests were conducted to evaluate the feasibility of using the by-products of thermal hydrolysis of sewage sludge as barrier layer materials in the final cover systems for landfills. In addition, testing methods for freezing-thawing (KS F 2332) and wetting-drying (KS F 2330) cycles were conducted to assess the effects of cold and hot soil climates starting from pavement. These tests yielded positive results for alternative materials for the barrier layer in a final cover system for a landfill.     

Utilization of Broken Rice for the Production of Poly(3-hydroxybutyrate)

The feasibility of utilizing non edible rice (broken rice) for production of fine materials such as poly(3-hydroxybutyrate) (PHB) was considered as one of the alternative ways of keeping the environment clean for sustainable development. Thus, production of PHB from broken rice by simultaneous saccharification and fermentation (SSF) was investigated. During the SSF process, the rice (15% w/v) material was hydrolyzed to glucose, which was utilized by Cupriavidus necator for growth and production of PHB. The PHB content reached 38% at 58 h fermentation. The PHB had weight average molar mass (Mw) and polydipersity index of 3.82 × 10⁵ (g/mol) and 4.15, respectively. Differential calorimetric scan of the PHB showed a melting temperature (Tm) of 176 °C. Given that the PHB was a homopolymer (which consisted of (R)-3-hydroxybutyric acid monomers), it was thought that broken rice could be a raw material for production of both PHB and (R)-3-hydroxybutyric acid. This SSF process would not only help in the utilization of broken rice or non edible rice, but would also serve as a model for utilization of other raw materials that contain starch for production of PHB.     

Utilization of kaolin processing waste for the production of porous ceramic bodies

The kaolin processing industry generates large amounts of waste in producing countries such as Brazil. The aim of this study was to characterize kaolin processing waste and evaluate its suitability as an alternative ceramic raw material for the production of porous technical ceramic bodies. The waste material was physically and chemically characterized and its thermal behaviour is described. Several formulations were prepared and sintered at different temperatures. The sintered samples were characterized to determine their porosity, water absorption, firing shrinkage and mechanical strength. Fired samples were microstructurally analysed by X-ray diffraction and scanning electron microscopy. The results indicated that the waste consisted of quartz, kaolinite, and mica, and that ceramic formulations containing up to 66% of waste can be used for the production of ceramics with porosities higher than 40% and strength of about 70 MPa.     

The applicability of different waste materials for the production of lightweight aggregates

The applicability of different waste materials for the production of lightweight aggregates has been studied. The following waste materials were investigated: silica sludge, superfluous clay in the quarry, waste glass, and residue from the polishing process of different types of stone. SiC and MnO₂ were selected as foaming agents. Feldspar containing minerals and scrap glass were added in order to lower the softening point of the waste materials. The granules were prepared by mixing together finely ground waste with one or both of the selected foaming agents. The granules were then fired at different temperatures above the softening point of the glassy phase within the temperature range from 1150 to 1220 °C, where the foaming agent degasses, and the resulting gasses remain trapped in the glassy structure. The foaming process was observed by hot-stage microscopy. The properties of the so-obtained granules, such as their apparent density and compressive strength, were determined, and their microstructures were evaluating using SEM and polarizing microscopy.With the addition to clay of polishing residue from granite-like rocks, after firing at 1220 °C homogeneously porous granules with a density down to 0.42 g/cm³ were obtained, whereas with the addition to waste silica sludge of polishing residue from granite-like rocks and waste glass with a foaming agent, after firing at 1220 °C densities from 0.57 to 0.82 g/cm³ were obtained.     

A novel method for preparing phosphorus building gypsum (PBG)-based building materials with low water/gypsum ratios

Journal of Material Cycles and Waste Management - It is necessary to consider the dual problems of poor performance and low production efficiency that stem from the highly utilised water/gypsum...     

Utilization of alum sludge waste for production of eco-friendly blended cement

This work was focused on evaluating the suitability of replacing Portland cement (PC) by 5, 10 and 15 mass % of activated alum sludge waste (AAS) as a pozzolanic material. Exploitation of low-cost nanocomposite for bolstering the physical, mechanical, and stability against firing of PC–AAS-hardened composites was inspected. CuFe₂O₄ spinel nanoparticle with average particle size (~ 50 nm) was prepared. Inclusion of CuFe₂O₄ spinel in different PC–AAS-hardened composites bolsters their physicomechanical features at almost normal curing ages as well as their stability against firing. The positive impact of synthesized CuFe₂O₄ spinel was affirmed via TGA/DTG and XRD techniques, which indicated the presence of diverse hydration yields such as CSHs, CASHs, CFSH, and CuSH that enhance the overall physicomechanical characteristics and thermal stability of various PC–AAS-hardened composites. The composite containing (90 PC–10 AAS waste–2 CuFe₂O₄) offers many benefits from the economic and environmental view.

Graphical abstract

     

Utilization of date stones for production of activated carbon using phosphoric acid

Date stone wastes have been utilized for production of activated carbon by chemical activation with phosphoric acid using a fluidized-bed reactor. The effects of the activation time, activation temperature, impregnation ratio, and particle size on the yield and the adsorptive capacity towards iodine were studied. The yield and the quality of the activated carbon prepared by using H3PO4 were compared with that prepared from date stones using the same equipment, and under similar conditions by using ZnCl2 as an oxidizing agent. The maximum value of the iodine number of the activated carbon produced using H3PO4 in this work was about 495 under the following conditions: impregnation ratio 0.4, activation time 60 min, activation temperature 800 degrees C, particle size 0.60 mm. The iodine number for the produced activated carbon was higher when phosphoric acid was used, compared to that when zinc chloride was used as impregnation reagent; however, the yield obtained when H3PO4 was used was lower than the yield when ZnCl2 was used. The iodine number increases significantly with increasing the activation temperature. By increasing the impregnation ratio at the same temperature, the iodine number decreased sharply and an oscillation is noticed for all the cases but it was clearer at 800 degrees C. The average variation of the iodine number for the whole range of particle size used in this work is +/-10%.     

Utilization of molasses spentwash for production of bioplastics by waste activated sludge

Present study describes the treatment of molasses spentwash and its use as a potential low cost substrate for production of biopolymer polyhydroxybutyrate (PHB) by waste activated sludge. Fluorescence microscopy revealed the presence of PHB granules in sludge biomass which was further confirmed by fourier transform-infra-red spectroscopy (FT-IR) and ¹³C nuclear magnetic resonance (NMR). The processing of molasses spentwash was carried out for attaining different ratios of carbon and nitrogen (C:N). Highest chemical oxygen demand (COD) removal and PHB accumulation of 60% and 31% respectively was achieved with raw molasses spentwash containing inorganic nitrogen (C:N ratio = 28) followed by COD removal of 52% and PHB accumulation of 28% for filtered molasses containing inorganic nitrogen (C:N ratio = 29). PHB production yield (Y_p/s) was highest (0.184 g g^?1 COD consumed) for deproteinized spentwash supplemented with nitrogen. In contrast, the substrate consumption and product formation were higher in case of raw spentwash. Though COD removal was lowest from deproteinized spentwash, evaluation of kinetic parameters suggested higher rates of conversion of available carbon to biomass and PHB. Thus the process provided dual benefit of conversion of two wastes viz. waste activated sludge and molasses spentwash into value-added product-PHB.     

Utilization of amorphous rice husk ash for the synthesis of ZSM-5 zeolite under low temperature

The present study deals with the production and characterization of ZSM-5 zeolite under low temperature using amorphous rice husk ash as an alternative cheap silica source. Rice husk was combusted at various temperatures for the production of amorphous silica. The resulted amorphous silica ash was then utilized without any other treatment as a starting material for the synthesis of ZSM-5 zeolite using low temperature and under atmospheric pressure. For comparison, the high-temperature synthetic approach, the hydrothermal treatment under high temperature and autogenous pressure with the autoclave process, was also applied for the synthesis of ZSM-5 zeolite. The low-temperature method led successfully to the synthesis of highly siliceous zeolite of type ZSM-5. The produced materials were characterized using a variety of analytical techniques, including X-ray diffraction, Fourier transformation infrared spectroscopy, thermogravimetry–differential thermogravimetry analyses, scanning electron microscopy, electron dispersion X-ray analysis and nitrogen porosimetry. The results show that the utilization of an industrial by-product in abundance as a starting material can lead through a simple inexpensive technique to the synthesis of a high value added microporous material with many potential applications.     

Utilization of municipal solid waste incineration fly ash for sulfoaluminate cement clinker production

The feasibility of partially substituting raw materials with municipal solid waste incineration (MSWI) fly ash in sulfoaluminate cement (SAC) clinker production was investigated by X-ray diffraction (XRD), compressive strength and free expansion ratio testing. Three different leaching tests were used to assess the environmental impact of the produced material. Experimental results show that the replacement of MSWI fly ash could be taken up to 30% in the raw mixes. The good quality SAC clinkers are obtained by controlling the compositional parameters at alkalinity modulus (C(m)) around 1.05, alumina-sulfur ratio (P) around 2.5, alumina-silica ratio (N) around 2.0~3.0 and firing the raw mixes at 1250 °C for 2h. The compressive strengths of SAC are high in early age while that develop slowly in later age. Results also show that the expansive properties of SAC are strongly depended on the gypsum content. Leaching studies of toxic elements in the hydrated SAC-based system reveal that all the investigated elements are well bounded in the clinker minerals or immobilized by the hydration products. Although some limited positive results indicate that the SAC prepared from MSWI fly ash would present no immediate thread to the environment, the long-term toxicity leaching behavior needs to be further studied.     

Optimization of co-digestion of various industrial sludges for biogas production and sludge treatment: Methane production potential experiments and modeling

Optimal biogas production and sludge treatment were studied by co-digestion experiments and modeling using five different wastewater sludges generated from paper, chemical, petrochemical, automobile, and food processing industries situated in Ulsan Industrial Complex, Ulsan, South Korea. The biomethane production potential test was conducted in simplex-centroid mixture design, fitted to regression equation, and some optimal co-digestion scenarios were given by combined desirability function based multi-objective optimization technique for both methane yield and the quantity of sludge digested. The co-digestion model incorporating main and interaction effects among sludges were utilized to predict the maximum possible methane yield. The optimization routine for methane production with different industrial sludges in batches were repeated with the left-over sludge of earlier cycle, till all sludges have been completely treated. Among the possible scenarios, a maximum methane yield of 1161.53 m³ is anticipated in three batches followed by 1130.33 m³ and 1045.65 m³ in five and two batches, respectively. This study shows a scientific approach to find a practical solution to utilize diverse industrial sludges in both treatment and biogas production perspectives.     

Benefits of supplementing an industrial waste anaerobic digester with energy crops for increased biogas production

Currently, there is increasing competition for waste as feedstock for the growing number of biogas plants. This has led to fluctuation in feedstock supply and biogas plants being operated below maximum capacity. The feasibility of supplementing a protein/lipid-rich industrial waste (pig manure, slaughterhouse waste, food processing and poultry waste) mesophilic anaerobic digester with carbohydrate-rich energy crops (hemp, maize and triticale) was therefore studied in laboratory scale batch and continuous stirred tank reactors (CSTR) with a view to scale-up to a commercial biogas process. Co-digesting industrial waste and crops led to significant improvement in methane yield per ton of feedstock and carbon-to-nitrogen ratio as compared to digestion of the industrial waste alone. Biogas production from crops in combination with industrial waste also avoids the need for micronutrients normally required in crop digestion. The batch co-digestion methane yields were used to predict co-digestion methane yield in full scale operation. This was done based on the ratio of methane yields observed for laboratory batch and CSTR experiments compared to full scale CSTR digestion of industrial waste. The economy of crop-based biogas production is limited under Swedish conditions; therefore, adding crops to existing industrial waste digestion could be a viable alternative to ensure a constant/reliable supply of feedstock to the anaerobic digester.     

Investigation of the usability of boron industrial waste as filler in conveyor belt production

Journal of Material Cycles and Waste Management - In the rubber industry, fillers are used to improve certain properties of rubber composites and to make rubber compound recipes cheaper. In this...