Recycling PC and TV waste glass in clay bricks and roof tiles

Disposal of PC monitors and TV sets is a growing problem, with over 40% of the weight of these systems comprised of waste glasses with high Pb (funnel) or Ba–Sr concentrations (panel), making them unsuitable for recycling and manufacturing new glass. A possible way to re-use these glasses is in the manufacturing of clay bricks and roof tiles. This possibility was appraised by laboratory simulation of the brickmaking process and technological characterization of unfired and fired products. The recycling of both funnel and panel glasses into clay bodies is technologically feasible, resulting in a substantially reduced plasticity behaviour during shaping–drying (implying a reduction of mechanical strength), and a promotion of sintering during firing. No significant release of Pb, Ba, and Sr was observed during the firing and leaching test for the carbonate-poor body; in contrast, some Pb volatilization during firing and Sr leaching were observed for the carbonate-rich body. Additions of 2 wt.% appear to be practicable, while 5 wt.% glass induces unacceptable modifications of technological properties. The recommended amount is within 2 and 4 wt.%, depending on the characteristics of the clay bodies. The main constraint is that the glass must have a particle size below the limit of the pan mills used in brickmaking (<1 mm).     

Management of agricultural biomass wastes: Preliminary study on characterization and valorisation in clay matrix bricks

In this work the feasibility of using woody agricultural biomass wastes as grapes and cherries seeds, sawdust, as pore forming agent, and sugar cane ash, as silica precursor, in bricks, were reported.Sawdust and grapes and cherries seeds, thanks to their organic substances content, during their combustion, bring an energetic support in the bricks firing phase and act as pore forming agent. Usually the addition of this kind of waste is limited to 10 wt.% in order to reach an equilibrium between positive (weight and shrinkage decrease and porosity increase) and negative (increase of water absorption and mechanical resistance decrease) effects. The results show that grapes and cherries seeds, added in a percentage of 5 wt.% to a brick formulation, have better influence with respect to the sawdust, maintaining the mechanical properties of the fired brick (950 °C), showing modulus of rupture around 21–23 MPa with a weight reduction of 3–10% (respect to the standard one). Regarding the sugar cane ash, the addition of 5 wt.% improves the mechanical properties (modulus of rupture around 27 MPa) and no weight decrease is observed. These results confirmed the role played by this kind of agricultural waste, which thanks to its high silica content (61 wt.%) is capable to demonstrate a filler and plasticity reducing effect on the brick bodies. Tests carried out highlighted that the addition of these by-products (5 wt.%) do not change negatively the main technological properties measured (water absorption, linear shrinkage, flexural resistance, etc.) and permit to hypothesize their use to obtain bricks with both insulating and higher mechanical properties using a pore agent forming or silica carrier alternative raw materials, respectively.     

Effects of using arsenic–iron sludge wastes in brick making

The arsenic–iron sludge generated in most of the treatment systems around the world is discharged into the nearest watercourse, which leads to accumulative rise of arsenic and iron concentrations in water. In this study, attempts were made to use the arsenic–iron sludge in making bricks and to analyze the corresponding effects on brick properties. The water treatment plant sludge is extremely close to brick clay in chemical composition. So, the sludge could be a potential substitute for brick clay. This study involved the addition of sludge with ratios 3%, 6%, 9% and 12% of the total weight of sludge–clay mixture. The physical and chemical properties of the produced bricks were then determined and evaluated and compared to control brick made entirely from clay. Results of different tests indicated that the sludge proportion and firing temperature were the two key factors in determining the quality of bricks. The compressive strength of 3%, 6%, 9% and 12% sludge containing brick samples were found to be 14.1 MPa, 15.1 MPa, 9.4 MPa and 7.1 MPa, respectively. These results indicate that the compressive strength of prepared bricks initially increased and then decreased with the increase of sludge proportion. Leaching characteristics of burnt bricks were determined with the variation of pH at a constant temperature. The optimum amount of sludge that could be mixed with clay to produce good bonding of clay–sludge bricks was found to be 6% (safely maximum) by weight.     

Sinterability study of ceramic bodies made from a mixture of mineral coal bottom ash and soda-lime glass cullet.

The aim of this study was to investigate the sinterability to improve the technical properties of ceramic bodies made from coal bottom ash and soda-lime glass cullet. Different mixtures of bottom ash and glass cullet were formulated. The amount of bottom ash was 100, 70, 50 and 30 wt.%. The particle size distribution was the same for all formulations. The mixture containing 50 wt.% bottom ash also had its particle size distribution changed. Samples were formed by dry pressing and then fired at 950, 1050 and 1150 degrees C. Samples were evaluated for linear shrinkage, water absorption, flexural mechanical resistance, scanning electronic microscopy, pyroplastic deformation and thermodilatometric analysis. The higher firing temperature led to a decrease in water absorption and increased linear shrinkage, mechanical resistance and pyroplastic deformation. This effect was also observed for addition of glass up to 50 wt.%. The effect of smaller particles of bottom ash was more significant for linear shrinkage and mechanical resistance of ceramic bodies fired at 1150 degrees C. The use of a finer powder contributed to increase these properties. The influence of finer particles on water absorption and mechanical resistance of ceramic bodies fired at 950 and 1050 degrees C was not significant.     

Utilization of textile effluent wastewater treatment plant sludge as brick material

In the present work, the feasibility of using sludge generated in wastewater treatment plants of textile industry as a partial replacement for clay in the conventional brick manufacturing process is examined. Physico-chemical properties of the sludge and clay were studied. The characteristics of bricks with replacement of sludge (0–50 %) with an increment of 3 % were determined. All the brick samples satisfied the requirements of Indian Standards norms in terms of weight loss on ignition. The bricks with sludge up to 15 % satisfied the prescribed norms for compressive strength and water absorption. Results also showed that the brick weight loss on ignition was mainly attributed to the organic matter content in the sludge being burnt off during the firing process. The characteristics of bricks such as efflorescence, density and weight loss on ignition for bricks with replacement of clayey soil with textile sludge up to 15 % also satisfied the requirements of the Indian Standard. Thus, textile sludge up to 15 % can be effectively added to make brick material.     

Assessment of the recycling potential of fresh concrete waste using a factorial design of experiments

Recycling of industrial wastes and by-products can help reduce the cost of waste treatment prior to disposal and eventually preserve natural resources and energy. To assess the recycling potential of a given waste, it is important to select a tool capable of giving clear indications either way, with the least time and work consumption, as is the case of modelling the system properties using the results obtained from statistical design of experiments. In this work, the aggregate reclaimed from the mud that results from washout and cleaning operations of fresh concrete mixer trucks (fresh concrete waste, FCW) was recycled into new concrete with various water/cement ratios, as replacement of natural fine aggregates. A 3² factorial design of experiments was used to model fresh concrete consistency index and hardened concrete water absorption and 7- and 28-day compressive strength, as functions of FCW content and water/cement ratio, and the resulting regression equations and contour plots were validated with confirmation experiments. The results showed that the fresh concrete workability worsened with the increase in FCW content but the water absorption (5–10 wt.%), 7-day compressive strength (26–36 MPa) and 28-day compressive strength (32–44 MPa) remained within the specified ranges, thus demonstrating that the aggregate reclaimed from FCW can be recycled into new concrete mixtures with lower natural aggregate content.     

Effect of organic residues addition on the technological properties of clay bricks

The objective of this study is to investigate the utilization potential of several organic residues in clay bricks. Sawdust, tobacco residues, and grass are widespread by-products of industrial and agricultural processes in Turkey. These residue materials have long cellulose fibres. Sawdust and tobacco residues generally are used as fuel, and the grass is utilized for agricultural purposes. The insulation capacity of brick increases with the increasing porosity of the clay body. Combustible, organic types of pore-forming additives are most frequently used for this purpose. For this reason, increasing amounts of organic residues (0%, 2.5%, 5% and 10% in wt.) were mixed with raw brick-clay. All samples were fired at 900 degrees C. Effects on shaping, plasticity, density, and mechanical properties were investigated. The organic residue additions were found to be effective for pore-forming in the clay body with the clay maintaining acceptable mechanical properties. It was observed that the fibrous nature of the residues did not create extrusion problems. However, higher residue addition required a higher water content to ensure the right plasticity. As a result, sawdust, tobacco residues, and grass can be utilized in an environmentally safe way as organic pore-forming agents in brick-clay.     

Recycling of Malaysia’s electric arc furnace (EAF) slag waste into heavy-duty green ceramic tile

Recently, various solid wastes from industry such as glass waste, fly ash, sewage sludge and slag have been recycled into various value-added products such as ceramic tile. The conventional solutions of dumping the wastes in landfills or incineration, including in Malaysia are getting obsolete as the annual huge amount of the solid wastes would boost-up disposal cost and may cause permanent damage to the flora and fauna. This recent waste recycling approach is much better and greener as it can resolve problems associated with over-limit storage of industrial wastes and reduce exploration of natural resources for ceramic tile to continuously sustain the nature. Therefore, in this project, an attempt was made to recycle electric arc furnace (EAF) slag waste, obtained from Malaysia’s steel making industry, into ceramic tile via conventional powder compaction method. The research work was divided into two stages. The first stage was to evaluate the suitability of EAF slag in ceramic tile by varying weight percentage of EAF slag (40 wt.%, 50 wt.% and 60 wt.%) and ball clay (40 wt.%, 50 wt.% and 60 wt.%), with no addition of silica and potash feldspar. In the second stage, the weight percentage of EAF slag was fixed at 40 wt.% and the percentage of ball clay (30 wt.% and 40 wt.%), feldspar (10 wt.% and 20 wt.%) and silica (10 wt.% and 20 wt.%) added was varied accordingly. Results obtained show that as weight percentage of EAF slag increased up to 60 wt.%, the percentage of apparent porosity and water absorption also rose, with a reduction in tile flexural strength and increased porosity. On the other hand, limiting the weight percentage of EAF slag to 40 wt.% while increasing the weight percentage of ball clay led to a higher total percentage of anorthite and wollastonite minerals, resulting in higher flexural strength. It was found that introduction of silica and feldspar further improved the flexural strength due to optimization of densification process. The highest flexural strength, lowest apparent porosity and water absorption of EAF slag based tile was attained at the composition of 40 wt.% EAF slag – 30 wt.% ball clay – 10 wt.% feldspar – 20 wt.% silica. The properties of ceramic tile made with EAF slag waste (up to 40 wt.%), especially flexural strength are comparable to those of commercial ceramic tile and are, therefore, suitable as high flexural strength and heavy-duty green ceramic floor tile. Continuous development is currently underway to improve the properties of tile so that this recycling approach could be one of the potential effective, efficient and sustainable solutions in sustaining our nature.     

Incorporation of sewage sludge in clay brick and its characterization.

This study reports the use of sewage sludge generated from sewage treatment plant (STP) as raw material in a clay brick-making process. The physico-chemical and mineralogical characterization of the sewage sludge and clay were carried out in order to identify the major technological constraints and to define the sludge pretreatment requirements if necessary. Moreover, the effects on processing conditions and/or on changes of typical final characteristics are also evaluated. Bricks were produced with sewage sludge additions ranging from 10 to 40% by dry weight. The texture and finishing of the surface of sludge-amended clay bricks were rather poor. As for the physical and chemical properties, bricks with a sludge content of up to 40 wt.% were capable of meeting the relevant technical standards. However, bricks with more than 30 wt.% sludge addition are not recommended for use since they are brittle and easily broken even when handled gently. A tendency for a general degradation of brick properties with sludge additions was observed due to its refractory nature. Therefore, sludge bricks of this nature are only suitable for use as common bricks, which are normally not exposed to view, because of poor surface finishing.     

Reusability of sewage sludge in clay bricks

Bricks produced from sewage sludge in different compositions were investigated. Results of the tests indicated that the sludge proportion is a key factor in determining the brick quality. Increasing the sludge content results in a decrease in brick shrinkage, bulk density, and compressive strength. Brick weight loss on ignition was mainly due to the contribution of the contained organic matter from the sludge being burnt off during the firing process, as well as inorganic substances found in both clay and sludge. The physical, mechanical, and chemical properties of the bricks that were supplemented with various proportions of dried sludge from 10 to 40wt% and generally complied with the General Specification for Brick as per the Malaysian Standard MS 7.6:1972, which dictates the requirements for clay bricks used in walling in general. A standard leaching test method also showed that the leaching of metals from the bricks is very low.     

Effect of addition of pond ash and fly ash on properties of ash-clay burnt bricks.

Two industrial solid waste products generated by Indian coal-fired power plants, namely pond ash and fly ash, were used in combination with local clay to develop building bricks. The clay were mixed with the two different ashes in the range 10 to 90 wt.%, hydraulically pressed and fired at 1000 degrees C. The fired products were characterized for various quality properties required for building bricks. The properties of the optimal compositions were compared with conventional red clay bricks including the developed microstructures and the comparative study generally showed that te ash-clay bricks were of superior quality to the conventional products.     

Recycling of cathode ray tube panel glasses as aggregates of concrete blocks and clay bricks

While the cathode ray tube (CRT) funnel containing lead could be transported to a smelting facility to recover lead, which could be an available option in domestic, a proper technology to recycle a CRT panel must be developed. Thus, it was suggested that CRT panel glass be used as aggregates of concrete blocks and clay bricks. Samples of blocks and bricks were fabricated with CRT powders and tested to measure their strength and absorption rate to determine their qualities, and environmental soundness was determined by measuring the leaching rate of hazardous metals. For concrete blocks, CRT panel glass powders incorporated as aggregates up to 40 % replacing stone powder was proposed as the proper condition for manufacturing blocks. Around 2 % of CRT panel incorporated into clay brick to substitute Kaoline was suggested to fabricate the best quality of clay brick. Results of leaching test met the criteria with much less concentration of hazardous metals, even lead compound containing in the CRT funnel. To conclude, the use of CRT panel powder after crushing it to the proper size as an aggregate of concrete blocks or clay bricks could be one of the appropriate alternatives to recycle for CRT glass waste being generated drastically in a short term.     

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.     

Effect of OH/NCO Molar Ratio on Properties of Soy-Based Polyurethane Networks

Polyurethane networks from soybean oil have a number of valuable properties, which are determined by their chemical composition and cross-linking density. Changing the molar ratio of reacting groups can vary the latter. In this work we have varied the NCO/OH molar ratio (isocyanate index) from 1.05 to 0.40 in a soy polyol/MDI system, and tested physical and mechanical properties. The degree of swelling in toluene increased from 52–206% by decreasing isocyanate index from 1.05–0.4. The sol fractions and network densities determined from swelling in toluene were compared with ones obtained using the network formation theory based on branching processes. The comparison of experimental sol fractions and network densities with those predicted by theory of network formation suggest that 5–10% of bonds are lost in cycles and that high entanglement contributions increase the network densities. Polymers prepared with NCO/OH ratios from 1.05–0.8 were glassy while the others were rubbery, and that was reflected in their properties. Glass transition temperature (DSC) of the networks decreased from 64–7°C, tensile strength from 47–0.3 MPa, and elongation at break increased from 7–232%. The activation energy of the glass transition, determined from dielectric spectra, varied from 222–156 kJ/mol as the molar ratio of NCO to OH groups decreased from 1.05–0.4.     

Recycling of iron foundry sand and glass waste as raw material for production of whiteware.

The purpose of this study was to evaluate the production feasibility of triaxial whiteware using sand from cast iron moulds as a raw material instead of silica, and recycled glass in place of feldspar. Formulations were prepared using sand, glass waste, and white-firing clay such that only 50% of the composition was virgin material (clay). The ceramic bodies were formed by pressing and fired at different temperatures (between 1100 and 1300 degrees C). Specimens were characterized in terms of green density prior to firing; and their flexural strength, linear shrinkage, and water absorption were measured after firing. The microstructure was determined by scanning electron microscopy. Possible environmental impacts of this recycling process were also evaluated, through solubility and leaching tests, according to Brazilian standards. Gaseous emissions during the firing process were also analysed. The results showed that it is possible to produce triaxial ceramics by using such alternative raw materials.     

Fast firing of tiles containing paper mill sludge, glass cullet and clay

The paper describes results obtained in the development of a previous research. We study here, in fast firing, the sintering behaviour and measure some properties of tiles containing a mixture of 60 wt% of paper mill sludge and 40 wt% of glass cullet. The behaviour of this material is compared to those displayed by materials obtained by the same mixture added with 10, 20 and 30 wt% of a natural red clay. In parallel, the same properties are measured also on a reference blend, which is presently used to produce commercial tiles. We show that powders containing 60 wt% of paper sludge and 40 wt% of glass cullet to which 30 wt% of clay is added give rise to materials that display a stable sintering process and have good hardness and strength and therefore could be used for the industrial production of tiles.     

Soda-Treated Sisal/Polypropylene Composites

Treated sisal fibers were used as reinforcement of polypropylene (PP) composites, with maleic anhydride-grafted PP (MAPP) as coupling agent. The composites were made by melting processing of PP with the fiber in a heated roller followed by multiple extrusions in a single-screw extruder. Injection molded specimens were produced for the characterization of the material. In order to improve the adhesion between fiber and matrix and to eliminate odorous substances, sisal fibers were treated with boiling water and with NaOH solutions at 3 and 10 wt.%. The mechanical properties of the composites were assessed by tensile, bend and impact tests. Additionally, the morphology of the composites and the adhesion at he fiber–matrix interface were analyzed by SEM. The fiber treatment led to very light and odorless materials, with yields of 95, 74 and 62 wt.% for treatments with hot water, 3 and 10 wt.% soda solution respectively. Fiber treatment caused an appreciable change in fiber characteristics, yet the mechanical properties under tensile and flexural tests were not influenced by that treatment. Only the impact strength increased in the composites with alkali-treated sisal fibers.     

Recycling of steel slag and glass cullet from energy saving lamps by fast firing production of ceramics

The paper reports on some experimental results obtained from the production of ceramics containing steel slag and glass cullet from exhaust energy saving lamps mixed in different proportions. Blending of components was done by attrition milling. Pressed powders were fast fired (50 min, cold to cold) in air up to several temperatures in the range 1000–1140 °C. The sintering behaviour was studied by shrinkage and water absorption measurements. Density, strength and hardness of the fired bodies were determined and XRD were examined. The fired samples were finally tested in acidic environment in order to evaluate their elution behaviour and consequently their possible environmental compatibility. It is observed that the composition containing 60 wt.% of steel slag and 40 wt.% of glass cullet displayed the best overall behaviour.     

Hydrolytic Degradation of PPDO/PDLLA Blends Containing the Compatibilizer PLADO

The poly(para-dioxanone) (PPDO)/poly poly (dl-lactide) (PDLLA) blends containing various contents of compatibilizer (0, 1, 3, 5, 10 %) were prepared by solution co-precipitation, which were dissolved in 1,1,1,3,3,3-hexafluoro-2-propanol (HFIP) to form 10 % wt/vol solutions. Then in vitro hydrolytic degradation of PPDO/PDLLA blends containing poly (dl-lactide-co-para-dioxanone) (PLADO) as the compatibilizer was studied by the changes of weight loss, water absorption, thermal properties, surface morphology and mechanical properties of samples in phosphate buffered saline (pH 7.44) at 37 °C for 8 weeks. During the degradation, the weight loss and water absorption increased significantly for all blends, whereas hydrolysis rate of blends varied with the blend composition. The samples’ glass transition temperature decreased notably, while the degrees of crystallinity increased. Compared with uncompatibilized PPDO/PDLLA blends, PPDO/PDLLA blends with compatibilizer exhibited higher hydrolysis rate. The results suggested that the compatibilizer (PLADO) accelerated the hydrolysis rate of PPDO/PDLLA blends during the degradation.     

Effects of Preparation Parameters on Properties of Soy Protein-Based Fiberboard

The effects of manufacturing parameters on mechanical properties of medium density fibreboard (MDF) bonded with modified soy protein-based glue were studied to find an appropriate manufacture technology. Physical properties of MDF made with different amount of wax emulsion were measured. Results indicated that water repellent had no obvious influence on physical properties of soy protein-based MDF boards. The fiberboards bonded with soy protein-based glue showed stronger water resistance properties than those bonded with urea–formaldehyde (UF) resins. Furthermore, the soy protein-based MDF boards had good quality [25.2% 24 h soak thickness swell (TS), 29.9 MPa modulus of rupture (MOR), 3130 MPa modulus of elasticity (MOE)], which met requirements of Chinese national standard. Practical processing parameters were obtained by orthogonal experiment, i.e., glue content 8.0%, hot-press temperature 200 °C, and hot-press time 150 s.