Characteristics of bricks made from waste steel slag

The characteristics of bricks made from steel slag were investigated in this research. Slag addition was shown to reduce the required firing temperature. When the firing temperature was greater than 1050 degrees C and the slag addition less than 10%, the bricks met ROC national standard CNS 3319 third-class brick for builders. The percentage of slag increased as the quartz and kaolin decreased in the sintered samples while the magnesium aluminum silicate and calcium silicate increased. There were no new crystal phases observed in these samples.     

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.     

Stabilization/solidification of ashes in clays used in the manufacturing of ceramic bricks.

This paper presents the results of the lixiviation of metals from different mixtures of fly and bottom ashes that have been stabilized and solidified in clays used in the manufacture of bricks. The ashes used for this study were obtained from a Hoffmann-type brick furnace adapted for the incineration of municipal solid waste during the manufacturing of ceramic bricks. The ashes were stabilized in clay in different proportions of clay:ash mix (99:1, 95:5, 90:10, 80:20 and 60:40). Such mixes were used to manufacture bricks that were calcined at a temperature ranging from 50 to 1100 degrees C. The clay, ashes and manufactured bricks were characterized using X-ray diffraction, fluorescent X-ray, thermogravimetry, differential thermal analysis, atomic absorption spectroscopy and scanning electronic microscopy. In addition, toxicity characteristic leaching procedure lixiviation tests were performed according to the EPA 1311 method for the determination of heavy metals. The results showed an affinity between clay and ash, and also that the bricks manufactured with these mixtures present low lixiviation levels. The tests also showed the highest decrease in the concentration of arsenic, nickel, chromium, zinc and silver for 99:1 mixtures. The 95:5 mixture was found to be the most favourable for the stabilization (greater concentration decrease) of lead and cadmium. Selenium was the metal with the lowest concentration change whereas arsenic, nickel, chromium, zinc and cadmium showed the greatest concentration change in all mixtures, with the exception of cadmium in the mixture 99:1.     

Use of gold mill tailings in making bricks: a feasibility study.

Mill tailings dumps at Kolar Gold Fields, Karnataka, are creating environmental problems. One of the solutions to these problems is to use the mill tailings for some useful purpose. This study examined the possibility of making bricks from the mill tailings with some additives in laboratory experiments. Samples of the mill tailings and the additives were analysed for particle size distribution, Atterberg limits and specific gravity. The plasticity index of the mill tailings being zero, they could not be used directly for making bricks. Therefore some additives that had plasticity or binding properties were mixed with the mill tailings. Ordinary Portland cement, black cotton soils and red soils were selected as additives. Each of the additives was mixed separately with the mill tailings in different proportions by weight and a large number of bricks were prepared using metallic moulds. The bricks were termed as cement-tailings bricks or soil-tailings bricks, depending on the additives used. The cement-tailings bricks were cured for different periods and their corresponding compressive strengths were determined. The bricks with 20% of cement and 14 days of curing were found to be suitable. The soil-tailings bricks were sun-dried and then fired in a furnace at different temperatures. The quality of bricks was assessed in terms of linear shrinkage, water absorption and compressive strength. The cost analysis revealed that cement-tailings bricks would be uneconomical whereas the soil-tailings bricks would be very economical.     

Recycling of electrolytic manganese solid waste in autoclaved bricks preparation in China

China has played a dominant role in global electrolytic manganese metal (EMM) production, accounting for over 98 % of the total world capacity since 2008. However, with the rapid development of the EMM industry and depletion of mineral ores, electrolytic manganese solid waste (EMSW) is piling up, so more large-scale landfills are needed. The environmental problems generated by EMSW pose severe threats to soil and ground water, and have become the hot issues in society. The aim is to consume and recycle EMSW, and the primary route is to make autoclaved bricks. However, less attention has been given to the procedure and strength-forming mechanism of EMSW bricks, not to mention the production line of the brick. On the basis of physical and chemical property analysis, the pretreatment process of EMSW was indispensable to solidify/stabilize the heavy metals, such as Mn, Zn, Cd, Pb, etc.. This paper expatiated on the procedure of making EMSW autoclaved bricks, analyzed in detail the strength formed by different cementitious materials with cement properties, and introduced the practical engineering of EMSW autoclaved bricks. The results showed that the pretreatment process with quicklime was effective in solidifying/stabilizing the heavy metals. The compressive strength of EMSW bricks reached 10.05 MPa when quicklime 9 % (w/w) added. Cement may be an ideal cementitious material to create EMSW bricks of high strength in experiments and on the production line. Quicklime and cement used simultaneously produced a lower strength than that when adding cement alone because the gypsum from EMSW and an alkali could generate deleterious effects, e.g., expansion or burst. In the production line of EMSW bricks, an appropriate mix proportion to make high-quality autoclaved bricks was determined: EMSW 30–40 %, cement 10–20 %, and aggregates 40–60 %. The low content of heavy metals tested by toxicity leaching may deduce that the EMSW autoclaved bricks have low environmental risk. However, long-term environmental risk evaluation will be needed, requiring more tests and leaching modeling. Employing EMSW to make high-quality autoclaved bricks may be a promising waste-to-resource strategy.     

Effects of recycled glass substitution on the physical and mechanical properties of clay bricks

In this study, wasted glasses from structural glass walls up to 45 wt.% were added into clay mixtures in brick manufacturing process. Physical and mechanical properties of clay bricks were investigated as functions of the wasted glass content and the firing temperature. The results indicated that with proper amount of wasted glasses and firing temperature, clay bricks with suitable physical and mechanical properties could be obtained. The compressive strength as high as 26–41 MPa and water absorption as low as 2–3% were achieved for bricks containing 15–30 wt.% of glass content and fired at 1100 °C. When the glass waste content was 45 wt.%, apparent porosity and water absorption was rapidly increased.     

Reprocessing of metallurgical slag into materials for the building industry

Several methods of reprocessing metallurgical (blast furnace) slag into materials for the building industry, based on melting aggregates with submerged combustion, were developed and tested. The first method involves melting hot slag with some additives directly in a slag ladle with a submerged gas-air burner, with the objective of producing stabilized slag or glass-ceramic. The second method involves direct draining of melted slag from a ladle into the slag receiver, with subsequent control of the slag draining into the converter where special charging materials are added to the melt, with the objective of producing glass-ceramic. A third method involves melting cold slag with some additives inside a melting converter with submerged gas-air burners, with the objective of producing glass-ceramic fillers for use in road construction. Specific to the melting process is the use of a gas-air mixture with direct combustion inside the melt. This feature provides melt bubbling to help achieve maximum heat transfer from combustion products to the melt, improve mixing (and therefore homogeneity of the melt), and increases the rate of chemical reactions. The experimental data for different aspects of the proposed methods are presented. The reprocessed blast-furnace slag in the form of granules can be used as fillers for concretes, asphalts, and as additives in the production of cement, bricks and other building materials. As well, reprocessed blast-furnace slag can be poured into forms for the production of glass-ceramic tiles.     

Fly ash bricks development using concrete waste debris and self-healing bacteria

Journal of Material Cycles and Waste Management - In this study, an effort has been made to use concrete waste debris for the manufacturing of fly ash bricks as a sustainable material. Though in...     

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.     

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.     

Co-gasification of solid waste and lignite - a case study for Western Macedonia

Co-gasification of solid waste and coal is a very attractive and efficient way of generating power, but also an alternative way, apart from conventional technologies such as incineration and landfill, of treating waste materials. The technology of co-gasification can result in very clean power plants using a wide range of solid fuels but there are considerable economic and environmental challenges. The aim of this study is to present the available existing co-gasification techniques and projects for coal and solid wastes and to investigate the techno-economic feasibility, concerning the installation and operation of a 30MW(e) co-gasification power plant based on integrated gasification combined cycle (IGCC) technology, using lignite and refuse derived fuel (RDF), in the region of Western Macedonia prefecture (WMP), Greece. The gasification block was based on the British Gas-Lurgi (BGL) gasifier, while the gas clean-up block was based on cold gas purification. The competitive advantages of co-gasification systems can be defined both by the fuel feedstock and production flexibility but also by their environmentally sound operation. It also offers the benefit of commercial application of the process by-products, gasification slag and elemental sulphur. Co-gasification of coal and waste can be performed through parallel or direct gasification. Direct gasification constitutes a viable choice for installations with capacities of more than 350MW(e). Parallel gasification, without extensive treatment of produced gas, is recommended for gasifiers of small to medium size installed in regions where coal-fired power plants operate. The preliminary cost estimation indicated that the establishment of an IGCC RDF/lignite plant in the region of WMP is not profitable, due to high specific capital investment and in spite of the lower fuel supply cost. The technology of co-gasification is not mature enough and therefore high capital requirements are needed in order to set up a direct co-gasification plant. The cost of electricity estimated was not competitive, compared to the prices dominating the Greek electricity market and thus further economic evaluation is required. The project would be acceptable if modular construction of the unit was first adopted near operating power plants, based on parallel co-gasification, and gradually incorporating the remaining process steps (gas purification, power generation) with the aim of eventually establishing a true direct co-gasification plant.     

Environmental effects of using clay bricks produced with sewage sludge: leachability and toxicity studies

Use of sewage sludge from wastewater treatment plants as a raw material for making clay bricks has been analyzed to be an option to dumping sludges into landfills. This alternative has been shown feasible and interesting due to the high rate of use of ceramic materials in the building sector. However, it meets with some environmental issues and some prejudices on the part of users. This work shows some leachability and toxicity tests (outgassing and offgassing) which demonstrate the environmental compatibility of these ceramic products to be used as building materials and even in deconstruction of the building once its useful life is ended.     

Use of Pb blast furnace slag as a partial substitute for fine aggregate in cement mortar

The technical properties of cement mortars containing natural fine aggregate that is replaced by lead blast furnace slag at 25 and 35% level were assessed at fixed water-to-cement (W/C) ratio and at fixed flow table value. The leachabilities of some toxic elements from the cement mortars were also assessed to test the environmental suitability of the slag for use in preparation of cement mortar. At fixed W/C ratio, the strength of the mortar decreased with increase of the slag content. On the other hand, at fixed consistency, strength increased with increasing slag content in the mortar composition. The concentrations of some toxic elements in the leachates collected from the mortars containing slag were slightly higher than for the control mortar, but the concentrations in the leachates remained within the regulatory limits for recycling in construction applications. For most elements, leaching from a mortar containing 35% of slag was similar to that from a mortar containing 25% of slag. Therefore, 35% of natural sand can be beneficially replaced with Pb slag to produce cement mortar without affecting the mechanical and leaching properties studied in this work.     

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.     

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.     

Changes in mineralogical and leaching properties of converter steel slag resulting from accelerated carbonation at low CO2 pressure

Steel slag can be applied as substitute for natural aggregates in construction applications. The material imposes a high pH (typically 12.5) and low redox potential (Eh), which may lead to environmental problems in specific application scenarios. The aim of this study is to investigate the potential of accelerated steel slag carbonation, at relatively low pCO₂ pressure (0.2 bar), to improve the environmental pH and the leaching properties of steel slag, with specific focus on the leaching of vanadium. Carbonation experiments are performed in laboratory columns with steel slag under water-saturated and -unsaturated conditions and temperatures between 5 and 90 °C. Two types of steel slag are tested; free lime containing (K3) slag and K1 slag with a very low free lime content. The fresh and carbonated slag samples are investigated using a combination of leaching experiments, geochemical modelling of leaching mechanisms and microscopic/mineralogical analysis, in order to identify the major processes that control the slag pH and resulting V leaching. The major changes in the amount of sequestered CO₂ and the resulting pH reduction occurred within 24 h, the free lime containing slag (K3-slag) being more prone to carbonation than the slag with lower free lime content (K1-slag). While carbonation at these conditions was found to occur predominantly at the surface of the slag grains, the formation of cracks was observed in carbonated K3 slag, suggesting that free lime in the interior of slag grains had also reacted. The pH of the K3 slag (originally pH ± 12.5) was reduced by about 1.5 units, while the K1 slag showed a smaller decrease in pH from about 11.7 to 11.1. However, the pH reduction after carbonation of the K3 slag was observed to lead to an increased V-leaching. Vanadium leaching from the K1 slag resulted in levels above the limit values of the Dutch Soil Quality Decree, for both the untreated and carbonated slag. V-leaching from the carbonated K3 slag remained below these limit values at the relatively high pH that remained after carbonation. The V-bearing di-Ca silicate (C2S) phase has been identified as the major source of the V-leaching. It is shown that the dissolution of this mineral is limited in fresh steel slag, but strongly enhanced by carbonation, which causes the observed enhanced release of V from the K3 slag. The obtained insights in the mineral transformation reactions and their effect on pH and V-leaching provide guidance for further improvement of an accelerated carbonation technology.     

Environmental impact of ferrochrome slag in road construction

Vargon Alloys in Western Sweden is one of the largest producers of ferrochrome slag in Europe. Ferrochrome slag is a by-product from the production of ferrochrome, an essential component in stainless steel. Extensive tests have been carried out on the physical properties of the ferrochrome slag from Vargon Alloys and it was found to be highly suitable as road construction material. The composition and leaching tests of the ferrochrome slag show that the chromium content is high, 1-3%, although leaching under normal conditions is very low. With the exception of potassium (K), which had a potential leaching capacity (availability test) of around 16%, the leaching of chromium, nickel, zinc and other elements was just a few per cent. However, all these tests were conducted in the laboratory. What happens out in the field, under the influence of acid rain and biological activity, and how does this compare with the laboratory results? To answer this question an investigation was carried out to study the environmental impact of ferrochrome slag in roads that were built in 1994. The investigation includes soil sampling (total content and leachable amounts of metals) and groundwater analysis (filtered and non-filtered samples). In addition, a new method involving the bio-uptake of chromium and other metals by the roots of the dandelion (Taraxacum officinale) was tested. The results show that there was a low migration of particles from the slag to the underlying soil and that the leaching into the groundwater was also low for all the elements analysed. However, there seemed to be a significant uptake of Cr by plants growing with their roots in the slag. An investigation of plant uptake was an important complement to laboratory leaching tests on alternative materials.     

Construction demolition wastes, Waelz slag and MSWI bottom ash: a comparative technical analysis as material for road construction

The objective of the study is to analyze the technical suitability of using secondary materials from three waste flows (construction and demolition waste (CDW), Waelz slag and municipal solid waste incineration (MSWI) bottom ash), under the regulations and standards governing the use of materials for road construction. A detailed technical characterization of the materials was carried out according to Spanish General Technical Specifications for Road Construction (PG3). The results show that Waelz slag can be adequate for using in granular structural layers, while CDW fits better as granular material in roadbeds. Likewise, fresh MSWI bottom ash can be used as roadbed material as long as it does not contain a high concentration of soluble salts. This paper also discusses the adequacy of using certain traditional test methods for natural soils when characterizing secondary materials for use as aggregates in road construction.     

Characteristics of element distributions in an MSW ash melting treatment system

Thermal treatment of municipal solid waste (MSW) has become a common practice in waste volume reduction and resource recovery. For the utilization of molten slag for construction materials and metal recovery, it is important to understand the behavior of heavy metals in the melting process. In this study, the correlation between the contents of elements in feed materials and MSW molten slag and their distributions in the ash melting process, including metal residues, are investigated. The hazardous metal contents in the molten slag were significantly related to the contents of metals in the feed materials. Therefore, the separation of products containing these metals in waste materials could be an effective means of producing environmentally safe molten slag with a low hazardous metals content. The distribution ratios of elements in the ash melting process were also determined. The elements Zn and Pb were found to have a distribution ratio of over 60% in fly ash from the melting furnace and the contents of these metals were also high; therefore, Zn and Pb could be potential target metals for recycling from fly ash from the melting furnace. Meanwhile, Cu, Ni, Mo, Sn, and Sb were found to have distribution ratios of over 60% in the metal residue. Therefore, metal residue could be a good resource for these metals, as the contents of Cu, Ni, Mo, Sn, and Sb in metal residue are higher than those in other output materials.