SEWAGE SLUDGE ASH AS A MATERIAL FOR LIGHTWEIGHT CONCRETE

GUIDED BY : ASST. PROF. MRS ANISHA THOMAS DEPT.OF CIVIL ENGG MARIAN ENGG COLLEGE

PRESENTED BY: BINOY CYRIAC ROLL NO: 8621 S 7, CIVIL ENGG MARIAN ENGG. COLLEGE

INTRODUCTION
Sewage sludge Current management options Need for recycling sewage sludge Scope of use in lightweight concrete

Contd

Fig : Emission of sewage sludge from factory outlet Source : (www.worstedwitch.com)

LITERATURE REVIEW
K.J Mun A study on using expanded clay and organic sludge for manufacturing of super lightweight aggregate, Korea, May 2002. Fang-Chih Changa, Shang-Lien Loa - Research Center for Environmental Pollution Prevention and Control Technology, Graduate Institute of Environmental Engineering,National Taiwan University, Taiwan, ROC, 30 November 2006

MATERIAL DESCRIPTION
Sewage sludge ash is the by-product produced during the combustion of dewatered sewage sludge in an incinerator. It is primarily a silty material with some sand-size particles. Specific size range and properties depend on the type of incineration system and the chemical additives.

Contd

Fig : Sewage sludge Source : (www.qmsciencefrench.wordpress.com)

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PHYSICAL PROPERTIES
It is a silty-sandy material. Up to 90 percent particles are less than 0.075 mm (No. 200 sieve) in size. Relatively low organic and moisture content. Permeability and bulk specific gravity properties are similar to those of a natural inorganic silt. Non-plastic material.
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CHEMICAL PROPERTIES
Element
Silicon (Si) Calcium (Ca) Iron (Fe) Aluminum (Al) Magnesium (Mg) Sodium (Na) Potassium (K) Phosphorus Sulfur (S) Carbon (C)

Oxide
(SiO2) (CaO) (Fe2O3) (Al2O3) (MgO) (Na2O) (K2O) (P2O5) (SO3) -

Elemental Concentration (%)

5.6 - 25.7 1.4 - 42.9 1.0 - 16.4 1.1 - 8.5 0.6 - 1.9 0.1 - 0.8 0.3 - 1.6 1.2 - 4.4 0.3 - 1.2 0.6 - 2.2

Oxide concentration (%)

14.4 - 57.7 8.9 - 36.9 2.6 - 24.4 4.6 - 22.1 0.8 - 2.2 0.1 - 0.7 0.07 - 0.7 3.9 - 15.4 0.01 - 3.4 -

Contd
Trace metal concentrations (e.g., lead, cadmium, zinc, copper) are typically higher than concentrations found in natural fillers or aggregate. This has resulted in some reluctance to use this material.

Recent investigations (leaching tests) suggest that these trace metal concentrations are not excessive and do not pose any measurable leaching problem.

PREPARATION OF SEWAGE SLUDGE ASH(SSA)

Manfactured by the incineration of dewatered sewage sludge ash. At present, two major incineration systems are employed : 1. Multiple hearth 2. Fluidized bed

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Contd

Figure : Simplified sludge incinerator flow diagram. Source : ( www.wikipedia.com)

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SSA IN LIGHTWEIGHT CONCRETE

Manufacture of lightweight aggregate

Fig : Flow chart of the manufacturing process for lightweight aggregate. Source : (Construction and building materials journal)

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QUALITY TESTS OF LIGHTWEIGHT AGGREGATE

Five types of lightweight aggregate(LWA) manufactured on trial and a commercial lightweight aggregate for nonstructural concrete were tested for comparison. Abrasion loss - Los Angeles abrasion Crushing value - static crushing loading Impact value - and impact loading Their respective loss of mass was determined. Some samples selected were observed by scanning electron microscopy (SEM).

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Contd

Fig : Composite made of water treatment sludge Source : (Construction and building materials journal) 14

RESULTS AND DISCUSSION

. Qualities of lightweight aggregate manufactured on trial Table : Physical properties and chemical compositions of raw materials Type of Wa Orga Inorg Calo raw materi al ter co nic com anic com rific valu Sio2 Al2O3 TiO2 Fe2O3 MgO CaO Na2O K2O MnO P2O5 Chemical compositions (%)

nte poun poun e nt (% ) d cont ent (%) d cont ent (%) 13.80 52 8 20.94 0.94 8.98 2.21 4.06 1.30 3.11 0.12 5.31 (kJ/k g)

Sewag e sludge Clay 15

83. 10.17 6.75 08

7.13

92.87 -

66.7 19.28 0.98

6.63

1.63

0.43

0.95

3.13

0.13

0.11

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Table : Heavy metal contents of sewage sludge

Heavy metal content (mg/kg)

Ti 1204.3 Cr 83.6 Mn Co Ni 88.62 Cu 710.53 Zn As Mo 113.46 Cd 5.92 Pb 126.82 1094.02 15.68 1648.02 71.21

Density of the lightweight aggregate decreases with the increase in sewage sludge content. Decrease in density is attributed to the internal sintering due to the calorification and combustion of organic materials and the accelerated expansion due to gas generation. LWA with clay: sewage sludge ratios of 100:300 to 100:500 have a similar density to the commercial lightweight aggregate.

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Contd
The water absorption of the LWA tends to gradually decrease with the increase in the sewage sludge content and with the decrease in the density.

Fig : Effect of clay to sewage sludge ratios on density and water absorption of LWA Source : (Construction and building materials journal) 17

Contd
Table : Abrasion loss, crushing value and impact value of lightweight aggregate with various claysewage sludge ratios Type of LWA Clay: sewage ratio (by mass) Manufactured lightweight aggregate on trial 100:100 100:200 100:300 100:400 100:500 Commercial lightweight aggregate 18.2 18.2 18.5 19.8 20.2 19.6 31.3 32.5 35.5 35.8 36.1 35.1 Abrasion loss (%) Crushing value (%) 29.9 31.3 32.1 33.3 33.9 33.0 Impact value (%)

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Contd

Fig : Microstructures of lightweight aggregate with various claysewage sludge ratios: (a) Clay:sewage sludge = 100:100 ; (b) Clay: sewage sludge = 100:300; (c) Clay:sewage sludge = 100:500; (d) Clay:sewage sludge = 100:100; (e) Clay:sewage sludge = 100:300 and (f) Clay:sewage sludge = 100:500 Source : (Construction and building materials journal)

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CONCRETE MADE OF LIGHTWEIGHT AGGREGATE

Raw materials LWA (coarse) with the ratios of clay: sewage sludge ratio of 100:100%, 100:300%, and 100:500%, and a commercial LWA for nonstructural concrete were used as samples. Fine aggregate river sand Superplasticizer of a commercial melamine type to prevent segregation.

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QUALITY TESTS FOR LIGHTWEIGHT CONCRETE

Cylindrical samples of 100 mm diameter and 200 mm height Prism samples of dimensions 60 x 60 x 240 mm, and Plate samples of dimensions 140 x 160 x 40 mm were made. Tested for : - compressive and flexural strength, density, water absorption, and thermal conductivity at a curing age of 14 days.
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Contd

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Fig : Concrete produced with SSA composite after testing to rupture under axial compression. Source : (Construction and building materials journal)

RESULTS AND DISCUSSION

Table : Properties of concrete using lightweight aggregate
Series Type of lightweight Compressive aggregate strength (MPa) LWC-A 100:100 (Clay:Sludge) LWC-B 100:300 (Clay:Sludge) LWC-C 100:500 (Clay:Sludge) LWCCo. Commercial product. 15.4 3.1 1430 11.8 0.617 15.9 3.3 1410 10.2 0.593 16.4 3.3 1450 10.2 0.652 17 Flexural strength (MPa) 3.6 1500 Density (kg/m2) Water absorption (%) 9.6 Thermal conductivity (W/mK) 0.733

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DEDUCTIONS
When sewage sludge content increases up to 75% density and water absorption of LWA is reduced. LWA with optimum sewage sludge content is similar or superior in physical properties to the commercial LWA for nonstructural concrete. The compressive and flexural strengths of concrete decrease gradually, and the adiabatic effect becomes more beneficial.

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LEACHABILITY OF METALS FROM SLUDGE-BASED LWA

Table : Total concentrations and leaching concentrations of metal sludge Element Total concentrations (mg/kg) Lead (Pb) Cadmium (Cd) Copper (Cu) Zinc (Zn) Total Chromium(Cr) Chromium (Cr+6) Arsenic (As) Mercury (Hg) 2452 22 275 15 3050 41 118 9 2492 39 34 2 BDL BDL Leaching concentrations (mg/l)a 61.4 1.7 7.4 0.3 96.0 2.5 BDLb 68.0 1.4 3.6 0.2 BDL BDL 5.0 1.0 15.0 No limit 5.0 2.5 5.0 0.2 TCLP limits (mg/l)

a - Extraction fluid #1: pH 4.930.05, b - BDL: below detection limit (<0.002 mg/l).

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EXPERIMENTAL PROCEDURE

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Fig : Flowchart of sequential extraction procedure (Source : Journal of hazardous materials)

RESULTS AND DISCUSSION

Effect of sintering temperature on sludge-based LWA

Fig : Total metal concentrations at different sintering temperatures. Source: (Journal of hazardous materials) 27

ALTERNATIVE USES OF SSA

As a mineral additive in cement concrete Mixing with nano-SiO2 in the manufacture of tiles Use in the manufacture of bricks Use for soft soil improvement Use in asphaltic pavement construction, etc.

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CONCLUSION
Health hazard caused by sewage sludge Problem of disposal Solution by burning it, and using the ash productively Feasible use in lightweight aggregate Other possible uses

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REFERENCES
[1] Mun KJ. A study on using expanded clay and organic sludge for manufacturing of super lightweight aggregate (in Korean). Proceedings of the Conference of the Korea Society of Waste Management, Seoul, Korea. May 2002; p. 24346. [2] Soh YS, Mun KJ. Manufacturing of sintered lightweight aggregate using paper mill sludge ash (in Korean). J Korean Concr Inst 1991;13(1):1149. [3] Tay, J.H, Show, K.Y., Hong, S.Y., Potential Reuse of Wastewater Sludge for Innovative Aplications in Construction Industry, Bulletin of the College of Engineering,N.T.U., n. 86 (Oct), pp. 103-112, 2002. [4] A. Kilic, C.D. Atis, E. Yasar, F. Ozcan, High-strength lightweight concrete made with scoria aggregate containing mineral admixtures, Cem. Concr. Res. 33 (10) (2003) 15951599. [5] A. Short,W. Kinniburgh, Lightweight Concrete. Building Research Establishment, Garston Watford, UK, 1976. [6] J.I. Bhatty, K.J. Reidt, Moderate strength concrete from lightweight sludge ash aggregate, Cem. Compos. Lightweight Concr. 11(3), 1989 Page 179187.

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