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SEWAGE SLUDGE ASH AS A
MATERIAL FOR LIGHTWEIGHTCONCRETE
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
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INTRODUCTION
Sewage sludge
Current management options
Need for recycling sewage sludge
Scope of use in lightweight concrete
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Contd
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Fig : Emission of sewage sludge from factory outlet
Source : (www.worstedwitch.com)
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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
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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 typeof incineration system and the chemical additives.
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Contd
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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 aresimilar to those of a natural inorganic silt.
Non-plastic material.
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CHEMICAL PROPERTIES
Element Oxide Elemental Concentration
(%)
Oxide
concentration (%)
Silicon (Si) (SiO2) 5.6 - 25.7 14.4 - 57.7
Calcium (Ca) (CaO) 1.4 - 42.9 8.9 - 36.9
Iron (Fe) (Fe2O3) 1.0 - 16.4 2.6 - 24.4
Aluminum (Al) (Al2O3) 1.1 - 8.5 4.6 - 22.1
Magnesium
(Mg)(MgO) 0.6 - 1.9 0.8 - 2.2
Sodium (Na) (Na2O) 0.1 - 0.8 0.1 - 0.7
Potassium (K) (K2O) 0.3 - 1.6 0.07 - 0.7
Phosphorus (P2O5) 1.2 - 4.4 3.9 - 15.4
Sulfur (S) (SO3) 0.3 - 1.2 0.01 - 3.4
Carbon (C) - 0.6 - 2.2 -
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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 thatthese trace metal concentrations are not excessive
and do not pose any measurable leaching problem.
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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) manufacturedon 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
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RESULTS AND DISCUSSION
. Qualities of lightweight aggregate manufactured on trial -
Type of
raw
materi
al
Wa
ter
co
nte
nt
(%
)
Orga
nic
com
poun
d
cont
ent
(%)
Inorg
anic
com
poun
d
cont
ent
(%)
Calo
rific
valu
e
(kJ/k
g)
Chemical compositions (%)
Sio2 Al2O3 TiO2 Fe2O3 MgO CaO Na2O K2O MnO P2O5
Sewag
e
sludge
83.
08
10.17 6.75 13.80
8
52 20.94 0.94 8.98 2.21 4.06 1.30 3.11 0.12 5.31
Clay - 7.13 92.87 - 66.7 19.28 0.98 6.63 1.63 0.43 0.95 3.13 0.13 0.11
Table : Physical properties and chemical compositions of raw materials
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Contd
Heavy metal content (mg/kg)
Ti Cr Mn Co Ni Cu Zn As Mo Cd Pb
1204.3 83.6 1094.02 15.68 88.62 710.53 1648.02 71.21 113.46 5.92 126.82
Table : Heavy metal contents of sewage sludge
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 graduallydecrease 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)
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Contd
Type of LWA Clay: sewage ratio
(by mass)
Abrasion loss (%) Crushing value
(%)
Impact value (%)
Manufactured
lightweight
aggregate on trial
100:100 18.2 31.3 29.9
100:200 18.2 32.5 31.3
100:300 18.5 35.5 32.1
100:400 19.8 35.8 33.3
100:500 20.2 36.1 33.9
Commercial
lightweight
aggregate
- 19.6 35.1 33.0
Table : Abrasion loss, crushing value and impact value of lightweight aggregate
with various claysewage sludge ratios
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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 usedas 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 mmheight
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
Fig : Concrete produced with SSA composite after testing to rupture
under axial compression.
Source : (Construction and building materials journal)22
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RESULTS AND DISCUSSION
Series Type of lightweight
aggregate
Compressive
strength
(MPa)
Flexural
strength
(MPa)
Density
(kg/m2)
Water
absorption
(%)
Thermal
conductivity
(W/mK)
LWC-A 100:100
(Clay:Sludge)
17 3.6 1500 9.6 0.733
LWC-B 100:300
(Clay:Sludge)
16.4 3.3 1450 10.2 0.652
LWC-C 100:500
(Clay:Sludge)
15.9 3.3 1410 10.2 0.593
LWC-Co.
Commercial product. 15.4 3.1 1430 11.8 0.617
Table : Properties of concrete using lightweight aggregate
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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 orsuperior in physical properties to the commercial LWA
for nonstructural concrete.
The compressive and flexural strengths of concretedecrease gradually, and the adiabatic effect becomes
more beneficial.
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LEACHABILITY OF METALS
FROM SLUDGE-BASED LWA
Element Total
concentrations
(mg/kg)
Leaching
concentrations
(mg/l)a
TCLP limits
(mg/l)
Lead (Pb) 2452 22 61.4 1.7 5.0
Cadmium (Cd) 275 15 7.4 0.3 1.0
Copper (Cu) 3050 41 96.0 2.5 15.0
Zinc (Zn) 118 9 BDLb No limit
Total Chromium(Cr) 2492 39 68.0 1.4 5.0
Chromium (Cr+6) 34 2 3.6 0.2 2.5
Arsenic (As) BDL BDL 5.0
Mercury (Hg) BDL BDL 0.2a - Extraction fluid #1: pH 4.930.05, b - BDL: below detection limit (
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EXPERIMENTAL PROCEDURE
Fig : Flowchart of sequential extraction procedure
(Source : Journal of hazardous materials)26
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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
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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 (inKorean). 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). JKorean Concr Inst 1991;13(1):1149.
[3] Tay, J.H, Show, K.Y., Hong, S.Y., Potential Reuse of Wastewater Sludge for Innovative Aplications inConstruction 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 containingmineral 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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