Utilization of sewage sludge ash in ultra-high performance concrete (UHPC): Microstructure and life-cycle assessment

Data driven design of ultra high performance concrete prospects and application

Ultra-high performance concrete (UHPC) is a specialized class of cementitious composites that is increasingly used in various applications, including bridge decks, connections between precast components, piers, columns, overlays, and the repair and strengthening of bridge elements. The mechanical and durability properties of UHPC are significantly influenced by factors such as low water-to-binder ratios, the inclusion of supplementary cementitious materials (SCMs), and fiber reinforcement. Machine learning (ML) has been employed to predict the performance of UHPC and optimize its mixture designs by using various raw materials. This study first provides a comprehensive review of ML applications in UHPC, focusing on predicting workability, mechanical, and thermal properties. The use of data crossing, generative AI, physics-guided ML models, and field-applicable software are explored as practical directions for future research. This study also develops ML models to predict the compressive strength of UHPC by using a database containing 1300 data-records. The influence of various input variables is evaluated using SHapley Additive exPlanations (SHAP), revealing that chemical compositions have relatively minor impacts, given the material types used. By excluding insignificant variables, the models enhance both efficiency and accuracy in predicting strength. This advancement facilitates optimized material design and performance prediction while reducing the experimental workload required to inform ML models. Adding more diverse data to the database could further enhance the prediction performance and generalizability of the proposed ML models.

Perspectives on innovative non-fertilizer applications of sewage sludge for mitigating environmental and health hazards

As waste production increases and resources become limited, sewage sludge presents a valuable resource with potential beyond traditional land use and incineration. This review emphasizes exploring innovative non-fertilizer applications of sewage sludges and advocates for viewing wastewater treatment plants as sources of valuable feedstock and carbon sequestration. Innovative uses include integrating sewage sludge into construction materials such as asphalt pavements, geopolymer, cementitious composites, and masonry blocks. These methods not only immobilize heavy metals and mitigate environmental hazards but also support carbon sequestration, contrasting with incineration and land application methods that release carbon into the atmosphere. The review also addresses emerging technologies like bio-adhesives, bio-binders for asphalt, hydrogels, bioplastics, and corrosion inhibitors. It highlights the recovery of valuable materials from sewage sludge, including phosphorus, oils, metals, cellulose, and polyhydroxyalkanoates as well as enzyme production. By focusing on these non-fertilizer applications, this review presents a compelling case for re-envisioning wastewater treatment plants as sources of valuable feedstock and carbon sequestration, supporting global efforts to manage waste effectively and enhance sustainability.

Utilization of industrial wastes in non-sintered bricks: microstructure and environmental impacts

Recycling industrial solid wastes as building materials in the construction field exhibits great environmental benefits. This study designed an eco-friendly non-sintered brick by combining multiple industrial solid wastes, including sewage sludge, fly ash, and phosphorus gypsum. The mechanical properties, microstructure, and environmental impacts of waste-based non-sintered bricks (WNBs) were investigated comprehensively. The results revealed that WNB exhibited excellent mechanical properties. In addition, steam curing could further promote the strength development of WNB. The compressive strength of WNB with 10 wt% of sewage sludge reached 13.5 MPa. Phase assemblage results indicated that the incorporation of sewage sludge promoted the generation of ettringite. Mercury intrusion porosimetry results demonstrated that the pore structure of WNB varies with the dosage of sewage sludge. Life-cycle assessment results revealed that the energy consumption and CO2 emission of WNB were 45% and 17% lower than those of traditional clay bricks. Overall, the development of WNB in this study provided insights into the co-disposal of industrial solid wastes.

Comparative Analysis of Laboratory-Made and Industrial-Made Sewage Sludge Ash: Implications for Effective Management Strategy Development

In the pursuit of environmentally and economically sustainable sewage sludge ash (SSA) management methods, researchers often employ laboratory-made SSA (L-SSA) as a substitute for industrial-made SSA (I-SSA) produced in fluidized bed furnaces. To check whether L-SSA is a material that imitates I-SSA well, the fractionation of metals whose presence is a significant problem during SSA management was performed. In addition, the grain distribution, specific surface area, and textural properties of the tested materials were examined. Differences in total Pb and Hg content and mobility of Cu, Ni, Mn, and Zn were observed between I-SSA and L-SSA. Larger particle sizes of L-SSA compared to I-SSA were confirmed, while comparable textural properties and specific surface area of both types of materials were maintained. Based on the results, it was concluded that L-SSA is chemically different compared to I-SSA, and that L-SSA should not be used as a reference in research focused on the design of SSA management methods. Moreover, fractionation of metals was performed in disposed fluidized beds (FBs), which are diverted to non-hazardous waste landfills without prior analysis. It has been proven that studied metals are present in FBs as abundantly as in SSA, while Cu, Mn, and Ni may show higher mobility than in I-SSA.

Designing low-carbon fly ash based geopolymer with red mud and blast furnace slag wastes: Performance, microstructure and mechanism

In order to tackle the environmental problems induced by Portland cement production and industrial solid wastes landfilling, this study aims to develop novel ternary cementless fly ash-based geopolymer by recycling red mud and blast furnace slag industrial solid wastes. The fresh-state properties, mechanical strength, water permeability, phase assemblage and microstructure were systematically investigated to evaluate the performance variation and reveal the hydration mechanism for geopolymers with different mixing proportions. The results showed that a higher slag content or a lower red mud content could result in the higher fluidity and shorter setting time for fresh mixture. The existence of slag promoted the transformation of N-A-S-H to C-A-S-H gel, which contributed to higher compressive strength and better resistance to water penetration. However, an excessive incorporation of 30% red mud may impede the generation of N-A-S-H gel and form more flocculent-like loose hydrates, thus to mildly degrade the mechanical strength and anti-permeability. The synergetic utilization of red much and blast furnace slag in fly ash-based geopolymer led to much less CO2 emission compared with the condition that red much or slag was singly added, which demonstrated prominent environmental advantages for such kind of ternary cementless geopolymer with equivalent mechanical strength.

A green ultra-high performance geopolymer concrete containing recycled fine aggregate: Mechanical properties, freeze-thaw resistance and microstructure

The shortage of natural aggregate poses challenges and offers new opportunities for the construction industry. Under this background, the emergence of recycled aggregates sheds new lights on building aggregate. In this study, a green ultra-high performance geopolymer concrete (UHPGC) containing recycled fine aggregate (RFA) was prepared. To assess the feasibility of RFA and reveal the reaction mechanism of UHPGC, the reaction process, mechanical properties, freeze-thaw resistance and microstructure were systematically studied. The heat evolution results indicate that the control of reaction process could be achieved by adjusting the precursor component. A compact microstructure with extremely low porosity could be formed in the UHPGC specimens, which contributes to their good mechanical properties and freeze-thaw resistance. Good compatibility in the interface transition zone between fiber, paste and RFA could be observed, indicating great potential in the manufacture of UHPGC by alkali-activation technology. A considerable environmental benefit could be obtained in UHPGC when compared to ordinary ultra-high performance concrete (UHPC). This study is expected to offer more insights into the application of recycled aggregate and the manufacture of green UHPC.

Designing low-carbon cement-free binders for stabilization/solidification of MSWI fly ash

Low-carbon and high-efficiency binder is desirable for sustainable treatment of municipal solid waste incineration fly ash (MSWI FA). In this study, CaO or MgO was used to activate ground granulated blast furnace slag (GGBS) to form calcium silicate hydrate and magnesium silica hydrate gel for stabilization/solidification of hazardous MSWI FA. Experimental results showed that potential toxic elements (PTEs), such as Pb and Zn, significantly inhibited the formation of reaction products in CaO-GGBS system due to the complexation between Ca(OH)₂ and PTEs, whereas PTEs only had insignificant inhibition on transformation from MgO to Mg(OH)₂ in MgO-GGBS system, resulting in lower leachabilities of PTEs and higher mechanical strengths. Stabilization/solidification experiments demonstrated that MSWI FA (70 wt%) could be recycled by MgO-GGBS binder (30 wt%) into blocks with desirable 28-day compressive strengths (3.9 MPa) and PTEs immobilization efficiencies (99.8% for Zn and 99.7% for Pb). This work provides mechanistic insights on the immobilization mechanisms of PTEs in CaO/MgO-GGBS systems and suggests a promising MgO-GGBS binder for low-carbon treatment of MSWI FA.