Effect of experimental variables on the inertization of galvanic sludges in clay-based ceramics

Immobilization of Metals in Fired Clay Brick Incorporated with Aluminium-Rich Electroplating Sludge: Properties and Leaching Analysis

Electroplating sludge is the hazardous waste discarded from the plating and extractive metallurgical process which can only be disposed of at a secured landfill. In this study, the physical and mechanical properties, as well as metal leaching analysis, of fired clay brick incorporated with electroplating sludge (0%, 2%, 4%, 6%, 8% and 10%) were determined. The physical and mechanical properties of bricks, such as firing shrinkage, dry density, initial rate of absorption, water absorption and compressive strength, were tested according to British standard 3921:1985 and British standard EN772:1. Furthermore, the metal leachability was determined by using the toxicity characteristic leaching procedure (TCLP) method 1311. The results show that the utilization of an electroplating-sludge brick up to 4% could enhance physical and mechanical properties, such as reducing the water absorption from 18.3% to 16.1% and increasing the compressive strength from 25.6 MPa to 41.6 MPa. The result also show that 4% of aluminium-rich electroplating sludge incorporated into the brick is the most suitable amount, as it leached less metal concentration and complied with USEPA standards. The metals which were most present in the electroplating sludge (aluminium and iron) drastically reduced from 193,000 ppm to 0.1372 ppm and from 4160 ppm to 0.144 ppm, respectively. Therefore, the electroplating sludge could be fully utilized in the fired clay brick as an alternative to producing low-cost building materials whilst decreasing the levels of disposal of metal sludge on the secured landfill.

Ceramisation of hazardous elements: Benefits and pitfalls of the inertisation through silicate ceramics

The addition of wastes to silicate ceramics can considerably expand the compositional spectrum of raw materials with a possible inclusion of hazardous components. The present work quantitatively examines relevant literature to determine whether the benefits of incorporating hazardous elements (HEs) into silicate ceramics outweigh the pitfalls. The mobility of various HEs (Ba, Zn, Cu, Cr, Mo, As, Pb, Ni, and Cd) has been parameterised by three descriptors (immobilisation efficiency, mobilised fraction, and hazard quotient) using leaching data. HEs can be incorporated into both crystalline and glassy phases, depending on the ceramic body type. Moreover, silicate ceramics exhibit a remarkably high immobilisation efficiency (often exceeding 99.9%), as accomplished for Ba, Cd, Ni, and Zn elements. The pitfalls of the inertization process include an insufficient stabilisation of incorporated HEs, as indicated by the high hazard quotients (beyond the permissible limits established for inert materials) obtained in some cases for Mo, As, Cr, Pb, and Cu elements. Such behaviour is related to oxy-anionic complexes (Mo, As, Cr) that can form their own phases or are not linked to the tetrahedral framework of aluminosilicate glass. Pb and Cu elements are preferentially partitioned to glass with a low coordination number, while As and especially Mo are not always stabilised in silicate ceramics. These drawbacks necessitate conducting additional studies to develop appropriate inertisation strategies for these elements.

The reuse of waste glass for enhancement of heavy metals immobilization during the introduction of galvanized sludge in brick manufacturing

The mixing of galvanized sludge in fired clay brick manufacturing has been regarded as an alternative approach for the consumption of galvanized sludge. Decreasing the surface area and porosity of fired brick definitely lowers the risk of heavy metal release. In this study, a novel method is proposed to reduce the surface area and porosity of bricks and promote heavy metal immobilization by adding waste glass. The introduction of waste glass enhanced the physical and mechanical performances of fired clay bricks and resulted in an increase in bulk density and compressive strength and a decrease in water absorption. Microstructure analysis showed that the texture of the bricks turned from porous to smooth and homogeneous due to the introduction of waste glass. Porosity analysis showed that surface area and pore volume of fired brick were substantially reduced. When the added waste glass amount exceeded 15 wt%, the heavy metal concentrations that leached from bricks containing 10 wt% galvanized sludge fired at 950 °C met the regulatory requirement. These results demonstrate that waste glass can be reused to enhance the stabilization/solidification of heavy metals, during the mixing of hazardous waste in bricks and ceramics manufacturing process.

Toxicity assessment of untreated/treated electroplating sludge using human and plant bioassay

The purpose of this work was to assess the risk to the environment arising from the electroplating sludge from both chemical and toxicological point of view. Both approaches were used for the assessment of the treatment efficiency which consisted of CaO based solidification followed by thermal treatment at 400°C. The elemental composition was determined in the bulk samples and the leachates of untreated sludge. The toxicity of the leachate was determined using two human colorectal adenocarcinoma cell lines (Caco-2 and SW 480) and Hordeum vulgare L. based plant bioassay. The same toxicity tests were employed to the leachate of the treated sludge. Untreated sludge showed extremely high cytotoxic effect to both human and plant bio-system in dose-dependent manner. The percentages higher than 0.5% and 0.05% of the leachate caused significant cytotoxic effect on Caco-2 and SW 480 cells, respectively. The percentages of the leachate higher than 0.05% also showed significant toxic effect to H. vulgare L. bio-system with complete arrest of seed germination following the treatment with 100% to 5% of the leachate. The leachate of the treated sludge showed no toxicity to any of the test systems confirming the efficiency and justification of the employed procedures for the detoxification of electroplating sludge.

Utilization of sewage sludge in the manufacture of lightweight aggregate

This paper presents a comprehensive study on the possibility of sewage sludge management in a sintered ceramic material such as a lightweight aggregate. Made from clay and sludge lightweight aggregates were sintered at two temperatures: 1100 °C (name of sample LWA1) and 1150 °C (name of sample LWA2). Physical and mechanical properties indicate that the resulting expanded clay aggregate containing sludge meets the basic requirements for lightweight aggregates. The presence of sludge supports the swelling of the raw material, thereby causing an increase in the porosity of aggregates. The LWA2 has a lower value of bulk particle density (0.414 g/cm(3)), apparent particle density (0.87 g/cm(3)), and dry particle density (2.59 g/cm(3)) than it is in the case of LWA1 where these parameters were as follows: bulk particle density 0.685 g/cm(3), apparent particle density 1.05 g/cm(3), and dry particle density 2.69 g/cm(3). Water absorption and porosity of LWA1 (WA = 14.4 %, P = 60 %) are lower than the LWA2 (WA = 16.2 % and P = 66 %). This is due to the higher heating temperature of granules which make the waste gases, liberating them from the decomposition of organic sewage sludge. The compressive strength of LWA2 aggregate is 4.64 MPa and for LWA1 is 0.79 MPa. Results of leaching tests of heavy metals from examined aggregates have shown that insoluble metal compounds are placed in silicate and aluminosilicate structure of the starting materials (clays and sludges), whereas soluble substances formed crystalline skeleton of the aggregates. The thermal synthesis of lightweight aggregates from clay and sludge mixture is a waste-free method of their development.

Chromium liquid waste inertization in an inorganic alkali activated matrix: leaching and NMR multinuclear approach

A class of inorganic binders, also known as geopolymers, can be obtained by alkali activation of aluminosilicate powders at room temperature. The process is affected by many parameters (curing time, curing temperature, relative humidity etc.) and leads to a resistant matrix usable for inertization of hazardous waste. In this study an industrial liquid waste containing a high amount of chromium (≈ 2.3 wt%) in the form of metalorganic salts is inertized into a metakaolin based geopolymer matrix. One of the innovative aspects is the exploitation of the water contained in the waste for the geopolymerization process. This avoided any drying treatment, a common step in the management of liquid hazardous waste. The evolution of the process--from the precursor dissolution to the final geopolymer matrix hardening--of different geopolymers containing a waste amount ranging from 3 to 20%wt and their capability to inertize chromium cations were studied by: i) the leaching tests, according to the EN 12,457 regulation, at different curing times (15, 28, 90 and 540 days) monitoring releases of chromium ions (Cr(III) and Cr(VI)) and the cations constituting the aluminosilicate matrix (Na, Si, Al); ii) the humidity variation for different curing times (15 and 540 days); iii) SEM characterization at different curing times (28 and 540 days); iv) the trend of the solution conductivity and pH during the leaching test; v) the characterization of the short-range ordering in terms of TOT bonds (where T is Al or Si) by (29)Si and (27)Al solid state magic-angle spinning nuclear magnetic resonance (ss MAS NMR) for geopolymers containing high amounts of waste (10-20%wt). The results show the formation of a stable matrix after only 15 days independently on the waste amount introduced; the longer curing times increase the matrices stabilities and their ability to immobilize chromium cations. The maximum amount of waste that can be inertized is around 10 wt% after a curing time of 28 days.

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.

Zinc recovery and waste sludge minimization from chromium passivation baths

This work reports the feasibility of applying emulsion pertraction technology (EPT) aiming at zinc recovery and waste minimization in the zinc electroplating processes that include Cr (III) passivation. The assessment consists of firstly the lifetime extension of the passivation baths by selective removal of the tramp ions zinc and iron, and secondly, the recovery of zinc for further reuse. Spent passivation baths from a local industry were tested, being the major metallic content: Cr(3+) 9000mg L(-1), Zn(2+) 12,000mg L(-1), Fe(3+) 100mg L(-1). Working in a Liqui-Cel hollow fiber membrane contactor and using the extractant bis(2,4,4-trimethylpentyl) phosphinic acid, reduction of zinc and iron concentrations below 60mg L(-1) and 2mg L(-1), respectively were obtained, while trivalent chromium, the active metal that generates the passivation layer, was retained in the baths. Zinc was selectively transferred to an acidic stripping phase that in the experimental time reached a concentration of 157,000mg L(-1). Zinc recovery by electrowinning from the acidic stripping phase without any pretreatment of the electrolyte solution provided a purity of 98.5%, matching the lower commercial zinc grade. As a result of the extension of the life time of the passivation bath, significant environmental advantages are derived such as minimization of the volume of hazardous wastes and savings in the consumption of raw materials.

Evaluation of metal-ions containing sludges in the preparation of black inorganic pigments

Inorganic pigments were prepared from industrial wastes: galvanizing sludges resulting from Cr/Ni plating processes (S, G, and T) and a sludge generated from steel wiredraw process that is Fe-rich (F). These industrial wastes were characterized in order to determine the main compositional variations and discover their influence on the colour characteristics of pigments for glazes and ceramics. The toxic character was also investigated and established. Attempting to form the black spinel structure, several combinations of sludges were prepared and then calcined at 1000 °C. XRD and microscopy analysis confirmed the presence of nichromite for compositions with higher Ni amounts, while trevorite was detected in iron-rich formulations. The combination of S and F sludges (SF compositions) generates pigments with higher black colorimetric quality, which is similar to, and sometimes better than, a commercial black pigment. Pigments containing GF and TF sludges develop brown hues on glazes and on porcelain stoneware bodies, being this effect more evident upon industrial firing trials. The addition of minor amounts of cobalt or manganese enhances the black coloration, and might adjust some formulation deviations.

The bulk composition and leaching properties of electroplating sludge prior/following the solidification/stabilization by calcium oxide

Eighteen samples of electroplating sludge were taken from three vertical profiles of waste storage pond of the zinc plating facility. Dry matter and organic matter content, pH value, bulk concentrations and leachate composition were determined. A sludge sample with the highest zinc value in the leachate was treated with calcium oxide (10% to 70%) and the obtained solidificate was repeatedly tested. There were found significant variations of all measured parameters among the profiles of untreated waste. Dry matter content varied from 125 to 455 mgg(-1), organic matter varied from 94.3 to 293.9 mgg(-1), and pH value varied from 3.42 to 5.90 (mean 4.34). Iron content ranged from 38.4 to 191.4 mgg(-1) (mean 136 mgg(-1); RSD 0.25), while zinc ranged from 10.9 to 58.2 mgg(-1) (mean 33.4 mgg(-1); RSD 0.38). According to its DIN38414-S4 leachate composition, this material was not suitable for landfilling of inert waste since zinc and nickel mean values were 10 and 1.5 times higher, respectively, and maximum values 27 and 2.5 times higher, respectively, compared to the upper permissible limit. Maximum values of Cr(VI), Fe, Ni, Cu, and Zn in the DIN38414-S4 leachate were 0.183 mgL(-1), 34.085 mgL(-1), 1.052 mgL(-1), 0.829 mgL(-1) and 107.475 mgL(-1)L, respectively. Following the solidification/stabilization procedure with CaO (sample/CaO = 90/10), concentrations of Cr(VI), Fe, Cu and Zn were reduced 92, 44, 66 and 57 times, respectively, compared to the untreated sample. The addition of 50% of CaO into the sludge reduced zinc and nickel concentrations 79 and 45 times, respectively, in the DIN38414-S4 leachate of the solidified waste compared to the original sludge, thereby converting an hazardous waste into the inert material suitable for landfilling or reuse in the construction processes.

Preliminary evaluation of galvanic sludge immobilization in clay-based matrix as an environmentally safe process

This study attempts to determine the possibilities and limitations of the immobilization of galvanic wastes by their incorporation into clay-based materials. It focuses on the effects of several processing parameters such as the temperature of thermal treatment, the relative amount of sludge, and the physico-chemical aspects of the sample, on the fixing level of relevant metals (Zn, Ni, Fe, Mn, Pb, Cu, Cr) in thermally treated clay-based samples. The effectiveness of sludge inactivation was assessed by water-leaching test and conductivity measurements. In view of the potential use of the sludge stabilization products as construction materials, the linear shrinkage and bending strain of the fired samples was investigated. To characterize their morphology, mineralogy and composition, fired samples of clay and its mixtures with galvanic sludge were studied on a scanning electron microscope (SEM) coupled with an energy dispersive X-ray analyser (EDS) and X-ray diffractometer (XRD). It was found that the efficiency of metal immobilization is dependent on the clay composition and the temperature of the thermal treatment of the prepared mixtures. The thermal treatment of all samples at all temperatures resulted in the stabilization of all heavy metal ions (copper, nickel, iron, lead, manganese and zinc) with the exception of chromium.

Physical and chemical characterisation of metal finishing industrial wastes

In EU countries approximately 150,000 tons/year of galvanic sludges are generated by 4000 industrial units from the corresponding wastewater treatment plants. These sludges are generally classified as hazardous (European Waste Catalogue as adopted in Council Decision 2000/532/CE and as amended by Decisions 2001/118/EC, 2001/119/EC and 2001/573/CE), basically due to the presence of heavy metals. This work attempts to better understand the physical and chemical characteristics of these sludges, by studying 39 samples collected in different Portuguese industries that should represent all kinds of similar wastes independent of their place of generation. Chemical composition and leaching characteristics are given, together with density, grain size distribution, and specific surface area values. Statistical analysis was used for grouping the wastes according to chemical parameters, which might be useful to predict potential reuse as raw materials for different applications.