Leachability of metals from sludge-based artificial lightweight aggregate

Recycling dredged harbor sediment to construction materials by sintering with steel slag and waste glass: Characteristics, alkali-silica reactivity and metals stability

This work recovered the dredged sediment around Kaohsiung Harbor, Taiwan, for preparing lightweight aggregates (LWA), of which physicochemical properties as affected by the addition of basic-oxygen-furnace (BOF) slag and waste glass were investigated. LWA properties included water absorption, particle density, compressive strength, shrinkage, and microstructure of sintered pellets were evaluated to ensure feasibility of dredged harbor sediment reutilization technique. Results showed that adding appropriate amount of glass powders (~7%) to the mixtures of sediment and slag significantly reduced the water absorption (as low as 2.2%) of the sintered pellets and increase the compressive strength (as high as 23.1 MPa) of LWA, which were found to be controlled by open porosity and shrinkage. Excessive addition of glass (>10%) led to increase in internal pore sizes of the sintered pellets, and thus reduced the compressive strength. The alkali-silica reactivity (ASR) of the LWA was innocuous according to the ASTM C289 test. Sintering and glass addition improved the stability of heavy metal and environmental compatibility of the LWA. The recycling of waste sediment, slag, and glass for LWA production can provide an alternative for the disposal of dredge harbor sediment and has positive impact on waste reduction, which not only can reduce secondary contamination to the environment, but also can contribute to circular economy.

Migration characteristics and toxicity evaluation of heavy metals during the preparation of lightweight aggregate from sewage sludge

A lightweight aggregate (LWA) was manufactured from municipal sewage sludge, gangue, and coal ash. The product performance and environmental safety of the sintered material were evaluated by changing the sludge blending ratio and sintering temperature. The distribution and migratory transformation characteristics of heavy metals in LWA were examined by BCR sequential extraction in combination with inductively coupled plasma optical emission spectrometry (ICP-OES). The environmental safety performance of LWA was comprehensively evaluated by the OPTI index for the first time. The leaching concentration of the heavy metals Pb, Ni, Cu, and Zn in raw materials without sintering reached 1.17, 1.6, 7.84, and 7.56 mg/L, respectively, far exceeding the regulatory threshold value. At 1250 °C, sintering with 60% sludge content resulted in Cu and Zn leaching concentrations of only 0.41 mg/L and 0.37 mg/L, respectively. Furthermore, a big portion of heavy metals were in the residual fraction of sintered LWA. The proportion of comprehensive pollutant toxicity index is only 199.17. Additionally, the mechanical properties of sintered LWA exceed the standards stipulated in the GB/T1743.1-2010 standard. Using sewage sludge to manufacture lightweight aggregate is not only environmentally safe but also produces LWA with good engineering characteristics.

Leachate analysis of green and fired-clay bricks incorporated with biosolids

The substantial increase in biosolids production throughout the world requires sustainable routes for reuse. This study describes the leaching behaviour of potentially hazardous metals from the green and fired bricks incorporating four different biosolids samples from the Eastern treatment plant (ETP) and Western treatment plant (WTP) in Melbourne. The biosolids samples were characterized by XRD, XRF, TGA, particle size distribution, and organic content. The leaching of As, Ag, Ba, Be, Cd, Cr, Cu, Mo, Ni, Pb, Sb, Se, and Zn was evaluated for both the green and the fired bricks according to the Toxicity characteristic leaching procedure (TCLP) and the Australian bottle leaching procedure (ABLP). The leaching of heavy metals from both the green and the fired bricks was compared to investigate the effect of firing on the leaching capability of bricks. The results showed that the leaching of heavy metals from fired bricks was significantly lower than that for the green bricks. The ABLP concentrations of heavy metals were higher than those found using the TCLP method, mainly due to the higher specific surface area of the particles used in the ABLP method. Moreover, bricks were evaluated by the technological properties, such as compressive strength, density and water absorption.

Modification of Lightweight Aggregates' Microstructure by Used Motor Oil Addition

An admixture of lightweight aggregate substrates (beidellitic clay containing 10 wt % of natural clinoptilolite or Na-P1 zeolite) with used motor oil (1 wt %–8 wt %) caused marked changes in the aggregates’ microstructure, measured by a combination of mercury porosimetry (MIP), microtomography (MT), and scanning electron microscopy. Maximum porosity was produced at low (1%–2%) oil concentrations and it dropped at higher concentrations, opposite to the aggregates’ bulk density. Average pore radii, measured by MIP, decreased with an increasing oil concentration, whereas larger (MT) pore sizes tended to increase. Fractal dimension, derived from MIP data, changed similarly to the MIP pore radius, while that derived from MT remained unaltered. Solid phase density, measured by helium pycnometry, initially dropped slightly and then increased with the amount of oil added, which was most probably connected to changes in the formation of extremely small closed pores that were not available for He atoms.

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.

Recycling of spent adsorbents for oxyanions and heavy metal ions in the production of ceramics

Spent adsorbents for oxyanion forming elements and heavy metals are classified as hazardous materials and they are typically treated by stabilization/solidification before landfilling. The use of lime or cement for stabilization/solidification entails a high environmental impact and landfilling costs are high. This paper shows that mixing spent adsorbents in the raw material for the production of ceramic materials is a valuable alternative to stabilize oxyanion forming elements and heavy metals. The produced ceramics can be used as construction material, avoiding the high economic and environmental impact of stabilization/solidification followed by landfilling. To study the stabilization of oxyanion forming elements and heavy metals during the production process, two series of experiments were performed. In the first series of experiments, the main pollutant, Mo was adsorbed onto iron-based adsorbents, which were then mixed with industrial sludge (3 w/w%) and heated at 1100°C for 30 min. Mo was chosen, as this element is easily adsorbed onto iron-based adsorbents and it is the element that is the most difficult to stabilize (i.e. the highest temperatures need to be reached before the concentrations in the leachate are reduced). Leaching concentration from the 97/3 sludge/adsorbent mixture before heating ranged between 85 and 154 mg/kg; after the heating process they were reduced to 0.42-1.48 mg/kg. Mo was actually stabilized, as the total Mo concentration after addition was not affected by the heat treatment. In the second series of experiments, the sludge was spiked with other heavy metals and oxyanion forming elements (Cr, Ni, Cu, Zn, As, Cd and Pb) in concentrations 5 times higher than the initial concentrations; after heat treatment the leachate concentrations were below the regulatory limit values. The incorporation of spent adsorbents in ceramic materials is a valuable and sustainable alternative to the existing treatment methods, saving raw materials in the ceramics production process and avoiding the use of stabilizing agents. Besides, spent adsorbents added to the raw material for ceramic products, may improve their aesthetic and structural properties.

Leachability of heavy metals from lightweight aggregates made with sewage sludge and municipal solid waste incineration fly ash

Lightweight aggregate (LWA) production with sewage sludge and municipal solid waste incineration (MSWI) fly ash is an effective approach for waste disposal. This study investigated the stability of heavy metals in LWA made from sewage sludge and MSWI fly ash. Leaching tests were conducted to find out the effects of MSWI fly ash/sewage sludge (MSWI FA/SS) ratio, sintering temperature and sintering time. It was found that with the increase of MSWI FA/SS ratio, leaching rates of all heavy metals firstly decreased and then increased, indicating the optimal ratio of MSWI fly ash/sewage sludge was 2:8. With the increase of sintering temperature and sintering time, the heavy metal solidifying efficiencies were strongly enhanced by crystallization and chemical incorporations within the aluminosilicate or silicate frameworks during the sintering process. However, taking cost-savings and lower energy consumption into account, 1100 °C and 8 min were selected as the optimal parameters for LWA sample- containing sludge production. Furthermore, heavy metal leaching concentrations under these optimal LWA production parameters were found to be in the range of China’s regulatory requirements. It is concluded that heavy metals can be properly stabilized in LWA samples containing sludge and cannot be easily released into the environment again to cause secondary pollution.

Thermal treatment of solid waste in view of recycling: Chromate and molybdate formation and leaching behaviour

Elevated Cr and Mo concentrations are often found in leachates of thermally treated solid waste, but there is no general explanation for this so far. Therefore, we studied the leaching behaviour after thermal treatment as a function of heating temperature and residence time for two types of solid waste: contaminated sludge and bottom ash from municipal solid waste incineration. The leaching behaviour of both waste streams was compared with experiments on synthetic samples, allowing deduction of a general mechanism for Cr and Mo leaching. Cr and Mo showed a similar leaching behaviour: after an initial increase, the leaching decreased again at higher temperatures. Oxidation of these elements from their lower oxidation states to chromate and molybdate at temperatures up to 600 °C was responsible for the increased leaching. At higher temperatures, both Mo and Cr leaching decreased again owing to the formation of an amorphous phase, incorporating the newly formed chromate and molybdate salts, which prevents them from leaching.

Heating temperature dependence of Cr(III) oxidation in the presence of alkali and alkaline earth salts and subsequent Cr(VI) leaching behavior

In this paper, the temperature dependence of Cr(III) oxidation in high temperature processes and the subsequent Cr(VI) leaching was studied using synthetic mixtures. It was experimentally shown that in the presence of alkali and alkaline earth salts, oxidation of Cr(III) takes place, consistent with thermodynamic calculations. Heating of synthetic mixtures of Cr2O3 and Na, K, or Ca salts led to elevated leaching of Cr(VI); in the presence of Na, more than 80% of the initial Cr(III) amount was converted to Cr(VI) at 600-800 °C. Kinetic experiments allowed explanation of the increase in Cr(VI) leaching for increasing temperatures up to 600-800 °C. After reaching a maximum in Cr(VI) leaching at temperatures around 600-800 °C, the leaching decreased again, which could be explained by the formation of a glassy phase that prevents leaching of the formed Cr(VI). By way of illustration, Cr(VI) formation and leaching was evaluated for a case study, the fabrication of ceramic material from contaminated sludge. Based on the proposed reaction mechanisms, countermeasures to prevent Cr oxidation (addition of NH4H2PO4, heating under inert atmosphere) were proposed and successfully tested for synthetic mixtures and for the case study.

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.

Production of lightweight aggregates from mining and industrial wastes

Washing aggregate sludge from a gravel pit, sewage sludge from a wastewater treatment plant (WWTP) and a clay-rich sediment have been physically, chemically and mineralogically characterized. They were mixed, milled and formed into pellets, pre-heated for 5 min and sintered in a rotary kiln at 1150 degrees C, 1175 degrees C, 1200 degrees C and 1225 degrees C for 10 and 15 min at each temperature. The effects of the raw material characteristics, heating temperatures and dwell times on the loss on ignition (LOI), bloating index (BI), bulk density (rho(b)), apparent and dry particle densities (rho(a), rho(d)), voids (H), water absorption (WA(24h)) and compressive strength (S) were determined. All the mixtures presented a bloating potential taking into consideration the gases released at high temperatures. The products obtained were lightweight aggregates (LWAs) in accordance with Standard UNE-EN-13055-1 (rho(b)<or=1.20 g/cm(3) or particle density<or=2.00 g/cm(3)). LWAs manufactured with 50% washing aggregate sludge and 50% clay-rich sediment were expanded LWAs (BI>0) and showed the lowest apparent particle density, the lowest water absorption and the highest compressive strength. It was possible to establish three groups of LWAs on the basis of their properties in comparison to Arlita G3, F3 and F5, commercially available lightweight aggregates manufactured in Spain. Our LWAs may have the same or similar applications as these commercial products, such as horticulture, prefabricated lightweight structures and building structures.