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Journal of Cleaner Production 101 (2015) 174e179

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Journal of Cleaner Production


journal homepage: www.elsevier.com/locate/jclepro

Study on feasibility of reutilizing textile effluent sludge for producing


concrete blocks
Bao Jian Zhan, Chi Sun Poon*
Department of Civil and Environmental Engineering, The Hong Kong Polytechnic University, Hung Hom, Kowloon, Hong Kong

a r t i c l e i n f o a b s t r a c t

Article history: With an increasing interest in recycling and reusing waste, there is a need to carry out research on
Received 13 October 2014 exploring ways to transform industrial wastes into construction materials. This paper attempts to explore
Received in revised form the feasibility of reutilizing textile effluent sludge (TES) for producing concrete blocks with a pretreat-
5 March 2015
ment step. The lime-based pretreatment process was adopted to remove ammonia in TES which had
Accepted 28 March 2015
been found to lead to bad odor and strength loss of the concrete blocks. The concrete blocks were
Available online 6 April 2015
prepared with an aggregate to cement ratio of 12, 10 and 6. The pretreated TES was adopted to replace
the fine aggregate at a mass ratio ranging from 0% to 30%. The compressive strength and drying shrinkage
Keywords:
Textile effluent sludge
values were determined to evaluate the performance of concrete blocks containing TES. The results
Lime-based pretreatment indicated that the lime-based pretreatment process can lower the ammonia concentration in TES
Concrete block significantly. The concrete blocks with a lower TES content and lower ammonia concentration had higher
Ammonia compressive strength and better volume stability. When the TES content in the concrete blocks was
Leaching about 10%, the concrete blocks with an aggregate to cement ratio of 10 can satisfy the minimum strength
requirement for non-load bearing applications. Meanwhile, the result of leaching test indicated that the
toxic trace metals present in textile effluent sludge could be stabilized/solidified and metal leaching from
the concrete blocks is not a concern.
© 2015 Elsevier Ltd. All rights reserved.

1. Introduction petroleum solid waste was also investigated with cement-based S/S
process (Karamalidis and Voudrias, 2007). It was found that in-
Textile industry involves processing or converting raw material/ clusion of cement blended with pozzolanic materials increased the
fabric into finished clothing materials via several processes which leachability of most polycyclic aromatic hydrocarbons in solidified
consume large amount of water and produces polluting waste ef- sludge samples. Sewage sludge from have been studied for fired
fluents (Karthikeyan and Mohan, 1999) containing non- bricks production, but high content of this sludge resulted in a
biodegradable and toxic dissolved substances (Khatri et al., 2014). degradation of mechanical strength and absorption of fired bricks
Previous studies confirmed that the levels of pollutants in textile (Ingunza et al., 2011).
effluent were considerably higher than the discharge limits stipu- Several kinds of waste are also reused in combination with
lated by local regulations (Noorjahan, 2011; Paul et al., 2012). cement for producing concrete products, including waste marble
Therefore, treatment of the textile effluent before discharge is (Gencel et al., 2012), ferrochromium slag (Gencel et al., 2013) and
almost mandatory leading to the production of huge volumes of CRT funnel glass (Ling and Poon, 2014). Recently, reutilization of
textile effluent sludge. Besides landfill disposal of the sludge, there sewage sludge ash (SSA) was reported to manufacture blocks with
are growing interests in trying to re-utilize the sludge. best performance by replacing 10% sand with SSA (Francisco et al.,
Currently, cement based binders are extensively adopted for 2014). Even another study assessed the potential feasibility of
treating industrial solid waste containing radioactive or hazardous reusing lime-dried sludge as a replacement of limestone material
substances to prevent the leaching of contaminants to the envi- for clinker production (Xu et al., 2015). Rala et al. (2015) have
ronment (Batchelor, 2006). Stabilization of hydrocarbons in explored the feasibility of reuse the marble slurry to partially
replace cement for concrete production. They found that 10% of
cement replaced by marble slurry was the optimum content to
* Corresponding author. Tel.: þ852 2766 6024; fax: þ852 2334 6389. produce concrete with the requisite strength and enhanced
E-mail address: cecspoon@polyu.edu.hk (C.S. Poon). durability.

http://dx.doi.org/10.1016/j.jclepro.2015.03.083
0959-6526/© 2015 Elsevier Ltd. All rights reserved.
B.J. Zhan, C.S. Poon / Journal of Cleaner Production 101 (2015) 174e179 175

As early as 1980s, sludge from wastewater treatment plants had


been studied and reused for producing fired clay bricks, and the
results indicated that the compressive strength was acceptable
while the texture and finish on the surface of bricks were rather
poor (Tay, 1987). The reuse potential of textile effluent sludge for
the production of cement-sludge bricks was also confirmed in
previous study (Hema and Suneel, 2009), and the compressive
strength of the product could even meet the requirement of
structural application as described in the India standard. However,
the density and compressive strength of the cement brick
decreased with increasing amounts of sludge in the brick. The
negative effects of textile effluent sludge on properties of concrete
block were also demonstrated in some other studies. Herek et al.
(2012) suggested that incorporating no more than 20% by mass of
sludge could lead to good quality concrete bricks in terms of me-
chanical characteristics; leaching and solubilization tests proved
the sludge brick were inert. Balasubramanian et al. (2006) also
reported an investigation on replacing 10%, 20% and 30% of cement Fig. 1. Raw textile effluent sludge.
with textile effluent sludge to produce flooring tiles, pavement
blocks, hollow blocks, solid blocks and burnt clay bricks. It was
concluded that a maximum of 30% substitution for cement with Several pre-treatment methods listed below had been tried:
textile effluent sludge may be possible in fabrication of non-load Method A: The as received sludge were pre-dried at 105 C for
bearing building materials. 24 h, and then ground manually to fine particles smaller than 5 mm
Few studies gave a valid explanation for the adverse effects of in size (Fig. 2). The particle size distribution was determined and
textile effluent sludge on properties of cement-sludge mixtures. It the results are presented in Table 2. The prepared TES was used for
was speculated that the presence of chloride and sulfates in sludge making the blocks similar to the reference sample;
resulted in decline in strength (Raghunathan et al., 2010); Pandey Method B: The prepared TES from process A was mixed with
et al. (2011) inferred that Zn and Pb salts in the sludge caused lime before concrete blocks casting. Before mixing with cement and
precipitation of protective coatings around cement grains during aggregates, the TES was mixed with lime and water for 5 min using
cement hydration, leading to a decrease in compressive strength. a planetary mixer, with a proportion of TES: lime: water ¼ 1: 0.25:
In this paper, an investigation of assessing the feasibility of 0.6;
reutilizing a textile effluent sludge (TES) with high concentrations Method C: The prepared TES from process A was mixed with
of ammonia is reported. Pretreating processes for the TES were lime for 5 min with a proportion of TES: lime: water ¼ 1: 0.25: 0.6;
attempted in order to alleviate the deleterious effects of TES on the and then the mixture were aged for 24 h in the laboratory
properties of cement-sludge mixtures. Then, the pretreated sludge (23 ± 2  C, 65 ± 10%RH) before concrete blocks casting;
was used as a partial replacement of fine aggregate to produce Method D: The as received TES was mixed with lime for 5 min
concrete blocks. The evaluation of the concrete blocks was con- with a proportion of TES: lime ¼ 1: 0.07, and then the mixture were
ducted in terms of compressive strength and drying shrinkage. aged for 24 h in the laboratory environment (23 ± 2  C, 65 ± 10%RH)
before concrete blocks casting.
2. Materials and experimental program The basic route for the all pretreatment methods is sketched in
Fig. 3. After the pretreatment process, the NH4eN concentrations of
2.1. Characteristics of textile effluent sludge the pretreated sludge were also determined using the HACH
Method 8155 (Hach Company, 2003).
The textile effluent sludge (TES) was obtained from a bleaching
and dyeing factory which is located in Guangdong Province of 2.3. Concrete block casting
Chinese mainland. The sludge collected (as shown in Fig. 1) was
generated from the wastewater treatment process of the factory. 2.3.1. Mix proportions of concrete blocks
A series of physical and chemical tests were conducted to charac- Four series (A, B, C and D) of concrete block mixes were designed
terize the sludge. The analysis results of the TES are shown in to reuse the sludge corresponding to the four pretreating method of
Table 1. TES mentioned above.
The cement used was ASTM Type I Portland cement. Crushed
2.2. Pretreatment methods fine granite passing 5 mm sieve was used as the fine aggregate,
while the crushed granite with a nominal size of 10 mm was used as
Considering the high concentration of ammonia (NH4eN) in the the coarse aggregate. Aggregate to cement ratios (A/C) of 6, 10 and
sludge, it was necessary to remove the ammonia salts in TES for two 12 were adopted. The pretreated sludge was used to replace the fine
main reasons. First, ammonia is a strong odors compound which aggregate with different mass ratios. The amount of water added
would be unacceptable to the workers handling the TES, and the varied slightly with the different mixes, and was dependent on the
ultimate users of TES related products. Moreover, a previous study amount of pretreated sludge (normally the pre-treated TES had a
on reusing ammonia contaminated fly ash in cement mortar and higher water demand than natural aggregates) used. The details of
concrete demonstrated that the presence of ammonia can inhibit mix proportions for concrete blocks are presented in Table 3.
cement hydration and thus lower the compressive strength (Kim
et al., 2007). In this study, anhydrous lime (CaO) was chosen to 2.3.2. Fabrication of concrete blocks
remove ammonia from TES as it is the cheapest source of alkali to The experimental procedure of concrete blocks casting is
produce hydroxide ions (OH), which can convert ammonium ions illustrated in Fig. 4. Specimens with dimensions of
in the sludge to ammonia gas (released). 70 mm  70 mm  70 mm, and 25 mm  25 mm  285 mm were
176 B.J. Zhan, C.S. Poon / Journal of Cleaner Production 101 (2015) 174e179

Table 1
Characterization of TES.
a b
Oxides Value (% dry mass) Trace metals Value (mg/Kg dry mass)

Al2O3 6.20 Ag <1


SiO2 3.40 As <5
P2O5 2.79 Ba 46.83
SO4 24.95 Cd 18.39
CaO 0.87 Cr 110.01
TiO2 0.53 Cu 455.11
MnO 0.82 Hg <5
Fe2O3 60.45 Ni 63.38
Others Pb 304.04
Water Content (% wet weight) 75.24 Se <2
c
Loss-on-ignition (% dry mass) 11.81 Si 26.48
d
NH4eN (mg/kg wet weight) 1692 Zn 291.40
e
Specific gravity (oven-dried) 1.14
a
The oxides are determined using X-Ray Fluorescence (XRF) method.
b
Trace metals are determined according to US EPA Method 200.7.
c
Loss on ignition is determined according to BS EN 12879.
d
NH4eN concentration is measured using the HACH Method 8155.
e
Specific gravity is determined using pyknometers according to BS 733-2.

demolded. The samples for compressive strength testing were


wrapped by plastic films for moist curing; the samples for drying
shrinkage testing were put into a drying shrinkage chamber (20  C,
50%RH) after 28-day standard moist curing.

2.4. Test methods

Compressive strength tests were conducted after 7 and 28 days


of moist curing, in accordance with the procedures described in BS
EN 12390-3 (BSI, 2009). The drying shrinkage test was determined
using the method specified in BS 6073 (BSI, 2008).
Furthermore, considering the presence of heavy metal in the
textile effluent sludge, the toxicity characteristic leaching proce-
dure (TCLP) was performed using the fractured particles from an
optimum mix according to the US EPA Method 1311(U.S. EPA, 1990).
The fractured particles after the compressive strength testing at 28
day and were crushed to pass through a 10 mm sieve. 20 g of
Fig. 2. Ground TES (<5 mm) after oven-dried. crushed sample was put into 400 ml of the TCLP leachant (prepared
by diluting 5.7 mL of glacial acetic acid in 2 L of distilled water) for
tumbling 18 h in a rotary mixer. The mental concentration in the
prepared for the determination of compressive strength and drying leachate was then determined using an inductively coupled
shrinkage. Once the mixing procedure was completed, the mixed plasma-optical emission spectral photometer (ICP).
materials were cast into steel molds in three layers. The amounts of
materials for each sample were determined by the mold internal 3. Results and discussion
volume and the target density of blocks. After each of the first two
layers was filled, compaction was applied manually using a 3.1. Compressive strength
hammer and a wooden stem. After the third layer was filled, a
compressive force with a pressure of 30 MPa was applied for about The compressive strength for all the samples after 7-day and 28-
30 s to mechanically compact the mix within the mold. The excess day curing age are shown in Table 4.
materials were then removed with a trowel. The fabricated blocks, For the samples in Series A, there was a significant reduction in
in the steel molds, were covered by a plastic sheet and left in the compressive strength after adding the TES into the blocks. Even
laboratory environment (23 ± 2  C, 65 ± 10%RH) for 24 h, and then only 10% of fine aggregate was replaced by TES (A-10), the 7-day

Table 2
Particle size distribution of pre-dried TES.

Sieve size Mass retained, g Percentage retained, % Cumulative percentage passing, %

5 mm 0 0.0 100.0
2.36 mm 17.8 6.9 93.1
1.18 mm 47.9 18.7 74.4
600 mm 77.9 30.3 44.1
300 mm 64.3 25.0 19.0
150 mm 32.5 12.7 6.3
75 mm 10.0 3.9 2.5
<75 mm 6.3 2.5 /
B.J. Zhan, C.S. Poon / Journal of Cleaner Production 101 (2015) 174e179 177

Fig. 3. Sketch of pretreatment methods for TES.

Table 3
Mix proportions for concrete blocks prepared with TES.

Series Notation Pre-treatment % of fine aggregate Aggregate Cement Fine aggregate Coarse aggregate
method of TES substituted with TES to cement ratio

Series A A-00 A 0 12 1 7.8 4.2


A-10 10
A-20 20
A-30 30
Series B B-00 B 0 10 1 6.5 3.5
B-05 5
B-10 10
B-15 15
Series C C-10S C 10 6 1 3.9 2.1
C-10T 10 10 1 6.5 3.5
Series D D-00 D 0 6 1 3.9 2.1
D-10 10
D-15 15
D-20 20

compressive strength was reduced by almost 80% while the 28-day When 5% of fine aggregate was replaced by TES, the B-05 sam-
compressive strength was reduced by 70%, compared to the refer- ples attained a satisfactory compressive strength value after 7 days
ence samples (A-00). Further increase in TES dosage in the concrete moist curing, which was considerably higher than 7 MPa. Never-
blocks had little impact on the compressive strength. However, theless, even after 28-day curing, the compressive strength of B-10
except the reference sample, the 7-day compressive strength of the and B-15 samples was still around 4.4 MPa.
samples in Series A did not meet the minimum requirement of Both two mixes in Series C were prepared with 10% fine
7 MPa according to BS 6073-1. aggregate substituted with TES, but with different aggregate to
cement ratios. Apparently, the compressive strength value for
concrete blocks (Ce10S) after 7-day and 28-day curing was
acceptable once an aggregate to cement ratio of 6 was adopted.

Table 4
Properties of concrete blocks prepared with TES.

Series Notation Compressive strength, MPa 14-day Drying


shrinkage value, %
7-day 28-day

Series A A-00 23.6 ± 1.0 25.6 ± 1.0 0.0451 ± 0.0021


A-10 5.1 ± 0.5 8.4 ± 0.3 0.0705 ± 0.0013
A-20 3.1 ± 0.1 4.8 ± 0.3 0.0926 ± 0.0040
A-30 2.9 ± 0.2 4.3 ± 0.3 0.1142 ± 0.0031
Series B B-00 27.6 ± 1.3 34.2 ± 1.3 0.0604 ± 0.0012
B-05 19.1 ± 0.5 23.4 ± 0.2 0.0688 ± 0.0023
B-10 2.7 ± 0.2 4.5 ± 0.1 0.0677 ± 0.0038
B-15 2.3 ± 0.2 4.4 ± 0.3 0.0789 ± 0.0027
Series C C-10S 22.8 ± 1.3 35.6 ± 2.5 0.0495 ± 0.0020
C-10T 6.3 ± 2.1 16.9 ± 0.8 0.0589 ± 0.0013
Series D D-00 e 52.1 ± 0.2 e
D-10 30.3 ± 1.1 43.3 ± 0.7 0.0477 ± 0.0020
D-15 5.9 ± 0.3 28.7 ± 0.8 e
D-20 2.9 ± 0.3 23.3 ± 1.1 e
Fig. 4. Fabrication of concrete blocks in lab.
178 B.J. Zhan, C.S. Poon / Journal of Cleaner Production 101 (2015) 174e179

Fig. 5. Comparison of drying shrinkage value of concrete blocks from different series.

While 7-day compressive strength of concrete blocks with an


aggregate to cement ratio of 10 (C-10T) failed to meet the minimum
requirement of 7 MPa. Fig. 6. Strength loss (f) against sludge content in concrete blocks.

For the concrete blocks in Series D, only the 7-day compressive


strength for concrete blocks prepared with 10% fine aggregate
replaced with pretreated TES was higher than the minimum of selected as the optimum mix based on the testing results of me-
7 MPa. However, after 28 days curing age, the compressive strength chanical property and volume stability. Two batches of fractured
far exceeded 7 MPa even 20% fine aggregate was replaced with TES. particles were collected from specimen D-10 and 3 measurements
were made for each batch. The results are listed in Table 5. Compared
3.2. Drying shrinkage with the maximum allowable values given by US EPA, none of them
exceeded the limits, even the most abundant elements (Cu, Pb, Zn)
Adoption of concrete blocks with smaller drying shrinkage can presented in the as received TES. Therefore, the toxic trace metals
lead to a reduction in probability of developments of drying- present in textile effluent sludge could be stabilized/solidified and
shrinkage cracks of masonry walls. The 14-day drying shrinkage metal leaching from the concrete blocks is not a concern.
values for all the samples are listed in Table 4. Apparently, partial
replacement of fine aggregate with pretreated TES resulted in a
significant increase in 14-day drying shrinkage of the concrete 3.4. Discussion
blocks. For the blocks in Series A and B, the 14-day drying shrinkage
values of all the samples were beyond the maximum allowable According to the results tabulated in Table 4, it can be easily
values of 0.060%, as prescribed in BS 6073. The drying shrinkage noticed that the compressive strength of concrete blocks (Series A,
value even reached 0.1142% when 30% of fine aggregate in concrete B and D) was reduced with the increase in replacement ratio of fine
blocks (A-30) were replaced with TES. As shown in Fig. 5, a com- aggregate with the pretreated TES. However, given the use of
parison of drying shrinkage value was made between the concrete different aggregate to cement ratios for samples in Series A, B and
blocks containing TES with different pretreating methods. It was D, it is inappropriate to compare the compressive strength of
important to note that, regardless of the aggregate to cement ratio, concrete blocks directly. In order to give a quantitative measure of
there is no discoverable connections between the drying shrinkage the effect of pretreatment of TES on the mechanical property of the
and TES content of concrete blocks. However, the drying shrinkage concrete block, a strength loss factor (f) is defined as:
values for the samples in Series C and D-10 were still acceptable.
f ¼ ð1  sr =sÞ  100% (1)

3.3. Metal leaching Where, sr is 28-day compressive strength of concrete blocks pre-
pared with the pretreated TES, while s is 28-day compressive
Taking into account of maximizing the TES utilization in concrete strength of concrete blocks without TES (ref). Thus, f ranges from 0 to
blocks and easy operation of TES pretreatment, the sample D-10 was 100% as sr is always smaller than s for the samples in the same series.

Table 5
TCLP results of concrete blocks containing TES.

Elements Limits (mg/L) Batch 1 Batch 2


a
Mean value, mg/L RSD, % Mean value, mg/L RSD, %

Ag 5.0 0.01 2.5 0.01 1.8


As 5.0 <0.1 e <0.1 e
Ba 100.0 0.31 1.0 0.32 1.0
Cd 1.0 <0.01 e <0.01 e
Cr 5.0 0.02 4.0 0.01 1.3
Cu 1.0 0.11 8.1 0.10 1.2
Hg 0.2 <0.1 e <0.1 e
Ni 1.0 0.03 5.0 0.03 1.1
Pb 5.0 <0.1 e <0.1 e
Se 1.0 0.07 23.7 <0.05 e
Zn 5.0 0.01 0.3 0.01 0.7
a
RSD e Relative standard deviation.
B.J. Zhan, C.S. Poon / Journal of Cleaner Production 101 (2015) 174e179 179

4. Conclusion

Based on the results and discussion presented above, it can be


concluded that it is feasible to reuse the textile effluent sludge for
producing non-load bearing concrete blocks with acceptable
compressive strength and volume stability when appropriate pre-
treatment processes are used. It is a fact that the compressive
strength of the concrete blocks decreased significantly with the
increase of TES content. The experimental results indicated that the
ammonia level in TES was the main cause of the weakening effects.
The lime pretreatment process proposed in this study can
dramatically lower the NH4eN concentrations and improve the
properties of the blocks. The toxic trace metals present in textile
effluent sludge can be stabilized well by cement hydration
products.

Fig. 7. NH4eN concentration in sludge pretreated with different methods.


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