Heliyon 9 (2023) e17517

Contents lists available at ScienceDirect

Heliyon
journal homepage: www.cell.com/heliyon

Development of value-added sustainable products from paper mill

sludge: An experimental approach
R. Maheswaran a, *, M.K. Marichelvam a, S.P. Asok a
a
Department of Mechanical Engineering, Mepco Schlenk Engineering College, Sivakasi, 626005, Tamilnadu, India

A R T I C L E I N F O A B S T R A C T

Keywords: The disposal of paper mill sludge waste generated by the paper industry is a tough and chal­
Paper mill sludge (PMS) lenging task. In this work, an attempt is made to develop various value-added products namely
Fly ash bricks, briquettes, ground chakra base, and eco-friendly composites from the secondary paper mill
Brick
sludge (PMS). The secondary PMS was initially dewatered to remove the moisture content,
Briquettes
Eco-friendly composites
ground to powder, and mixed with cement, MSand. quarry dust, and fly ash to produce bricks.
Sustainability The brick specimens were tested for compressive strength, water absorption, and efflorescence as
per the standards and found to be 5.29 ± 0.11 N/mm2, 3.84 ± 0.13% respectively, and have NIL
efflorescence. The PMS is mixed with paraffin wax and compressed in a squeeze moulding to form
briquettes and observed that the percentage of ash content in the briquette is 66.6% which is less
than that of the PMS. Further, a ground chakra base is produced using a slurry of starch and dried
in a heater at 60◦ exhibiting better properties. An eco-friendly composite pottery product was
developed by mixing PMS, clay, and starch and tested for breakage.

1. Introduction

Paper mill sludge (PMS) is a secondary waste produced by the paper industries. The different types of sludge produced from the
pulp and paper mills were addressed in Ref. [1]. Fly ash is a waste generated from coal combustion in power plants. It may be either
low calcium fly ash or high calcium fly ash based on the type of coal used for combustion. Fly ash bricks are one of the latest de­
velopments in construction materials. However, fly ash is considered to be a toxic material. It produces cancer for inhaling people. To
utilize the waste PMS effectively, in this work, an attempt is made to develop various value-added products.
The characteristics of the PMS were described in Ref. [2]. The difficulties with the disposal of the PMS were also demonstrated. The
different techniques for the disposal of PMS were also explained in detail. Ahmadi & Al-Khaja [3] studied the physical and chemical
properties of the PMS. They mixed the PMS with the concrete mix and evaluated the various properties like compressive strength,
splitting, flexural, water absorption, and density. They concluded that the concrete with 5% PMS showed better properties and could
be used for concrete masonry construction. Demir et al. [4] utilized the waste materials from Kraft pulp production to manufacture raw
brick clay. Geng et al. [5] manufactured fibreboard from the primary sludge of a paper mill. They proved that the primary sludge had
better mechanical properties. Zule et al. [6] investigated the chemical properties and biodegradability of PMS. They reported that the
PMS could be useful for different applications after proper pre-treatment processes.
Balwaik & Raut [7] also proved that paper pulp could be used to replace cement in concrete. They prepared different samples by

* Corresponding author.
E-mail address: rmaheshin@yahoo.com (R. Maheswaran).

https://doi.org/10.1016/j.heliyon.2023.e17517
Received 2 November 2022; Received in revised form 20 June 2023; Accepted 20 June 2023
Available online 21 June 2023
2405-8440/© 2023 The Authors. Published by Elsevier Ltd. This is an open access article under the CC BY-NC-ND license
(http://creativecommons.org/licenses/by-nc-nd/4.0/).
R. Maheswaran et al. Heliyon 9 (2023) e17517

varying the weight percentage of paper pulp, water, cement, fine aggregate, and coarse aggregate. The test results revealed that the
compressive strength, splitting tensile strength, and flexural strength of the prepared concrete samples were better. Fava et al. [8]
proposed a mechanical separation practice to extract the sludge and the paper mill sludge ash was produced by combusting it. The
paper mill sludge ash was used as an add-on material in mortars and concrete production. As per the conclusions made by Quaye et al.
[9], PMS must be carbonized under optimum conditions before being mixed with a suitable amount of soil to supply a bigger yield in
agricultural fields and no additional minerals are required.
Likon & Trebše [10] studied the various techniques available to effectively utilize the PMS. They reported that the economics of the
process should be considered while implementing any waste management process. Lim et al. [11] mixed the PMS ash with the plaster
of Paris at various proportions and evaluated the compressive properties of the composites. The compressive strength and the density
of the plaster of Paris with 1% of PMS ash were 8.55 MPa and 1590 kg/m3. This result proved that the plaster of Paris with 1% PMS ash
could be used as a good construction material. Monosi et al. [12] developed lightweight ash from the de-inking sludge. They proved
that the developed ash could be used as a better binder material. Pitroda et al. [13] used the hypo sludge from the paper mill industries
to manufacture the concrete mix. They evaluated the compressive % split strengths of concrete for various proportions of hypo sludge.
Raut et al. [14] developed bricks by using PMS, rice husk ash, and cement.
Buruberri et al. [15] manufactured betilic & Portland clinkers using paper pulp industrial wastes. Cusidó et al. [16] illustrated the
Physico-chemical properties of the binary mixtures of clay and paper sludge. Talsania & Pitroda [17] developed pervious concrete
using the PMS. They proved that the compressive strength of the pervious concrete was good as the sludge behaved like cement. Goel &
Kalamdhad [18] concluded that the PMS consists of various fluxing agents and it could be used for manufacturing commercial bricks.
The heating of PMS would not develop any phase transformation. They manufactured different brick specimens by keeping the weight
percent of PMS to 5%, 10%, 15%, and 20%. The samples with 10% PMS provided better results.
Goel & Kalamdhad [19] also reported a detailed review of the bricks manufactured using the PMS and degraded municipal solid
waste. Mavroulidou & Awoliy [20] suggested that the cement could be replaced partially by the PMS in the concrete with glass
aggregate. Singh et al. [21] developed lightweight bricks using the Deinking PMS. They concluded that lightweight bricks had better
properties and could be used for construction applications. Azrizal et al. [22] investigated the physical, chemical, and reactive
properties of ash developed from the PMS and concluded that the ash could be used for different products in the building industries
such as brick, concrete, etc. Banevičienė et al. [23] burned the PMS at 900 ◦ C and its impact on the physical-mechanical properties of
the cementitious matrix and evaluate its usage/utilization possibilities in cementitious materials. They prepared various specimens by
varying the weight percentage of the PMS. They proved that the 5% PMS would provide optimal results. Zainith et al. [24] proposed
different techniques for the disposal of PMS. Astrauskas & Grubliauskas [25] developed composite panels using PMS and clay as the
binding material. The composite panels were used for sound absorption. They concluded that the sound absorption coefficient depends
on the density of PMS. Recently, Haile et al. [26] reported that various value-added materials such as carbon fiber, bioplastic, fibers,
and eco-friendly composites could be derived from the PMS. Mohammed et al. [27] developed rubberized bricks. They produced
geopolymer interlocking bricks using crumb rubber as the sole fine aggregate. They reported that the bricks had poor compressive
strength and could be used as a non-load-bearing material. Al-Fakih et al. [28] addressed the various waste materials and the methods
used to develop bricks in detail. Al-Fakih et al. [29] also developed rubberized concrete interlocking brick. They replaced the Portland
cement with fly ash and the sand with crumb rubber. They evaluated the performance of the bricks by conducting various tests. Soucy
et al. [30] developed wood-plastic composites using paper mill sludge. They investigated the effect of the paper mill sludge on the
physical and mechanical properties of high-density polyethylene (HDPE). Zalyhina et al. [31] developed bricks using the paper in­
dustry slag. They added slag at various percentages and investigated the physical and mechanical properties of the brick samples. Jele
et al. [32] addressed different products from three different types of pulp and paper mill sludge materials. Akinwande et al. [33]
proposed the manufacturing of paper bricks using waste paper and glass. They conducted the design of experiments using four factors.
The response surface method was also used by them. Recently, Abushammala et al. [34] produced various energy and high-value
materials from paper waste materials.
From the above literature review, it is evident that most of the researchers proposed the development of one product either brick or
concrete using the PMS. However, in the present work, an attempt is made to develop several value-added products from the PMS. The
objective of this work is to develop bricks, Briquettes, ground chakra bases, and eco-friendly composites using the waste PMS. Brick
samples were developed by mixing the PMS with MSand, quarry dust, and cement. In Fly ash brick manufacturing, sand is used as a
base material, fly ash is used as a filler material, and lime and gypsum are used as binders. Instead of lime and gypsum, cement is used
in the present work. In this study, the PMS combined with fly ash is used as a filler material. Several brick samples were prepared and
tested as per the standards. The results are impressive. The PMS was also used to develop briquettes that could be used as a secondary
fuel source in the paper industry. The PMS was mixed with sawdust and paraffin wax to make the briquettes using the compression
moulding machine. The ground chakra base and the eco-friendly composites are the other value-added products developed from the
PMS. The PMS slurry was made by mixing the PMS with the starch and water. The slurry was used to make the ground chakra base
using the hot-pressing method. The PMS was added with sand, starch, and bentonite to manufacture the eco-friendly composites using
the pottery technique.
To the best of our knowledge, this would be the first reported application to develop many value-added products using the waste
PMS. Further, the performance of those products was validated by conducting several tests as per the standards. The developed
products would help increase the profit of the paper mill. This would also minimize the environmental impact significantly. The next
section illustrates the materials and methods used in the present work.

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2. Materials and methods

Paper Mill Sludge (PMS) is the main material used. The PMS comes as the waste by-product in the paper industry. It is in a semi-
solid state and is in wet condition. The sludge required for the project was supplied by Sri Krishna Paper Mills, Sivakasi, Tamilnadu,
India. The sludge was dried in the sun to remove the water content present in the sludge. Then, the sludge was finely powdered using a
mixture. The powdered paper mill sludge was used in the process. Fly ash is a thin grey powder made up primarily of spherical, glassy
particles that is a by-product of coal-fired power plants. MSand is a type of man-made sand made by crushing huge hard stones,
primarily boulders or granite, into fine particles, which are then washed and carefully graded. It is frequently used in construction as a
substitute for river sand, mostly in the preparation of concrete and mortar mix. Quarry dust is described as the residue, tailing, or other
non-volatile waste materials left over after rocks have been extracted and processed into tiny particles less than 4.75 mm. Quarry dust
can be used as a partial replacement for sand in concrete in the building sector. The fly ash, MSand, and quarry dust were supplied by
VR Bricks, Sevalpatti, Tamilnadu, India. A binder is a substance used in construction that sets, hardens, and clings to other materials to
bind them together. Cement is a binder used in this work. The cement was purchased from the local market at Sivakasi, Tamilnadu,
India. The other materials required for manufacturing the briquettes, eco-friendly composites, and ground chakra base are purchased
from the local market at Sivakasi, Tamilnadu, India. The next section demonstrates the different techniques used to develop the value-
added products.

2.1. Methods

The various processes undergone before the manufacturing process are listed below. The measured quantity of sludge was taken in
the dry cloth and it was pressed by the roller. Due to the pressure, water is coming out from the sludge. Then, the dewatered sludge was
dried in the Sunlight for 24 h and the moisture was removed from the sludge. The dried PMS was then ground to reduce the size of the
particles. The PMS powder is shown in Fig. 1a.

2.1.1. Characterization of PMS

The various tests conducted on the paper mill sludge are described below.

2.1.1.1. Fourier Transform Infrared Spectroscopy (FTIR). Fourier Transform Infrared Spectroscopy, commonly known as FTIR Analysis
or FTIR Spectroscopy, is a technique for identifying organic, polymeric, and inorganic materials. Infrared light is used to scan test
materials and examine chemical characteristics using the FTIR analysis method.

2.1.1.2. Scanning electron microscope (SEM). SEM analysis is a strong investigative tool that produces complex, high-magnification
images of a sample’s surface topography using a focussed stream of electrons (SEM, model: JEOL JSM-6390). After being exposed
to a highly focused beam of electrons from electron cannon, SEM relies on the detection of high-energy electrons released from the
surface of a sample. Using the SEM objective lens, this beam of electrons was focused on a narrow area on the sample surface.

2.1.1.3. Energy dispersive X-Ray Analysis (EDAX). The Energy Dispersive X-Ray Analysis (EDX), often known as EDS or EDAX, is used
to determine the elemental composition of materials. The imaging capability of the microscope identifies the specimen of interest in
EDX systems, which are attachments to Electron Microscopy equipment (Scanning Electron Microscopy (SEM) or Transmission
Electron Microscopy (TEM)). EDX analysis produces spectra with peaks corresponding to the elements that make up the real
composition of the sample under investigation. The EDAX analysis was done for the PMS and the fly ash.
The next section illustrates the brick manufacturing method.

Fig. 1. a) Powdered PMS. b) Brick Compression Machine. c) Brick samples.

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2.2. Preparation of brick samples

The standard size of the brick was 230 mm × 110 mm X 75 mm. The sample bricks were manufactured in a nearby brick
manufacturing company (VR Bricks, Sevalpatti, Tamilnadu, India). The composition of the lightweight brick (LWB) using PMS is given
in Table 1. The mixture was initially placed in the grinder for mixing and the mixture was transferred to the brick compression machine
(Fig. 1 b) using a belt conveyor. The mixture was first filled in the base plate of the machine and then a pressure of 250 bar was applied
to the base plate by the machine. The sample bricks (Fig. 1 c) with the standard shape of the die were obtained at the bottom and were
transferred out by the moving conveyor at the bottom and the bricks were carefully taken out. Then, the sample bricks were dried in
sunlight for 24 h. The bricks were moved to the storage yard. The bricks were sprayed with water and this is called curing. The bricks
were cured for the next 3 days. The sample bricks were placed in the sunlight again for drying purposes for the next 12 days for
obtaining the required strength.

2.3. Testing of sample bricks

The various tests namely compression test, water absorption test, and efflorescence test were carried out to find the properties of
bricks and they are explained below.

2.3.1. Compression test

The sample bricks were immersed in water at room temperature for 24 h. Then, the surface water was removed using a dry cloth.
The voids in the bed faces of sample bricks were flushed with cement mortar. The sample bricks were dried for 24 h at room tem­
perature and soaked in the water for another 3 days for curing. The samples were taken out and traces of moisture were removed. The
samples were placed with a flat face as a horizontal and mortar-filled face facing upwards between the plates of the testing machine. An
axial load at a uniform rate of 14 N/mm2 per minute was applied till failure occurs and the maximum load at failure was recorded. The
load at failure shall be the maximum load at which the specimen fails to produce any further increase in the indicator reading on the
testing machine.

2.3.2. Water absorption test

The durability of the brick is ensured by conducting the water absorption test. The water absorption test is also important to prove
the safety of the brick. A 24-h immersion cold water test was used to conduct the water absorption test. The water absorption test was
conducted as per the IS: 3495 standards. The sample bricks were kept in an oven that maintained an average temperature of 110 ◦ C.
The sample bricks were taken out and the initial weights of the bricks are measured and noted. Then, the dried bricks are dipped in cold
water for 24 h. The samples were taken out and the traces of water present in the brick surfaces were removed with a cloth. After 3 min
the samples were weighed and the weights were noted.

2.3.3. Efflorescence test

The efflorescence test of bricks was conducted as per the IS: 3495 standards. The sample bricks were kept in a 150 mm diameter
porcelain tray containing 25 mm depth of distilled water at room temperature (20–30 ◦ C) till the entire water was absorbed or
evaporated. The distilled water was again filled to a 25 mm depth in the dish and allowed to be absorbed by the brick or evaporated.
The presence of efflorescence was finally noted after 24 h.

2.4. Manufacturing of briquettes

This section explains the briquettes manufacturing technique. The briquettes were manufactured by varying the composition of
sludge, sawdust, and paraffin wax, and the optimal composition was found and as shown in Table 2. Starch, gypsum, bentonite powder,
and candle wax were used as binder materials at the beginning. However, the binding nature of the above materials was insignificant.
The briquettes made using the sawdust particles also showed poor performance. Hence, the paraffin wax was used as the binder which
provided rigidity since it was a petroleum product. The Briquettes manufacturing process is explained below.
The water content in the sludge was removed using the dewatering method. In this method, the sludge was filled in a circular
container. At one end of the container, a screener was placed to drain water. Then, the container was placed in the dewatering ma­
chine. With the help of hand power, the sludge was pressed and the water was removed. Fig. 2(a) shows the dewatering method. The
dewatered sludge was then dried to remove the moisture content to the maximum extent. The process of drying sludge also reduces the

Table 1
The Composition of sample bricks.
S. No Materials Composition (in %)

1 MSand 31
2 Quarry Dust 31
3 PMS 16
4 Fly ash 16
5 Cement 6

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Table 2
Composition of briquettes.
Sample Number Sludge (g) Sawdust (g) Paraffin wax (g)

1 50 30 20
2 75 15 10
3 40 40 20
4 15 75 10

Fig. 2. (a) Dewatering method. (b) Mixture contains the secondary PMS, sawdust, and Paraffin wax. (c) Die. (d) Pellets manufactured.

volume of the product, storage space, transportation, and packaging cost. The dewatered sludge was dried under sunlight or placing it
in a heating chamber at 60–70 ◦ C. The volatile contents in the sludge were removed and at 103 ◦ C the moisture content will be reduced
by a significant level. Then, 75% of the dried sludge was taken and mixed with 15% of the sawdust. This mixture was then mashed
finely till the sawdust was bound with the sludge. Then, 10% of paraffin wax was added to this mixture as a binder material. Paraffin
wax was first melted by heating and poured into the mixture of sludge and sawdust. Thus, it enhanced the adherence property of this
mixture, and hence all the particles were bound together into a single mixture. The mixture is then poured into the compression die.
The process was repeated till the required height of 4 cm was obtained. Then, the top of the die was placed over the hole and pressed to
extrude the pellets from the die. Pellets made are then dried in sunlight for 2–3 days due to the presence of sawdust. A compact pellet
was obtained after it was dried. Figures [2 (b) to 2(d)] show the mixture containing the dried secondary PMS, sawdust, and paraffin
wax, the die, the process, and the pellets manufactured. The next section addresses the various tests performed on the briquettes.

2.5. Testing of briquettes

Tests such as the ash test, volatile matter test, and moisture test were performed to evaluate the briquettes and these tests are

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addressed in this section.

2.5.1. Ash test

The ash test was carried out to determine the percentage of ash content present in a sample. A sample of known mass was placed in a
muffle furnace at 900 ◦ C for about 1 h using a crucible without a lid. The weight loss was measured and it was the ash content of the
sample.

2.5.2. Volatile matter test

The percentage of volatile matter present in the sample is determined by this test. In this test also, a known weight of the sample was
placed in a muffle furnace at 720 ◦ C for about 7 min using a crucible which is closed with a lid.

2.5.3. Moisture test

The presence of moisture content in the sample decreases the calorific value. The lesser moisture content indicates the higher
calorific value of the samples. The moisture test was done by placing a known weight of a sample in an air heat oven at 105 ◦ C for about
2 h.
The next section presents the ground chakra base manufacturing method.

2.6. Ground chakra base manufacturing

The secondary PMS, starch, Paraffin wax, and water were used as raw materials for the manufacture of the ground chakra base. This
ground chakra base is widely used in the fireworks industry. A punch and die set was used to manufacture the required shape of the
ground chakra base. A hot plate was also used to heat the chemicals. Different compositions were tried by varying the composition of
sludge, starch, and water, and the composition with 58% of sludge, 27% of starch, and 15% of water was found to be optimal. The
sludge, starch, and water were mixed thoroughly and the composition was made semi-solid. The die was placed over the hot plate. The
hot plate was switched on and the temperature was set to 120 ◦ C. The temperature was monitored continuously. When the temperature
reached the value of 60 ◦ C, the Paraffin wax was evenly applied on the surface of the die where the sample is to be placed present in the
form of liquid. After placing the sample in the die, the punch was placed on the sample in the die. The temperature of the hot plate was
monitored continuously. When the temperature in the plate reached 120 ◦ C, the sample was hardened. The temperature was main­
tained at 120 ◦ C for 5 min to get the required shape. The process of manufacturing the ground chakra base is shown in Fig. 3. The
ground chakra base was tested on the ground and the performance was compared with those commercially available in the market. The
performance of the ground chakra base was very similar to that of the commercial ground chakra bases. The next section illustrates the
manufacturing of eco-friendly composite using the PMS.

2.7. Eco-friendly composites manufacturing

For manufacturing the eco-friendly composites, dried secondary PMS, sand, starch, and Bentonite were used as the raw materials.

Fig. 3. The manufacturing process of ground chakra base.

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The process and the produced eco-friendly composites are shown in Fig. 4. The raw materials were taken and mixed thoroughly. The
eco-friendly composite was manufactured by the sintering technique. The optimal sintering temperature was in the range of
100–120 ◦ C. The tests conducted on the briquettes were also used to analyze the properties of the eco-friendly composites. The amount
of ash content, moisture content, and volatile matters are almost similar in eco-friendly composites. However, more investigations are
to be done to analyze the performance of eco-friendly composites. The results and discussions are available in the next section.

3. Results and discussions

The test results of the PMS sludge and the developed value-added products are discussed in this section.

Fig. 4. The eco-friendly composites Manufacturing process.

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3.1. FTIR results of sludge

The FTIR result of the PMS is shown in Fig. 5. FTIR spectrum of PMS was recorded in the range of 400 cm− 1 – 4000− 1. A broad peak
looked at 3372 cm− 1 corresponds to –OH groups arising from carbohydrates and polyphenols. Then, aliphatic –CH and –CH2 stretching
frequency appeared at 2923 cm− 1. The carbonyl group (–C– – O) takes place at 1427 cm− 1. The alkyl amine groups (–NH–) appeared at
1010 and 1030 cm− 1. The existence of inorganic carbonate at 874 cm− 1 confirmed that carbonyl groups in the form of inorganic salts in
PMS. Furthermore, at 712 cm− 1 the –CH out-of-plane bending vibration was observed. These results are summarized in Table 3.

3.2. SEM with EDAX

Field emission scanning electron microscopy (FESEM) was conducted to deliver further information about the surface morphology
of PMS. By applying a voltage of 100 kV, the electron was produced. It was given sputter-coating to enhance its conductivities and
obtained FESEM were shown in Fig. 6 (a) and (b). The FESEM images of PMS presented in Fig. 6 (a) and (b) appear like a smooth
surface with a lot of segments with a size of 100 nm and plate morphology. The various elements present in the PMS and the fly ash are
depicted in Table 4. From the results, it may be concluded that the PMS could be used as a replacement for fly ash in brick
manufacturing.

3.3. Properties of brick samples

The compressive strength, water absorption, and Efflorescence test results of the sample bricks are depicted in Table 5. The
compressive strength of the sample bricks was 5.29 ± 0.11 N/mm2. The compressive strength of common building brick is only 3.5 N/
mm2 [35]. The compressive strength of the bricks developed from the PMS is greater than that of the rubberized geopolymer inter­
locking bricks. The maximum compressive strength of the rubberized geopolymer interlocking bricks [27] is only 3.98 N/mm2. The
compressive strength of the bricks manufactured using the PMS is 32% more than the rubberized geopolymer interlocking bricks.
Hence, it is evident that the bricks manufactured using the PMS could be used for construction purposes. The mean water absorption of
the sample bricks is 3.84 ± 0.13%. But, the rubberized geopolymer interlocking bricks have more than 25% water absorption. As per
the standards, water absorption should be within the range of 15–20% by weight [36]. Hence, the bricks produced from the PMS have
better water absorption properties. The bricks should not show white patches when soaked in water for 24 h and then allowed to dry in
the shade. The white patches are due to the presence of sulphate of calcium, magnesium, and potassium. Such white batches were not
observed in the sample bricks. So, the efflorescence test results for the sample bricks are nil. The test results show a better performance
of the sample bricks.

3.4. Test results of the briquettes

The percentage of ash content in the briquette is 66.6% which is less than that of the PMS (74.4%). The addition of sawdust in
sludge might have decreased the percentage of ash produced. The ash content of pure coal is only 45% which is lesser than our product.
The percentage of volatile matters present in the briquettes is higher (55%) when compared with the secondary PMS (46%). But, the
volatile matter present in the coal is about 32% and it is lesser than our product. The percentage of moisture content present in the
briquettes (26%) is nearly half the value present in the secondary PMS (50.4%). The moisture content of the coal is very low and it is
nearly about 12%. The test results show that the produced briquettes could not replace conventional fuels like coal used in the in­
dustries. However, the briquettes may be used to produce some amount of heat energy which would be used in the paper mill industry
itself. However, further investigations are required to analyze the performance of the briquettes.

Fig. 5. FTIR result of the PMS.

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Table 3
The FTIR frequencies and their corresponding reasons.
FTIR frequency (cm–1) Reasons

712.65 -CH out of plane bending

874.66 Bending–C– –O inorganic carbonate
1010.63 Alkyl amine
1030.88 Alkyl amine
1427.23 Stretching –C–
–O inorganic carbonate
1797.53 –O Fatty acid group
C–
2923.88 Aliphatic CH and CH2 stretching groups
3372.30 OH group in carbohydrates, and polyphenols

Fig. 6. (a) SEM image of the PMS with 10 μm & 2.50 KX. (b) SEM image of the PMS with 100 μm & 250 ×

Table 4
EDAX test result comparison of PMS and Fly Ash.
Element Weight % (Sludge) Weight % (Fly ash)

Oxygen 48.0 45.15

Carbon 21.8 7.94
Calcium 19.8 31.93
Aluminium 2.2 2.33
Silicon 2.8 9.13
Potassium 0.6 1.24
Iron 0.9 2.27

Table 5
Properties of the brick samples.
Sample No. The load at failure (Peak Load), KN Compressive Strength (N/mm2) Water Absorption (%) Efflorescence

1 131.56 5.20 4.004 Nil

2 137.25 5.42 3.636 Nil
3 136.16 5.38 3.854 Nil
4 132.24 5.22 3.720 Nil
5 130.56 5.16 3.921 Nil
6 136.28 5.38 3.876 Nil

3.5. Test results of the ground chakra base

The conventional ground chakra base is made of greyboard material which is too expensive. By using the PMS sludge, a good-
quality ground chakra base was made and as shown in Fig. 3. This indicates that the cost of the ground chakra base could be

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reduced using the PMS. Also, it reduces the environmental impact caused by the greyboard manufacturing process.

3.6. Test results of the eco-friendly composites

Fig. 4 showed the TGA thermograph of the PMS. The flow of nitrogen is 50 mL/min with maintaining the heating rate of 10 ◦ C. The
loss of mass of PMS increases along with the increase in temperature and major changes were observed between 40 ◦ C and 700 ◦ C.
From the TG curve shown in Fig. 4, two major losses of weight were observed. The first major loss in weight occurred in the tem­
perature range of 320 ◦ C–350 ◦ C due to the loss of water and organics which have very low boiling points. The second stage of loss in
weight was mainly due to the decomposition of carbohydrate and aliphatic compounds in PMS. Finally, the resulting residue of the
PMS was obtained when the temperature was about 690 ◦ C. Using the pry techniques [37,38], the pots were manufactured and are
shown in Fig. 4.
From the above test results, it is evident that the PMS could be used for manufacturing various value-added products. These value-
added products would help the paper industries to dispose of the sludge effectively. The developed products generate additional
revenue for the paper industry. The impact of sludge on the environment might be minimized by these products. The developed
products would be helpful to society also.

4. Conclusions

The world moves towards a sustainable environment today. If it is possible to reduce a small percentage of any waste, it would be a
great contribution to saving our world. In the present work, several value-added products like bricks, briquettes, ground chakra bases,
and eco-friendly composites were developed from the waste of secondary paper mill sludge. Among these products, the brick shows
better results in terms of compressive strength, moisture content, and Efflorescence properties. The compressive strength of the sample
bricks was 5.29 ± 0.11 N/mm2. The mean water absorption of the sample bricks is 3.84 ± 0.13%. The efflorescence test results for the
sample bricks are nil. The ground chakra base manufactured from the PMS shows better performance. However, the properties of the
briquettes and the eco-friendly composites were not investigated. This is a limitation of the present work. Further, the cost analysis of
the products was not done. The performance of the briquettes and the eco-friendly composites would be investigated by conducting
more tests in the future. The economic analysis and the commercialization of the product are some more future scopes of our work.

Author contribution statement

Rathinam Maheswaran: Conceived and designed the experiments; Performed the experiments.
Marichelvam M K: Contributed reagents, materials, analysis tools or data; Wrote the paper.
Asok S P: Analyzed and interpreted the data.

Data availability statement

No data was used for the research described in the article.

Declaration of competing interest

The authors declare that they have no known competing financial interests or personal relationships that could have appeared to
influence the work reported in this paper.

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