Development of lightweight aggregates from stone cutting sludge, plastic wastes and sepiolite rejections for agricultural and environmental purposes

Natural field freeze-thaw process leads to different performances of soil amendments towards Cd immobilization and enrichment

Cadmium (Cd) soil pollution is a global issue affecting crop production and food safety. Remediation methods involving in-situ Cd immobilization have been developed, but their effectiveness can diminish under seasonal freeze-thaw aging processes. In this study, we assessed the field performance of four soil treatments at a seasonally frozen rice paddy. Amendments were applied at 2 wt%, including: (i) sepiolite (a 2:1 clay mineral), (ii) superphosphate, (iii) biochar (produced by rice husk at 500 °C for 2 h), and (iv) joint application of biochar & superphosphate (1:1 mixture by weight). Immobilization performance was determined as DTPA extractable Cd and plant uptake in various organs. Overall, the four treatments significantly reduced Cd bioavailability during the plant growth period, with average DTPA-extractable concentrations decreasing by 43%, 34%, 39% and 45% for the four treatments, respectively, relative to untreated soil (control). Rice grain yields from the superphosphate and the joint application treatments increased by 8.0% and 11.8%, respectively, and Cd accumulation within those grains reduced by 14.3% and 48.9%, respectively. During the winter non-growth period, freeze-thaw aging facilitated Cd mobilization, with DTPA-extractable Cd increasing by 16.9% in the control soil, relative to the initial period. However, this reduced to 10.9%, 14.4%, 7.6% and 5.0%, for the sepiolite, superphosphate, biochar and joint application treatments, respectively. Overall, the joint application of biochar and superphosphate provided the best performance in terms of both long-term Cd immobilization and rice production enhancement, offering a green remediation option for risk management at Cd contaminated rice paddies in seasonally frozen regions.

Sustainable Use of Sludge from Industrial Park Wastewater Treatment Plants in Manufacturing Lightweight Aggregates

The aim of this study was to investigate the development of a process for manufacturing lightweight aggregates (LWAs) by incorporating sludge from wastewater treatment plants in industrial parks with reservoir sediments. The research was divided into two stages: laboratory-scale firing and large-scale firing. In the laboratory-scale stage, a high-temperature furnace was used for trial firing. In the large-scale stage, a commercial rotary kiln was used for trial firing for mass production. The test results showed that the water absorption, dry loose bulk density, and crushing strength of the sintered LWAs were 14.2–26.9%, 634–753 kg/m³, and 1.29–2.90 MPa, respectively. Moreover, the water absorption of the sintered LWAs increased as the percentage of added sludge increased. In addition, the dry loose bulk density of the sintered LWAs gradually decreased as the percentage of added sludge increased. Moreover, the results of the heavy metal toxicity characteristic leaching procedure (TCLP) dissolution test for the LWAs produced by blending 30–50% sludge were all lower than the standard value required by the Taiwan Environmental Protection Agency for general industrial waste. The strength grade of the sintered LWAs was 20 MPa. From this point of view, the sintered LWAs that were studied under the test conditions could be used as aggregates for lightweight concrete and would allow it to have a reasonable strength of greater than 20 MPa.

Utilisation of Recycled Silt from Water Treatment and Palm Oil Fuel Ash as Geopolymer Artificial Lightweight Aggregate

The global consumption of aggregate in the construction field is increasing annually, especially in concrete production. With the development of the economy and increase of the population, the demand for concrete and, therefore, a huge amount of aggregate has increased significantly. This issue is pressing and needs to be addressed. Lightweight aggregate (LWA) is one possible solution. This study investigated the potential use of artificial LWA manufactured from alkaline-activated palm oil fuel ash (POFA) with silt due to its properties and performances. Six mixes containing up to 60% silt by total weight combined with optimised activated POFA were analysed. The artificial LWA was synthesised through a pelletising and sintering process at 1150 °C. The increase in the activated POFA proportion in the mixture induced changes in the properties of artificial LWA, including the physical and mechanical properties, durability, and microstructure. The analytical results showed that all of the artificial aggregates were categorised as LWA, based on BS EN 13055. The artificial LWA with 40% activated POFA and 60% silt had the highest crushing strength and acceptable properties for construction applications. This study summarised the performances of the final products and highlighted the different uses of imported silt and POFA as building materials for minimising environmental impacts.

Effectiveness of two lightweight aggregates for the removal of heavy metals from contaminated urban stormwater

Contaminated runoff stormwater from urban environments carries several contaminants to water bodies, thereby affecting the health of living beings and ecological systems. Among all the contaminants, heavy metals possess high toxicity and impact water quality. The stormwater management through green infrastructures composed by adequate materials can provide an excellent solution, simultaneously ensuring the appropriate hydraulic performance and contaminant removal rate. The proposed research aims at the elimination of heavy metals (i.e. Ni, Cu, Zn, Cd and Pb) through column experiments by selecting four possible and novel treatments for urban stormwaters. Two lightweight aggregates (Arlita and Filtralite) were tested separately and in combination with CaCO₃. The study determines the efficiency and lifetime of each treatment by varying the interaction time between the filter materials and contaminated water and the type of filter. The observed removal mechanisms were closely related to the changes in pH due to the interactions between water and different materials. The reductions in heavy metal concentrations depend on the type of heavy metal, interaction time and type of filter material. Results indicate that the combined use of CaCO₃, Arlita and Filtralite did not improve the removal rates of heavy metals. However, it decreased the efficiency of the decontamination process. The significance of this study lies on the removal efficiency of Arlita and Filtralite as decontamination treatments. Both the tested lightweight aggregates led to a considerable decrease in the heavy metal concentrations in urban runoff stormwater although Filtralite was particularly efficient. After 4 weeks, the treatments were still successfully reducing and stabilising 99% of the heavy metals in the contaminated stormwater. These results confirm that the lifetime of the tested lightweight aggregates is adequate and emphasise, as a novel application of these materials, on their feasibility for the improvement of urban stormwater quality.

Manufacturing of lightweight aggregates from biomass fly ash, beer bagasse, Zn-rich industrial sludge and clay by slow firing

A 70:30 black-white clay mixture (C) has been blended with different proportions of three wastes: bagasse from beer production (BG), a flux sludge used in galvanization (FS) and fly ash enriched to 60% with K₂O from a biomass plant (FA). A complete characterization of the raw materials was performed. Mixtures of C and FA for 15, 17.5 and 20 wt% of K₂O were blended with water, shaped into prismatic specimens, oven-dried, muffle-sintered at 1000-1200 °C, and finally crushed into lightweight aggregates (LWAs). The amounts of FA corresponding to K₂O = 20% for a temperature, T, of 1000 °C (LWA variety C20K-1000) yielded the best technological properties: oven-dry density of 1.22 g/cm³, water absorption of 39.8% and open porosity of 48.6%. Therefore, other specimens containing BG and FS were sintered according to the same protocol considering K₂O = 20% and T = 1000 °C. White aggregates were also obtained at 1000 °C (C-1000 variety) from C-mixture (without FS, FA and BG). The addition of BG (5,7 and 10 wt%) did not mean any improvement with respect to C20K-1000, and in the case of FS (25-40%), the development of red color was fostered, which could be interesting for gardening or ornamental purposes. A leaching test conducted on the aggregate with 40 wt% FS showed that the concentration of heavy metals was below the permitted environmental thresholds. Although the leachable Zn concentration of the aggregate (205 ppm) was reduced by 85% with respect to the original residue, it is still high enough for crops that demand this metal. The outcome of this investigation proves the usefulness of recycling agricultural and industrial wastes to obtain high quality LWAs for agriculture or gardening.

Application of Recycled Ceramic Aggregates for the Production of Mineral-Asphalt Mixtures

This paper describes a method of designing and producing innovative mineral–asphalt mixtures, which utilize waste aggregate from the recycling of sanitary ceramics. The work presents the basic properties of the ceramic material, the investigation concerning the microstructure of the aggregate obtained from the grinding of waste, and a comparison with the images obtained for the aggregates usually employed in mineral–asphalt mixtures. The mixtures were designed for the application in the wearing course. Four series of mixtures were prepared. In the first and second, the ceramic aggregate constituted a partial substitute for dolomite, whereas in the third, we substituted granodiorite, and the fourth series contained only dolomite. The mixtures were examined for the content of soluble binder, the bulk density of samples, the presence of voids, the space filled with binder, and the susceptibility to water and frost corrosion. The obtained results were compared with the standard requirements. The microstructure as well as the contact zone in the considered mineral–asphalt mixtures are presented based on research conducted by means of a scanning electron microscope (SEM).