Recycling hazardous textile effluent sludge in cement-based construction materials: Physicochemical interactions between sludge and cement

Upcycling textile sludge into magnesium oxychloride cement: Physical properties, microstructure, and leaching behavior

Textile sludge is a by-product produced during the wastewater treatment process in the textile printing and dyeing industry. Textile sludge is rich in heavy metal elements, which makes it a potential risk to the surrounding environment. This study designs a magnesium oxychloride cement (MOC) components to solidify harmful substances in textile sludge and studies the influence of textile sludge ash (TSA) on the mechanical properties and microstructure of MOC samples. The results indicated that adding 5 %-20 % TSA is beneficial for increasing the compressive strength of air-cured MOC paste and improving its water resistance. Meanwhile, the MOC sample shows volume expansion in 168 h, which is related to the further hydration of residual MgO. Incorporating 10 %-20 % TSA substantially increased the volume expansion ratio of the mixture compared to plain MOC sample. In addition, the porosity of TSA-modified MOC after water curing did not change significantly compared to the sample before water curing, while the pore structure of plain MOC after water curing significantly coarsened. This is mainly because TSA reacts with MOC and generates Mg-Al-Cl-Si-H and Mg-Cl-Si-H gels, consequently improving the water stability of MOC sample. At the nanoscale, the 3/5-phase crystal and unreacted MgO content in the 15 % TSA-modified MOC sample is relatively reduced by 7.79 % and 25 %, respectively, compared to the plain sample, but the 13 % gel phase is detected. In addition, the MOC component can effectively solidify heavy metal elements in textile sludge. For the leachate of 20 % TSA-modified MOC paste, the Ni element is not detected, and its solidifying effect on heavy elements such as Zn and Mn exceeded 99 %.

Coagulation-flocculation treatment for batik effluent as a baseline study for the upcoming application of green coagulants/flocculants towards sustainable batik industry

The batik industry has been one of the main family businesses in most of the east-coast region of the Malaysian peninsula for many years. However, appropriate water treatment is still a major challenge for this industry. Stringent laws introduced by the Malaysian authorities and the intention to protect the environment are factors that drive researchers to search for suitable, appropriate, affordable and efficient treatment of batik wastewater. Treatment research on batik wastewater is still lacking and coagulation-flocculation treatment using alum was introduced and chosen as a stepping stone toward the selection of green coagulants. This study aimed to determine the best conditions for alum flocculation-coagulation using a standard jar test method. Four main factors were investigated: alum dosage (0.1-3.5 g/L), pH (4-11), settling time (0.5-24 h) and rapid mixing rate (100-300 rpm). Results obtained were further analysed statistically using SPSS software prior to determining the significant effect of variable changes. From this study, the best conditions for batik wastewater treatment using the flocculation-coagulation process were found to be at alum dosage of 1.5 g/L, pH 8, 4 h settling time and a rapid mixing rate of 100 rpm. Chemical oxygen demand (COD), turbidity, colour and total suspended solids (TSS) were removed by 70.7, 92.2, 88.4 and 100%, respectively, under these conditions. This study showed that batik wastewater can be treated by the coagulation-flocculation process using chemical means of alum. This indicates the need for forthcoming developments in natural-based-coagulant-flocculants toward the sustainability of the batik industry.

Effect of curing regime on the immobilization of municipal solid waste incineration fly ash in sustainable cement mortar

Stabilizing/solidificating municipal solid waste incineration fly ash (MIFA) with cement is a common strategy, and it is critical to study the high-value utilization of MIFA in ordinary Portland cement (OPC) components. With this aim, binary-binding-system mortar was produced by partially replacing OPC (∼50%) with MIFA, and the effects of different curing regimes (steam curing and carbonation curing) on the properties of the cement mortar were studied. The results showed that the setting time of the cement paste was shorten with the increase of MIFA content, and steam curing accelerated the hardening of the mixture. Although the incorporation of MIFA reduced the strength of the mortar, compared to conventional curing method, steam curing and carbonation curing increased the 3-d strength of the mortar. For high-volume MIFA mortars, the CO₂-cured samples had the highest long-term strength and lowest permeability. The incorporation of MIFA increased the initial porosity of the mortar, thereby significantly increasing the carbonation degree and crystallinity of the reaction product - CaCO₃. Steam curing also further narrowed the difference in the hydration degree between MIFA-modified sample and plain paste, which may be due to the enhanced hydraulic reactivity of MIFA at high temperatures. Although the incorporation of MIFA increased the porosity of the mortar, this waste-derived SCM refined the bulk pore structure and decreased the interconnected porosity. Additionally, the heavy metal leaching contents of MIFA-modified mortars were all below 1%, which meet the requirements of Chinese standards. Compared with standard curing, steam curing and carbonation curing made the early-age and long-term performance of MIFA-modified mortar better, which can promote the efficient application of MIFA in OPC products.

Reuse of lead glass sludge in the fabrication of thermally insulating foamed glass with outstanding properties and high Pb-stabilization

This study represents the sustainable/safe consumption of lead glass sludge (LGS) in the fabrication of thermally insulating foamed glass via sintering (750-950º C) and chlorination processes. The impact of selected additives including calcium chloride (CaCl₂) and sodium hydroxide (NaOH) on the foaming efficiency and Pb-stabilization has been deeply investigated. LGS is mainly lead silicate material with considerable content of calcium carbonate, which acts as foaming agent during sintering process. The newly developed foamed-materials exhibited thermal conductivity of 0.054-0.136 W/m.K, density of 0.23-1.10 g/cm³, porosity of 63.3-92.6%, and compressive strength of 0.10-2.69 MPa. X-ray diffraction proved that the immobilization mechanism was attributed to the transformation of free Pb within LGS into insoluble ganomalite Pb₉Ca₅MnSi₉O₃₃ phase. Adding NaOH enhanced the foaming process accompanied by a significant reduction in Pb-leaching. Incorporating CaCl₂ has resulted in a retardation in Pb-leaching, which associated with Pb-stabilization and Pb-vaporization. In an attempt to reduce CO₂-emission, the potential use of alkali-rich-wastewater (AW) as eco-friendly alkali source in lieu of NaOH was studied. Regardless of the variation in Pb-concentrations in leachates, all samples recorded Pb-concentrations lower than the safe limit (≤ 5 mg/l), achieving Pb-immobilization of 95.98-99.87%. The significantly reduced thermal conductivity and enhanced Pb-immobilization efficiency along with the reasonable compressive strength summarize the major innovation presented in this study.

Comparison of reactive azo dye removal with UV/H2O2, UV/S2O82- and UV/HSO5- processes in aqueous solutions

Advanced oxidation processes (AOPs) are an effective choice for removal of reactive azo dyes used in the textile industry due to high solubility and low degradability. Within the scope of this study, reactive orange 122 (RO122) azo dye was removed using the UV-based AOPs of ultraviolet (UV) radiation, UV/hydrogen peroxide (UV/H₂O₂), UV/persulfate (UV/S₂O₈^2-), and UV/peroxymonosulfate (UV/HSO₅^-). Oxidant concentration, initial solution pH, initial RO122 concentration, different anions (Cl^-, NO₃^- and SO₄^2-), and solution temperature effects were compared. With only UV radiation (254 nm), 19.5% RO122 removal occurred at the end of 120 min. The RO122 removal reduced with the UV/oxidant processes at pH 9. Experimental results revealed RO122 removal followed pseudo-first-order (PFO) kinetics. There was a linear correlation identified between initial oxidant concentration and the PFO kinetic rate constant (k₁). Among the three UV-based processes, with oxidant concentration 50 mg/L, temperature 20 °C, and pH 5, RO122 removal efficiency was in the order UV/H₂O₂ > UV/HSO₅^- > UV/S₂O₈^2-. RO122 removal rate increased as initial oxidant concentration and temperature increased and reduced as initial RO122 concentration increased. Energy requirements and oxidant costs were assessed. The UV/H₂O₂ process was concluded to be the most efficient and economic process for RO122 removal.

Unified, simple and decentralized treatment process for synthetic and real-time dye contaminated wastewaters

The aim of this study is to develop a simple, economical and effective treatment scheme to treat effluents from small scale textile dyeing units and tanneries, which have been set up in rural areas. The physicochemical properties of real time effluents procured from these industries were analysed. The workflow required for treating these effluents were ascertained by preliminary tests carried out on synthetically created solutions. A novel treatment scheme for tannery and textile dye effluents sludge volume reduction by the use of sodium hypochlorite was identified. Effective methods for the safe disposal and recycling of all the by-products generated from different steps were discussed. The proposed scheme was successfully able to decolourize and detoxify both the tannery and textile dyeing effluent with over 90% removal of both COD and BOD. The impacts of the treatment scheme on 14 different effluent parameters were reported. The methodology developed in this study may be utilized to construct simple localized treatment units for handling effluents in isolated rural areas. This preliminary treatment at the source, will help in the reduction of the load on the local treatment plants and prevent their choking.

Development of nanoporous textile sludge based adsorbent for the dye removal from industrial textile effluent

The development of a novel textile sludge based activated carbon (TSBAC) adsorbent and its performance for the treatment of textile dyeing effluent, have been explained in this paper. TSBAC was prepared by the thermal treatment of textile effluent treatment sludge followed by the chemical activation using phosphoric acid. Characterization of TSBAC resulted in enhanced specific surface area (123.65 m²/g) along with the presence of active surface functional groups including -OH, -COOH, -CO. TSBAC showed superior adsorption capacity for methylene blue (123.6 mg/g), reactive red 198 (101.4 mg/g), and reactive yellow 145 (96.8 mg/g) individually, and from the synthetic textile effluent (106 mg/g). The pseudo-second order model and Langmuir isotherm model were found to be fitted well with batch experimental data. The results of the continuous column studies showed that adsorption capacity for methylene blue, reactive red 198, reactive yellow 145 are 101.8 mg/g, 76.6 mg/g, and 75.1 mg/g respectively, and the synthetic textile effluent resulted in an adsorption capacity value of 79.1 mg/g. The reuse potential of TSBAC was proved by effective dye removal up to six reuse cycles. The leachability studies proved that the used adsorbent could be safely disposed of without any harmful effect to the environment.

Microencapsulation of zinc plating waste using silicone polymers

This paper deals with the treatment of hazardous zinc-bearing waste using hydraulic binders and silicone polymers, with the aim to allow its safe disposal into landfill. The waste was solidified using hydraulic binders in the first step and then encapsulated using silicone polymers. Samples were characterised using x-ray fluorescence, x-ray diffraction, and scanning electron microscopy. The effectiveness of the process was evaluated by leaching tests in distilled water and in an acidic environment according to Toxicity Characteristic Leaching Procedure. The effect of porosity and pH on the release of pollutants was also studied. Zinc and chloride were identified as the most significant pollutants in the waste. Portland cement did not stabilize them efficiently. The two-step treatment with Portland cement and silicone binders decreased, in the best case, the concentration of zinc and chloride in acidic extracts from 12,400 mg/L and 38,300 mg/L to 21.9 mg/L and 74 mg/L, respectively, and the treated waste complied with regulatory requirements for hazardous waste disposal into landfills. The two-step treatment was also found as a more effective method than microencapsulation using a silicone binder alone. The factor that most affects leachability appears to be the porosity of the encapsulated waste.

Stabilization of hazardous lead glass sludge using reactive magnesia via the fabrication of lightweight building bricks

This study focused on the stabilization of lead glass sludge (LGS) using reactive magnesia (MgO) via the fabrication of lightweight building bricks. Two types of MgO with different reactivities were prepared by the thermal treatment of magnesium carbonate at 800 °C and 1200 °C (MgO-800 and MgO-1200, respectively). The fabrication of bricks and Pb stabilization were performed by wet mixing LGS with MgO followed by humidity incubation. Results showed that the Pb immobilization and performance of the produced bricks were strongly affected by MgO reactivity, curing time, and LGS-MgO weight ratios. Pb immobilization was performed by the transformation of soluble lead into an insoluble hydrocerussite phase, particularly in hydrated mixtures with high MgO content (> 25 wt%). Pb immobilization inside a magnesium silicate hydrate skeleton is the main mechanism in the hydrated samples containing 25 wt% MgO. To achieve "sustainability," we recommend the use of a hydrated mixture containing 75 wt% of LGS and 25 wt% of MgO-800 in the production of building bricks because this mixture exhibits high compressive strength, high Pb immobilization, low energy demand, and low environmental pollution.

Alkali-cation-incorporated and functionalized iron oxide nanoparticles for methyl blue removal/decomposition

Enhancing the rate of decomposition or removal of organic dye by designing novel nanostructures is a subject of intensive research aimed at improving waste-water treatment in the textile and pharmaceutical industries. Despite radical progress in this challenging area using iron-based nanostructures, enhancing stability and dye adsorption performance is highly desirable. In the present manuscript alkali cations are incorporated into iron oxide nanoparticles (IONPs) to tailor their structural and magnetic properties and to magnify methyl blue (MB) removal/decomposition capability. The process automatically functionalizes the IONPs without any additional steps. The plausible mechanisms proposed for IONPs incubated in alkali chloride and hydroxide solutions are based on structural investigation and correlated with the removal/adsorption capabilities. The MB adsorption kinetics of the incubated IONPs is elucidated by the pseudo second-order reaction model. Not only are the functional groups of -OH and -Cl attached to the surface of the NPs, the present investigation also reveals that the presence of alkali cations significantly influences the MB adsorption kinetics and correlates with the cation content and atomic polarizability.