Potential re-use of sewage sludge as a raw material in the production of eco-friendly bricks.

Wastewater (sewage) treatment plants generate a high volume of sludge that, although it is classified as class II-A (not inert) non-hazardous waste, is commonly disposed of in sanitary landfills. Hence the environmental urge to assess its valorization possibilities. The present study describes the use of a sewage sludge as raw material in the production of red ceramic bricks by extrusion, focusing on the technological changes brought about by the presence of the sludge during the plastic forming process, in terms of the plasticity of the mixture and its subsequent extrudability. To quantitatively identify the best moisture conditions for the extrusion of high-quality products, shear strain amplitude sweep (torsional) tests were conducted on green (moist) prismatic samples produced with different moisture and sludge contents. For sewage sludge contents up to 10 wt%, the optimal moisture content was identified at 31-33 wt%. Higher water demand was identified for 15 wt% of sludge, for which optimal extrusion results required 35 wt% moisture. The total linear shrinkage after drying and firing, as well as the water absorption, were within the limits required for ceramic bricks for all the sludge contents. The results for compressive strength of the fired bricks also demonstrate that the incorporation of up to 15 wt% sewage sludge into the clay mixture is highly feasible for the production of extruded ceramic bricks.

Effect of Gypsum on the Early Hydration of Cubic and Na-Doped Orthorhombic Tricalcium Aluminate.

The tricalcium aluminate (C3A) and sulfate content in cement influence the hydration chemistry, setting time and rheology of cement paste, mortar and concrete. Here, in situ experiments are performed to better understand the effect of gypsum on the early hydration of cubic (cub-)C3A and Na-doped orthorhombic (orth-)C3A. The isothermal calorimetry data show that the solid-phase assemblage produced by the hydration of C3A is greatly modified as a function of its crystal structure type and gypsum content, the latter of which induces non-linear changes in the heat release rate. These data are consistent with the in situ X-ray diffraction results, which show that a higher gypsum content accelerates the consumption of orth-C3A and the subsequent precipitation of ettringite, which is contrary to the cub-C3A system where gypsum retarded the hydration rate. These in situ results provide new insight into the relationship between the chemistry and early-age properties of cub- and orth-C3A hydration and corroborate the reported ex situ findings of these systems.

Role of Adsorption Phenomena in Cubic Tricalcium Aluminate Dissolution.

The workability of fresh Portland cement (PC) concrete critically depends on the reaction of the cubic tricalcium aluminate (C3A) phase in Ca- and S-rich pH >12 aqueous solution, yet its rate-controlling mechanism is poorly understood. In this article, the role of adsorption phenomena in C3A dissolution in aqueous Ca-, S-, and polynaphthalene sulfonate (PNS)-containing solutions is analyzed. The zeta potential and pH results are consistent with the isoelectric point of C3A occurring at pH ∼12 and do not show an inversion of its electric double layer potential as a function of S or Ca concentration, and PNS adsorbs onto C3A, reducing its zeta potential to negative values at pH >12. The S and Ca K-edge X-ray absorption spectroscopy (XAS) data obtained do not indicate the structural incorporation or specific adsorption of SO42- on the partially dissolved C3A solids analyzed. Together with supporting X-ray ptychography and scanning electron microscopy results, a model for C3A dissolution inhibition in hydrated PC systems is proposed whereby the formation of an Al-rich leached layer and the complexation of Ca-S ion pairs onto this leached layer provide the key inhibiting effect(s). This model reconciles the results obtained here with the existing literature, including the inhibiting action of macromolecules such as PNS and polyphosphonic acids upon C3A dissolution. Therefore, this article advances the understanding of the rate-controlling mechanism in hydrated C3A and thus PC systems, which is important to better controlling the workability of fresh PC concrete.

A Scanning Transmission X-ray Microscopy Study of Cubic and Orthorhombic C3A and Their Hydration Products in the Presence of Gypsum.

This paper shows the microstructural differences and phase characterization of pure phases and hydrated products of the cubic and orthorhombic (Na-doped) polymorphs of tricalcium aluminate (C3A), which are commonly found in traditional Portland cements. Pure, anhydrous samples were characterized using scanning transmission X-ray microscopy (STXM), X-ray photoelectron spectroscopy (XPS) and X-ray diffraction (XRD) and demonstrated differences in the chemical and mineralogical composition as well as the morphology on a micro/nano-scale. C3A/gypsum blends with mass ratios of 0.2 and 1.9 were hydrated using a water/C3A ratio of 1.2, and the products obtained after three days were assessed using STXM. The hydration process and subsequent formation of calcium sulfate in the C3A/gypsum systems were identified through the changes in the LIII edge fine structure for Calcium. The results also show greater Ca LII binding energies between hydrated samples with different gypsum contents. Conversely, the hydrated samples from the cubic and orthorhombic C3A at the same amount of gypsum exhibited strong morphological differences but similar chemical environments.

Increase of the reactivity of densified silica fume by sonication treatment.

Five silica fumes from different manufacturers were subjected to ultrasonic treatment in order to decrease particle agglomeration and improve particle dispersion. The effectiveness of the sonication was observed as a reduction in particle size distribution of sonicated silica fume (SSF) compared to non-sonicated silica fume. SSF was added to Portland cement, and then the hydrated paste was analysed by thermogravimetric analyses (TGA/DTG) and scanning electron microscopy (SEM/EDX). The results were compared with those of control pastes made with untreated densified silica fume (DSF), as well as a reference cement paste of ordinary Portland cement (OPC). A maximum grade of de-agglomeration by the sonication was obtained, with a high volume of particles of diameter less than 1 µm. Images obtained by transmission electron microscopy (TEM) of the SSF showed sintered particles that could not be fragmented by the treatment. Micro-structural characterisation results showed an increase in the reactivity of the silica fume after the treatment.