University of Wollongong Research Online University of Wollongong Thesis Collection 1954-2016 University of Wollongong Thesis Collections 1991 "Biofly brick": engineering euser of fly ash and sewage sludge wastes Fady G. Sidrak University of Wollongong Follow this and additional works at: https://ro.uow.edu.au/theses University of Wollongong Copyright Warning You may print or download ONE copy of this document for the purpose of your own research or study. The University does not authorise you to copy, communicate or otherwise make available electronically to any other person any copyright material contained on this site. You are reminded of the following: This work is copyright. Apart from any use permitted under the Copyright Act 1968, no part of this work may be reproduced by any process, nor may any other exclusive right be exercised, without the permission of the author. Copyright owners are entitled to take legal action against persons who infringe their copyright. 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For further information contact the UOW Library: [email protected] BIOFLY BRICK' ENGINEERING REUSE OF FLY ASH AND SEWAGE SLUDGE WASTES by Fady G. Sidrak Thesis submitted to the Department of Civil and Mining Engineering of the University of Wollongong in partial fulfillment of the reguirements for the degree of UNIVERSITY 09 WOLLONGONG LIBRARY Master of Engineering Honours 1991 013171 The LORD has done great things for us, and we are filled with joy Psalm 126:3 To my wife, Mary It was more work for you ACKNOWLFDnKMRNTS The project was conducted under the guidance and supervision of Dr. M. Sivakumar, Senior Lecturer in Civil Engineering and who is also the "Biofly" project leader. The project is co-supervised by Associate Professor Robin N. Chowdhury. I would like to express my gratitude, for their help and backing to: Dr. M. Sivakumar Thank you for the many extra hours of help, mental refurbishing, constant friendships, understanding and guidance. Associate Professor Robin N. Chowdhury For help with specific problems related to logistics and mechanics of research and technical help in engineering problems. This study is being carried out by the University of Wollongong within the Water Engineering and Geomechanics Research program, Department of Civil & Mining Engineering and is financially supported by: The Electricity Commission of New South Wales; The Water Board - Sydney, Illawarra and Blue Mountains, and Boral Limited The author wishes to express sincere appreciation to Dr. A. Samarin, Director, Boral Research for his assistance, Mr. John Bacchus and Mr. Ian Finney of the Water Board and Mr. Peter Wood of the Electricity Commission for their input and contribution. The author also wishes to thank all the employees at Boral Research Laboratory & Materials Laboratory for their help and co-operation. Finally, the author wishes to express his indebtedness and sincere appreciation to his wife, Mary, daughter, Shery, and son, Kyrillos, for their patience and sacrifice throughout this investigation. ABSTRACT Two of the greatest solid waste disposal problems are fly ash emitted from power plants and sewage sludge generated from municipal waste treatment plants. In an effort to introduce beneficial disposal alternatives, it was hypothesized that these waste products could be combined to produce a solidified material suitable for use in brick making. It is an innovative approach in solid waste reuse technology. This research describes detailed laboratory investigation of small specimens with different proportions of fly ash, sewage sludge and clay/shale to determine the physical suitability of the mixtures and viability for use as a brick to be called "Biofly Brick". Laboratory procedures for the manufacture of specimens are presented and the results of tests of compressive strength, absorptivity, efflorescence and examination for pitting due to lime particles are reported. Assessment of these structural properties were evaluated according to the Australian Standards which indicate that the small specimens of Biofly bricks are similar (if not better) in comparison to properties of ordinary bricks. Other properties, such as shrinkage and density were evaluated. Waste leaching studies, exhaust gas analysis, and health issues have also been reported. Statistical analysis were performed on the compressive strength data to establish confidence limits, standard deviation and coefficient of variation. Laboratory experimental results indicated that, it is clearly possible and viable to use unattractive residues such as sewage sludge and fly ash together with clay/shale and transfer them to an attractive stable product such as "Biofly Brick". Bricks produced in the laboratory were shown to have less weight per unit volume, without the loss of strength and significant energy savings in comparison to ordinary bricks. -iv- CONTENTS LIST Page Dedication ............................................ i Acknowledgements ...................................... ii A b s t r a c t ......................... iii List of T a b l e s ....................................... ix List of F i g u r e s .........................................xvii CHAPTER ONE: INTRODUCTION 1.1 Introduction ..................................... 1 1.2 Aims & Scope of P r o j e c t ......................... 3 CHAPTER TWO: LITERATURE REVIEW 2.1 Fly Ash Characteristics......................... 5 2.2 Chemical Reactions of Fly Ash and Related M a t e r i a l s ....................................... 12 2.3 Fly Ash Combined with Inorganic Sl u d g e s ......... 13 2.4 Sewage Sludge Characteristics .............. 15 2.5 Environmental Hazards from Land Disposal of Sludge and Fly A s h ........................... 21 2.5.1 S l u d g e ................................... 21 2.5.2 Fly A s h ................................... 25 2.6 Fly Ash Combined with Wastewater S l u d g e ........ 26 2.7 Summary of the Findings of the Literature R e v i e w ............................................ 29 CHAPTER THREE: SOLIDIFICATION APPROACH 3.1 Introduction..................................... 31 3.2 Fixation Technology ............................. 32 3.2.1 Cement-Based Techniques ........ ..... 33 3.2.2 Lime-Based Techniques ........ ' ........... 36 3.2.3 Thermoplastic Techniques ................ 36 3.2.4 Organic Polymer Techniques .............. 38 3.2.5 Encapsulation Techniques ................ 39 3.2.6 Self-Cementing Techniques ................. 39 3.2.7 Classification........................... 40 -v- CQNTENTS LIST - (Cont'd.) Page 3.3 Specific Solidification Processes ............... 42 3.3.1 Ceramics and Insulation................... 42 3.3.2 C o n c r e t e ................................. 42 3.3.3 Aggregates ............................... 43 3.3.4 Embankments, Road Base, and Landfill . 45 3.4 Summary of the Solidification Approaches and their Relevance to "Biofly Brick" .......... 47 CHAPTER FOUR: "BIOFLY" AND OTHER BRICKMAKING PROCESSES 4.1 Brickmaking Processes ........................... 51 4.1.1 Sludge Brick ............... 51 4.1.2 Fly Ash B r i c k ............................. 51 4.2 Definition and Types of B r i c k ................... 52 4.3 Brick History ................................... 54 4.4 Raw Materials for B r i c k .................... 56 4.5 Present Brick Manufacturing Processes .......... 57 4.6 Material Additions ............................... 62 4.7 "Biofly Brick" An Innovation in Brickmaking . 66 CHAPTER FIVE: RESEARCH METHODS 5.1 Laboratory Methods ............................... 68 5.1.1 Experimental Materials ................... 68 5.1.1.1 Fly Ash Investigation .......... 68 5.1.1.2 Sludge Investigation ............ 71 5.1.1.3 Clay/Shale Investigation ........ 74 5.1.2 Material Preparation ..................... 76 5.1.3 Material Storage ......................... 76 5.2 Experimental Procedures ......................... 76 5.3 Experimental Brick Manufacture ................... 77 5.3.1 Extruded Specimen Preparation ............ 77 - vi- CONTENTS LIST - (Cont'd.) Page 5.4 Testing Procedures ............................... 78 5.4.1 Specimen Testing ......................... 78 5.4.1.1 Compressive Strength ............ 79 5.4.1.2 Twenty Four Hour Water Absorption....................... 80 5.4.1.2.1 Five Hour Boiling Water Absorption ... 81 5.4.1.2.2 Saturation Coefficient.......... 81 5.4.1.3 Efflorescence ................... 82 5.4.1.4 Pitting Due to Lime Particles . 83 5.4.2 Leaching Test . ............................ 83 5.4.3 Exhaust Gas A n a l y s i s ..................... 84 5.4.3.1 General .................... 84 5.4.3.1.1 Apparatus: For Heavy M e t a l s ........ 84 5.4.3.1.2 Apparatus: For Gas Analysis