Insulating Refractory Bricks from Water Treatment Sludge and Rice Husk Ash

Ewais, Emad M.M.; Elsaadany, R. M.; Ahmed, Alaa H.; Shalaby, Nasser H.; Alanadouli, Bahgat E.

doi:10.1007/s11148-017-0071-6

Cited by 24 publications

(9 citation statements)

References 18 publications

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“…On the other hand, iron-based sludge increased the compressive/flexural strength of the ceramic samples by 7-97% compared to the reference values, for sludge addition below 10% (Kizinievič et al, 2013;Hassan et al, 2014). Furthermore, studies have shown that it is possible to produce ceramic bricks with mechanical properties similar to those of clay, with more considerable additions (> 50%) of sludge, combined with material with high silica concentration (Lin and Lin, 2005;Chiang et al, 2009;Hegazy et al, 2012;Wolff et al, 2015;Ewais et al, 2017).…”

Section: Bricks and Ceramic Productsmentioning

confidence: 99%

“…In Taiwan, Chiang et al (2009; 2010) produced lightweight bricks by mixing dry WTS and calcined rice husk, which showed improvements in mechanical properties. In addition, several other studies have demonstrated successful application of waste materials including WTS with a high concentration of silica in making ceramics and bricks with good mechanical performance (Hegazy et al, 2012;Wolff et al, 2015;Ewais et al, 2017).…”

Section: Bricks and Ceramic Productsmentioning

confidence: 99%

“…The durability of ceramic bricks depends primarily on water absorption (Huang et al, 2001;Hegazy et al, 2012;Ewais et al, 2017). According to Fernandes et al (2010), the deterioration of ceramic bodies is mainly due to the high capacity of the fluid to be stored in bricks, causing the reduction of mechanical resistance and useful life.…”

Section: Durabilitymentioning

confidence: 99%

See 2 more Smart Citations

Progress in manufacture and properties of construction materials incorporating water treatment sludge: A review

Gomes

Zhou

et al. 2019

Resources, Conservation and Recycling

175

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Water treatment sludge (WTS) management is a growing global problem for water treatment plants (WTPs) and governments. Considering the scarcity of raw materials in many parts of the planet and unique properties of WTS, extensive research has been conducted on the application of WTS in the production of construction materials such as roof tiles, bricks, lightweight aggregates, cement, concrete and geopolymers. This paper critically reviews the progress in the application of WTS in construction materials, by synthesizing results from recent studies.Research findings have revealed that incorporation of ≤ 10% alum-based sludge in ceramic bricks is satisfactory with a small reduction of mechanical performance. Using the iron-based sludge, the bricks presented better mechanical strength than the reference clay-bricks.Concerning WTS application in concrete, 5% replacement of cement or sand by WTS was considered as the ideal value for the application in a variety of structural and non-structural concrete without adverse effect on concrete mechanical performance. Furthermore, this paper discusses sludge-amended concrete in terms of durability, potential leaching of toxic elements and cost, and suggests topics for future research on the sustainable management of WTS.

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Section: Bricks and Ceramic Productsmentioning

confidence: 99%

Section: Bricks and Ceramic Productsmentioning

confidence: 99%

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Progress in manufacture and properties of construction materials incorporating water treatment sludge: A review

Gomes

Zhou

et al. 2019

Resources, Conservation and Recycling

175

View full text Add to dashboard Cite

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“…The low σ of RHA leads to a slow reduction of molten iron temperature during casting and helps to maintain uniform solidification. Ewais et al (2017) [39] have prepared the insulation refractory bricks using water treatment sludge with various amount of RHA (0-10 wt.%) and fired at 800-1200°C. Filter press and casting technique are used with the sludge, and sludge-RHA mixtures specimens, respectively.…”

Section: Porous Insulation Refractorymentioning

confidence: 99%

Sustainable ceramics derived from solid wastes: a review

Hossain

Roy

2020

Journal of Asian Ceramic Societies

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Wastes from different manufacturing processes and energy generation unite are attributed to the ecological and health issues. Instead of land-filling, the waste can be recycled or reused to convert marketable value-added products with high ecologic and economic interest. Ceramics are attracting particularly in waste recycling perceptions. From this eco-friendly propensity, in the last two decades, an increasing number of studies have demonstrated the possibility to use alternative ingredients in the place of conventional raw materials (e.g., most common ternary clay-quartz-feldspar system) for the fabrication of ceramics. Researchers are trying to incorporate the wastes and industrial by-products like fly ash (FA), rice husk ash (RHA), blast furnace slag (BFS), sludge, glass waste, polished tile waste, eggshell and others for making different ceramics. The present review is aimed to provide an up-to-date overview of the recent wastederived ceramics including refractories, glasses, whitewares, oxide and non-oxide ceramics with the correlation of waste incorporation limits, manufacturing routes, and properties of the ceramics. The investigation reveals that ceramic industries have huge potential to utilize the wastes as substitution of the natural raw materials. The waste to value-added ceramics conversion not only solves the disposal problems but also conserves the natural resources.

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“…The results are observed to improve mechanical strength by reducing porosity up to 20% of RHA addition. Ewais et al 18 have prepared insulation refractory using RHA (up to 10%) with water treatment sludge. Sembiring et al 19 have synthesized cordierite insulation refractory using RHA‐derived silica.…”

Section: Introductionmentioning

confidence: 99%

A replacement of traditional insulation refractory brick by a waste‐derived lightweight refractory castable

Hossain

Bae

Roy

2021

Int J Applied Ceramic Tech

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Lightweight insulation refractories are essential for high‐temperature performance to reduce energy consumption. This study investigates a new insulation material, that is, solid waste rice husk ash (RHA) derived lightweight refractory castable, replacing traditional insulation refractory brick. The RHA is generated after the burning of rice husk as biomass fuel. The RHA is used as an aggregate and alkali‐extracted silica sol from RHA as a binder to fabricate the insulation castable. The nanosilica containing (~30 wt%) sol is employed to synthesize the refractory castable by varying the sol amount (2.5‐12.5 wt% silica from sol). The castable specimens are cast by a vibro‐caster and fired at 900‐1200°C in a muffle furnace. The physic‐mechanical and thermal conductivity (κ) of the castable is investigated. At 1100°C with 10 wt% dry sol retaining sample shows an excellent apparent porosity (~65%), low bulk density (~ 0.8 g/cm3), and κ (0.136 W/m k) with sustainable compressive strength (6 MPa). The acquired results are a good match with the literature (other wastes‐derived insulation materials) and industrial (silica insulation brick) obtained data. These promising outcomes may inspire the refractory industries for using RHA as an aggregate and RHA extracted sol as a binder for making insulation castable.

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Insulating Refractory Bricks from Water Treatment Sludge and Rice Husk Ash

Cited by 24 publications

References 18 publications

Progress in manufacture and properties of construction materials incorporating water treatment sludge: A review

Progress in manufacture and properties of construction materials incorporating water treatment sludge: A review

Sustainable ceramics derived from solid wastes: a review

A replacement of traditional insulation refractory brick by a waste‐derived lightweight refractory castable

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