Production of artificial pumice from glass and paper sludge ash Peter Bi Department of Civil and Environmental Engineering Imperial College London ABSTRACT Paper sludge ash obtained from incineration of paper sludge and waste glass have been milled, uni-axially pressed and sintered at different temperatures. The artificial pumices produced were investigated by scanning electron microscopy (SEM). Mechanical properties assessed included water absorptions and density. Effects of sintering temperature, pressing pressure, pressing duration, raw materials milling time have been investigated. The optimum artificial pumice contains 90% glass and 10% PSA. It has been ball milled for 8 hours, pressed at 40kPa for 20 seconds and sintered at 800◦C. This produced a uniformly distributed fine pores structure with a mean density of 0.86 , water absorption of 65%.The research indicates that artificial pumice from PSA and waste glass has comparable properties to commercial available pumice. This simple approach represents a technically and commercially feasible option for PSA that contributes to the development of long term sustainable, resource efficient reuse applications for PSA. markets in the construction industry have led to an increasing demand for lightweight aggregates. Furthermore, lightweight materials can have various other commercial applications such as abrasive, concrete admixture and aggregate, horticulture and landscaping, absorbent in removing target pollutants, filtration and laundry stone washing (Farizoglu, 2003; Njau,. 2003; Rao , 2003). To relieve pressure on the demand for natural pumice, secondary materials should be considered in the production of artificial lightweight materials. Natural resources are finite; and extracting and processing pumice is very damaging and polluting for the natural environment. 1. Introduction Lightweight materials occur in nature or they can be industrially manufactured. The raw materials most frequently used for their production are clay and sedimentary rocks such as slates and shales (Conley, 1948; Riley, 1951) or zeolitic tuffs (Gennaro, 2007; Gennaro 2004). Industrial by-products such as fly ash (Huang, 2007; Aineto, 2005) bottom ash (Anagnostopoulos, 2009; Anagnostopoulos. 2010), sludge (Cheeseman, 2005; Laursen, 2006; Tsai, 2006) and waste glass (Cheeseman, 2010; Ducman, 2002) have also attracted considerable interest. A substantial volume of paper sludge ash (PSA) is generated from the newsprint, packaging and paperboard manufacturers. According to the Confederation of Paper Industries, a total of 125,000 tonnes of PSA was produced by mills in 2006, of which 88,000 tonnes were sold to a number of end markets in the UK and 37,000 tonnes were landfilled (Environment Agency, 2008). In the next few years, government plans to upgrade some of the existing mills and construct additional mills in England. The quantity of PSA is expected to increase to 300,000 tonnes per annum as manufacturers of magazine-grade paper and high quality World pumice production was estimated to be 17.1 million tonnes in 2010. The EU holds a significant part of the world supply (70% in 2010). United States of America (USA) consumes 0.43 million tonnes of pumice, 10% of which is being imported. Greece and Turkey remained the dominant import sources to the USA, representing 72% and 20% of the total imported amount respectively. Because of their cellular structure, light weight, and insulating properties significant quantities of pumice have been incorporated into construction materials since the Roman Empire (Meisinger, 1985). The recent growing 1 packaging board increase biomass energy systems. their use of secondary glass is therefore an area that merits attention. Paper sludge consists of short cellulose fibres, water, ink, soap and other minerals separated from the recycled paper feedstock. Despite the low heat value of mechanically dewatered paper sludge due to their high moisture and ash content; it can still be cocombusted with reject plastic and other biomass to generate energy as a result of the increasing costs of landfill and other forms of waste management, together with increasing costs of gas and electricity. PSA is a residue left behind from the incineration of paper sludge and other input materials from the recycling of newspaper-related products. It is a highly alkaline calcium alumino-silicate fine granular material and its moisture content is usually less than 0.1%. A range of waste materials has been tested for producing lightweight aggregates including lignite coal fly ash (Cheeseman, 2010; Anagnostopoulos, 2009), incinerator bottom ash (Cheeseman, 2004), heavy metal sludge cake and mining residues (Huang, 2007), sewage sludge ash (Cheeseman, 2005), rice hush ash (Chindaprasirt, 2009). Notable studies have demonstrated the potential of manufacturing lightweight aggregates from waste glass (Ducman, 2002; Cheeseman, 2010) as well as using recycled glass cullet as aggregates in concrete mixtures (Topçu, 2003; Shayan, 2004; Chidiac, 2011; Cheeseman, 2010). The above mentioned facts as well as past research findings conclude that PSA and secondary glass constitute potential candidates for the production of artificial pumice-like materials with properties similar to those of currently available natural pumice. To this end, the object of this research is to investigate the potential of a binary glass-PSA system for the production of pumice-like materials and provide a better understanding of key factors affecting the properties of the end-product. Current and potential markets for PSA depend on its composition and, in particular, its lime concentration. There is a potential for PSA to be used in a range of applications including as a liming agent applied to agricultural land, as a desiccant for animal bedding, stabilising sewage sludge and in block manufacture, as cement replacement material. The feasibility for PSA to be used in new applications depends on the specification, cost and restriction from relevant legislation. 2. Material and methodology The UK reported an amount of 550,000 tonnes of waste glass resulting from wine bottles in 2007. Around 80 per cent of the wine bottles were imported. In both the short and long term, these imports are expected to increase since glass remains one of the most appealing packaging options for brand owners, retailers and consumers. The majority of glass packaging produced in the UK is clear, and high levels of clear glass are exported, mostly as filled whisky bottles. There is limited UK green glass production but high imports of green glass. This results in a colour imbalance for the residual glass byproducts. The increase of mixed glass exacerbates the situation. Despite of the colour imbalance issue, FEVE (the European Container Glass federation) has reported that the growth of recycling rate increased dramatically from 29% in 2000 to 62% in 2009 (British Glass, 2011). The development of higher value alternative products for 2.1 Properties of materials In the present study, mixed colour glass cullet was received from Day Group Ltd. It is essentially a mix of coloured glass obtained from crushing glass containers such as wine bottles and jam jars separated and collected by local authorities recycling units. This postconsumer waste glass is tested according to BS 7533-3:2005 (Code of Practice for Laying Precast Concrete Paving Blocks and Clay Pavers for Flexible Pavements), and meets the grading requirements of that Standard. The material was of non-significant fibre contamination, graded through a 1.00 mm sieve. The glass cullet fraction that passed through the sieve would be used for further processing. Its chemical composition is presented in Tables 1. 2 Paper Sludge Ash (PSA) is supplied from Aylesford Newsprint Ltd. PSA is generated from the combustion of paper sludge in an onsite combustor. It is the secondary products at Aylesford Newsprint which utilizing the waste materials from the papermaking process. It is a heterogeneous, complex mix of crystalline phases (Table 2). evaluated by preparing different blends and milling them for 8 hours. Finally, the effect of temperature was evaluated for the mixes. Ball milling involves horizontal rotation of the cylindrical container so that the grinding media and solid materials cascade. Traditional wet ball milling was introduced to reduce the particle size distribution of the glass cullet for sintering process. Wet milling produces a relatively broad particle size distribution and is widely used in the ceramics industry. Moreover, it produces homogenous slurry suitable for subsequent processing. Particles are fractured by the mechanical impact of the grinding media. A batch of 500g of glass cullet and PSA is milled for different time durations. 500g of tap water is added along with 2500g of high density alumina balls. The amount of water and milling balls are fixed. The rotation speed is set to be 5 rpm. Table 1 Chemical composition of glass (Devaraj et al., 2009) Major oxides SiO2 CaO Na2O MgO Al2O3 K2O Fe2O3 SO3 wt % 75.8 12.0 7.3 2.3 1.4 0.6 0.3 0.2 Table 2 Oxides composition of PSA Oxide % CaO 61.16 SiO2 21.18 Al2O3 12.6 MgO 2.81 Fe2O3 0.934 K2O 0.392 TiO2 0.293 SO3 0.223 P2O5 0.14 SrO 0.136 ZrO2 0.0352 CuO 0.033 MnO 0.033 After the ball milling, sludge is dried for 24 h at 105 °C (Gallenkamp Hotbox oven). Afterwards, the dried material is grounded using mortar and pestle. Then the crushed powders are separated using a 300 μm stainless steel sieve to remove coarse particles unsuitable for preparing samples. The powder fraction being less than 300 μm would be used for uniaxial press to form a tilt. (Nannetti Hydraulic Press MIGNON S). The pressing pressure and pressing time would be varied. 2.2 Preparation of samples Once the tilts were prepared, they can be rapidly fired at the final temperature for 20 minutes (Lenton Furnace). The refractory block for holding the tilts had been pre-heated at the final sintering temperature. After sintering, the tilts were taken out and allowed to cool down at room temperature. The experimental systematic outline is depicted in Figure 1. Based on practical experience and theoretical understanding the most crucial factors foreseen to determine the properties of samples are: (i) weight percentage content of different raw materials, (ii) particle size of raw materials, (iii) sintering temperature. In additional, pressing pressure and time were also included in the design of the experiments. All the milled powders were pressed at pressures ranging from 40 to 90 kPa, sintered at 700, 800, 900 °C. Pressing times of 10 seconds and 20 seconds were tried on the 90% glass and 10% PSA samples, ball milled for 8 hours. The influence of fineness of raw materials on the properties of artificial pumice was evaluated by using different milling times on the 90% glass and 10% PSA samples. The impact of PSA content on the pumice properties was 3 Raw materials (Glass cullet, PSA) Pulverisation (Ball milling) samples. A small sieve was placed at the top of the tested sample to ensure full immersion. The samples were under water for 24 hours. The formula for density calculation is shown: [Eq.2] Water Where mdry is the dry mass, mimm is the immersed mass for samples impregnated by immersion under vacuum for 24 hours, msat is the saturated surface-dry mass of pellets in air and ρw is the density of water. Drying (105°C for 24 hours) Sieving (Less than 300 μm) 2.3.3 Water absorption The water absorption (WA24) was calculated as a percentage of the dry mass in accordance with the following formula: Pressing (Uniaxial press for 10 or 20 seconds) [Eq. 3] Sintering (700, 800 and 900 °C) The water absorption (WA24) is defined in BS EN 1097-6 (British Standards Institution, 2000) as the increase in the mass of the sample (oven dried) due to the water absorbed in the open pores of the particle. Artificial pumice tilt 2.3.4 Scanning electron microscopy (SEM) was used to examine the microstructure of fractured surface of the sintered samples (sample ID: PSA20_8_900_70_2). The chosen sample comprises of 90% glass and 10%PSA, pressed at 70 kPa with a 900°C firing temperature, 8 hours ball milled. Figure 1.Experimental process for artificial pumice tilts at laboratory-scale. 2.3 Characterisation of sintered products 2.3.1 Expansion The expansion is expressed as a percentage of the difference of initial thickness and final thickness of tilt divided by the initial thickness. The formula used is shown below: In SEM a beam of electrons strikes the specimen and penetrates into a depth depending on the energy of the beam and the nature of the sample. The interaction produces various emissions, which can provide different types of data depending on the detector used. Backscattered electrons are highly energetic electrons, while secondary electrons can knock electron out of their orbits around an atom, with enough energy to escape from the sample. The backscattered detectors produce an electron micrograph that indicates the difference in average atomic mass between the phases, while secondary detectors produce topographical micrographs of the sample. [Eq. 1] Where Di and Df are the measured thickness of tilt before and after firing respectively. A digital calliper was used to take four measurements for Di and Df of each pellet. The arithmetic mean of those measurements was substituted back into Equation 1. 2.3.2 Scanning electron microscopy Density on an oven-dried basis The dry density of the sintered tilts was determined using Archimedes Principle. (Kourti & Cheeseman, 2010) 6 small piece samples were taken from each sintered tilt. Degased water was used to immerse the 4 3. Test result and discussion d 3.1 Microstructure Figures 2 shows the microstructure of the samples consisting of 90% glass – 10% PSA after the raw material had been milled for 8 hours, pressed at 75kPa and sintered at 900 ºC, and that of the commercially available pumice (Lava Rock Ltd). a Figure 2.SEM microphotographs of samples made out of 90% - 10% PSA sintered at 800 ºC and Lava Rock pumice. a: general review of ‘artificial’ pumice ; b: closed-up view of inner pores of the ‘artificial’ pumice; c: general view of Lava Rock pumice; d: closed-up view of Lava Rock pumice. A highly crystalline structure can be observed for the Lava Rock pumice, it is a combination of small and larger crystals forming the inner structure of the specimen tested with different orientation patterns. Most of the crystals seem to be cracked while some others remain intact within the body of the sample. In terms of crystal shape, flat rectangular-shaped crystals can be observed with a size of approximately 10-15 µm. The material is porous due to significant crystal roughness. b On the other hand, distinct pores can be observed for the ‘artificial’ pumice. The size of the pores ranges from 5-60 µm. Pores are not interconnected while uniformly distributed along the body of the material. The surface of the pores is smooth attributed to the viscous phases formed during sintering as glass softens to effectively encapsulate the gases generated from the PSA fine particles in the tilt. c 3.2 Effect of firing temperature on properties of product Effect of firing temperature on density and water absorption for 8 hours milled samples pressed at 90 kPa are shown in Figures 3. Pumice data are plotted along in all graphs for immediate comparison. 5 The graphs show that an increase in temperature decreased the densities of products contain higher glass content, for instance, 80% and 90% glass tilts. However, the densities of samples consist of lower glass percentage such as 60% and 70% glass pumice increase with increasing temperature. Obtaining denser structures of samples contain higher percentage of PSA can be attributed to the excessive glass formation at higher temperatures. This densification of pumice increased the crushing strength. Carbon dioxide is released from carbon compounds at 700 ◦C. Gas forming reaction of takes place at 1100 ◦C. Since our firing temperature range is from 700 ◦C to 900◦C. Therefore gas evolves from instead of causes the bloating effect. High concentration of calcium containing minerals is found in PSA compare to glass cullet. The major crystalline phases exist in glass is . The melting temperature and viscosity of is higher than that of calcium containing minerals. Thus, it is expected that the melting temperature of glass cullet would be higher than that of PSA, leading to a lower melting point of the mixture. At 700◦C, sintering temperature is not high enough for the formation of liquid phase. The gas produced cannot be trap inside the material. Voids were filled up by the melting minerals through capillary action. At the temperature of maximum densification, all of the pores would be eliminated by creating more melting minerals. Once the level of viscosity was high enough to hold the gas at higher temperature and there were still enough available gas generating minerals, density of the product with higher PSA content would decrease with increase expansion. However, it is possible that the adequate glassy phase cannot effectively develop regardless of sintering temperature due to the presence of high percentage of PSA. As the temperature increases, it can be seen from Figure 3a that the densification rate was decreased. This effect can be observed more obvious from Figure 3b. These data suggest that possible that there were some pores structures have been created. However, the quantity of pores was not great enough to compensate the degree of densification. If the products were sintered at higher temperature, for instance 1000◦C or 1100◦C, decrease in density would be expected to occur. Figure 3.Effect of firing temperature on density (a) and water absorption (b) for 8 hour-ball milled samples pressed at 90kPa. 6 Although the quantity of gas forming agents reduces for artificial pumice contains lower PSA content, but the glassy phase developed at higher temperature effectively traps the gas generated. The combination of the internal combustion of the organic mineral and the highly viscous liquid phase results the density decrease in increasing temperature. As the expanding mineral is rapidly consumed, the reduction rate of the density drops. Therefore, it is possible for the high glass content samples to increase in density after minimum density is achieved at higher temperature as no pores are produced whereas more minerals are melted to fill up the void space. a 3.3 Effect of pressing pressure and pressing time on properties of product It can conclude that pressing time only has a small influence on the performance of the product as long as the tilts have been pressed for enough duration so that they do not fall apart easily. The effect of pressing pressure is more substantial. For all the samples processed at 700◦C, the density remains constant regardless of the presence of large errors at lower pressure in the range of 40kPa to 90kPa. This argument is also evident by the WA data with less measured error. As the sintering temperature increases to 800◦C, the density of all samples decreases with increasing pressing pressure. Denser particle arrangement leads to more expansion of the sintered tilts as more gas is encapsulated inside the material. The reduction rate is greater for pumices contain less PSA, for example 90% and 80% glass samples due to the formation of higher glassy phase. Tilts with higher PSA content at 900◦C exert the same behaviour. However, denser matrix of samples lower percentage of PSA can be achieved by increasing the pressing pressure at 900◦C. This phenomenon can be explained by in terms of expanding agent consumptions. Even though the liquid phase at 900◦C provided an appropriate environment for the capsulation of gas. However, majority of the calcium minerals was exhausted at this stage. Hence, further increasing in temperature cannot create more porosity. On the other hand, the increasing vitrification leads to closure of the existing space between unreacted particles. b 7 e c Figure 4. Effect of pressing pressure on density for 8 hour-ball milled samples containing 30(a), 20(b), 10(c) wt% PSA f d Figure 5. Effect of pressing pressure on water absorption for 8 hour-ball milled samples containing 30(d), 20(e), 10(f) wt% PSA 8 3.4 Effect of PSA content on properties of product The increase in PSA content for the samples sintered at 700◦C weakens the dense structure of artificial pumice since density of PSA is lower than that of glass and there was no significant expansion taken place. At 800◦C and 900◦C, expansions effectively occurred to reduce the density with increasing glass content from range 90% to 70%. For 60% glass tilts, even at higher temperature, the magnitude of densification still cannot compete with the combination impact of density drop due to higher PSA content and expansion behavior. Therefore, the density change of samples sintered at 800◦C and 900◦C decreases from PSA content of 30% to 40%. Figure 6.Effect of PSA content in the mix on density (a) and water absorption (b) for 8 hour-ball milled samples, pressed at 90kPa 3.5 Effect of milling time on properties of product As it can be seen from Figure 7, density decreases with increasing ball milling time. The density reduces significantly for the first 4 hours milling. Then it decreases less rapidly for the next 4 hours. The density drops much slower for the final 24 hours milling. Milling time effectively increases the WA. Finer particles can fill in the void spaces between coarse particles, whereby neck growth rate among particles can be boosted to form continuous liquid phase, rendering a better sintering rate. Combustion of fine and uniformly distributed carbon grains leads to the formation of a homogeneous porous structure. 9 are 22.836 and 776.605 μm respectively. A single distinct peak can be seen for 8 hours and 32 hours ball milling. The peak for 8 hours ball milling is sharper than that of 32 hours. The 10% volumes of particles are approximately 3 μm for 8 and 32 hours durations. The main difference is for the 50% and 90% volume sizes (Table 3). Table 3.Particle analysis data for different milling times Volume diameter 2h milling 8h milling 32h milling d10 22.836 2.748 2.924 d50 188.149 42.976 15.181 d90 776.605 248.208 110.338 3.6 Overall performance of samples The level of water adsorption was positively related to the density. The decrease of WA was proportional to increase of the density, vice versa. The relationship of WA and density can be visualised from Figure 8. It is not possible to produce pumice from PSA and glass far away from this curve. In others word, it indicates the feasible region of pumice production out of PSA and glass. Figure 7.Effect of milling time on density (a) and water absorption (b) for samples, pressed at 70kPa The particle size profile of different milling duration for the preparation of mixtures in experiment-1 was quite different. All curves; although only have one single peak, are not symmetric (Figure 8). 2-hour ball milling produces a width range of grain sizes. The particle size for 10 and 90 volume percentages 10 An inverse relationship between the two properties is obvious in Figure 8. Samples prepared with 10-20 wt% PSA after ball milling the raw materials for 8 hours fired at 800-900 ºC constitute promising results for a potentially commercial pumice-like product with properties comparable to those of natural pumice. always been an issue for the UK industry. PSA used in this research were received from Aylesford Newsprint Ltd that produces approximately 10,000 tonnes of PSA annually. Most of the industrial by-products are currently disposed in landfills or by incinerations. Landfill disposal costs in the UK for active waste rose to £64 per tonne in 2012. It is expected to increase significantly in the next few years. Therefore, landfill disposal of this problematic fraction of PSA represents a significant potential cost. The engineered pumice provides an excellent alternative to quarried pumice, being light, strong and consistent. The combination of resource sustainability and strong performance makes the engineered pumice attractive in a wide range of applications. Based on 2010 data, pumice typically sells in the UK for between £7 and £90 per tonne depending on the application. The quality of mixed colour glass is sufficient for the production. Therefore it is not difficult to cover various costs associated with artificial pumice manufactured from PSA and mixed colour glass. It is worth noticing that the exact cost depends on a number of factors such as the processing technique and location of the treatment plant. However, based on the properties of the artificial pumice, there appears to be potential for this product to manufacture as a replacement of natural pumice aggregate. Figure 9.Relationship between water absorption and density for all samples prepared including data for Lava Rock pumice. 3.7 Economical consideration The technical feasibility of using PSA and waste mixed color glass in the manufacture of artificial pumice has been successfully demonstrated at laboratory scale. Its market value is considered in detail below. Rapid industrial and economic developments in urbanisation cause an increase of waste volumes. Disposal of industrial residues has 11 Further investigation is required for the full understanding and optimisation of the manufacturing process of artificial pumice at pilot plant scale. Subsequent processing involving pressing and sintering in a furnace is expected to be similar to other commercially available lightweight aggregates that are typically manufactured from shales, clays and slates. Pressed tilts can be continuously delivered to the belt furnace with a hot zone of designated temperature for firing. The firing duration can be controlled by the rotation velocity of the belt. Another hot zone with glass melting temperature after the sintering process can be set in order to produce a tilt with flat surface. 4. Conclusion Pumice-like material produced from waste glass and PSA is feasible by using simple processing techniques including ball milling, pressing and sintering. A 90% glass-10% PSA sample prepared with raw materials having been ball milled for 8 hours, pressed at pressure 40kPa into a tilt and fired at 800 ºC produced the optimum product with a mean density of 0.86 g/cm3 and water absorption of 65%. Commercially available pumice had a mean density of 0.86 g/cm3, water absorption of 68%. The research indicates the market for high quality pumice could be substantial. It could replace natural pumice for a wide range of application such as abrasive, concrete admixture and aggregate, horticulture and landscaping, absorbent in removing target pollutants, filtration and laundry stone washing. ACKNOWLEDGEMENTS I would like to express my sincere gratitude to my supervisor, Professor Chris Cheeseman for his help and encouragement as well as detailed and constructive criticism. The completion of this thesis would not have been possible without his valuable insight. An increase in temperature decreased the densities of products contain higher glass content, for instance, 8 hours milled, 80% and 90% glass samples. However, the densities of samples consist of lower glass percentage such as 8 hours milled, 60% and 70% glass pumice increase with increasing temperature. I am also grateful to Miss Charikleia Spathi for her support and technical contribution in the course of this project. 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