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INTERNATIONAL JOURNAL OF ENGINEERING RESEARCH AND INDUSTRIAL APPLICATIONS

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International J. of Engg. Research & Indu. Appls. (IJERIA). ISSN 0974-1518, Vol.5, No. III (August 2012), pp. 213-224

REUSE OF TEXTILE MILL SLUDGE IN CEMENT BASED SOLID BLOCKS

SHRIKANT S. JAHAGIRDAR, S. SHRIHARI AND B. MANU

Abstract
Study deals with reuse of textile mill sludge in making cement bases solid blocks which can be used in practice for bulk usage of sludge. Textile sludge and fly ash are analysed by using XRF technique. Textile sludge is mixed with cement and later with combination of cement and fly ash to make solid blocks. Solid blocks are tested for compressive strength. To study the post effects of the sludge reuse, water used for curing (curing water) is also analysed for different parameters such as pH, EC, Solids, Hardness, chlorides etc by standard methods. Addition of fly ash reduces the leaching from the solid blocks. Compressive strength of cement and sludge blocks is 23.8 N/mm2, whereas solid blocks made of sludge, cement and fly ash shown compressive strength of 29 N/mm2. Reuse of textile mill sludge as building material will increase bulk usage of sludge in future, thus completely eliminating landfilling disposal option.

----------------------------------Keywords : Textile mill Sludge, Fly ash, curing water, compressive strength, XRF http: //www.ascent-journals.com

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1. INTRODUCTION Disposal of industrial solid waste is a growing and very serious problem faced by the global community. Textile industry, being one of the major and oldest sectors in India is also battling with the problem of ETP sludge disposal. Textile mill consumes large amount of water for the variety of wet operations. The wastewater thus generated is treated in Effluent treatment plant (ETP) by using chemicals such as Alum, Lime, Ferric chloride and polyelectrolyte. As a result of this large quantity of sludge is generated in primary and secondary clarifiers. Sludge is dried in sludge drying beds and sent for landfilling because of the chemical nature. Currently in India about 960 million tons of solid waste is being generated every year as by product during industrial, mining, municipal, agricultural and other processes. Out of this about 350 million tonnes are organic, about 290 million tons are inorganic of industrial and mining sector and about 4.5 million tons are hazardous in nature. Technology advancement resulted in alternative construction materials such as a substitute to traditional material like bricks, blocks, tile, aggregates, ceramic, cement, lime etc. To safeguard the environment efforts are being made for recycling different wastes and utilize them in value added applications [12]. The cost of construction materials is increasing incrementally. In India, the cost of cement during 1995 was 1.25 Rs/kg and in 2005 price increased 3 times. In case of bricks the price was 0.66 Rs/brick in 1995 and in 2005 the price was 1.9 Rs/brick. Also due to high transportation costs of these raw materials, demand and environmental restrictions, it is essential to find functional substitutes for conventional building materials in construction industry [12]. Stabilization of industrial waste should guarantee such a treatment and in such a way that waste would not be hazardous. This condition can be met if wastes are transformed into homogenous solid structures, having form of blocks or pellets and this process is called solidification. As a result of stabilization/solidification processes pollutants contained in waste are transformed into forms that are hardly soluble and distinguished by reduced toxicity. The product obtained has also definite compressive strength that enables its safe transportation and subsequent deposition [5]. Stabilization/solidification processing techniques normally involves simply mixing wastes with solidification binders. These processes are based on the hydraulic reactions of the hydraulic cements or pozzolanic

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reactions between Portland cement or lime and pozzolanic materials [1]. Thus, Cement can serve as good binder material for many types of waste sludges. Stabilization and solidification of sewage sludges with Portland cement can be done successfully with satisfactory compressive strength [14]. Industrial waste sludge can be used to produce high strength cementitious product [9]. Hospital waste ash [7], Sewage Sludge Ash (SSA) [11], Sludge from water treatment plant [8], de-inking sludge from waste paper recycling [15] and Municipal waste incinerator fly ash [6, 3] can also be used effectively in cement mortars. Use of the sludge generated in potable water filtration/cleaning operations (waste material) is made as workability-aid in rendering/plastering mortars [13]. Several researchers demonstrated the use of domestic and industrial sludge in cement mortars. Solidified electroplating sludge is used along with silica fume (CSF) and furnace slag (FS) for making solid blocks [2] is also has been reported. Partial substitution (15% or 30% by mass) of cement by Sewage Sludge Ash (SSA) does not strongly affect the strength of mortars cured at 40 C for 3- to 28-day curing periods [4]. On the other hand the effect of replacing 15% of Portland cement by SSA (sewage sludge ash) and their coarse and medium sized fractions is studied by using criterion of compressive and flexural strength of mortars [10]. To summarize textile mill sludge can be used for making solid blocks by using cement as a binding material.

2. MATERIALS AND METHODS 2.1 Materials Textile mill sludge in dried form is collected from Somany Evergreen Knits Pvt Ltd, MIDC Kondi, Solapur, Maharashtra state, India. The collected sludge is packed in polythene bags and stored in the laboratory at a dry place for further study. The cement required for the investigation is procured from local market in Solapur. Ordinary Portland cement 43 grade [Make JK brand] is used. Fly ash is collected from one of the local brick manufacturer. Origin of Fly ash is basically from Parali thermal power station. 2.2 Methods Collected textile mill sludge and fly ash samples are analysed for their chemical composition by XRF technique at IIT, Bombay.

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Oven Dried Textile Sludge (ODTS) is used for making the cubes. Following proportions (by weight) are used for making Sludge and cement (SC) blocks. 9:1, 8:2, 7:3, 6:4, 5:5, 4:6, 3:7 and 2:8 Blocks are cast and on the next day after deshuttering cubes are kept in water for curing. Cubes are checked for Compressive Strength after three, seven and twenty eight days of curing respectively. The curing water is also monitored for studying leaching pattern of the bricks/blocks. For this purpose variations in pH, EC and TDS over 28 days curing period are recorded by using Elico- make instruments. At the end of 28 days curing water is analysed for solids, hardness, chlorides and turbidity. Chemical parameters of curing water are analysed as per standard methods for examination of water and wastewater [15]. In next part of investigations sludge content is kept constant i.e., 30%. Cement is replaced by Fly Ash by weight in increments of 10% from 70% up to 20 %. Proportions are as follows for Sludge, Cement and Fly ash (SCF) blocks - 3:6:1, 3:5:2, 3:4:3:, 3:3:4,3:2:5 Deshuttered cubes are kept for curing on next day. Remaining procedure followed is same as stated in case of the sludge and cement blocks.

3. RESULTS AND DISCUSSION Basic parameters like density and specific gravity of the textile sludge are given in table 1
Table 1 : Basic Parameters of Textile Mill Sludge.

Sr. No. 1 2

Parameter Specific Gravity Dry density 1.2-1.5

Value

1200-1500 kg/m3

Specific gravity is less as compared to traditional fine aggregates. Results of major chemical compounds by XRF analysis for textile mill sludge and fly ash are shown in Table 2.
Table 2 : Principal chemical compounds in textile mill sludge and fly ash

Chemical compound

Presence in Textile mill sludge in %

Presence in Fly ash in %

Al2O3 CaO FeO

3.59 22.99 26.92

25.24 1.58 N.A.

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Chemical compound

Presence in Textile mill sludge in %

Presence in Fly ash in %

Fe2O3 P2O5 SiO2 TiO2

N.A. 3.47 15.16 1.32

4.78 0.17 65.44 1.35

Analysis shows, textile mill sludge contains less amount of SiO2 which means textile sludge lacks in binding property if it is used as additive in building material. But on the other hand it contains CaO, FeO in significant amount, which indicates it has potential to be used as building material. Fly ash contains SiO2 in large amount, which implies it can contribute to binding properties if it is used along with sludge in making solid blocks. Analysis of textile mill sludge by using EDAX (Electron dispersive) technique under Scanning Electron Microscope (SEM) showed heavy metals are absent. 3.1 Sludge and Cement solid blocks Figure 1 show results for average density of sludge and cement solid blocks. The density of SC blocks reduces with increase in sludge content because of the lesser specific weight of sludge as compared to that of cement.

Figure 1 : Density variations of Sludge and Cement Solid blocks

Figure 2 show results for 3, 7 and 28 days compressive strength of sludge and cement solid blocks.

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Figure 2 : Compressive Strength comparisons of different Proportions.

From above results, it can be seen Compressive strength increases as cement content increases. After 70% cement content there is no increase in compressive strength of cubes even though cement percentage increases. Optimum combination works out to be 30% ODTS and 70% and Cement. As cement content is too high it will make usage of these blocks uneconomical. Hence, in order to reduce the cement consumption and to make it economical fly ash is added. Analysis of curing water is done for determining Turbidity, total alkalinity, hardness, Chlorides and Solids and readings are as given in Table 3.
Table 3 : Analysis of Curing Water of Oven Dried Textile Mill Sludge and Cement Cubes. ODTM S % (By weight) 90 80 70 60 50 40 30 20 Cement % (By weight) 10 20 30 40 50 60 70 80 NA 38.9 34.2 29.5 26.9 8.4 7.2 7.0 Turbidity NTU Total Alkalinity mg/lit NA 64 76 84 88 90 108 90 Analysis of curing water Hardness mg/lit as CaCO3 NA 64 40 36 36 140 124 110 NA 5858 4603 3848 3408 2200 1450 880 NA 12400 8400 7000 6600 450 400 300 NA 3600 2400 2200 2400 300 200 150 NA 8800 6000 4800 4200 150 200 150 Chlorides mg/lit Solids (mg/lit) TS TDS TSS

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As per above observations, Turbidity reduces as sludge percentage reduces and cement percentage increases in cubes. Also, solids and chlorides go on reducing as sludge percentage reduces and cement percentage increases. This indicates that cement binds the ODTS and prevents leaching of contaminants. Fig 3 and Fig. 4 Shows variation in Electrical Conductivity (EC) and TDS of curing water over 28-days period.

Figure 3 : Variation of Electrical Conductivity (EC) of Curing Water.

Figure 4 : Variation of TDS of Curing Water.

From above Figures it is clear that pH of curing water varies in between 10 to 12 for all proportions. There is considerable reduction in EC and TDS of curing water as sludge percentage goes on reducing and cement content increases. Reason being cement binds the sludge. There is less leaching from the cubes as cement content increases because of improved binding between sludge and cement.

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3.2 Sludge, Cement and Fly ash Solid blocks Figure 5 show results for average density of sludge, cement and fly ash solid blocks.

Figure 5 : Density variations of Sludge and Cement Solid blocks

Density of blocks reduces as fly ash percentage increases. This is because of lesser specific weight of fly ash as compared to cement. It is observed that density of sludge, fly ash and cement blocks (SCF) is more as compared with the sludge and cement (SC) blocks Results for compressive strength of sludge, cement and fly ash blocks are shown in Fig. 6.

Fig.6. Compressive Strengths Comparison of Different Proportions. Compressive strength gradually increases but it falls at sludge 30%, Cement 20% and Fly ash 50% combination. Increase in compressive strength is may be because fly ash contains more SiO2 as compared to textile mill sludge, which increases binding capacity. Optimum combination works out to be sludge 30%, Cement 30% and Fly ash 40%

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Table 4 shows results for analysis of curing water for different parameters.
Table 4 : Analysis of Curing Water of Oven Dried Textile Mill Sludge, Fly Ash and Cement Cubes. ODTS % (By weight) Fly Ash % (By Weight) Cement % (By weight) Turbidit y NTU Total Alkalini tymg/lit 10 20 30 30 40 50 60 50 40 30 20 5.6 5.3 4.8 4.7 4.9 100 92 88 96 72 Analysis of curing water Hardness mg/ lit as CaCO3 312 300 284 276 264 Chlori desmg /lit 895 735 650 500 480 1320 1150 1080 1130 1060 480 420 390 410 410 840 730 690 720 650 Solids (mg/lit) TS TDS TSS

From above results it is clear that as Fly ash percentage increases it prevents development of micro cracks in the solid blocks. Because of this leaching gets reduced and turbidity, hardness, chlorides and solids are much less as compared to previous investigations on sludge and cement blocks. Fig. 7 and 8 shows variation in EC and TDS of curing water over 28-days period.

Figure 7 : EC variations of Curing Water.

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Figure 8 : TDS variation of Curing Water

EC and TDS reduces as Fly ash percentage increase and cement content decease. This indicates Fly ash helps in reducing leaching of sludge from the cubes.

CONCLUSION Textile Mill Sludge and Cement Blocks i. Cement can be added as a binding material in order to make sludge cement bricks. Compressive strength of bricks increases with cement percentage from 20% to 70%. If cement content is increased to 80% there is fall in compressive strength. This indicates optimum combination is 30% sludge and 70% cement which gives compressive strength of 23.8 N/mm2. ii. Curing water analysis shows there is decrease in leaching as cement content goes on increasing, also pH, EC, TDS reduces with increase in cement content. This means cement can be successfully used as a binding material along with textile mill sludge. iii. Density of blocks increases with increase in cement content i.e. decreases with increase in sludge content Textile Mill Sludge, Cement and Fly Ash Blocks i. Keeping sludge content constant i.e., 30%; cement can be replaced by fly ash in order to make the building blocks economical. ii. Addition of fly ash prevents leaching from the blocks significantly as compared to sludge and cement blocks.

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iii. Compressive strength increases gradually with increase in fly ash content. Optimum combination works out to be 30% Sludge, 30% Cement and 40% Fly Ash iv. Density of blocks goes on reducing with increase in fly ash content.

ACKNOWLEDGEMENTS Authors are thankful to whole time Director Mr. Sanjay Harane, Somany Evergreen Knits Pvt. Ltd., Solapur for his valuable support for carrying out this research.

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[14] Yan S., Crentsil K.S., and Shapiro G.. Reuse of de-inking sludge from waste paper recycling in cement mortar products. Journal of Environmental Management, 92: 2085- 2090, 2011. [15] Standard methods for examination of water and wastewater, American Public health Publication, 2005

Shrikant S. Jahagirdar
PhD Research Scholar, Department of Civil engineering, National Institute of Technology Karnataka, PO Srinivasnagar, Surathkal- 575025, India.

S. Shrihari
Professor, Department of Civil engineering, National Institute of Technology Karnataka, PO Srinivasnagar, Surathkal- 575025, India.

B. Manu
Assistant Professor, Department of Civil Engineering, National Institute of Technology Karnataka, PO Srinivasnagar, Surathkal- 575025, India.