A new application of sewage sludge utilization-Lightweight aggregate (LWA)

Mingwei Liu, Guoren Xu *, Guibai Li State Key Laboratory of Urban Water Resource and Environment Harbin Institute of Technology Harbin, China E-mail: lmw0812@yahoo.cn
AbstractLots of sewage sludge are generated each year as more wastewater treatment plants appeared in nowadays. How to disposal and utilize sewage sludge has become an urgent problem need to solved. The imposition of more stringent regulations about disposal and utilization of sewage sludge caused some of the traditional methods have been limited, so prompted a drive for alternative uses for sewage sludge. Many researchers have recognized sewage sludge as a resource with much potential for benecial reuse other than direct disposal. Because the silicon and aluminum-rich characteristics, the dried sludge also exhibits signicant specic surface area and cation exchange capacity. Therefore production of lightweight aggregate using dried sludge is a new effective approach for disposal of sludge. This paper seeks to review the published research in this field: it covers the means of production, the characteristics and the potential applications of LWA made from sewage sludge and other waste. Keywords-component; lightweight aggregate; sewage sludge utilization; heavy metal

because most sludge contains heavy metals, disease-causing pathogens, and organic and inorganic compounds. It is, therefore, of great significance to find a proper way to dispose wastewater treatment sludges to avoid secondary pollution [68]. The utilization of sewage sludge as a fertilizer has been limited by the imposition of legislation in recent years, currently, the primary alternatives to land application are incineration and landfill, but both are hampered by their poor public image. Moreover, incineration is both expensive and it gives rise to significant quantities of potentially hazardous ash [9]. Many researchers have recognized sewage sludge as a resource with much potential for benecial reuse other than direct disposal. Because the silicon and aluminum-rich characteristics, the dried sludge also exhibits signicant specic surface area and cation-exchange capacity. Therefore production of lightweight aggregate using dried sludge is a new effective approach for disposal of sludge. II. THE PROGRESS IN LWA MADE FOME SLUDGE AND
OTHER WASTE

I.

INTRODUCTION

Sewage sludge can be defined as the residue generated from the treatment of wastewater. The two principal types of sludges are primary sludge and secondary sludge. Primary sludge constitutes the material collected from the primary settling tanks employed in wastewater treatment plants (WWTPs). Secondary sludge, also known as biological sludge (BS), constitutes the sludge generated from the biological treatment of the wastewater drained from the settling tanks [1]. Chemical sludge is another commonly occurring form of sludge, and constitutes sludge that has been produced with the aid of chemicals. Typically the chemicals are used either to facilitate the precipitation of hard-to-remove substances, or to improve suspended solid removal [2]. In general, sludges and biosolids resulting from wastewater treatment operations are in liquid form, typically containing 0.515% total solids (TS). Most of them are organic compounds, with a broad range of volatile solids contents (50 80%), commonly from 75% to 80% of TS [3]. Sludge production and characteristics are highly dependent on the wastewater composition and the treatment used. Disposal of wastewater treatment sludge is a pressing environmental problem in now days, which is aggravated by its accumulation around the world [4,5]. Improper sludge disposal can pose risks to both public health and the environment

Anagnostopoulos and Stivanakis [10] utilized lignite combustion solid residues in the production of inflammable lightweight aggregates (LWA). The main residues bottom ash (BA) and fly ash (FA) from Megalopolis power plant, mixed in different proportions mixtures and sintered at 12001250 C. The study indicate that sintering of lignite combustion residues is an efficient method of utilization of carbon containing BA and production of LWA for structural and insulating purposes. Carbon content of BA is a key factor in LWA production. Chen et al. [11] reports the result of the investigation on manufacturing lightweight aggregate by incorporating municipal solid waste (MSW) incineration fly ashes and reaction ashes with reservoir sediments. The results demonstrate that the aggregate thus fabricated is non-hazardous for construction use. The reservoir sediments have high content of glass former oxides and low level of uxing oxides in its composition, and thus can be used as a feasible raw material for sintering lightweight aggregates. Cheeseman and Virdi [13] investigated the properties of lightweight aggregate (LWA) manufactured from the ash produced by fluidized bed incineration of sewage sludge. They found that manufacturing lightweight aggregate from sewage

Key Program of National Natural Science Foundation (51038003), RFDP-20092302110047 and NCET-08-161.

978-1-4577-0321-8/11/$26.00 2011 IEEE

3502

sludge ash may become increasingly viable as landfill disposal costs continue to increase and the costs of alternative natural aggregates obtained from increasingly distant locations also
[12] TABLE I. Chemical components analyses of dried sewage sludge (wt.%)

Kockal and Ozturan [15] studied the Influence of different lightweight fly ash aggregates on the behavior of concrete mixture. Low specic gravities of cold-bonded and sintered y ash aggregates were benecial to produce lightweight concretes with densities in the range of 18601943 kg/m3.

Chemical components analyses SiO2 16.28 Al2O3 6.35 Fe2O3 5.15 CaO 4.10 MgO 1.67 P2O5 1.65 K2O 1.12 others <0.89

Laursen [16] discussed industrial sludge and marine clay as light-weight aggregates, the result showed that good bloating Carbonaceous behavior during firing and the ceramic pellets (1-1.5 cm diameter) had densities well below that required for lightmatter weight aggregates.
<62.9

Chemical elements analyses Zn 0.19 Na 0.56 Fe 4.30 K 1.15 Mn 0.17 Al 6.66 Si 16.3 Ni 0.22 Cu 0.045 C 61.20 Ca 4.14 others <0.60 Mg 1.58 Cr 0.034 P 1.25

Zhao [17] have development a new kind of ceramic particlessludge-y ash ceramic particles(SFCP), was developed by employing dewatered sludge, clay, and y ash at high temperature (above 1100 C) with a mass ratio of 1:1:1. Because the SFCP must be sintered at temperatures above 1100C, pathogens existing in the sewage sludge can be destroyed and organics can be decomposed and gasied, so the products will not generate odors. Lee et al. [18] utilized power plant bottom ash as aggregates in fiber-reinforced cellular concrete showed that with a xed volume proportion of water, cement, and aggre-gates, ow characteristics of cement mortar using bottom ash were lower than cement mortar using normal river sand. Tsai et al. [19] investigates the characteristics of lightweight aggregates sintered from sewage sludge ash by modifying the proportion of the main components (SiO2 Al2O3ux). The results showed that amorphous SiO2 lowered the melting point and increased foaming; Al2O3 raised the compression resistance; y ash lowered the sintering temperature required. However, the composition of y ash can vary dramatically, resulting in a less predictable characteristic of aggregates. Wang et al.[20] used dry sewage sludge and coal ash to produce lightweight aggregate, The results indicated that using DSS enhanced the pyrolysisvolatilization reaction due to its high organic matter content, and decreased the bulk density and sintering temperature. However, the sintered products of unamended DSS were porous and loose due to the formation of large pores during sintering. Gonzlez [21] investigated the micro structure sand mineralogical compositions of lightweight aggregates manufactured with washing aggregate sludge, fly ash and used motor oil. Results showed that: (i) the presence of larger pores is related to a decrease in the dry particle density values, (ii) when the LWA lacks the external layer, the water absorption values were dependent on the size and amount of each type of pore (open or closed), and (iii) the neo-formation of Caplagioclase and the consumption of quartz improved the compressive strength values. Gins et al.[22] reported the experimental results obtained after casting concrete formulated with different mix proportions of municipal solid waste incineration by-products, bottom ash and air pollution control fly ash, as aggregates. Study showed the highest compressive strength test results, above 15 MPa, and the lowest amount of released trace metals in reference to the leaching test.

Fig. 1. Pictures of sludge ceramsite sintered at 850, 900, 950, 1000, 1100, and 1200C [12]

increase. The results indicate the potential for manufacturing high quality lightweight aggregate from the sterile, inert ash produced by sewage sludge incineration, using relatively simple processing and low temperature sintering. And found LWA made from sewage sludge ash have lower densities and low water absorption when fired between approximately 1050C and 1080 C. Researcher from Spain studied the washing aggregate sludge from a gravel pit, fly ash of the thermal power plant and used motor oil from cars for making the lightweight aggregate. LWAs manufactured with 75%:25% and 50%:50% proportions of washing aggregate sludge:y ash, heated at different temperatures and dwell times, were expanded LWAs (BI >0). They showed the lowest loose bulk density, the lowest dry and apparent particle density, the lowest water absorption and the highest compressive strength [14].

3503

Xu et al.[12] in order to investigate the effect of sintering temperature on the characteristics of sludge ceramsite and nd an optimal sintering temperature, dried sewage sludge, clay, and water glass were mixed at ratios of dried sewage sludge/clay = 33% and water glass/clay = 15%. The results indicate that the differences in thermal behaviours are caused by the compositional and structural variations; the ceramsite sintered at 1000C has more uniformly distributed ner pores (0.5 m < pore size < 10.0 m) Kockal and Ozturan [23] investigated the charact-eristics of lightweight fly ash aggregates with various binders produced by different heat treatments. The strength and specific gravity of all aggregates decreased with increasing the binder content (disregarding binder type) at the highest temperature.

Experimental results indicate that the characteristics are primarily influenced by sintering temperature. When the sintering temperature is increased from 1020 to 1050 degrees C, the specimens' compressive strength and bulk density increase significantly, while water absorption decreases obviously, indicating an improvement of densification due to sintering. Zou [29] used wastewater treatment sludge (WWTS) and drinking-water treatment sludge (DWTS) as ceramsite. Results show that WWTS and DWTS can be utilized for producing ceramsite with optimal contents of Fe2O3, CaO, and MgO ranging 58%, 2.757%, and 1.64%, respectively. Higher strength ceramsite with more complex crystalline phases and fewer pores can be obtained at 6% Fe2O3 8%. III. 4.LEACHING CHARACTERISTICS

Aggregates with low water absorption and high strength and specific gravity can be attributed to the dense structure with discontinuous and small size pores. Increasing binder content reduced water absorption at all temperatures.
Liao and Huang [24] studied the effects of CaO addition on lightweight aggregates produced from water reservoir sediment and found that C-S-H gel did not form with CaO addition. The bulk density and compressive strength of the lightweight aggregates meet the regulations for lightweight structural concrete. The properties of samples with 1% CaO by weight calcined at 1200 C match those of a commercial product. Water adsorption and compressive strength decreased with increasing CaO addition since more of the glassy phase formed, which sealed pores and led to few connections between pores. Wei et al. [25] used harbor sediment as lightweight aggregate. The results showed that increasing final process temperature tends to reduce the bulk density and crushing intensity of lightweight aggregate with a concomitant increase in water sorption capability. Lightweight aggregate with the lowest bulk density, 0.49 g cm-3 for the 5000 psi sample, was obtained with the heating process to 1150 C. Some researcher [26] studied municipal solid waste incinerator residues and aggregates derived from contaminated soil washing used as alternative aggregates for concrete production. The results showed that the reuse of pre-treated MSWI bottom ash and washed soil is possible, either from technical or environmental point of view, while it is not possible for the raw wastes. Then, the natural aggregate was partially and totally replaced with these recycled aggregates for the production of concrete mixtures that were characterized by conventional mechanical and leaching tests. Tang [27] reported the investigation of rotary kiln manufactured lightweight aggregates (LWA) using fine sediment deposits dredged from the Shihmen Reservoir in Taiwan. The investigation revealed the sediments contain all the necessary elements to enable the bloating and calcining processes within the commercial kiln. When exposed to the high heat of the kiln, the extruded sedimentary material undergoes dramatic changes, developing a hard ceramic shell and a porous core comprised of non-interconnected capillaries. Wang [28] investigated the sintering behavior of dried sewage sludge and the related sintering mechanisins.

Chang [30] investigated the reachability of metals from sludge-based artificial lightweight aggregate. The results revealed that the leaching concentrations of Cd, Cr, Cu, and Pb present in the non-sintered raw aggregate pellets reached 7.4, 68.0, 96.0, and 61.4 mg/l, respectively, far exceeding the regulatory threshold. Sintering at 1150 C for 15 min results in stronger chemical bonds being formed between the elements. Sloot et al. [31] studied the Leaching behavior of synthetic aggregates made of recycle waste. The leaching curves as a function of pH are very similar, which can be regarded as a characteristic for synthetic aggregate. Apparently, the process characteristics tend to produce a material with similar properties in spite of varying inputs. This can be used for Quality Control of the production process with a concise test addressing the most crucial leaching aspects. Xu et al. [32] investigate stabilization of heavy metals in ceramsite made with sewage sludge. The results indicate that leaching contents of heavy metals do not change above 1000C and sintering temperature has a significant effect on stabilization of heavy metals in ceramsite; leaching contents of heavy metals decrease as pH increases and increase as H2O2 Concentration increases. XRD analysis reveals that the heavy metals exist in steady forms, mainly Pb2O(CrO4), CdSiO3, and CuO at 1100 C. It is therefore concluded that heavy metals are properly stabilized in ceramsite and cannot be easily released into the environment again to cause secondary pollution. IV. APPLICATION

Novel media-sludge-fly ash ceramic particles (SFCP) employed in an upflow lab-scale A/O BAF were investigated for synthetic wastewater treatment by Han, S.[33]. Under the optimal conditions, 90% CODcr, more than 98% NH3-N and approximately 70% TN were removed. The feasibility of SFCP as biolm support by BAFs was veried very satisfactorily according to the results of characteristics of SFCP and leaching toxicity tests. Novel media-ultra-lightweight sludge ceramics (ULSC) employed in an up flow lab-scale biological aerobic filter (BAF) were investigated for pharmaceutical advanced wastewater treatment [34].

3504

(1) The feasibility of ULSC as ller by BAFs in pharmaceutical advanced wastewater treatment was veried to be satisfactory according to the properties of ULSC. (2) The optimum conditions were PW/DW of 4:1, HRT of 6 h and A/L of 5:1 according to the requirement of the national standard and cost of running. A/L of 5:1 was smaller and this bioler was easily backwashed. (3) The optimum conditions of this BAF system can supply reference for design in practical projects V.
CONCLUTIONS

[15]

[16]

[17]

[18]

Because the silicon and aluminum-rich characteristics, many researchers have recognized sewage sludge as a resource with much potential for benecial reuse other than direct disposal. Therefore production of lightweight aggregate using dried sludge is a new effective approach for disposal of sludge. Studies have shown that lightweight aggregate is a safe method of sludge treatment, and can be applied to wastewater treatment. REFERENCE
[1] S. Ren, Assessing wastewater toxicity to activated sludge: recent research and developments, Environment International 30 (8), 1151 1164. 2004. I. S. Turovskiy, P .K. Mathai, Wastewater Sludge Processing, John Wiley & Sons, Inc., Hoboken, New Jersey. 2006. M. Von Sperling, R. F. Gonalves, Sludge characteristics and production,. Sludge Treatment and Disposal. IWA Publishing, London, UK. 2007. Y. Liu, Chemically reduced excess sludge production in the activated sludge process, Hemosphere, 50, pp.17, 2003 A. Adegoroye, N. Paterson, "The characterisation of tars produced during the gasification of sewage sludge in a spouted bed reactor." Fuel 83(14-15):pp. 1949-1960, 2004. A. Bagreev, T. J. Bandosz, Efficient desulfurization adsorbents obtained by pyrolysis of sewage sludge derived fertilizer modified with spent mineral oil, Environ. Sci. Technol, 38, PP.345351, 2004. A. Fuliana, J. A.Conesa, R. Font, Formation and destruction of chlorinated pollutants during sewage sludge incineration, Environ. Sci. Technol, 38, pp.29532958, 2004. M. B. Folgueras, R. M. Daz, J. Xiberta,; M. Alonso, Effect of inorganic matter on trace element behavior during combustion of coalsewage sludge blends, Energy Fuels, 21, pp.744755, 2007. D. Fytili, A. Zabaniotou, "Utilization of sewage sludge in EU application of old and new methods-A review," Renewable & Sustainable Energy Reviews 12(1), pp.116-140, 2008. I. M. Anagnostopoulos, V. E. Stivanakis "Utilization of lignite power generation residues for the production of lightweight aggregates," Journal of Hazardous Materials 163(1), pp.329-336, 2009. H. J. Chen, S. Y. Wang, et al., "Reuse of incineration fly ashes and reaction ashes for manufacturing lightweight aggregate," Construction and Building Materials 24(1), pp.46-55, 2010. G. R. Xu, J. L. Zou., "Effect of sintering temperature on the characteristics of sludge ceramsite," Journal of Hazardous Materials 150 pp.394400, 2007. C. R. Cheeseman, and G. S. Virdi "Properties and microstructure of lightweight aggregate produced from sintered sewage sludge ash," Resources, Conservation and Recycling 45(1), pp. 18-30, 2005. B. Gonzlez-Corrochano, J. Alonso-Azcrate, "Characterization of lightweight aggregates manufactured from washing aggregate sludge

[19]

[20]

[21]

[22]

[2] [3]

[23]

[24]

[4] [5]

[25] [26] [27]

[6]

[7]

[28]

[8]

[29]

[9]

[30]

[10]

[31] [32]

[11]

[12]

[33]

[13]

[34]

[14]

and fly ash," Resources, Conservation and Recycling 53(10), pp.571581. 2009. N. U. Kockal, T. Ozturan, "Effects of lightweight fly ash aggregate properties on the behavior of lightweight concretes," Journal of Hazardous Materials 179(1-3), pp.954-965, 2010. K. Laursen, T. J. White, "Recycling of an industrial sludge and marine clay as light-weight aggregates," Journal of Environmental Management 80(3), pp.208-213, 2006.. Y. Q. Zhao, Q. Y. Yue, "Research on sludge-fly ash ceramic particles (SFCP) for synthetic and municipal wastewater treatment in biological aerated filter (BAF)," Bioresource Technology 100(21), pp.4955-4962, 2009. H. K. Lee, H. K. Kim, "Utilization of power plant bottom ash as aggregates in fiber-reinforced cellular concrete," Waste Management 30(2), pp. 274-284, 2010. C. C. Tsai, K.S. Wang, "Effect of SiO2-Al2O3-flux ratio change on the bloating characteristics of lightweight aggregate material produced from recycled sewage sludge," Journal of Hazardous Materials 134(1-3), p.87-93, 2006. X. Wang, Y. Jin, "Development of lightweight aggregate from dry sewage sludge and coal ash," Waste Management 29(4), pp.1330-1335, 2009. B. Gonzlez-Corrochano, J. Alonso-Azcrate, "Microstructure and mineralogy of lightweight aggregates produced from washing aggregate sludge, fly ash and used motor oil," Cement and Concrete Composites 32(9), pp. 694-707, 2010. O. Gins, J. M. Chimenos, "Combined use of MSWI bottom ash and fly ash as aggregate in concrete formulation: Environmental and mechanical considerations," Journal of Hazardous Materials 169(1-3), pp.643-650, 2009. N. U. Kockal, T. Ozturan, "Characteristics of lightweight fly ash aggregates produced with different binders and heat treatments," Cement and Concrete Composites 33(1), pp. 61-67, 2011. Y. C. Liao, C. Y. Huang, "Effects of CaO addition on lightweight aggregates produced from water reservoir sediment," Construction and Building Materials 25(6), pp.2997-3002. 2011. Y. L. Wei, J. C. Yang, "Recycling of harbor sediment as lightweight aggregate," Marine Pollution Bulletin 57(6-12), pp. 867-872, (2008). S. Sorlini, A. Abb, "Recovery of MSWI and soil washing residues as concrete aggregates," Waste Management 31(2), pp. 289-297, 2011. C. W. Tang, , H. J. Chen, "Production of synthetic lightweight aggregate using reservoir sediments for concrete and masonry," Cement and Concrete Composites 33(2), pp.292-300, 2011. X. R. Wang, Y. Y. Jin, "A research on sintering characteristics and mechanisms of dried sewage sludge," Journal of Hazardous Materials 160(2-3), pp. 489-494, 2008. J.L. Zou, G. R. Xu, "Ceramsite obtained from water and wastewater sludge and its characteristics affected by Fe2O3, CaO, and MgO," Journal of Hazardous Materials 165(1-3), pp.995-1001, 2009. F.C. Chang, S. L. Lo, "Leachability of metals from sludge-based artificial lightweight aggregate," Journal of Hazardous Materials 146(12), pp.98-105, 2007. H. A. vander Sloot, D. Hoede, "Leaching behaviour of synthetic aggregates," Waste Management 21(3), pp.221-228, 2001. G. R. Xu, J. L. Zou, "Stabilization of heavy metals in ceramsite made with sewage sludge," Journal of Hazardous Materials 152(1), pp.56-61, 2008. S. Han, Q. Yue, "Effect of sludge-fly ash ceramic particles (SFCP) on synthetic wastewater treatment in an A/O combined biological aerated filter," Bioresource Technology 100(3), pp.1149-1155, 2009. S. Wu, Q. Yue,. "Preparation of ultra-lightweight sludge ceramics (ULSC) and application for pharmaceutical advanced wastewater treatment in a biological aerobic filter (BAF)," Bioresource Technology 102(3), pp. 2296-2300, 2011.

3505