In partial completion of course on

Recent Advances in Construction Materials (CEL768)

Submitted by

Sandeep Jain (2014CET2226)

Submitted to

Dr. Shashank Bishnoi

Department of Civil Engineering

Indian Institute of Technology (IIT), Delhi

A PRESENTATION ON

“UTILIZATION OF WASTE PAPER SLUDGE IN

CONSTRUCTION INDUSTRY”

PRESENTATION OUTLINE

Introduction

Background

Characterization

Physical Properties

Chemical Composition

Mineralogical Composition

Utilization in Concrete Production

Utilization in Structural Ceramic and Clay Brick production

Denouement

References

INTRODUCTION

Need: The mother of all discoveries

Exponential population growth

Greater demand for construction

Increasing pressure on utilization natural resources and their depletion

What is Waste Paper Sludge ?

Industrial by-product from paper manufacturing

Also known as:

Paper De-inking sludge (García et al., 2007)

Wastepaper Sludge Ash (Segui et al., 2012)

Hypo-Sludge (Pitroda et al., 2013)

INTRODUCTION

Fig. 1. Global Paper Production 2013 (By Region) (Source: PPI)

Manufacturing of 1 ton of paper = 300Kg dry sludge (Bajpai P., 2015 )

3-8 cycles of possible recycling (García et al., 2007)

Present use of residual sludge:

a). In landfill

b). Incineration for energy recovery

INTRODUCTION

A vast horizon of possibilities :

High volume of waste, Potential for re-use

Solution of waste management problem

New resource for construction industry

Reduction in CO2 emission

Supplementary Cementitious Material

Mineral Admixture

Partial replacement of binders in concrete

Raw material for clay brick manufacturing

Production of ceramics,

Soil stabilization in road works,

BACKGROUND

In this study:

Characterization of waste paper sludge

Activation mechanisms

Pozzolanic reactivity

Reaction kinetics

Effect on durability

Other possible re-uses of waste paper sludge.

Foremost use in Concrete production

Varying Composition

CHARACTERIZATION

Physical Properties

Specific Gravity = 2.5 to 3 g/cm3 (Hydrostatic weighting in kerosene )

Fineness = varying results from 3000 to 6000 cm2/g (Blaine Apparatus)

Particle size distribution = highly inconsistent and dependent on

grinding

Color = Light to medium gray and may vary as per raw composition.

SEM Results = Highly Porous Structure, agglomeration

High water and plasticizer demand

Workability issues

CHARACTERIZATION

Fig. 2a and 2b. SEM Observation for Waste Paper Sludge by Segui et al. (2012) and García et al. (2007)

CHARACTERIZATION

Chemical Composition:

chemical composition is dependent on the temperature and time of

calcination

Calcium oxide (CaO)

Silica (SiO2)

Alumina (Al2O3)

constituting to about 40-50% of total

Significant amount of loss on ignition (LOI)

CHARACTERIZATION

Oxide (%) CaO SiO2 Al2O3 MgO Fe2O3 TiO2 Na2O SO3 K2O P2O5 LOI

Frías et al. (2014)

700˚C/2h 40.2 22.3 14.6 2.4 0.6 0.3 0.1 0.3 0.4 0.2 18.52

Gluth et al. (2013)

* 44.18 22.33 11.97 2.42 0.59 0.36 0.24 3.64 0.40 - 13.34

Segui et al. (2012)

850˚C 45.5 28.0 13.2 4.0 1.3 0.7 0.4 1.3 0.7 0.4 5.7

García et al. (2007)

700˚C/2h 47.1 13.9 8.3 1.6 0.5 0.3 0.2 - 0.3 0.2 26.7

Table 1: Chemical Composition of Waste Paper Sludge

Some traces of chloride ions and other metals like zinc; copper; lead; barium

and chromium may also be present sometimes depending upon the industrial

whitening method used.

CHARACTERIZATION

Mineralogical Composition

Organic: Cellulose (C12H20O10)

Crystalline mineral compounds

calcite (CaCO3)

kaolinite (Al2O3.2SiO2.2H2O)

free lime (CaO),

quartz (SiO2)

talc (Mg3Si4O10(OH)2) (Frías et al., 2014)

Gluth et al. (2013) and Segui et al. (2012) also detected gehlenite

(Ca2Al2SiO7) as main crystalline mineral phase

Presence of portlandite (Ca(OH)2) is confirmed by Gluth et al. (2013)

CHARACTERIZATION

Fig. 3. Ternary diagram for Waste Paper Sludge (Segui et al., 2012)

CHARACTERIZATION

Fig. 4. XRD patterns showing mineralogical composition Waste Paper Sludge at different

calcination temperature (Frías et al., 2014)

CHARACTERIZATION

Fig. 5a. XRD patterns for un-hydrated Waste Paper Sludge. T: talc, CH: portlandite, Q: quartz,

Cc: calcite, G: gehlenite, C: lime, C3A: tricalcium aluminate, C2S: belite (Gluth et al., 2013)

CHARACTERIZATION

Fig. 5b. XRD patterns for Waste Paper Sludge. α: calcium silicate, c: calcite, g: gehlenite,

L: free lime, m: merwinite, M: mayenite (Segui et al., 2012)

UTILIZATION IN CONCRETE PRODUCTION

As supplementary cementitious material, or as partial replacement of

binder or as hydraulic mineral admixture

Calcination temperature and time period = 650-750ºC/2 hours

García et al. (2007)

Fig. 6. Pozzolanic activity of calcined Waste Paper Sludge with commercial metakaolin

(García et al., 2007)

UTILIZATION IN CONCRETE PRODUCTION

Fig. 7. Comparison of Compressive Strength (García et al., 2007)

UTILIZATION IN CONCRETE PRODUCTION

Segui et al. (2012): experimented on utilization of waste paper sludge as

hydraulic binder by preparing a paste with water with water to binder ratio

of 0.5

Setting and hardening of paste

lime gets hydrated to calcium hydroxide resulting in favorable alkaline

environment for other phases to react to form C-S-H gel.

Expansion due to metallic aluminium

Unsoundness due to free lime

UTILIZATION IN CONCRETE PRODUCTION

Gluth et al. (2013): extensive research on reaction products and strength

development of waste paper sludge activated with water and alkalis (NaOH

and KOH)

monocarboaluminate (CO3-AFm) is the principle reaction production in

both cases

Fig. 8. Strength of Waste Paper Sludge mortars: (a) Compressive (b) Flexural (Gluth et al., 2013)

UTILIZATION IN CONCRETE PRODUCTION

Frías et al. (2014):

Fig. 9. Pozzolanic reactivity of Waste Paper Sludge (Frías et al., 2014)

UTILIZATION IN CONCRETE PRODUCTION

Frías et al. (2014):

Fig. 10. Initial setting time variation for 10% blended cement (Frías et al., 2014)

UTILIZATION IN CONCRETE PRODUCTION

Frías et al. (2014):

Fig. 12. Improved resistance to freeze-thaw cycles for blended cement

with Waste Paper Sludge (Frías et al., 2014)

UTILIZATION IN STRUCTURAL CERAMIC

AND CLAY BRICK PRODUCTION

Cusidó et al. (2015): confirmed that clay brick production with partial

addition of waste paper sludge is a technically feasible solution.

binary mixture of clay and waste paper sludge under various formulations

Outcomes

improvement in the thermal and acoustical insulation-can be attributed to the

porous structure.

Compressive Strength >10MPa with avg. of 39MPa, but overall decrease,

fragility compensated by improved ductility

With increase in % replacement-thermal conductivity decrease by 38%, drastic

increase in water absorption (300% increment)

No VOC emission

DENOUEMENT

Highly varying chemical and mineralogical composition

primarily contains calcium oxide (CaO), silica (SiO2), and alumina (Al2O3) and

presence of other mineral and metal oxides depends on raw material, processing

technique, grade of paper, quality and quantity of recycled paper used.

Porous structure : attributed to free lime and alumina

Causes workability issues, increased water & plasticizer demand, high LOI

Enables soil stabilization in road works, improved thermal and acoustic

insulation, expansion

Activation: Highly dependent on Temperature & Time period of

calcination

Shows high hydraulic and pozzolanic reactivity( both for water-activated

and alkali-activated) comparable to commercial MK, SF, FA

DENOUEMENT

Presence of portlandite

Possible use in ternary blends as activator

Improved compressive strength: For judicious use up to 10-20%

Accelerated setting time: attributed to presence of organic matter

Improved resistance to aggressive chemical environment and

resistance against freeze-thaw cycles

Socio-economic and environmental benefits

REFERENCES

Bajpai, P. (2015) “Generation of Waste in Pulp and Paper Mills”, Springer

International Publishing Switzerland (2015) DOI 10.1007/978-3-319-11788-1_2

Cusidó, J.A.; Cremades, L.V.; Soriano, C.; Devant, M. (2015) “Incorporation of

Paper Sludge in Clay Brick Formulation: Ten years of Industrial Experience”,

Applied Clay Science, Vol. 108 (2015) 191–198

Frías, M.; Rodríguez, O.; Sánchez de Rojas, M.I. (2014) “Paper Sludge, an

Environmentally Sound Alternative Source of MK-based Cementitious Materials. A

review”, Construction and Building Materials, Vol. 74 (2015) 37–48

Gluth, J.G.G.; Lehmann, C.; Rübner K.; Kühne H. (2013) “Reaction Products and

Strength Development of Wastepaper Sludge Ash and the Influence of Alkalis”,

Cement & Concrete Composites, Vol. 45 (2014) 82–88

Segui, P.; Aubert, J.E.; Husson, B.; Measson, M. (2012) “Characterization of

Wastepaper Sludge Ash for its Valorization as a Component of Hydraulic Binders”,

Applied Clay Science, Vol. 57 (2012) 79–85

García, R.; Vigil de la Villa, R.; Vegas, I.; Frías, M.; Sánchez de Rojas, M.I. (2007)

“The Pozzolanic Properties of Paper Sludge Waste”, Construction and Building

Materials, Vol. 22 (2008) 1484–1490

THANK YOU !