Recycling of an industrial sludge and marine clay as light-weight aggregates.

The geographical limitations of Singapore, its restricted natural resources and voluminous municipal and industrial waste streams, make environmental management a major challenge for the island state. In an attempt to find ways to reduce importation of raw materials and the waste sent to landfill, light weight aggregates were produced from marine clay and a CaF(2)-rich semiconductor industry sludge. Aggregates were produced in a bench-scale rotary kiln with three clay/sludge loadings (90/10, 70/30 and 50/50%). All three mixtures showed good bloating behavior during firing and the ceramic pellets (1-1.5cm diameter) had densities well below that required for light-weight aggregates. In the initial tests, the pore sizes of the aggregates were in general too large resulting in high water absorption. Comparisons between the composition of the two waste products and the aggregates showed a significant loss of fluorine (40-60%) during processing; a problem which may require flue gas treatment. Leach testing showed that the formed aggregates would not pose a human or environmental hazard in terms of fluorine mobilization.

Synthetic aggregates from combustion ashes using an innovative rotary kiln.

This paper describes the use of a number of different combustion ashes to manufacture synthetic aggregates using an innovative rotary 'Trefoil' kiln. Three types of combustion ash were used, namely: incinerated sewage sludge ash (ISSA); municipal solid waste incinerator bottom ash (MSWIBA-- referred to here as BA); and pulverised fuel ash (Pfa). The fine waste ash fractions listed above were combined with a binder to create a plastic mix that was capable of being formed into 'green pellets'. These pellets were then fired in a Trefoil kiln to sinter the ashes into hard fused aggregates that were then tested for use as a replacement for the natural coarse aggregate in concrete. Results up to 28 days showed that these synthetic aggregates were capable of producing concretes with compressive strengths ranging from 33 to 51 MPa, equivalent to between 73 and 112% of that of the control concrete made with natural aggregates.