View of “PARTIALLY REPLACEMENT OF CLAY BY SEWAGE TREATMENT PLANT SLUDGE IN BRICK”

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VOLUME: 08,Special Issue 02, Paper id-IJIERM-VIII-II, March 2021

“PARTIALLY REPLACEMENT OF CLAY BY SEWAGE TREATMENT PLANT SLUDGE IN BRICK”

1Neelesh Vishwakarma, ²Prof. Charan Singh Thakur

1,2 Department of Civil Engineering, SRGI, Jabalpur, Madhya Pradesh, India

Abstract:- It is well known the fact that any type of waste or residue that is receive from several production cycles, farming, or any household sector that cannot be utilized is an undesirable material. It is necessary to get rid of such useless material. This waste causes adverse effects on the climate. Such waste also gives rise to various bacterial and virus disease that affects the health of all the creatures in this planet including humans, and animals.

One of the major of them is sludge that is the waste left from the sewage treatment plant. It is a semi-solid material that remains as a byproduct in the sewage treatment plant.

In many countries, this sludge has become a major challenge due to its high treatment cost and its danger to both climate and humans. The spreading of sludge is one of the prominent problems in both small and big countries and even in small to big cities as they are facing a shortage of land where they can dispose this sludge, and its related cost to dump it together with the concern of the sludge that it may affect the environment. This work is based on the utilization of this sludge to manufacture bricks. The concept involves the mixing of sewage sludge in different portions from 20, 30, 40 up to 50 by weights and making them with any standard dirt brick organization. As per the specialized guidelines, 40% mixing of sludge with other materials was important for making such bricks. A brick that contains more than 30% of the sludge was not chosen because they were brittle and so not fit for use in any construction. Such bricks were broken easily with hands if not operated carefully and its color was also not as per set standards. From this research and investigation, this work can easily solve the disposable problem that every country is facing and can also improve its economical structure.

Keyword: Brick manufacturing, Environmental waste, FlyAsh, Sludge content, material strength.

1. INTRODUCTION

In numerous nations, sludge is a difficult issue because of its high treatment costs and the dangers to climate and human wellbeing. The sludge presents progressively troublesome issue to urban communities of all sizes on account of the shortage of reasonable removal destinations, expanding work costs, and natural concerns. Sludge produced at water treatment plants ought to be dealt with and driven in an earth sound way.

Coagulant sludge is created by water treatment plants, which utilize metal salts, for example, aluminum sulfate (alum) or ferric chloride as a coagulant to eliminate turbidity.

The conventional act of releasing the sludge straightforwardly into a close by stream is turning out to be less worthy on the grounds that these releases can abuse the permissible stream norms. The releasing of sludge into water body prompts aggregate ascent of aluminum fixations in water, sea-going creatures,

and, thusly, in human bodies. A few analysts have connected aluminum's contributory impact to event of Alzheimer's illness, youngsters mental impediment, and the regular impacts of hefty metals gathering. The developing interest for Waste usage has made strong Wastes like sludge and destruction Waste a fundamental creation of this investigation. The chance of decrease of the creation costs gives a solid rationale to utilization of this waste. The most essential structure material for development of houses is the traditional brick.

The fast development in the present development industry has obliged the structural designers in looking for more effective and solid options a long ways past the restrictions of the ordinary brick creation. Various examinations had made genuine strides in assembling bricks from a few of waste materials. In any case, the conventional mean of bricks

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VOLUME: 08,Special Issue 02, Paper id-IJIERM-VIII-II, March 2021

creation which has carried unsafe effects on the setting has not yet been changed or supplanted by more proficient and feasible one. On the off chance that the usage of the waste like sludge in clay bricks normally effectsly affects the properties like lightweight bricks with improved shrinkage, porosity, warm properties, and strength. The lightweight bricks will diminish the transportation and made expense. Besides, with this waste fuse it will lessen mud content in the terminated clay brick, and afterward diminish the assembling cost and become conservative for development.

2. SEWAGE TREATMENT PLANT SLUDGE

Sewage sludge known as to the remaining, semi solid material that is created as a side-effect during sewage treatment of mechanical or metropolitan wastewater. The term septage is additionally refering to sludge from straightforward wastewater treatment however is associated with basic on location disinfection frameworks, like septic tanks.

At the point when new sewage or wastewater enters an essential settling tank, around half of the suspended strong

matter will settle out in 90 minutes. This assortment of solids is known as crude sludge or essential solids and is supposed to be "new" before anaerobic cycles become dynamic. The sludge will get putrescent in a brief timeframe once anaerobic microbes dominate, and should be taken out from the sedimentation tank before this occurs.

The measure of sewage sludge delivered is corresponding to the sum and centralization of wastewater treated, and it additionally relies upon the sort of wastewater treatment measure utilized. It very well may be communicated as kg dry solids per cubic meter of wastewater treated. The all out sludge creation from a wastewater treatment measure is the amount of sludge from essential settling tanks (on the off chance that they are important for the interaction setup) in addition to abundance sludge from the organic treatment step.

Sewage sludge is delivered from the treatment of wastewater in sewage treatment plants and comprises of two fundamental structures — crude essential sludge and auxiliary sludge, otherwise called actuated sludge on account of the enacted sludge measure.

Table 1: Typical Chemical Properties of Dry Sludge S No. Particulars % of Content

1 SiO2 34.68

2 Al2O3 10.46

3 Fe2O3 7.84

4 MgO 13.55

5 CaO 25.2

3. LITREATURE REVIEW

S.No. Researchers Work

1

Badr El-Din EzzatHegazy, Hanan Ahmed Fouad and Ahmed

Mohammed Hassanin, (2012)

This task manages the subject of implanting the bricks with water sludge, silica smoke, and rice husk. The water sludge is produced from the treatment of water with alum. Discarding sludge again to the streams raises the groupings of aluminum oxides in water, which has been connected to Alzheimer's sickness. The utilization of water treatment plant (WTP) sludge in assembling of constructional components accomplishes both the monetary and ecological advantages. Because of the comparative mineralogical sythesis of mud and WTP sludge, this examination explored the total replacement of brick earth by sludge consolidated with a portion of the rural and modern Wastes, for example, rice husk ash (RHA) and silica smolder (SF). Three distinctive

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VOLUME: 08,Special Issue 02, Paper id-IJIERM-VIII-II, March 2021

arrangement of sludge to SF to RHA extents by weight were attempted, which were (25: 50: 25%), (50: 25: 25%), and (25: 25: half), individually. Every brick arrangement was terminated at 900, 1000, 1100, and 1200oC. The physical and mechanical properties of the created bricks were then decided and assessed by Egyptian Standard Specifications (E.S.S.) and contrasted with control earth brick. From the acquired outcomes, it was presumed that by working at the temperature normally rehearsed in the brick furnace, a combination comprises of half of sludge, 25% of SF, and 25% of RHA was the ideal materials extents to create brick from water sludge consolidated with SF and RHA. The delivered bricks properties were clearly better than the 100% earth control-brick and to those accessible in the Egyptian market.

4. METHODOLOGY

This chapter presents the methodology followed for the study. For achieving the objectives of the study, the work was planned on the following work elements:

 Study Area.

 Manufacturing Process 4.1 Study Area

In capital city of Madhya Pradesh, study area covers Sewage Treatment Plant (STP) based on attached growth system i.e.

Trickling filter treatment technology and situated at Mata Mandir Bhopal. The waste water and sewage generated from the New Market, South T.T. Nagar, Mata Mandir, Platinum Plaza and Gitanjali complex areas got treated at this STP.

However due to its final discharge in untreated drain, huge quantity of untreated sewage meet PanchsheelNallah which further treated in STP of Ekant Park. The STP authorities have not made provision for separate holding tank for storing the sewage during peak hours. It was observed that the entire treatment unit is working as holding tank and there was no Bio-mass in the trickling filter.

The arms attached with the trickling filter were found corroded and no sludge was found in sludge drying beds. The STP located at MATA MANDIR constructed mainly for the treatment of ground wastewater and sewage generated from

the various area mention above in Bhopal.

The STPs deal with the time of formation of state capital with 1MGD (i.e.4.56MLD) capacity and commissioned by Hindustan Dorr-Oliver Limited, from State Govt. The treatment plant consist screen chamber, grit chamber, clari digestor, trickling filter, clarifier and sludge drying beds.

Satellite image indicating Layout plan of the said Plant is shown in Fig. 1. Process Flow Diagram of Sewage Treatment Plant.

With Trickling Filter Technology at Mata Mandir Bhopal.

Wastewater treatment plants are developed to shield the climate from exorbitant over-burdening from various types of toxins. These plants should satisfy the suitable profluent guidelines.

Under strange interaction conditions at sewage treatment plants bring about the arrival of profluent that may contain poisons and unsuitably significant degrees of risky natural and inorganic materials into different water bodies and the overall climate. This investigation depends on joined development framework for example Streaming channel wastewater treatment frameworks since they are among the most generally utilized frameworks. This treatment plant comprise screen chamber, coarseness chamber, clari-digestor, streaming channel, clarifier and sludge drying beds.

4.1.1 Physical Properties of Sludge:

Table 2: Typical Physical Properties of Sludge

S NO. PROPERTIES RESULTS

1 Specific Gravity 1.34-1.45

2 Bulk Density, kg/m3 687

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3 Water Absorption,% 0.6

4 Clay And Sulphate Content, % 0.1-0.5 4.1.2 Sample Preparation:

Four different mixing ratios were tried. The batching proportions of raw materials required to produce brick was done by weight with dimensions of 19X9X9 centimetres. The trial ratios are shown in Table below:

In this undertaking sludge, mud and flyash are the significant fixings. They are blend in with one another in extent as notice in table above to develop a brick.

The accompanying advances are taken for making bricks:

1. Works start with raw material collection with required compositions for example mud, flyash and sludge are combine as one and added water with sprinkle. Furthermore, blending of material appropriately for a duration of 12 to 16 hours.

2. After 12 to 16 hours the blend is again blended appropriately by adding some water. All the blending is done physically with hand and feet.

3. After blending the chunk of blend is taken, rolled with sand and slapped into frame (mould). The

frame utilized for this investigation is metal shape. Also, this frame is unfilled at drying region where blocks are placed in dry region under daylight.

4. When block are kept in daylight after two days they are turned over to facilitate uniform drying and prevent from warping.

5. After 8 to 10 days they are fit to be burnt in furnace. The green blocks organized in oven and insulation is furnished with mud pack. Fire openings are left to ignite the furnace that will subsequently fixed to keep the heat inside.

6. This is kept up for week. Following seven days oven is dismantled and block are arranged by shading (colour). Shading means that the degree of consuming.

Table 3: Different Proportion of Trial Samples Sr.

No. Different Percentage

of Sludge Clay

Soil Fly

Ash Water

1 0% 100% 0%

As per require d

2 10% 80% 10%

3 20% 70% 10%

4 30% 60% 10%

5 40% 50% 10%

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VOLUME: 08,Special Issue 02, Paper id-IJIERM-VIII-II, March 2021

Fig. 1: Moulded Brick Sample Following laboratory tests are

performed on different specimens of brick according to Indian standards code and it is compared to the specimens of brick which are locally available brick.

4.2 Testing of Bricks

Following tests shall have conduct on brick sample

1. Compressive Strength Test (as per IS-3495(Part-1):1992

2. Water Absorption Test (as per IS- 3495(Part-2):1992

3. Soundness Test

4.2.1 Compressive Strength Test:

1. This test is performed according to IS: 3495-PART 1-1992 method.

2. To perform this test this work use compressive testing machine.

3. Brick is compressed till crushing of brick occurred, by applying uniform load at rate 14 N/mm2 4. The all the reading occurred on

testing machine are measured and noted.

5. According to the reading obtain the crushing strength of all brick are calculated by using formula:

Compressive Strength = Maximum load at failure / Avg. area of bed face (mm)

Fig. 2 Compression Testing of Bricks

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VOLUME: 08,Special Issue 02, Paper id-IJIERM-VIII-II, March 2021

4.2.2 Water Absorption Test:

Water assimilation test on bricks are directed to decide sturdiness property of blocks like level of consuming, quality and conduct of blocks in enduring.

Procedure: The example is dried in a ventilated broiler at a temperature of 105 to 1150C; till it achieves significantly consistent mass. The example is cooled to room temperature and its weight is recorded (M1).

1. The dried example is submerged totally in tidy up water at a room temperature of 27±20C for 24 hours.

2. The example is then taken out and any hints of water are cleared out

with a sodden fabric and the example is gauged. The weighing is finished 3 min after the example has eliminated from water (M2).

3. Water Absorption rate by mass following 24 hours submersion in chilly water is given by following recipe:

4. In no case it ought to be more prominent than 20% by the prerequisite determined by IS Code for top notch block.

Fig. 3 Water Absorption test of Bricks Table 4: Compressive Strength Of Bricks Sr.

No.

Different Percentage of Sludge

Length

(mm) Breadth

(mm) Maximum load

Compressive strength (N/mm2)

1 0% 190 100 9.21 4.38

2 10% 190 100 8.95 4.1

3 20% 190 100 8.4 3.8

4 30% 190 100 6 2.9

5 40% 190 100 5.1 2.6

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5. CONCLUSION

The study will provide you with the concept that one can effectively use sludge as a raw material in the manufacturing process of the brick that too of standard shape and color as that of other bricks. Simply dumping or disposal of sludge was not an accurate solution to get rid of the sludge as it requires more space and there were environmental issues. So to overcome all such problems it is better to manufacture bricks with this waste residue. Using 105 to 20% of sludge in the manufacturing of brick was found sufficient to manufacture bricks of appropriate strength. Also, such bricks were similar to class A bricks in terms of water absorption properties that are 14 to 15%. The brick that this work have manufactured by this process is fit to use in any type of construction with different load capacity. The plastic limit of the bricks is zero.

 Dry sludge is found for free and plenty and so the production cost of a brick is reduced.

 After performing further research this work find out that the brick that this work manufactured was similar to soil in properties

 Based on further experimentation regarding the water absorption properties of such bricks on the varying percentage of sludge this work found out that water absorption of the bricks was reduced to 20% when this work replace the soil with the dry sludge. The compressive strength of the bricks was also increased when this work increase the percentage of the dry sludge as compare to old bricks. In replacing

20% of dry sludge with the soil this work had found that bricks gained better compressive strength.

Thus, this project also shows that the weight of the bricks was also reduced if this work replace the soil with dry sludge and so became light in weight. The use of such sludge in making bricks will reduce the non-ferrous, and ferrous metal industries which dispose of their waste on grounds that give rise to land pollution and create health hazards to people. By this, this work can achieve a pollution- free cleaner environment and this work also get a construction material that is cheap to produce and is stronger than the current one.

REFERENCES

1. “Incorporation of water sludge, silica fume, and rice husk ash in brick making” By- Badr El-Din EzzatHegazy, Hanan Ahmed Fouad and Ahmed Mohammed Hassanain.

2. “BRICKS MANUFACTURED FROM SLUDGE” By- Joo-Hwa Tay.

3. “Durability of Bricks Cast With Industrial Sludge” By - G. Reddy Babu1, N. Venkata Ramana.

4. “Utilization of Textile Mill Sludge in Burnt Clay Bricks” By - Shrikant S Jahagirdar1, S. Shrihari2, B Manu3 1 NITK, Surathkal, India.

5. “CHARACTERISATION AND

PERFORMANCE EVALUATION OF WATER WORKS SLUDGE AS BRICKS MATERIAL”

By- AnyakoraNkolika Victoria.

Table 5: Water Absorption test of Bricks S NO. Different Percentage

of Sludge Water Absorption Percentage (%)

1 0% 10.30%

2 10% 12.25%

3 20% 14.93%

4 30% 17.49%

5 40% 21.50%