Skip to main content

Advertisement

SpringerLink
Log in

Valorizing hazardous lead glass sludge and alumina flakes filling waste for the synthesis of geopolymer building bricks

  • Research Article
  • Published:
Environmental Science and Pollution Research Aims and scope Submit manuscript

Abstract

Geopolymer bricks from lead glass sludge (LGS) and alumina flakes filling (AFF) waste were synthesized in the present work. AFF waste was chemically treated to prepare sodium aluminate (NaAlO2) powder. Silicate source (untreated LGS and thermally treated one at 600 °C (LGS600)) and sodium oxide (Na2O) concentration (as NaAlO2) were the compositional parameters, which affected the physical and mechanical properties (compressive strength, water absorption, and bulk density) of the prepared bricks. High organic matter content inside LGS caused a retardation effect on the geopolymerization process, resulting in the formation of hardened bricks with modest 90-day compressive strengths (2.13 to 4.4 MPa). Using LGS600 enhanced the mechanical properties of the fabricated bricks, achieving a maximum 90-day compressive strength of 22.35 MPa at 3 wt.% Na2O. Sodium aluminosilicate hydrate was the main activation product inside all samples, as confirmed by X-ray diffraction and thermal analyses. Acetic acid leaching test also proved that all LGS600-NaAlO2 mixtures represented Pb concentrations in leachates lower than the permissible level of characteristic leaching procedures, indicating the mitigation of environmental problems caused by these wastes.

This is a preview of subscription content, log in via an institution to check access.

Access this article

Log in via an institution

Price excludes VAT (USA)
Tax calculation will be finalised during checkout.

Instant access to the full article PDF.

Institutional subscriptions

Fig. 1
Fig. 2
Fig. 3
Fig. 4
Fig. 5
Fig. 6
Fig. 7
Fig. 8
Fig. 9
Fig. 10
Fig. 11

Similar content being viewed by others

Data availability

All data and materials will be available upon request.

References

  • Abdel-Gawwad HA, Mohamed SA, Mohammed MS (2019) Recycling of slag and lead-bearing sludge in the cleaner production of alkali activated cement with high performance and microbial resistivity. J Clean Prod 220:568–580

    Article  CAS  Google Scholar 

  • Abdel-Gawwad HA, Mohammed MS, Heikal M (2020a) Ultra-lightweight porous materials fabrication and hazardous lead-stabilization through alkali-activation/sintering of different industrial solid wastes. J Clean Prod 244:118742

    Article  CAS  Google Scholar 

  • Abdel-Gawwad HA, Sanad SA, Mohammed MS (2020b) A clean approach through sustainable utilization of cement kiln dust, hazardous lead-bearing, and sewage sludges in the production of lightweight bricks. J Clean Prod 273:123129

    Article  CAS  Google Scholar 

  • Abdel-Gawwad HA, Mohammed MS, Ads EN (2020c) A novel eco-sustainable approach for the cleaner production of ready-mix alkali activated cement using industrial solid wastes and organic-based activator powder. J Clean Prod 256:120705

    Article  CAS  Google Scholar 

  • Abdel-Gawwad HA (2021) Thermo-alkali activation of talc for the production of a novel white one-part alkali-activated magnesia-based cement. Constr Build Mater 306:124909

    Article  CAS  Google Scholar 

  • Abdel-Gawwad HA, Abd El-Aleem S, Zayed A (2021) Stabilization of hazardous lead glass sludge using reactive magnesia via the fabrication of lightweight building bricks. J Hazard Mater 403:124017

    Article  CAS  Google Scholar 

  • Abdel-Gawwad HA, Mohammed MS, Arif MA et al (2022) Reuse of lead glass sludge in the fabrication of thermally insulating foamed glass with outstanding properties and high Pb-stabilization. Environ Sci Pollut Res 29:47209–47224

    Article  CAS  Google Scholar 

  • Abdelrahman EA, Alharbi A, Subaihi A, Hameed AM, Almutairi MA, Algethami FK, Youssef HM (2020) Facile fabrication of novel analcime/sodium aluminum silicate hydrate and zeolite Y/faujasite mesoporous nanocomposites for efficient removal of Cu (II) and Pb (II) ions from aqueous media. J Mater Res Technol 9(4):7900–7914

    Article  CAS  Google Scholar 

  • Abolhasani A, Samali B, Aslani F (2022) Rice husk ash incorporation in calcium aluminate cement concrete: life cycle assessment, hydration and strength development. Sustainability 14(2):1012

    Article  CAS  Google Scholar 

  • Ahmed MM, El-Naggar KAM, Tarek D et al (2021) Fabrication of thermal insulation geopolymer bricks using ferrosilicon slag and alumina waste. Case Stud Cons Mater 15:00737

    Google Scholar 

  • Ahmad M, Rashid K, Hameed R, et al. (2022) Physico-mechanical performance of fly ash based geopolymer brick: influence of pressure− temperature− time. Journal of Building Engineering 104161

  • Akinshipe O, Kornelius G (2018) Quantification of atmospheric emissions and energy metrics from simulated clamp kiln technology in the clay brick industry. Environ Pollut 236:580–590

    Article  CAS  Google Scholar 

  • Akinshipe O (2013) The development of an “emission Inventory Tool” for brick making clamp kilns. M.Sc. thesis. University of Pretoria

  • Arslan C, Gencel O, Borazan I, Sutcu M et al (2021) Effect of waste-based micro cellulose fiber as pore maker on characteristics of fired clay bricks. Constr Build Mater 300:124298

    Article  CAS  Google Scholar 

  • ASTM C134 – 95 (2016) Standard test methods for size, dimensional measurements, and bulk density of refractory brick and insulating firebrick. https://www.astm.org/Standards/C134.htm

  • ASTM C20 – 00 (2015) Standard test methods for apparent porosity, water absorption, apparent specific gravity, and bulk density of burned refractory brick and shapes by boiling water. https://www.astm.org/Standards/C20.htm

  • ASTM C62 (2017) Standard specification for building brick (solid masonry units made from clay or shale).

  • ASTM C67 / C67M – 19 (2019) Standard test methods for sampling and testing brick and structural clay tile. https://www.astm.org/Standards/C67.htm

  • Chavez RH (2021) Energy analysis of two coupled brick kilns: an experimental study. Clean Techn Environ Policy 23(8):2235–2249

    Article  Google Scholar 

  • Chen K, Lin WT, Liu W (2021) Effect of NaOH concentration on properties and microstructure of a novel reactive ultra-fine fly ash geopolymer. Adv Powder Technol 32(8):2929–2939

    Article  CAS  Google Scholar 

  • Chindaprasirt P, Rattanasak U (2018) Fire-resistant geopolymer bricks synthesized from high-calcium fly ash with outdoor heat exposure. Clean Techn Environ Policy 20(5):1097–1103

    Article  CAS  Google Scholar 

  • da Silva RT, Dias DP, França FCC et al (2018) Metakaolin-based geopolymer mortars with different alkaline activators (Na+ and K+). Constr Build Mater 178:453–461

    Article  Google Scholar 

  • De Silva GS, Perera BVA (2018) Effect of waste rice husk ash (RHA) on structural, thermal and acoustic properties of fired clay bricks. J Build Eng 18:252–259

    Article  Google Scholar 

  • dos Reis GS, Cazacliu BG, Cothenet A et al (2020) Fabrication, microstructure, and properties of fired clay bricks using construction and demolition waste sludge as the main additive. J Clean Prod 258:120733

    Article  Google Scholar 

  • Elkersh H (2014) Innovative cleaner production technique: foam glass production from lead crystal glass sludge. M.Sc. Thesis, School of Sciences and Engineering, the American University in Cairo, Egypt

  • ElKersh H, El-Haggar S (2015) Recycling of lead crystal glass sludge to produce foam glass. Int J Environ Technol Manag 18(5-6):448–464

    Article  CAS  Google Scholar 

  • EPA U (1992) Method 1311. Toxicity characteristic leaching procedure. US Environmental Protection Agency Washington, DC, USA

  • Goergens J, Manninger T, Goetz-Neunhoeffer F (2020) In-situ XRD study of the temperature-dependent early hydration of calcium aluminate cement in a mix with calcite. Cem Concr Res 136:106160

    Article  CAS  Google Scholar 

  • Gong B, Deng Y, Yang Y et al (2017) Effects of microwave-assisted thermal treatment on the fate of heavy metals in municipal solid waste incineration fly ash. Energy Fuel 31(11):12446–12454

    Article  CAS  Google Scholar 

  • Gorla G, Civati F, Maurich C et al (2022) New strategies to quantify aluminum hydroxide in powder coatings by thermogravimetric analysis and ATR-FT-MIR spectroscopy coupled with chemometrics. Microchem J 172:107005

    Article  CAS  Google Scholar 

  • Hashemi A, Cruickshank H (2015) Embodied energy of fired bricks: the case of Uganda and Tanzania. In: 14th International Conference on Sustainable Energy Technologies (Nottingham, England)

  • Hasnaoui A, Ghorbel E, Wardeh G (2021) Effect of curing conditions on the performance of geopolymer concrete based on granulated blast furnace slag and metakaolin. J Mater Civ Eng 33(3):04020501

    Article  CAS  Google Scholar 

  • Hodhod OA, Alharthy SE, Bakr SM (2020) Physical and mechanical properties for metakaolin geopolymer bricks. Constr Build Mater 265:120217

    Article  CAS  Google Scholar 

  • Irigoyen-Arredondo MS, Moreno-Sánchez XG, Escobar-Sánchez O, et al. (2022) Essential (Cu, Zn) and nonessential (Pb, Cd) metals in the muscle of leopard groupers (Mycteroperca rosacea) from a mining port in the Gulf of California, Mexico: human health risk assessment. Environ Sci Pollut Res 1-11

  • Jannat N, Al-Mufti RL, Hussien A et al (2022) Influences of agro-wastes on the physico-mechanical and durability properties of unfired clay blocks. Constr Build Mater 318:126011

    Article  Google Scholar 

  • Jin F, Gu K, Al-Tabbaa A (2014) Strength and drying shrinkage of reactive MgO modified alkali-activated slag paste. Constr Build Mater 51:395–404

    Article  Google Scholar 

  • Jonbi J, Fulazzaky MA (2020) Modeling the water absorption and compressive strength of geopolymer paving block: an empirical approach. Measurement 158:107695

    Article  Google Scholar 

  • Kadir AA, Mohajerani A (2015) Effect of heating rate on gas emissions and properties of fired clay bricks and fired clay bricks incorporated with cigarette butts. Appl Clay Sci 104:269–276

    Article  Google Scholar 

  • Kumbhar S, Kulkarni N, Rao A, Rao B (2014) Environmental life cycle assessment of traditional bricks in Western Maharashtra. Energy Procedia 54:260–269

    Article  Google Scholar 

  • Li J, Hashimoto Y, Riya S, Terada A et al (2019) Removal and immobilization of heavy metals in contaminated soils by chlorination and thermal treatment on an industrial-scale. Chem Eng J 359:385–392

    Article  CAS  Google Scholar 

  • Li J, Li J, Wei H et al (2021) Alkaline-thermal activated electrolytic manganese residue-based geopolymers for efficient immobilization of heavy metals. Constr Build Mater 298:123853

    Article  CAS  Google Scholar 

  • Linda BN, Aboubakar MA, Hounkpè BJ et al (2021) The effect of polymer waste addition on the compressive strength and water absorption of geopolymer ceramics. Appl Sci 11(8):3540

    Article  Google Scholar 

  • Marrocchino E, Zanelli C, Guarini G, Dondi M (2021) Recycling mining and construction wastes as temper in clay bricks. Appl Clay Sci 209:106152

    Article  CAS  Google Scholar 

  • Nath SK, Kumar S (2019) Role of alkali concentration on reaction kinetics of fly ash geopolymerization. J Non-Cryst Solids 505:241–251

    Article  CAS  Google Scholar 

  • Pacewska B, Nowacka M, Aleknevičius M et al (2013) Early hydration of calcium aluminate cement blended with spent FCC catalyst at two temperatures. Procedia Eng 57:844–850

    Article  CAS  Google Scholar 

  • Provis JL, Van Deventer JSJ (eds) (2009) Geopolymers: structures, processing, properties and industrial applications. Elsevier

    Google Scholar 

  • Ramadan M, Amin MS, Waly SA, Mohsen A (2021) Effect of high gamma radiation dosage and elevated temperature on the mechanical performance of sustainable alkali-activated composite as a cleaner product. Cem Concr Compos 121:104087

    Article  CAS  Google Scholar 

  • Rovnaník P (2010) Effect of curing temperature on the development of hard structure of metakaolin-based geopolymer. Constr Build Mater 24(7):1176–1183

    Article  Google Scholar 

  • Saif MS, El-Hariri MO, Sarie-Eldin AI, et al. (2022) Impact of Ca+ content and curing condition on durability performance of metakaolin-based geopolymer mortars. Case Stud Constr Mater :e00922

  • Sajan P, Jiang T, Lau C et al (2021) Combined effect of curing temperature, curing period and alkaline concentration on the mechanical properties of fly ash-based geopolymer. Clean Mater 1:100002

    Article  CAS  Google Scholar 

  • Shen G, Xue M, Wei S et al (2013) Influence of fuel mass load, oxygen supply and burning rate on emission factor and size distribution of carbonaceous particulate matter from indoor corn straw burning. J Environ Sci 25(3):511–519

    Article  CAS  Google Scholar 

  • Sutcu M, Erdogmus E, Gencel O, Gholampour A et al (2019) Recycling of bottom ash and fly ash wastes in eco-friendly clay brick production. J Clean Prod 233:753–764

    Article  Google Scholar 

  • Taha Y, Benzaazoua M, Hakkou R et al (2016) Natural clay substitution by calamine processing wastes to manufacture fired bricks. J Clean Prod 135:847–858

    Article  CAS  Google Scholar 

  • Temuujin J, van Riessen A, MacKenzie KJD (2010) Preparation and characterisation of fly ash based geopolymer mortars. Constr Build Mater 24(10):1906–1910

    Article  Google Scholar 

  • Tuyan M, Andiç-Çakir Ö, Ramyar K (2018) Effect of alkali activator concentration and curing condition on strength and microstructure of waste clay brick powder-based geopolymer. Compos Part B 135:242–252

    Article  CAS  Google Scholar 

  • Van der Kuijp TJ, Huang L, Cherry CR (2013) Health hazards of China’s lead-acid battery industry: a review of its market drivers, production processes, and health impacts. Environ Health 12(1):1–10

    Google Scholar 

  • Yaseen N, Irfan-ul-Hassan M, Saeed AUR et al (2022) Sustainable development and performance assessment of clay-based geopolymer bricks incorporating fly ash and sugarcane bagasse ash. J Mater Civ Eng 34(4):04022036

    Article  CAS  Google Scholar 

  • Youssef N, Rabenantoandro AZ, Dakhli Z et al (2019) Reuse of waste bricks: a new generation of geopolymer bricks. SN Appl Sci 1(10):1–10

    Article  Google Scholar 

  • Zainal FF, Hussin FWM, Nordin MNA, et al. (2022) The effect of curing temperature on the properties of kaolin geopolymer paste. In Journal of Physics: Conference Series (Vol. 2169, No. 1, p. 012029). IOP Publishing

  • Zeyad AM, Magbool HM, Tayeh BA et al (2022) Production of geopolymer concrete by utilizing volcanic pumice dust. Case Stud Cons Mater 16:00802

    Google Scholar 

  • Zhang L (2013) Production of bricks from waste materials–a review. Constr Build Mater 47:643–655

    Article  Google Scholar 

  • Zhang B, Yuan P, Guo H et al (2021) Effect of curing conditions on the microstructure and mechanical performance of geopolymers derived from nanosized tubular halloysite. Constr Build Mater 268:121186

    Article  CAS  Google Scholar 

Download references

Acknowledgements

The authors extend their appreciation to Researchers Supporting Project number (RSP2022R433), King Saud University, Riyadh, Saudi Arabia.

Funding

This work is funded by Researchers Supporting Project number (RSP-2021/343), King Saud University, Riyadh, Saudi Arabia.

Author information

Authors and Affiliations

  1. Raw Building Materials and Processing Technology Research Institute, Housing and Building National Research Center (HBRC), 87 El-Tahreer St., Dokki, Giza, 12311, Egypt

    Hamdy A. Abdel-Gawwad & Salah Kassem

  2. Department of Civil Engineering, College of Engineering, King Saud University, Riyadh, 11421, Saudi Arabia

    Aref Abadel & Hussam Alghamdi

  3. Department of Civil Engineering, McMaster University, Hamilton, ON, Canada

    Moncef L. Nehdi

  4. Building Physics Institute (BPI), Housing & Building National Research Center (HBRC), Cairo, Egypt

    Hamad Shoukry

Authors
  1. Hamdy A. Abdel-Gawwad
    View author publications

    You can also search for this author in PubMed Google Scholar

  2. Salah Kassem
    View author publications

    You can also search for this author in PubMed Google Scholar

  3. Aref Abadel
    View author publications

    You can also search for this author in PubMed Google Scholar

  4. Hussam Alghamdi
    View author publications

    You can also search for this author in PubMed Google Scholar

  5. Moncef L. Nehdi
    View author publications

    You can also search for this author in PubMed Google Scholar

  6. Hamad Shoukry
    View author publications

    You can also search for this author in PubMed Google Scholar

Contributions

Hamdy A. Abdel-Gawwad: conceptualization—original draft; writing—review and editing; methodology; investigation

Salah Kassem: methodology; formal analysis; investigation

Aref A. Abadel: data curation; funding acquisition; investigation

Moncef L. Nehdi: data curation; funding acquisition; investigation

Hamada Shoukry: methodology; investigation; data curation

Corresponding author

Correspondence to Hamdy A. Abdel-Gawwad.

Ethics declarations

Ethics approval

Not applicable

Consent to participate

Not applicable

Consent to publish

All authors agree about submission to the journal.

Competing interests

The authors declare no competing interests.

Additional information

Responsible Editor: Philippe Garrigues

Publisher’s note

Springer Nature remains neutral with regard to jurisdictional claims in published maps and institutional affiliations.

Rights and permissions

Springer Nature or its licensor holds exclusive rights to this article under a publishing agreement with the author(s) or other rightsholder(s); author self-archiving of the accepted manuscript version of this article is solely governed by the terms of such publishing agreement and applicable law.

Reprints and permissions

About this article

Check for updates. Verify currency and authenticity via CrossMark

Cite this article

Abdel-Gawwad, H.A., Kassem, S., Abadel, A. et al. Valorizing hazardous lead glass sludge and alumina flakes filling waste for the synthesis of geopolymer building bricks. Environ Sci Pollut Res 30, 5267–5279 (2023). https://doi.org/10.1007/s11356-022-22562-3

Download citation

  • Received:

  • Accepted:

  • Published:

  • Issue Date:

  • DOI: https://doi.org/10.1007/s11356-022-22562-3

Keywords

Search

Navigation