Fired brick production using phosphogypsum and phosphate mining waste

Abstract

The main objective of this study is to propose advanced solutions for recycling phosphogypsum (PG) in the construction industry. In Morocco, PG has been produced in large quantities (around 20 million tons) by a series of phosphoric acid manufacturing plants for many years. To address this issue, fired bricks were created using PG and red clay (RC), a waste material from Moroccan phosphate mines. The pressed brick samples were dried at 105 °C and then fired at temperatures between 900 and 1100 °C for 2–5 h. The PG, RC, and sintered briquettes were characterized and analyzed through thermogravimetric analysis (TGA), X-ray diffraction (XRD), scanning electron microscopy (SEM), physical properties and response surface methodology (RSM). The Toxicity characteristic leaching procedure test (TCLP) was also conducted on the raw materials and the fired brick samples to assess contamination risk. At all temperatures, the addition of PG results in a microstructure with high porosity that significantly impacts the mechanical characteristics. Despite this, the mechanical and physical performance of the fired brick samples meet the required standards. The TCLP test results did not detect any release of contaminants. The samples fired at 1056 °C for 4.5 h with a PG content of 40% demonstrate optimal conditions, exhibiting a notable bending strength of 13.15 MPa, a moderate density, and minimal water absorption. These findings indicate a promising and sustainable future trend in the construction industry by incorporating PG in fired brick production, providing a viable solution for waste management. Furthermore, comparing the results with previous works highlights the significant improvements achieved in terms of meeting industry standards and minimizing contamination risks associated with the utilization of mine wastes in fired bricks.