Sanitary Ware Waste Research Articles

Cement-bonded wood panels filled with duroplast sanitary ware wastes

Cement-bonded wood panels filled with duroplast sanitary ware wastes

High-temperature resistance of ceramic sanitaryware waste and fly ash-based geopolymer and hybrid geopolymer mortars produced at ambient curing conditions

In this study, five different hybrid geopolymer mortar mixtures were prepared, incorporating two different geopolymers and low percentages of Portland cement (PC), (16.6 % and 33.3 %). In geopolymer mixtures, 100 % ceramic sanitaryware waste (SW) and 100 % fly ash (FA) were used as precursor materials. In hybrid mixtures, the precursor materials include FA+ PC, SW+PC, and FA+SW+PC. The flexural and compressive strengths of mortars were determined up to 56 days to investigate their strength development. Additionally, the mortars were exposed to elevated temperatures up to 800 °C, separately. After the high-temperature exposure, phase (XRD) and microstructure (SEM/EDS) analyses were conducted on the selected mortars. All the hybrid geopolymers had higher flexural and compressive strengths than the geopolymers for all the curing ages. The highest 28-day flexural and compressive strength values of 5.3 MPa and 37.0 MPa were obtained on the mixture where FA+SW+PC precursors were used in equal amounts, respectively. The geopolymer and hybrid geopolymer mortars (containing 16.6 % PC) performed well under the high-temperature effect up to 800ºC. The strength values of all the mortars were obtained higher at 800ºC than at 600ºC. After high-temperature exposure, additional crystalline phases such as gehlenite were detected in hybrid mortars.

Ability of Ceramic Composite Beads as a Pre-treatment for Laundry Wastewater and Preparation of the Process

Abstract The escalating demand for laundry services, particularly in university districts, has raised concerns about its impact on biodiversity. The situation becomes even more critical when wastewater is discharged into drainage systems without adequate treatment. This study aimed to enhance laundry wastewater treatment by employing ceramic composite beads using ceramic sanitary ware waste and chitosan. The investigation began by characterizing laundry wastewater to identify its specific attributes. Subsequently, the study quantified the removal of zinc as a metal during the laundry wastewater treatment process. Laundry wastewater characteristics were assessed using various parameters, including pH, chemical oxygen demand (COD), total suspended solids (TSS), and turbidity. The result revealed that the treatment of laundry wastewater with ceramic composite beads adsorbent successfully achieved over 50 % reduction in zinc concentration. These findings showed that the ceramic composite bead exhibited an efficiency for metal removal from the laundry wastewater for safe disposal.

Valorization of ceramic sanitary waste into Resilient phosphoric acid-based geopolymers for sustainable construction: Thermal, mechanical, and microstructural properties

The construction industry's heavy reliance on conventional cement production contributes significantly to global carbon dioxide emissions, prompting the need for eco-friendly building materials. Geopolymers, synthesized from natural materials like clay and fly ash, offer a sustainable alternative to traditional cement. This paper investigates the development of phosphoric acid-activated geopolymers with sanitary ware waste (SWW) as aggregates, aiming to create high-performance, environmentally friendly building materials. Various particle sizes of SWW were incorporated into the geopolymer matrix, revealing a strong relationship between particle size and compressive strength. The inclusion of SWW improved compressive strength, with a notable 83 % increase at 30 % SWW content. Fourier transform infrared spectroscopy (FTIR) and X-ray diffraction (XRD) analyses highlighted the formation of new bonds in the geopolymeric gel, while scanning electron microscopy (SEM) showed microcracks and good adhesion between SWW particles and the geopolymer matrix. Thermal resistance tests demonstrated that SWW-reinforced geopolymers exhibited improved resistance to high temperatures compared to the reference geopolymer. XRD analysis of thermally treated geopolymers revealed the transformation of amorphous phases into stable crystalline phases. SEM/EDX mapping confirmed the presence of silica-rich phases, contributing to the materials' mechanical properties and thermal resistance. This study underscores the potential of SWW-based geopolymers as sustainable, high-performance building materials.

Design of the usability of ceramic sanitary ware waste in cement production using the Taguchi method

The cement process is one of the industries where energy is consumed intensively. High levels the amount of carbon dioxide emission reaches since the nature of the raw materials used in its production. At this point, using industrial wastes and by-products containing oxides such as calcium, silica, alumina, and iron oxides blended cement reduces energy consumption and carbon dioxide emissions. In this study, the effects of using ceramic sanitary ware waste (CSW) instead of clinker on the cement grinding stage were investigated. The grinding tests were carried out with clinker in a ball mill, according to grinding parameters as ball filling ratio, ball diameter, and grinding time by using Taguchi method for optimization of cement grinding condition. The reference and blended cements with CSW were determined compressive strength.

Cleaner Environment Approach by the Utilization of Ceramic Sanitaryware Waste in Portland Cement Mortar at Ambient and Elevated Temperatures

Cleaner Environment Approach by the Utilization of Ceramic Sanitaryware Waste in Portland Cement Mortar at Ambient and Elevated Temperatures

Eco-friendly geopolymer concrete based on metakaolin and ceramics sanitaryware wastes

The sanitary ceramics industry generates huge quantities of wastes notwithstanding all the efforts made to improve the manufacturing process. The aim of the present work is to investigate the potential reuse of sanitary ceramics wastes as an aggregate to manufacture metakaolin based geopolymer concrete. The effect of granulometry and added quantity of SCW on the properties of metakaolin based geopolymer matrix was assessed via physical, mechanical and microstructural properties. the results indicate that the developed concretes exhibit higher mechanical performance compared to conventional concretes and to reference geopolymer. It was also shown that the increase in aggregate particle size had a significant influence on the compressive strength as well as the density and porosity. The microstructure in the interfacial transition zone (ITZ) between the recycled ceramic aggregate and the paste was observed to be more compact.

Sanitary Ware Waste as a Source for a Valuable Biodiesel Catalyst

Biofuel is a type of fuel that is made from biomass using modern techniques rather than the relatively slow geological processes that lead to the development of fossil fuels. In Europe, biodiesel is the most widely used biofuel. The sanitary ware industry generates a lot of hazardous waste, such as waste gypsum molds. These molds are broken, pulverized, and reacted with NaCO3 to make CaCO3, which is then heated to produce CaO. The resulting CaO catalyzes the reaction between waste frying oil and methanol for biodiesel synthesis. To evaluate the effect of reaction parameters on the production of biodiesel, the independent reaction parameters that were chosen are as follows: reaction temperature in the range 50–70°C, methanol to oil (M:O) molar ratio in the range 9–15, catalyst loading in the range 1–5%, and time in the range 2–6 hrs. The influence of the independent factors on the reaction-dependent responses was evaluated and it was found that reaction temperature and methanol-to-oil ratio have a major effect on the biodiesel yield. Reaction condition optimization has been studied to maximize biodiesel yield at minimum reaction conditions. The optimum process conditions are 93.4% biodiesel yield at an M:O molar ratio of 15 : 1, catalyst loading of 1%, reaction temperature of 53.6°C, and reaction time of 2 h. The results showed that resulted biodiesel catalyst (CaO) can be used one time; then, a fresh catalyst will be used.

Precipitated silica, alkali silicates and zeolites from construction and demolition waste materials

The construction and demolition industry generates a large volume of wastes, which are used in the same industry to elaborate new cementitious materials. However, the use of the mentioned wastes to prepare other type of silicate materials has been little reported. In the present work, silica, sodium silicate, potassium silicate, SAPO-34 zeolite and zeolite X, phillipsite, and sodalite were prepared using local sand waste, concrete, ceramic sanitary ware waste and building block. First, the wastes were characterized to know the elemental composition and mineralogical phases. Further alkaline fusion was carried out with NaOH and KOH, respectively. The products obtained in this step were neutralized with H2SO4 solution to form precipitated silica with high purity. For the zeolite experiments, SAPO-34 zeolite was synthesized using the precipitated silica, sodium aluminate, and H3PO4. Low Si/Al ratio zeolites were synthesized using the sodium silicate and like potassium silicate. The results of XRD technique show the formation of amorphous sodalite and phillipsite zeolites. Pure zeolite X was obtained only with the sodium silicate prepared from the ceramic ware waste; however, the use of an alternative aluminum source could be used with the other wastes to promote the formation of pure zeolites. With the non-conventional use of construction and demolition industry wastes, new technical opportunities were demonstrated herein to obtain functional materials promoting the circular economy and sustainable development.

Mechanical and microstructural characteristics of geopolymer mortars at high temperatures produced with ceramic sanitaryware waste

Excessive amounts of solid wastes are generated by the ceramic sanitaryware sector in the world. Recycling ceramic wastes is one of the crucial solutions to ensure their elimination. This experimental study investigates the mechanical and microstructural characteristics of geopolymer mortars with recycled ceramic sanitaryware waste powder (CSW) exposed to high temperatures. The geopolymer mixtures are produced using CSW with four different molarity (10, 12, 14, and 16 M) of NaOH as alkali-activator and two water/binder ratios (0.45 and 0.50). The investigated properties of the CSW-based Mortars (CSW-M) are the flowability, unit weight, apparent porosity, flexural strength, compressive strength, phase, and microstructure utilizing X-ray diffractometry (XRD), and scanning electron microscopy (SEM/EDS). The increase in NaOH concentration is observed to improve the flow workability of CSW-M and reduce the apparent porosity and water absorption of specimens. Mechanical test results indicate that strength values of CSW-M increase with increasing NaOH molarity. The highest strength is obtained on the CSW-M made with 16 M NaOH and 0.45 w/b ratio. The crystalline phases are determined to be mullite, quartz and albite derived from ceramic sanitaryware waste. Additionally, zeolite is formed by the secondary reaction product after elevated temperatures. Performance analysis results reveal that using ceramic sanitaryware waste is a strong alternative material as a binder to produce geopolymer mortars and contributes to the elimination of the waste.

Influence of the use of sanitary ware waste in self-compacting concrete production

In the production of concrete and mortar, fine and coarse aggregates from non-renewable natural resources are normally consumed. In order to minimize the environmental impacts caused by the extraction of these resources, recycled aggregates of different natures and granulometries has been use in the production of cement composites. The purpose of this paper was to investigate the influence of replacing natural sand by sanitary ware waste (SWW) on the properties of self-compacting concrete (SCC). Concretes were produced with replacement of fine sand by SWW in 20%, 40%, 60% and 80%. The SCC had their properties evaluated in the fresh and hardened state. The results shows that the increase in replacement teres reduces the scattering, fluidity and passing ability of the SCC. There was an increase in compressive strength from 30.1 MPa to 35.3 MPa at 28 days, when considering the 20% and 40% replacement mixes. The replacement contents of 60% and 80% had very similar values. The tensile tests by diametrical compression showed statistically equal values for all analyzed traits. Water absorption increased with higher levels of residues in concrete. The set of tests performed allow to affirm that replacements between 20% and 60% of SW resulted in concretes according requirements for self-compacting concretes, with structural application recommendation for various situations. For classification and indication of use, the tests results should be observed in each of the mixtures. In this way, sanitary were waste have the potential to be used as a substitute for natural sand, reducing the consumption of natural resources.

Potential use of ceramic sanitary ware waste as pozzolanic material

This paper evaluated the pozzolanic activity of ceramic sanitary ware (CSW) waste when blended with Portland cement (PC). CSW waste units were broken, crushed and milled to reduce their particle size. These particles were characterized by scanning electron microscopy (SEM-EDX), laser granulometry, X-ray fluorescence (XRF) and X-ray diffraction tests (XRD), and were then used to replace 0–50wt.% PC CEM I 42.5R in pastes and mortars. Workability of the fresh mortars was assessed by the flow-table spread test, and the mechanical properties and microstructure (thermogravimetry, SEM-EDX, XRD and Fourier transform infrared spectroscopy tests) were investigated in samples cured at 20°C for up to 365 days. No significant workability variations were observed with increasing waste contents and, although pozzolanic activity of CSW was relatively slow, it improved with the curing time, and mortars prepared with up to 25wt.% ceramic waste satisfied the requirements established for other pozzolanic materials, such as fly ash.

Investigation of Usability of Ceramic Sanitaryware Wastes in Geopolymer Mortar Production

Bu çalışmada, seramik sağlık gereci (vitrifiye) üretimi esnasında ortaya çıkan hatalı/ıskarta ürünlerin öğütülmesi ile elde edilen atık tozlar alkali ile aktive edilerek geopolimer harçlar üretilmiştir. Üretilen harçlara farklı sıvı/bağlayıcı oranı ve aktivatör molaritesinin etkisi araştırılmıştır. Bu amaçla sıvı bağlayıcı 0,45 ve 0,50 oranlarında 10, 12, 14 ve 16 M NaOH çözeltilerinde karışımlar hazırlanmıştır. Üretilen harç karışımlarına 80°C’de 24 saat ısıl kür ve 28 güne kadar havada kür uygulanmıştır. Numunelere işlenebilirlik, birim ağırlık, eğilme ve basınç dayanımı, su emme ve boşluk oranı deneyleri uygulanmıştır. Numunelerin sıvı/bağlayıcı oranı 0,50 iken molaritenin artması mekanik özelliklere olumlu etkisi olmamakta ancak işlenebilirliği iyileştirmektedir. 0,45 sıvı/bağlayıcı oranında ise molaritenin artışı dayanımda önemli gelişme göstererek 16 M NaOH konsantrasyonunda yaklaşık 34 MPa basınç dayanımı elde edilmiştir. Ancak artan dayanım, çevresel ve ekonomik koşullar açısından geopolimer harç üretimi için uygun molaritenin sıvı/bağlayıcı oranı 0,45’de 12 M NaOH olduğu belirlenmiştir.

Investigation on effect of process parameters in abrasive Jet Machining process using full factorial design

Abrasive Jet Machining (AJM) process is one of the unconventional machining process used to cut various materials including soft and hard materials. Alumina and silica are majorly used as abrasive materials due to its chemical and abrasion resistance. In this paper, abandoned Ceramic Sanitary Ware (CSW) wastes are used as abrasive materials in AJM process. Since, CSW wastes contain major amount of alumina and silica compositions. Initially, ball milling machining process is carried out to convert CSW wastes into micro particles. Then, sieving is performed to segregate the particles with its size. Stand of distance, pressure and particle size are considered as most influencing parameters in AJM process. Hence, Full Factorial design is utilized for three process parameters and three levels. The nozzle with a mixing chamber is designed and fabricated to perform drilling operation in the glass work piece. L27 experiments are carried out to evaluate Material Removal Rate (MRR) and Hole Diameter (HD) during drilling process of glass work piece. Further, the effect of each process parameters on MRR and HD is validated. From the analysis, it is found that pressure is most influencing parameters affecting MRR whereas HD greatly depends on particle size.

Rendering Mortars with Low Sand and Cement Content. Incorporation of Sanitary Ware Waste and Forest Biomass Ashes

The incorporation of wastes in new materials and products is an emerging trend, reducing virgin materials’ consumption and landfill deposition and the associated environmental impacts. Cement-based mortars can encapsulate some wastes, with the benefits stated above. In three previous researches, it was found that forest biomass bottom ashes (up to 15% by volume of cement), powder of sanitary ware (up to 20% by volume of sand) and sanitary ware particles above 2 mm (100% by volume of sand) can be incorporated in rendering mortars, replacing cement or sand. Several tests were performed, and it was found that each waste’s incorporation presents advantages and limitations, when compared with a reference mortar. In this research, the aim was to take advantage of the best features of each waste, combining them in order to optimize the new mortars’ characteristics. Therefore, mortars with one, two and three wastes were analysed in this research. The ternary mix mortar had a volume of wastes equal to 83%, resulting in a mortar with 15% less cement (by volume) and without any natural aggregate (all replaced with the sanitary ware wastes). The fresh, water and mechanical behaviour of the mortars with and without wastes are presented in this research. It was concluded that it is possible to take advantage of the best features of each waste and achieve mortars simultaneously with high volume of wastes and a better performance than the reference mortar (without wastes).

Re-use of abandoned sanitary ware waste as abrasive particles for abrasive jet machine

In recent years, the growth in the machinery industries has emerged to produce the ceramic components which are non-bio degradable wastes. In this paper, the abrasive particles are produced through a rehash of ceramic sanitary ware wastes to machine the glass material in the abrasive jet machining process. Beforehand, computational fluid dynamics (CFD) analysis is performed on the nozzle to evaluate the flow velocity at the corresponding pressure distributions. It results that the velocity of 810 m/s is achieved at the outlet of the nozzle. The nozzle is designed based on the consequent results of flow analysis. Further, the sanitary ware wastes from washbasin urinals, sinks, bathtubs, toilets, etc are collected and renewed to the form of abrasive particles using sieving and segregation processes. The mixing chamber is fabricated and abrasive particles, dry air is made to mix in the mixing chamber. Then mixed particles are made to flow out to the working chamber through the outlet opening. The high jet velocity of the air and abrasive particle mixture has impinged through a convergent nozzle for machining the glass workpiece in the abrasive jet machining process. Moreover, the performance characteristics of abrasive particles in the abrasive jet machining process are evaluated.

Management of sanitary ware wastes as supplementary cementing materials in concretes

A large amount of ceramic sanitary ware wastes (SW) results from the production and after demolition processes. This study proposes the use of SW as supplementary cementing materials (SCM) in concrete to contribute with construction and demolition waste management. Experiments were carried out on concretes and pastes using different proportions of SW-replacement. Physical, mechanical, and durable behavior of concrete was evaluated and how concrete was affected by the cement hydration process. The incorporation of SW to Portland cement to make concrete reduces the permeability in the matrix and refines the capillary pores, improving the mechanical properties and the behavior in aggressive environments, such as chlorides. The results show that it is recommended the use of SW as SCM to produce concretes with mechanical properties and durability comparable to those of a conventional concrete, at 28 days.

Recycling Of The Mixture Resulted From Sanitary Ware Waste, Roller Kiln Waste And Ceramic Tiles Sludge Waste In The Manufacturing Of Ceramic Floor Tiles

Ceramic tiles industry is a big source for wastes that have a bad effect on the environment. The first source of waste is associated with roller kilns as it needs a periodic surface grinding to its rollers which results in a waste powder. The second type of waste is ceramic tiles sludge which produced from a water treatment plant. The third waste is sanitary ware waste which coming out from sanitary ware industry. The main aim of this paper is to investigate the ability of substituting part of the main body mixture of floor tiles by these three types of waste powder. Many Experiments were done on the raw materials. Rectangular tile specimens were moulded, dried and fired. Sintering parameters and mechanical properties were determined. The sample that consist of 2% Roller Kiln, 39% Ceramic tiles sludge, 15% sanitary ware waste, and 44% Floor tiles mixture has the optimum properties.

Recycling ceramic waste as a raw material in sanitary ware production

Abstract This study characterized discarded sanitary ware waste (SWW) that could not meet quality requirements. To understand the composition of such SWW, samples were collected, processed, and characterized. This SWW was used to substitute granite in ceramic slips, and the final recycled sanitary ware compositions of 5%, 10%, 25%, 50% and 100% were obtained. Then, the mixtures were evaluated based on density, rheology, linear shrinkage, water absorption, and flexural strength. The results for viscosity and pyroplastic deformation in specimens containing the ceramic waste were better than the reference slip used in a production line. Results for density, water absorption and linear shrinkage showed no significant difference from the control samples. Although the replacement of more than 5% of granite reduced the flexural strength, no tested specimen was below the minimum value required by the industry.

Properties of concrete manufactured with use of ceramic sanitary ware waste as aggregate

ABSTRACT In concrete manufacture, cement (Portland type is the most used), water and aggregates (classified into coarse and fine) are used. With the use of several raw materials the generation of waste is inevitable, both in construction and in other sectors, such as the industries producing ceramic materials. Among the types of waste from such industries, can be mentioned the ceramic scrap (from the sanitary ware industry). According to the above, the aim of this research was to study the addition of ceramic scrap as a coarse aggregate in different proportions in the concrete formulation. In order to do this, was select wastes from an industry in the south of Minas Gerais (Brazil), and prepare specimens to determine the fresh (slump test, adhesiveness and porosity) and hardened (compression strength) of concrete. Were fabricated five concrete formulations, one reference (RC) and four with ceramic scrap substituted for coarse aggregate in the proportions of 25% (CSC-I), 50% (CSC-II), 75% (CSC-III) and 100% (CSC -IV). Fresh concretes, two formulations did not show adhesiveness (CSC-III and CSC-IV) and two a small water runoff (CSC-I and CSC-II), however, without compromising the concrete’s workability. Regarding the compression strength, the average values presented were very good, including the formulation with 100% ceramic scrap (fc = 47.78 MPa). Another important aspect observed in the rupture modes was the small adhesion between the ceramic scrap and the mortar due to the glazing in the contour of the waste. As for the porosity of the concretes, those with 25%, 75% and 100% of ceramic scrap in their composition presented lower values than the reference concrete.