Environmental Risk Analysis Based on Characterization of Ground Oily Sludge

Oily sludge is recognized as hazardous waste. To reduce the potential danger and harmful factors of oily sludge, it is very important to analyze its environmental risk. In this paper, the characterization of oily sludge from Shengli Oilfield in China was tested experimentally, including the composition content, particle size, microscopic morphology, heavy metal content, organic composition, inorganic composition, and thermogravimetric analysis, which were used to analyze environmental risks. The results show that the oil content of oily sludge is as high as 10.3%, which will cause serious pollution. It is calculated that China can recover 772.5 million liters of oil and reduce 553.9 million kg of carbon emissions compared with incineration in one year, if the oily sludge can be managed effectively. The content of heavy metals such as Ba, Zn, Cr, As, Ni, Se, Be, and Hg in oily sludge exceeds the standard. It will restrain the self-healing ability of soil, pollute groundwater, and endanger animals and plants. The organic matter of oily sludge is concentrated in C₁₁ to C₂₉. It contains a large amount of benzene series and polycyclic benzene hydrocarbons, which can lead to cancer in the human body. Inorganic substances in oily sludge are mixed with some additives, which can not only reduce the toxicity of heavy metals, but also be used as building materials. The median particle size D₅₀ of oily sludge is 0.91 μm, and it spreads all over the narrow pores. Generally, it needs to be treated under high temperature conditions, which will cause secondary pollution to the environment. The research content of this paper provides a theoretical reference for the management of oily sludge.     

Image Analysis of Surface Porosity Mortar Containing Processed Spent Bleaching Earth

Image analysis techniques are gaining popularity in the studies of civil engineering materials. However, the current established image analysis methods often require advanced machinery and strict image acquisition procedures which may be challenging in actual construction practices. In this study, we develop a simplified image analysis technique that uses images with only a digital camera and does not have a strict image acquisition regime. Mortar with 10%, 20%, 30%, and 40% pozzolanic material as cement replacement are prepared for the study. The properties of mortar are evaluated with flow table test, compressive strength test, water absorption test, and surface porosity based on the proposed image analysis technique. The experimental results show that mortar specimens with 20% processed spent bleaching earth (PSBE) achieve the highest 28-day compressive strength and lowest water absorption. The quantified image analysis results show accurate representation of mortar quality with 20% PSBE mortar having the lowest porosity. The regression analysis found strong correlations between all experimental data and the compressive strength. Hence, the developed technique is verified to be feasible as supplementary mortar properties for the study of mortar with pozzolanic material.     

Mechanical Properties of Crumb Rubber Mortar Containing Nano-Silica Using Response Surface Methodology

Crumb rubber (CR) from scrap tires is used as a partial replacement of fine aggregates in cement paste. This promotes the sustainable development of the environment, economy, and society, as waste tires are non-biodegradable and flammable. They occupy large landfill areas and are breeding grounds for mosquitoes and rodents. Inclusion of CR in mortar leads to several improvements on the mixture properties such as ductility, toughness, and impact resistance. However, it exhibits lower strengths and Modulus of Elasticity (ME). Therefore, to promote the use of mortar containing CR, it is vital to improve its mechanical strength. Past studies proved that nano-silica (NS) improves the strength of concrete due to the physico-chemical effects of NS. This study aims to examine the mechanical properties of crumb rubber mortar containing nano-silica (NS-CRM) and to develop models to predict these properties using Response Surface Methodology (RSM). Two variables were considered, CR as partial replacement to sand by volume (0%, 7.5%, 15%), and NS as partial replacement to cement by weight (0%, 2.5%, 5%). The results demonstrated a significant improvement in the mechanical properties of CRM when incorporating NS, and the models developed using RSM were acceptable with a 2% to 3% variation.     

Influence of Cement Replacement with Sewage Sludge Ash (SSA) on the Heat of Hydration of Cement Mortar

The amount of fly ash from the incineration of sewage sludge is increasing all over the world, and its utilization is becoming a serious environmental problem. In the study, a type of sewage sludge ash (SSA) collected directly from the municipal sewage treatment plant was used. Five levels of cement replacement (2.5%, 5%, 7.5%, 10% and 20%) and unchanged water-to-binder (w/b) ratio (0.55) were used. The purpose of the study was to evaluate the effect of sewage sludge ash (SSA) on the hydration heat process of cement mortars. The heat of the hydration of cement mortars was monitored by the isothermal calorimetric method for 7 days at 23 °C. The analysis of chemical composition and particle size distribution was performed on the tested material. The tests carried out have shown that SSA particles have irregular grain morphology and, taking into account the chemical composition consists mainly of oxides such as CaO, P₂O₅, SiO₂ and Al₂O₃. The concentration of these compounds affects the hydration process of cement mortars doped with SSA. In turn, the content of selected heavy metals in the tested ash should not pose a threat to the environment. Calorimetric studies proved that the hydration process is influenced by the presence of SSA in cement mortars. The studies showed that the rate of heat generation decreased (especially in the initial setting period) with the increasing replacement of cement by SSA, which also reduced the amount of total heat compared to the control cement mortar. With increasing mass of the replacement of cement with SSA up to 20%, the 7-day compressive strength of the mortar samples decreases.     

Effect of Oily Sludge Treatment with Molten Blast Furnace Slag on the Mineral Phase Reconstruction of Water-Quenched Slag Properties

Blast furnace slag, which is the main by-product of the ironmaking process discharged at 1450 °C, contains high-quality sensible heat, while oily sludge is the main solid waste produced in the process of gas exploration, storage, and transportation. The energy and resource utilization of blast furnace slag is complementary to the environmentally friendly treatment of oily sludge, which has provided a new idea for the multi-factor synergistic cycle and energy transformation of the two wastes. The pyrolysis of the oily sludge with the molten blast furnace slag was conducted in the current paper. Results showed that the oily sludge was rapidly pyrolyzed, and the heavy metal elements in the oily sludge were solidified. The solidification rate of the heavy metals exceeds 90%, except for vanadium. The reconstituted water-quenched blast furnace slag still has good activity, and it will not affect the further use of the slag after pyrolysis (BFS-P).     

Investigation of the Residual Mechanical and Porosity Properties of Cement Mortar under Axial Stress during Heating

The preload load on concrete during heating is considered to cause a ‘densification’ of cement mortar which led to the increased compressive strength. In order to assess the influence of coupled load and heating effects on porosity characteristics of concrete, the porosity of mortar after mechanical and thermal loading was measured by X-ray computed tomography (X-ray CT). The preload at pre-stress ratios of 0, 0.2, 0.4, and 0.6 (ratio of stress applied to the specimen to its compressive strength at room temperature) were applied on mortar specimens during heating. The residual compressive strengths of the heated and stressed mortar specimens were tested after cooling to room temperature. Combined analyses of the residual compressive strength test results and porosity test results, it shows that the porosity of the specimens under the coupled stressing and heating conditions were slightly lower than that under the unstressed conditions; however, the conclusion that the increase of compressive strength of stressed mortar was caused by the ‘densification’ of cement paste was insufficient. The preload reduced the cracks in the mortar, especially the crack induced due to the thermal mismatch in aggregates and hardened cement paste (HCP), and this may account for the increased compressive strength of stressed mortar.     

Evaluating the Influence of Elevated Temperature on Compressive Strength of Date-Palm-Fiber-Reinforced Concrete Using Response Surface Methodology

Due to its availability and affordable processing, date palm fiber (DPF) is among the natural and sustainable fibers used in cementitious composites. Furthermore, DPF is an agricultural, organic, and fibrous material that when subjected to higher temperature can easily degrade and cause reduction in strength. Therefore, the influence of elevated temperatures on the unit weight and strengths of DPF-reinforced concrete needs to be examined. Under this investigation, DPF is used in proportions of 0–3% weight of binder to produce a DPF-reinforced concrete. Silica fume was utilized as a supplemental cementitious material (SCM) in various amounts of 0%, 5%, 10%, and 15% by weight to enhance the heat resistance of the DPF-reinforced concrete. The concrete was then heated to various elevated temperatures for an hour at 200 °C, 400 °C, 600 °C, and 800 °C. After being exposed to high temperatures, the weight loss and the compressive and relative strengths were examined. The weight loss of DPF-reinforced concrete escalated with increments in temperature and DPF content. The compressive and relative strengths of the concrete improved when heated up to 400 °C, irrespective of the DPF and silica fume contents. The heat resistance of the concrete was enhanced with the replacement of up to 10% cement with silica fume when heated to a temperature up to 400 °C, where there were enhancements in compressive and relative strengths. However, at 800 °C, silica fume caused a significant decline in strength. The developed models for predicting the weight loss and the compressive and relative strengths of the DPF-reinforced concrete under high temperature using RSM have a very high degree of correlation and predictability. The models were said to have an average error of less than 6% when validated experimentally. The optimum DPF-reinforced concrete mix under high temperature was achieved by adding 1% DPF by weight of binder materials, replacing 12.14% of the cement using silica fume, and subjecting the concrete to a temperature of 317 °C. The optimization result has a very high desirability of 91.3%.     

Resistance of Soda Residue–Fly Ash Based Geopolymer Mortar to Acid and Sulfate Environments

The early mechanical performances of low-calcium fly ash (FFA)-based geopolymer (FFA–GEO) mortar can be enhanced by soda residue (SR). However, the resistance of SR–FFA–GEO mortar to acid or sulfate environments is unclear, owing to the various inorganic calcium salts in SR. The aim of this study was to investigate the long-term mechanical strengths of up to 360 d and evaluate the resistance of SR–FFA–GEO mortar to 5% HCl and 5% Na₂SO₄ environments through the losses in compressive strength and mass. Scanning Electron Microscopy (SEM), Energy-Dispersive Spectroscopy (EDS) and Fourier Transform Infrared Spectrometer (FTIR) experiments were conducted for the SR–FFA–GEO mortars, both before and after chemical attack, to clarify the attack mechanism. The results show that the resistances of the SR–FFA–GEO mortar with 20% SR (namely M10) to 5% HCl and 5% Na₂SO₄ environments are superior to those of cement mortar. The environmental HCl reacts with the calcites in SR to produce CaCl₂, CO₂ and H₂O to form more pores under HCl attack, and the environmental Na⁺ cations from Na₂SO₄ go into Si-O-Al network structure, to further enhance the strength of mortar under Na₂SO₄ attack. These results provide the experimental basis for the durability optimization of SR–FFA–GEO mortars.     

Strength and Permeability Properties of Pervious Concrete Containing Coal Bottom Ash Aggregates

This study investigates the strength and permeability properties of pervious concrete-containing coal bottom ash (CBA) aggregates. Two pervious concrete mixtures were fabricated with different aggregate size distributions. One mixture contained CBA aggregates with a single-type distribution and the other mixture contained CBA aggregates with a hybrid-type distribution. The test parameters of the CBA pervious concrete included the water/cement (W/C) ratio and compaction level to investigate their effects on the properties. W/C ratios of 0.25, 0.30, and 0.35 were considered for the mixture, and compaction levels of 0.5, 1.5, and 3.0 MPa were applied to fabricate the pervious specimen. The increase in the W/C ratio reduced the strength by approximately 20% to 30% of the CBA pervious concrete. The increase in the compaction level reduced the permeability by approximately four to five times but significantly increased the strength of the CBA pervious concrete. The test results indicate that the use of single-type CBA or hybrid CBA aggregates with different size distributions affected the properties of the pervious concrete. The strength of specimens, including hybrid CBA aggregates, was 30% to 45% greater than that of the specimens containing single-type CBA aggregates. Meanwhile, the use of hybrid CBA aggregates reduced the permeability of the CBA pervious concrete by approximately 20% to 35%. Finally, relationships between the strength properties, permeability characteristics and total void ratios of the CBA pervious concrete specimens are suggested based on the test results.     

Synthesis and Process Optimization of Electrospun PEEK-Sulfonated Nanofibers by Response Surface Methodology

In this study electrospun nanofibers of partially sulfonated polyether ether ketone have been produced as a preliminary step for a possible development of composite proton exchange membranes for fuel cells. Response surface methodology has been employed for the modelling and optimization of the electrospinning process, using a Box-Behnken design. The investigation, based on a second order polynomial model, has been focused on the analysis of the effect of both process (voltage, tip-to-collector distance, flow rate) and material (sulfonation degree) variables on the mean fiber diameter. The final model has been verified by a series of statistical tests on the residuals and validated by a comparison procedure of samples at different sulfonation degrees, realized according to optimized conditions, for the production of homogeneous thin nanofibers.     

Predicting the Compressive Strength of Concrete Containing Fly Ash and Rice Husk Ash Using ANN and GEP Models

Climate change has become trending news due to its serious impacts on Earth. Initiatives are being taken to lessen the impact of climate change and mitigate it. Among the different initiatives, researchers are aiming to find suitable alternatives for cement. This study is a humble effort to effectively utilize industrial- and agricultural-waste-based pozzolanic materials in concrete to make it economical and environmentally friendly. For this purpose, a ternary blend of binders (i.e., cement, fly ash, and rice husk ash) was employed in concrete. Different variables such as the quantity of different binders, fine and coarse aggregates, water, superplasticizer, and the age of the samples were considered to study their influence on the compressive strength of the ternary blended concrete using gene expression programming (GEP) and artificial neural networking (ANN). The performance of these two models was evaluated using R², RMSE, and a comparison of regression slopes. It was observed that the GEP model with 100 chromosomes, a head size of 10, and five genes resulted in an optimum GEP model, as apparent from its high R² value of 0.80 and 0.70 in the TR and TS phase, respectively. However, the ANN model performed better than the GEP model, as evident from its higher R² value of 0.94 and 0.88 in the TR and TS phase, respectively. Similarly, lower values of RMSE and MAE were observed for the ANN model in comparison to the GEP model. The regression slope analysis revealed that the predicted values obtained from the ANN model were in good agreement with the experimental values, as shown by its higher R² value (0.89) compared with that of the GEP model (R² = 0.80). Subsequently, parametric analysis of the ANN model revealed that the addition of pozzolanic materials enhanced the compressive strength of the ternary blended concrete samples. Additionally, we observed that the compressive strength of the ternary blended concrete samples increased rapidly within the first 28 days of casting.     

Effect of Chemical Admixtures on Mechanical and Degradation Properties of Metallurgical Sludge Waste Concrete

This study extends the development of concretes with metallurgical sludge waste (MSW) by determining the effect of superplasticizers and air entrainment admixture (AEA). The MSW is a very fine powdery material, and in this case, it was used as a partial replacement of fine aggregate in the mixture. The reference ordinary concrete mixtures without MSW were created for evaluation. The results of concrete density, compressive strength, electrical resistivity, and rapid chloride permeability were obtained and some of them were measured continuously to determine the influence of the chemical admixtures on these characteristics over time. It was found that in general, the MSW substitution slightly lowers the mechanical and durability parameters, but MSW in combination with the chemical admixtures improves the compressive strength in comparison to the reference concrete with the addition of AEA.     

Properties of Blended Cement Containing Iron Tailing Powder at Different Curing Temperatures

The properties of blended cement containing 0%, 20%, and 50% iron tailing powder (ITP) at 20 °C and 60 °C were investigated by determining the hydration heat, microstructure, and compressive strength. The addition of ITP decreases the exothermic rate and cumulative hydration heat of blended cement at 20 °C. The high temperature increases the hydration rate and leads to the hydration heat of blended cement containing 20% ITP higher than that of Portland cement. Increasing the amount of ITP decreases the non-evaporable water content and Ca(OH)₂ content as well as compressive strength at both of the two studied temperatures. The addition of ITP coarsens the early-age pore structure but improves the later-age pore structure at 20 °C. The high temperature significantly improves the early-age properties of blended cement containing ITP, but it is detrimental to the later-age properties development. The reaction of ITP is limited even at high temperature. The large ITP particles bond poorly with surrounding hydration products under early high-temperature curing condition. The properties of blended cement containing a large amount of ITP are much poorer at high temperature.     

Temperature Optimization by Using Response Surface Methodology and Desirability Analysis of Aluminium 6061

Because aluminium is a lightweight and low-density material, its alloys, such as Al 6061 alloy, are extensively used in numerous automobile, defense, and aviation components. This study aims to develop a predictive model to investigate the impact of tool nose radius on the CNC turning process of Al 6061 alloy and better recognize the implications of operating machining considering cutting speed, rate of feed, cutting depth, and tool nose radius. The trials were carried out by using the response surface methodology (RSM), with an Al₂O₃ coated carbide tool as the cutter and an Al 6061 workpiece as the material. A mathematical model of the second-order was created. The analysis of variance (ANOVA) approach was used to analyze the performance characteristics of the turning operation. Individual desirability values from the desirability function analysis for the multi-responses are used to construct a composite desirability value. The ideal parameter levels were determined by using the composite desirability value, and the significant impact of parameters was assessed by using the analysis of variance. The minimum temperature attained at the machining parameters are 98.0 m/min cutting speed, 0.26 mm/rev rate of feed, 0.893 mm cutting depth, and 0.84 mm tool nose radius. The best total desirability value is 23.615 °C, indicating that the experimental results are close to the predicted values.     

Effect of Calcium Nitrate on the Properties of Portland–Limestone Cement-Based Concrete Cured at Low Temperature

The effect of calcium nitrate (CN) dosages from 0 to 3% (of cement mass) on the properties of fresh cement paste rheology and hardening processes and on the strength of hardened concrete with two types of limestone-blended composite cements (CEM II A-LL 42.5 R and 42.5 N) at different initial (two-day) curing temperatures (−10 °C to +20 °C) is presented. The rheology results showed that a CN dosage up to 1.5% works as a plasticizing admixture, while higher amounts demonstrate the effect of increasing viscosity. At higher CN content, the viscosity growth in normal early strength (N type) cement pastes is much slower than in high early strength (R type) cement pastes. For both cement-type pastes, shortening the initial and final setting times is more effective when using 3% at +5 °C and 0 °C. At these temperatures, the use of 3% CN reduces the initial setting time for high early strength paste by 7.4 and 5.4 times and for normal early strength cement paste by 3.5 and 3.4 times when compared to a CN-free cement paste. The most efficient use of CN is achieved at −5 °C for compressive strength enlargement; a 1% CN dosage ensures the compressive strength of samples at a −5 °C initial curing temperature, with high early strength cement exceeding 3.5 MPa but being less than the required 3.5 MPa in samples with normal early strength cement.     

Strength,Carbonation Resistance,and Chloride-Ion Penetrability of Cement Mortars Containing Catechol-Functionalized Chitosan Polymer

There have been numerous recent studies on improving the mechanical properties and durability of cement composites by mixing them with functional polymers. However, research into applying modified biopolymer such as catechol-functionalized chitosan to cement mortar or concrete is rare to the best of our knowledge. In this study, catechol-functionalized chitosan (Cat-Chit), a well-known bioinspired polymer that imitates the basic structures and functions of living organisms and biological materials in nature, was synthesized and combined with cement mortar in various proportions. The compressive strength, tensile strength, drying shrinkage, accelerated carbonation depth, and chloride-ion penetrability of these mixes were then evaluated. In the ultraviolet–visible spectra, a maximum absorption peak appeared at 280 nm, corresponding to catechol conjugation. The sample containing 7.5% Cat-Chit polymer in water (CPW) exhibited the highest compressive strength, and its 28-day compressive strength was ~20.2% higher than that of a control sample with no added polymer. The tensile strength of the samples containing 5% or more CPW was ~2.3–11.5% higher than that of the control sample. Additionally, all the Cat-Chit polymer mixtures exhibited lower carbonation depths than compared to the control sample. The total charge passing through the samples decreased as the amount of CPW increased. Thus, incorporating this polymer effectively improved the mechanical properties, carbonation resistance, and chloride-ion penetration resistance of cement mortar.     

Test and Microstructural Analysis of a Steel Slag Cement-Based Material Using the Response Surface Method

In this study, the silica fume replacement rate, fly ash replacement rate, and curing temperature were regarded as the independent variables, and the compressive and flexural strengths were regarded as the response values. The response surface method was used to construct the response surface polynomial regression model and obtain the optimal preparation parameters of a steel slag cement-based gel slurry (SCGS). The univariate and multivariate effects on the SCGS’s strength were investigated via analysis of variance and a three-dimensional surface model, and the hydration products and strength development law were characterized via scanning electron microscopy and X-ray diffraction. The actual compressive strengths at 3 and 28 d of age were 31.78 and 53.94 MPa, respectively, which were close to the predicted values (32.59 and 55.81 MPa, respectively), demonstrating that the optimized strengths were accurate and reliable. Further, the hydration reaction rate of SiO₂ in the silica fume and the physical filling effect of the inert components of fly ash and steel slag under the optimal parameters were the key factors for the early strength of the material. Moreover, continuous C₃S hydration in steel slag and the continuous excitation of the volcanic ash properties of fly ash were important factors for the later strength.     

Design of High Volume CFBC Fly Ash Based Calcium Sulphoaluminate Type Binder in Mixtures with Ordinary Portland Cement

Growing concerns on global industrial greenhouse gas emissions have boosted research for developing alternative, less CO₂ intensive binders for partial to complete replacement of ordinary Portland cement (OPC) clinker. Unlike slag and pozzolanic siliceous low-Ca class F fly ashes, the Ca- and S-rich class C ashes, particularly these formed in circulating fluidised bed combustion (CFBC) boilers, are typically not considered as viable cementitious materials for blending with or substituting the OPC. We studied the physical, chemical-mineralogical characteristics of the mechanically activated Ca-rich CFBC fly ash pastes and mortars with high volume OPC substitution rates to find potential alternatives for OPC in building materials and composites. Our findings indicate that compressive strength of pastes and mortars made with partial to complete replacement of the mechanically activated CFBC ash to OPC is comparable to OPC concrete, showing compared to OPC pastes reduction in compressive strength only by <10% at 50% and <20% at 75% replacement rates. Our results show that mechanically activated Ca-rich CFBC fly ash can be successfully used as an alternative CSA-cement type binder.     

Supercritical CO2 Curing of Resource-Recycling Secondary Cement Products Containing Concrete Sludge Waste as Main Materials

This study aims to develop highly durable, mineral carbonation-based, resource-recycling, secondary cement products based on supercritical carbon dioxide (CO₂) curing as part of carbon capture utilization technology that permanently fixes captured CO₂. To investigate the basic characteristics of secondary cement products containing concrete sludge waste (CSW) as the main materials after supercritical CO₂ curing, the compressive strengths of the paste and mortar (fabricated by using CSW as the main binder), ordinary Portland cement, blast furnace slag powder, and fly ash as admixtures were evaluated to derive the optimal mixture for secondary products. The carbonation curing method that can promote the surface densification (intensive CaCO₃ formation) of the hardened body within a short period of time using supercritical CO₂ curing was defined as “Lean Carbonation”. The optimal curing conditions were derived by evaluating the compressive strength and durability improvement effects of applying Lean Carbonation to secondary product specimens. As a result of the experiment, for specimens subjected to Lean Carbonation, compressive strength increased by up to 12%, and the carbonation penetration resistance also increased by more than 50%. The optimal conditions for Lean Carbonation used to improve compressive strength and durability were found to be 35 °C, 80 bar, and 1 min.     

Performance of Plain Concrete and Cement Blocks with Cement Partially Replaced by Cement Kiln Dust

The growth of the construction industry has led to the greater consumption of natural resources, which has a direct or indirect negative impact on the environment. To mitigate this, recycled or waste materials are being used as a partial substitute in the manufacture of concrete. Among these waste materials is cement kiln dust (CKD), which is produced during cement production. This study investigated the potential benefits of replacing part of the cement with CKD in two construction applications, i.e., plain concrete and cement blocks. This reflects positively on cost, energy, and the environment, since putting CKD in a landfill damages agricultural soil and plant respiration. In this study, an experimental program was carried out to study how replacing various percentages of ordinary portland cement (OPC) with CKD affected the compressive strengths, the tensile strengths, and the air contents of concrete and cement blocks. Although the results showed that the compressive and tensile strengths decreased as the amount of CKD increased, the air content of the concrete increased, which showed that 5% CKD was suitable for such applications. The results were used to propose two equations that approximate the concrete and cement block compressive strengths according to the CKD replacement percentage.