Juntao Ma*a,
Hao Zhenga,
Hao Qiua,
Yunfei Tanb and
Shunbo Zhaoa
aInternational Joint Research Lab for Eco-building Materials and Engineering of Henan, North China University of Water Resources and Electric Power, Zhengzhou 450045, China. E-mail: majuntao@ncwu.edu.cn
bZhengzhou Sewage Purification Co., Ltd, Zhengzhou 450045, China
First published on 29th July 2025
The rapid increase in sewage sludge (SS) production and the global pursuit of carbon neutrality have driven the demand for the high-value construction material utilization of SS. In this study, calcium-rich solid wastes—carbide slag (CS) and phosphogypsum (PG)—were co-calcined with SS at elevated temperatures (800–1000 °C) to address the insufficient cementitious activity of thermally activated sludge. The resulting products were used to replace 30% of ordinary Portland cement (OPC) in pastes. The effects of calcination temperature, CS addition, and PG addition on the properties of calcined SS and its pastes were systematically investigated using XRD, FTIR, SEM, T2NMR, and TG-DSC. Results showed that calcination at 800 °C converted kaolinite and muscovite in SS into amorphous reactive phases, significantly enhancing pozzolanic activity and mechanical strength. Co-calcination with CS and PG facilitated the formation of anorthite and calcium aluminate gels, further improving paste hydration (AFt, CH formation) and reducing its porosity. When CS and PG replaced 30% and 15% of SS, respectively, and the mixture was calcined at 800 °C, a clear synergistic hydration effect was observed. Response surface methodology identified the optimal conditions as 882.45 °C, 14.78% CS, and 2.62% PG, under which the compressive strength reached 85% of that of OPC, with a production cost of 190.19 RMB per t and carbon emissions of 529.17 kg CO2 e per t, both notably reduced compared to OPC. These results demonstrate that MWCS is a promising sustainable cementitious material for low-strength engineering applications or as a partial cement replacement.
The inherently low reactivity of SS presents a persistent challenge for its application as an SCM. High-temperature calcination, as a widely adopted thermal activation method, has been demonstrated to effectively enhance the pozzolanic activity of various aluminosilicate materials.24–26 Accordingly, numerous studies have systematically investigated the effects and mechanisms of thermal activation on the reactivity of SS. For instance, Tantawy et al. reported that calcination at 600–900 °C facilitated the dehydration of Al(OH)3 in SS, resulting in the formation of amorphous and reactive Al2O3 and silica gel, which are recognized as the principal contributors to the pozzolanic activity of SS. Their findings further indicated that calcination at 800 °C was sufficient to significantly enhance the reactivity of SS.27 Similarly, another study examined the evolution of SS reactivity following calcination at 600–800 °C, demonstrating that increasing temperature promoted the dehydroxylation of crystalline silicon and aluminum, thereby generating highly reactive amorphous phases within this range.28 Quantitative analysis by Chang et al. confirmed that the amorphous content in SS peaked at 800 °C, further substantiating the results of previous investigations.29 Moreover, Fernandes et al. assessed the reactivity of SS by monitoring calcium hydroxide (CH) consumption after calcination at 600–800 °C. Their results showed that CH consumption declined with increasing calcination temperature, suggesting that an optimal temperature is required to maximize the activation of SS reactivity.30 Although thermal activation has been shown to improve the pozzolanic activity of SS, the intrinsic lack of cementitious properties in thermally activated SS continues to restrict its widespread application. As a result, enhancing the cementitious properties of SS has emerged as a more promising research direction, since synergistic hydration with cement could broaden its application in low-carbon and high-value construction materials. Cementitious properties are primarily derived from the hydration of silicate minerals, such as C2S and C3S in Portland cement.31 For SS rich in silicon and aluminum, the deficiency of calcium is generally regarded as the critical factor limiting its cementitious performance.
The synergistic co-utilization of multiple solid wastes has become a widely accepted strategy for enhancing the cementitious properties of waste-derived materials. At elevated temperatures, calcium, silicon, and aluminum sourced from different types of solid wastes can interact synergistically to form cementitious phases.32,33 Numerous studies have demonstrated the effectiveness of multi-solid waste synergy under such conditions. For example, Sun et al.34 examined the feasibility of producing cementitious materials by co-calcining coal gangue, carbide slag, steel slag, and gypsum at high temperatures. Their findings indicated that the co-calcined product exhibited the formation of hydraulically active C2S and C4A3Š phases, and the 3 day heat of hydration was approximately 40% higher than that of ordinary Portland cement. In a similar vein, Duan et al.35 investigated the synergistic behavior of fly ash-carbide slag-flue gas desulfurization gypsum systems, showing that, after high-temperature calcination, these systems could hydrate to form AFt and C–S–H phases, thus overcoming the inability of the individual raw materials to hydrate independently. Gu et al.36 further explored the hydration mechanisms within such systems, demonstrating that variations in the Ca/Si ratio played a crucial role in the generation of C–S–H phases. Additional research has documented the successful synthesis of high-performance cementitious materials from mixtures of fly ash, carbide slag, and desulfurized gypsum through high-temperature calcination, achieving compressive strengths exceeding 70 MPa after 28 days of curing.37,38
In this study, carbide slag and phosphogypsum were individually co-calcined with SS at elevated temperatures. The hydration characteristics of the calcined sludge and its performance in cementitious pastes were systematically examined using X-ray diffraction (XRD), Fourier-transform infrared spectroscopy (FTIR), T2 nuclear magnetic resonance (T2NMR), scanning electron microscopy (SEM), and thermogravimetric-differential scanning calorimetry (TG-DSC). Response surface methodology was employed to optimize the mix design of multi-solid waste composite calcined sewage sludge (MWCS). The suitability of the optimized MWCS as a cementitious material was evaluated based on mechanical strength tests, as well as assessments of production cost and carbon emissions.
Materials | SiO2 | Al2O3 | Fe2O3 | CaO | MgO | SO3 | Na2O | TiO2 | K2O | P2O5 | Loss |
---|---|---|---|---|---|---|---|---|---|---|---|
SS | 38.97 | 11.71 | 4.09 | 3.44 | 2.11 | 3.69 | 1.12 | 0.47 | 2.15 | — | 31.92 |
CS | 3.23 | 1.08 | 0.24 | 67.9 | 0.12 | — | 0.13 | 0.32 | 1.1 | — | 25.88 |
PG | 3.19 | 0.57 | 1.25 | 38.25 | 0.18 | 48.98 | 0.13 | 1.1 | 0.08 | 1.19 | 3.88 |
OPC | 22.36 | 4.15 | 2.59 | 60.13 | 2.17 | 1.95 | 0.79 | — | — | — | 5.37 |
Apparent density (kg m−3) | Specific surface area (m2 kg−1) | Setting time (min) | Compressive strength (MPa) | Flexural strength (MPa) | |||
---|---|---|---|---|---|---|---|
Initial | Final | 3d | 28d | 3d | 28d | ||
3050 | 343 | 184 | 262 | 25.7 | 47.5 | 5.7 | 12.3 |
Paste groups | Water (g) | OPC (g) | SS (g) | Mix proportions for calcination of SS and multi-solid waste composite SS | ||||
---|---|---|---|---|---|---|---|---|
Raw material group | SS (%) | CS (%) | PG (%) | Temperature (°C) | ||||
P-C | 200 | 500 | 0 | C | — | — | — | — |
P-SS | 200 | 350 | 150 | SS | — | — | — | — |
P-SS-800/900/1000 | 200 | 350 | 150 | SS-800/900/1000 | 100 | — | — | 800 |
900 | ||||||||
1000 | ||||||||
P-SSxCS-800/900/1000 | 200 | 350 | 150 | SSxCS-800/900/1000 | 95 | 5 | — | 800 |
200 | 350 | 150 | 90 | 10 | — | |||
200 | 350 | 150 | 85 | 15 | — | 900 | ||
200 | 350 | 150 | 80 | 20 | — | |||
200 | 350 | 150 | 75 | 25 | — | 1000 | ||
200 | 350 | 150 | 70 | 30 | — | |||
P-SSyPG-800/900/1000 | 200 | 350 | 150 | SSyPG-800/900/1000 | 95 | — | 5 | 800 |
200 | 350 | 150 | 90 | — | 10 | |||
200 | 350 | 150 | 85 | — | 15 | 900 | ||
200 | 350 | 150 | 80 | — | 20 | |||
200 | 350 | 150 | 75 | — | 25 | 1000 | ||
200 | 350 | 150 | 70 | — | 30 |
Serials | Factors | Levels | ||
---|---|---|---|---|
−1 | 0 | 1 | ||
A | Temperature (°C) | 800 | 900 | 1000 |
B | CS additions (%) | 10 | 15 | 20 |
C | PG additions (%) | 0 | 3 | 6 |
Fig. 5 presents the FTIR spectra of SS before and after calcination at different temperatures. The absorption band observed at 3425 cm−1 in SS calcined at all three temperatures corresponds to the vibration of –O–H in structural water, with the largest peak area detected at 800 °C. This observation aligns with the variation in the muscovite diffraction peak in the XRD results, confirming that the most significant dehydration and dehydroxylation reactions occur at 800 °C. The asymmetric stretching vibration peaks of Si(AlIV)–O–Si in the 1000–1100 cm−1 region shift to higher wavenumbers and become broader, indicating that mineral dehydration reduces the interlayer spacing of silicate structures and decreases polyhedral crystallinity, thereby reflecting the impact of high-temperature calcination on the crystal structure. A new absorption band at 557 cm−1, attributed to the vibration of Al–O–Si, appears after calcination, with its maximum area observed at 1000 °C, suggesting significant phase transformations at this temperature. This finding is consistent with the formation and evolution of the mullite phase identified in the XRD analysis. The Si–O vibration band around 464 cm−1 indicates changes in the SiO2 crystal structure with increasing temperature.
Fig. 6 illustrates the microstructural evolution of SS before and after calcination at 800 °C (SS-800). The raw SS particles display irregular shapes, rough surfaces, and abundant pores, resulting in a loosely packed structure. In contrast, exposure to high-temperature calcination induces pronounced morphological and structural modifications in SS. During calcination at 800 °C, mineral dehydration and dehydroxylation processes lead to more uniform particle morphology and smoother surfaces. Moreover, the disruption of crystalline structures and subsequent formation of amorphous phases contribute to the densification of the microstructure.
The phase composition of the pastes at 3 and 28 days was analyzed by XRD, and the results are presented in Fig. 8. Since the pozzolanic reaction consumes CH (portlandite),47 changes in the intensity of the portlandite diffraction peaks can be used to evaluate the effect of SS calcined at different temperatures on the hydration behavior of the pastes. The results indicate that, compared to the OPC paste (P-C), the intensities of the CH diffraction peaks in the calcined SS–OPC pastes (P-SS-800/900/1000) were reduced at both 3 and 28 days, suggesting enhanced pozzolanic activity of the calcined SS. Notably, the CH peak intensities exhibited a more pronounced decrease at 28 days, implying a higher degree of pozzolanic reaction at this curing age. It is noteworthy that the lowest portlandite diffraction peak intensities at both 3 and 28 days were observed in the P-SS-800 paste, although the highest 3 day compressive strength was obtained for P-SS-900. This discrepancy can be attributed to the abundant formation of AFt (ettringite) in P-SS-900, which is known to positively influence early-age strength. Therefore, the high ettringite content in P-SS-900 accounts for its elevated 3 day strength. In contrast, the substantial reduction of portlandite in P-SS-800 indicates that SS calcined at 800 °C underwent the most effective pozzolanic reaction, resulting in greater CH consumption. These findings further confirm that calcination at 800 °C is sufficient to activate the pozzolanic reactivity of SS.
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Fig. 8 Phase composition of SS–OPC pastes with SS calcined at different temperatures ((a) 3 days; (b) 28 days). |
To corroborate the XRD results, phase changes and the quantitative analysis of CH in the 28 day pastes were further investigated by TG-DSC, as shown in Fig. 9. The TG curve represents the mass loss associated with mineral decomposition, while the DSC curve reflects the corresponding heat flow. Typically, the decomposition of minerals such as C–S–H, AFt, and AFm occurs below 400 °C.48 The mass loss observed between 400 °C and 500 °C is primarily attributed to the dehydration of CH.49 Compared with P-C, the incorporation of calcined SS led to only minor changes in the endothermic peak of CH, which is consistent with the variations in the portlandite diffraction peaks observed in the XRD results, indicating a limited reaction between calcined SS and CH. The DSC data further confirmed the limited pozzolanic reactivity of the calcined SS. Quantitative analysis revealed that the CH contents in the P-C, P-SS-800, P-SS-900, and P-SS-1000 pastes were 3.31%, 2.41%, 2.5%, and 2.59%, respectively, indicating that the pozzolanic reaction of SS calcined at 800 °C was the most significant.
![]() | ||
Fig. 9 TG-DSC results of 28 day SS–OPC pastes with SS calcined at different temperatures ((a) TG; (b) DSC). |
Fig. 10 presents the pore structure of the 28 day pastes as characterized by T2NMR. T2NMR facilitates the analysis of pore size distribution during the hydration process by measuring relaxation times.50 The spectra exhibit two principal peaks: the primary peak centered at approximately 6 ms and the secondary peak at around 30 ms, corresponding to large and small pores, respectively. The relative heights of the primary peaks for the four pastes are ranked as follows: P-SS-800 > P-SS-1000 > P-C > P-SS-900, indicating differences in small pore distribution and the influence of calcination temperature on the pore structure of SS–OPC pastes. Further analysis, using P-C as the control, revealed that for P-SS-800, the area of the primary peak decreased while the secondary peak remained unchanged, and both peaks shifted towards shorter relaxation times. This suggests that SS calcined at 800 °C reduced both the pore size and overall porosity of the paste. For P-SS-900, both the primary and secondary peak areas remained largely unchanged, but both peaks shifted slightly towards shorter relaxation times, indicating that the incorporation of SS calcined at 900 °C resulted in the transformation of some large pores into small pores and promoted a more uniform pore size distribution, without markedly affecting total porosity. In contrast, for P-SS-1000, although the primary peak area showed minimal change, the secondary peak area increased slightly, and both peaks shifted towards longer relaxation times, indicating that SS calcined at 1000 °C increased both the pore size and porosity of the paste.
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Fig. 11 Compressive strength of calcined SS–OPC pastes with varying CS/PG additions (a) CS 3 days; (b) CS 28 days; (c) PG 3 days; (d) PG 28 days. |
For pastes containing PG, the 3 day compressive strength at both 800 °C and 1000 °C initially increases and then decreases with increasing PG addition, reaching maxima at 5% (27.9 MPa) and 15% (20.5 MPa), respectively. At 900 °C, the strength demonstrates a trend of gradual decline, sharp drop, and fluctuation, with a local maximum (27.9 MPa) at 10% PG, but still lower than the control (Fig. 11c). At 28 days, only the P-SS25PG-1000 sample (47.7 MPa) exhibited higher strength than the control, while no significant changes were observed in the other samples (Fig. 11d). Thus, the highest 3 day and 28 day compressive strengths for PG-incorporated calcined SS–OPC pastes were observed in P-SS5PG-800 and P-SS25PG-1000, respectively. These findings suggest that the effect of PG addition is temperature-dependent: early-age strength enhancement is more readily achieved at 800 °C with a lower PG addition (5%), while long-term strength relies on the combination of 1000 °C and a higher PG addition (25%). Notably, the 28 day strengths of pastes calcined at 800 °C with low PG additions (<10%) were the highest among all samples.
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Fig. 12 Phase composition of calcined SS with different CS/PG additions ((a) 10% CS; (b) 20% CS; (c) 30% CS; (d) 5% PG; (e) 10% PG; (f) 15% PG). |
For samples with PG addition, anorthite and CA phases were detected at all temperatures, and their diffraction peak intensities increased with higher PG addition, indicating that PG promoted anorthite formation at elevated temperatures.52–54 This further demonstrates the interaction between temperature and PG addition. Moreover, CaO generated from the decomposition of PG at high temperatures, in combination with Al2O3, facilitated CA formation. The cementitious phases for all PG additions appeared most prominently in SS calcined at 800 °C, suggesting that this temperature is optimal for the decomposition and recombination of PG and SS minerals, thereby enhancing the cementitious properties of the calcined product.
The phase transformations of SS calcined with 30% CS addition or 15% PG addition at different temperatures were analyzed by FTIR to validate the XRD results. As shown in Fig. 13a, for SS calcined with 30% CS addition, the absorption peak at 3641 cm−1 is attributed to the dehydroxylation of kaolinite and its conversion into highly active metakaolinite.44 The increased area of the CO32− absorption peak at 1439 cm−1 indicates that CS decomposes at high temperature to form CaCO3, which, together with Al(OH)3, serves as a precursor for CA formation.52 This observation aligns with the XRD findings. The increased areas of the Si–O–Si stretching vibration peaks at 1000–1100 cm−1 and 774 cm−1 after calcination with CS indicate that the introduction of Ca2+ promotes the transformation of silicate mineral structures into amorphous phases. In contrast, the pronounced reduction in the areas of the Al–O–Si and Si–O bending vibration peaks at 557 cm−1 and 464 cm−1 reveals the transformation of the quartz crystal structure.
For SS calcined with 15% PG addition, the absorption peaks in the 1500–3000 cm−1 range disappeared, a trend similar to that of SS calcined without PG (Fig. 13b). The changes in the Si–O–Si stretching peaks at 1000–1100 cm−1 and 774 cm−1 are also attributed to the breakdown of the crystal structure at high temperatures and the formation of amorphous aluminosilicates. However, the peak area increased and was accompanied by a shift in wavenumber for the PG-added sample, indicating that Ca2+ and SO42− generated from the decomposition of PG promoted the polymerization of silicate minerals, resulting in the formation of calcium sulfoaluminate structures.55 The appearance of S–O bending vibration peaks at 678 cm−1 and 602 cm−1 further confirms the contribution of PG to the formation of sulfate-containing structures. Unlike the results for CS addition, the reappearance of the Si–O bending peak at 460 cm−1 suggests that PG addition during calcination doesn't significantly affect the crystal structure of quartz in SS.
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Fig. 14 Phase composition of 3 day calcined SS–OPC pastes with different CS/PG additions ((a) 10% CS; (b) 20% CS; (c) 30% CS; (d) 5% PG; (e) 10% PG; (f) 15% PG). |
For 3 day pastes with PG addition, characteristic AFt peaks were enhanced at all temperatures, attributable to the reaction between SO42− released from the thermal decomposition of PG and the aluminum source, which promotes AFt formation57 and is accompanied by CH consumption.58 At 800 °C, the intensity of the portlandite diffraction peak gradually decreased with increasing PG addition, further supporting this reaction mechanism. In contrast, at 900 °C and 1000 °C, the portlandite peaks first increased and then decreased, respectively, indicating that the reaction pathways of PG may vary with temperature. Further analysis showed that the thermal decomposition of PG also influences the formation of C2S among the hydration products. The °C released from PG can delay the transformation of C2S to inert γ-C2S,59 while enhancing the hydration activity of C2S.60 The trend of the C2S diffraction peak intensity was consistent with that of portlandite, confirming the synergistic effect of PG on the generation and hydration of C2S at different temperatures. Therefore, calcined SS with PG addition exhibited reaction characteristics similar to those observed in the CS-blended samples.
Fig. 15 presents the 28 day phase composition results of calcined SS–OPC pastes with 10%, 20%, and 30% CS or 5%, 10%, and 15% PG at different temperatures. The overall trends are generally consistent with those observed at 3 days. Notably, the sample containing 20% CS at 800 °C (P-SS20CS-800) exhibited substantially lower portlandite and quartz diffraction peak intensities than other groups, indicating that the combination of 800 °C and this CS addition is favorable for crystalline phase reactions and structural transformation. Meanwhile, the intensity of the AFt phase showed no significant difference between the 20% and 30% CS samples, suggesting that the early-stage influence of CA-generated AFt diminishes over time, while secondary hydration driven by pozzolanic reactions becomes more prominent at later ages.61 These results indicate that calcination at 800 °C with 20% CS addition is conducive to the long-term hydration reaction of the paste.
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Fig. 15 Phase composition of 28 day calcined SS–OPC pastes with different CS/PG additions ((a) 10% CS; (b) 20% CS; (c) 30% CS; (d) 5% PG; (e) 10% PG; (f) 15% PG). |
For the PG-incorporated pastes, the XRD results showed that at 800 °C, the portlandite peak intensity initially decreased and then increased with increasing PG addition, whereas at 900 °C and 1000 °C, the intensity first increased and then decreased. This variation suggests that PG addition affects the hydration reaction process at different temperatures. At elevated temperatures, the synergistic calcination of PG and SS enhanced the reactivity of C2S, thereby promoting the later-stage formation of CH. Thus, the diffraction peak intensities of C2S and CH can be used to evaluate the late hydration performance. The results revealed that for all three PG additions, the intensities of the portlandite and C2S peaks followed the order 900 °C > 1000 °C > 800 °C, and for the 15% PG samples, the portlandite peaks were the most pronounced at each temperature, indicating that this addition favors the pozzolanic reaction and the late hydration of C2S.
Fig. 16 shows the 28 day TG-DSC results for calcined SS–OPC pastes containing 30% CS addition or 15% PG addition at different temperatures. The CH mass loss data indicate that, for the 800 °C group, the value is slightly higher than that of P-C, remains unchanged at 900 °C, and is slightly lower at 1000 °C, suggesting that, across different calcination temperatures, the incorporation of calcined SS with 30% CS addition doesn't inhibit the hydration of OPC. In the DSC curves, the thermal effects associated with AFm and C–S–H are also more pronounced in the 800 °C sample, indicating a synergistic enhancement of hydration. Quantitative analysis revealed that the CH contents of P-C, P-SS30CS-800, P-SS30CS-900, and P-SS30CS-1000 were 3.31%, 3.46%, 3.38%, and 3.27%, respectively. The slight increase in CH content may be attributed to the hydration of C2S and C3S produced from calcined CS.
![]() | ||
Fig. 16 TG-DSC results of 28 day calcined SS–OPC pastes ((a) 30% CS TG; (b) 30% CS DSC; (c) 15% PG TG; (d) 15% PG DSC). |
For pastes containing 15% PG addition, the TG-DSC curves for all samples displayed decomposition peaks for AFm, confirming that PG provided a sulfur source during hydration and promoted AFm formation, consistent with the XRD results. Among the different calcination temperatures, P-SS15PG-800 exhibited the most significant mass loss and heat flow associated with AFm and C–S–H, indicating higher hydration activity at 800 °C. The CH content was significantly lower than that of P-C, with values for the four groups being 3.31%, 1.93%, 2.16%, and 2.18%, respectively, reflecting the consumption of CH during prolonged pozzolanic and hydration reactions.
Fig. 17 displays the T2NMR pore structure characteristics of 28 day calcined SS–OPC pastes containing 30% CS addition or 15% PG addition at different calcination temperatures. As shown in Fig. 17a, for pastes with 30% CS addition, the main peak heights follow the order: P-SS30CS-1000 > P-SS30CS-900 > P-SS30CS-800. Compared to P-C, the primary and secondary peaks of P-SS30CS-800 become lower and broader and shift toward shorter relaxation times, with a slight decrease in the primary peak area and little change in the secondary peak. This indicates that SS calcined at 800 °C reduces pore size and decreases porosity. For the 900 °C sample, the primary peak area increases slightly with a slight shift, and the secondary peak remains relatively unchanged, suggesting a reduction in small pore size while overall porosity remains stable. For the 1000 °C sample, both primary and secondary peak areas increase and shift toward longer relaxation times, indicating an overall increase in pore size and porosity.
For pastes with 15% PG addition, the main peak heights are ranked as P-SS15PG-1000 > P-SS15PG-900 > P-SS15PG-800. Compared to P-C, the primary and secondary peaks of the 800 °C sample become narrower and smaller, with the primary peak shifting toward shorter relaxation times and the secondary peak shifting toward longer relaxation times, indicating an increase in large pore size, a reduction in small pore size, and an overall decrease in porosity. In the 900 °C sample, the shapes of both peaks remain essentially stable, with only the secondary peak shifting, reflecting a slight increase in large pore size while the structure of small pores is maintained. In the 1000 °C sample, the primary peak increases in height and area, while the secondary peak becomes narrower and smaller, both shifting toward longer relaxation times, indicating a significant increase in both pore size and porosity.
Std | Run | A: temperature (°C) | B: CS addition (%) | C: PG addition (%) | 3 day compressive strength (MPa) | 28 day compressive strength (MPa) |
---|---|---|---|---|---|---|
5 | 1 | 800 | 15 | 0 | 27.59 | 58.50 |
11 | 2 | 900 | 10 | 6 | 25.16 | 55.15 |
6 | 3 | 1000 | 15 | 0 | 24.64 | 50.84 |
4 | 4 | 1000 | 20 | 3 | 21.97 | 47.53 |
2 | 5 | 1000 | 10 | 3 | 21.66 | 56.14 |
8 | 6 | 1000 | 15 | 6 | 21.99 | 53.36 |
17 | 7 | 900 | 15 | 3 | 32.79 | 49.58 |
16 | 8 | 900 | 15 | 3 | 33.32 | 50.32 |
1 | 9 | 800 | 10 | 3 | 26.26 | 54.16 |
12 | 10 | 900 | 20 | 6 | 24.32 | 52.71 |
15 | 11 | 900 | 15 | 3 | 33.30 | 50.24 |
10 | 12 | 900 | 20 | 0 | 28.88 | 52.61 |
14 | 13 | 900 | 15 | 3 | 32.88 | 51.17 |
3 | 14 | 800 | 20 | 3 | 23.87 | 57.92 |
9 | 15 | 900 | 10 | 0 | 28.91 | 51.72 |
7 | 16 | 800 | 15 | 6 | 28.60 | 55.25 |
13 | 17 | 900 | 15 | 3 | 32.05 | 50.15 |
Source | Sum of squares | Degrees of freedom | Mean square | F-value | P-value | Significance |
---|---|---|---|---|---|---|
Model | 274.64 | 9 | 30.52 | 110.77 | <0.0001 | Highly significant |
A | 21.32 | 1 | 21.32 | 77.39 | <0.0001 | Highly significant |
B | 1.09 | 1 | 1.09 | 3.95 | 0.0873 | Not significant |
C | 6.04 | 1 | 6.04 | 21.92 | 0.0023 | Highly significant |
AB | 1.82 | 1 | 1.82 | 6.62 | 0.0369 | Significant |
AC | 11.09 | 1 | 11.09 | 40.25 | 0.0004 | Highly significant |
BC | 0.164 | 1 | 0.164 | 0.5954 | 0.4656 | Not significant |
A2 | 72.35 | 1 | 72.35 | 262.63 | <0.0001 | Highly significant |
B2 | 117.51 | 1 | 117.51 | 426.55 | <0.0001 | Highly significant |
Fig. 18 illustrates the interactive effects of multiple variables on 3 day compressive strength. The interaction between calcination temperature and CS addition is characterized by a steep 3D response surface and dense contour lines, signifying a pronounced effect on the response variable (3 day strength). The interaction between calcination temperature and PG addition is also substantial, as evidenced by a steep response surface and relatively dense contour lines. In contrast, the response surface for PG addition and CS addition is relatively flat, with sparse contour lines, indicating a weaker influence on the response variable.
These results suggest that, among the single variables, the order of influence on 3 day compressive strength is: calcination temperature > PG addition > CS addition. For multi-factor interactions, the order is: calcination temperature and PG addition > calcination temperature and CS addition > PG addition and CS addition.
Source | Sum of squares | Degrees of freedom | Mean square | F-value | P-value | Significance |
---|---|---|---|---|---|---|
Model | 144.03 | 9 | 16 | 21.99 | 0.0002 | Highly significant |
A | 40.32 | 1 | 40.32 | 55.41 | 0.0001 | Highly significant |
B | 5.12 | 1 | 5.12 | 7.04 | 0.0328 | Significant |
C | 0.98 | 1 | 0.98 | 1.35 | 0.2839 | Not significant |
AB | 38.25 | 1 | 38.25 | 52.57 | 0.0002 | Highly significant |
AC | 8.32 | 1 | 8.32 | 11.44 | 0.0117 | Significant |
BC | 2.77 | 1 | 2.77 | 3.81 | 0.0919 | Not significant |
A2 | 27.22 | 1 | 27.22 | 37.41 | 0.0005 | Highly significant |
B2 | 5.12 | 1 | 5.12 | 7.04 | 0.0328 | Significant |
C2 | 11.5 | 1 | 11.5 | 15.81 | 0.0054 | Highly significant |
Residual | 5.09 | 7 | 0.7277 | |||
Lack of fit | 3.79 | 3 | 1.26 | 3.88 | 0.1114 | Not significant |
Error | 1.3 | 4 | 0.3254 | |||
Total | 149.12 | 16 |
Fig. 19 illustrates the interactive effects of multiple variables on 28 day compressive strength. As shown in the figure, the 3D response surface for calcination temperature and CS addition is steep, with dense contour lines, indicating a pronounced effect. The surface for calcination temperature and PG addition is moderately steep with relatively dense contour lines, suggesting a decrease in the level of significance. In contrast, the response surface for PG addition and CS addition is flat, with sparse contour lines, indicating a weaker influence.
In summary, the order of influence of single factors on 28 day compressive strength is: calcination temperature > CS addition > PG addition. For multi-factor interactions, the order is: calcination temperature and CS addition > calcination temperature and PG addition > PG addition and CS addition.
3 day compressive strength (MPa) | Mean 3 day compressive strength (MPa) | Deviation of 3 day compressive strength (%) | 28 day compressive strength (MPa) | Mean 28 day compressive strength (MPa) | Deviation of 28 day compressive strength (%) |
---|---|---|---|---|---|
32.37 | 32.12 | 2.87 | 54.75 | 55.32 | 4.79 |
33.16 | 56.80 | ||||
32.15 | 55.81 | ||||
31.95 | 54.63 | ||||
31.17 | 54.59 |
To address concerns regarding experimental errors in Table 8, all compressive strength tests were conducted in triplicate under identical curing and testing conditions, and the average value was calculated. The maximum deviation for the 3 day compressive strength was 2.87%, and for the 28 day compressive strength was 4.79%, both below the commonly accepted threshold of 5% for cement-based materials. This demonstrates that the reproducibility and reliability of the experimental results are sufficient for scientific analysis and practical application, and that both R1 and R2 can effectively predict the 3 day and 28 day compressive strengths of MWCS paste replacing 30% of OPC.
Materials | Cost (RMB per t) | Carbon emissions (kg CO2 e per t) | ||||
---|---|---|---|---|---|---|
Grinding | Calcination | Total | Grinding | Calcination | Total | |
SS | 2.79 | 48.68 | 51.48 | 2.19 | 38.22 | 40.41 |
CS | 0.09 | 1.54 | 1.63 | 0.07 | 1.21 | 1.28 |
PG | 0.50 | 8.71 | 9.21 | 0.39 | 6.84 | 7.23 |
The economic and environmental benefits of MWCS were evaluated by comparison with the costs and carbon emissions of the material's traditional processing (MTP). As of January 2025, the price of OPC was 546 RMB per t, with carbon emissions of 735 kg CO2 e per t.51 The traditional processing costs for SS, CS, and PG were 300 RMB per t, 100 RMB per t, and 60 RMB per t, respectively, with carbon emissions of 500 kg CO2 e per t, 20 kg CO2 e per t, and 12 kg CO2 e per t.
Fig. 20 compares the costs and carbon emissions between MTP and MWCS. Compared with MTP, the cost of MWCS was reduced from 342.94 RMB per t to 190.19 RMB per t, representing a 44.54% decrease. When replacing 30% OPC, the carbon emissions decreased from 748.88 kg CO2 e per t to 529.17 kg CO2 e per t, a reduction of 29.34%. The development and application of MWCS thus effectively reduce both the cost and carbon emissions compared to MTP.
The composition and hydration performance of multi-solid waste composite calcined sewage sludge (MWCS) are primarily influenced by the following factors: (1) the relative content of calcium, silicon, aluminum, and sulfur in the raw materials, especially the Ca/Si and Ca/S ratios, which determine the formation of key hydration products; (2) the specific dosage and combination of each component (sewage sludge, carbide slag, and phosphogypsum), which modulate the balance and synergy of reactive species; and (3) the calcination temperature, which affects the extent of phase transformation and the generation of amorphous active phases. Adjusting the calcium content mainly regulates the pozzolanic activity and promotes the formation of calcium silicate and aluminate hydrates, while sulfate ions introduced by phosphogypsum influence the generation of ettringite and pore structure. These factors interact to determine the hydration mechanism and cementitious efficiency of MWCS, making the regulation strategy universally applicable to different types of industrial solid wastes.
The enhanced cementitious performance of MWCS is attributed to the synergistic chemical reactions among the silicon–aluminum phases in sewage sludge, calcium sources in carbide slag, and sulfate sources in phosphogypsum during high-temperature calcination. Specifically, the decomposition of kaolinite and muscovite in sludge generates amorphous silica and alumina, which react with calcium oxide (from CS) to form calcium silicate hydrate (C–S–H) and calcium aluminate phases. Meanwhile, the introduction of sulfate ions (from PG) facilitates the formation of ettringite (AFt), further optimizing the microstructure of the hydrated paste. These coupled reactions not only enhance the early and late strength development but also promote the densification of the pore structure, as demonstrated by XRD, FTIR, and NMR analyses. Thus, the regulation of calcium and sulfur components enables precise control of the hydration pathways and the optimization of cementitious properties.
(1) The crystalline structures of potentially pozzolanic minerals in SS, such as kaolinite and muscovite, were converted into amorphous phases after high-temperature calcination, thereby activating the pozzolanic reactivity of SS. As the calcination temperature increased from 800 °C to 1000 °C, this transformation diminished, indicating that 800 °C is the threshold temperature for effectively activating the pozzolanic potential of SS.
(2) The additions of CS and PG significantly influenced the cementitious properties of SS. XRD and FTIR analyses revealed that, at 30% CS addition or 15% PG addition, the amorphous reactive silica and alumina produced from the high-temperature decomposition of SS reacted optimally with the decomposition products of CS or PG, resulting in the best cementitious effect. The optimal reaction temperature was identified as 800 °C.
(3) When SS calcined at 800 °C was used to replace 30% of OPC in paste, both 3 day and 28 day compressive strengths were maximized. Microstructural analyses indicated that calcination at 800 °C imparted the highest pozzolanic activity to SS, promoting secondary hydration of CH in the paste. CS facilitated the formation of cementitious phases such as CA, while PG decomposition contributed to C3S formation and enhanced its reactivity. These effects supported the generation of hydration products such as AFt and CH, ultimately reducing the pore size and porosity of the paste.
(4) Response surface methodology was used to evaluate the effects of single factors and their interactions on 3 day and 28 day compressive strengths, and to optimize the MWCS mix design. Calcination temperature had the greatest influence on both strengths, with PG addition mainly affecting 3 day strength and CS addition mainly affecting 28 day strength. Among interactions, calcination temperature combined with PG addition most impacted 3 day strength, while calcination temperature combined with CS addition most impacted 28 day strength. The optimal mix proportion was 882.45 °C, 14.78% CS, and 2.62% PG.
(5) The optimized MWCS achieved a production cost of 190.19 RMB per t and carbon emissions of 529.17 kg CO2 e per t, representing reductions of 44.54% in cost and 29.34% in carbon emissions compared to conventional processes. The MWCS developed through thermal activation and synergistic utilization of multiple solid wastes exhibits remarkable economic and environmental advantages. The optimized MWCS can be used as a cementitious material for low-strength engineering applications or as a partial replacement for cement.
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