污水污泥页岩建筑材料制备与性能研究
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摘要
城市生活污水处理将产生大量含水率非常高的污水污泥,已成为城市化快速发展过程中必须面临的重大环境问题之一。现有的污水污泥填埋、堆肥、焚烧等处置方式要么无害化不彻底,要么成本过高,难以处置排放量迅速增长的污水污泥,因此研究新的污水污泥资源化利用方式非常必要。本论文根据页岩建筑材料对原材料的要求和烧制过程的特点,将高含水率污水污泥与来源广泛的页岩进行混合,以污水污泥中的水分作为页岩建筑材料制品生产过程中必须外加的水分,同时利用污水污泥中有机物来补充页岩建筑材料制品烧制过程中的热值,使得污水污泥用于页岩建筑材料制备具有技术经济和环保优势。
本文研究首先根据页岩陶粒和烧结砖制备对于原材料的要求,选择了不同处理工艺的污水处理厂经过压滤脱水后得到的高含水率污水污泥,研究了污泥粒径分布范围、化学与矿物组成等,并与页岩进行对比,还研究了污水污泥与页岩混合后的塑性指数,另外,还采用TG-DTA对污水污泥的热值进行了分析。结果显示污水污泥的化学、矿物组成与页岩比较接近,颗粒非常细小,主要集中0.15mm以下,且具有较高的塑性指数,与页岩混合后可以明显改善页岩的塑性,适合页岩陶粒的成球和页岩烧结砖坯的制备,页岩陶粒料球抗冲击性能明显增强。另外,污水污泥放热量较大,在250℃~550℃的升温过程放出热量可超过3000J/g。
本文进行了污水污泥页岩烧结砖的研究,先固定污泥掺量,变化烧成温度、升温速率和保温时间等因素,进行实心和多孔污泥页岩烧结砖的烧制。结果表明污泥掺量30%时可以烧制出体积密度1600 kg/m3左右,抗压强度10MPa以上的实心砖,掺加污水污泥可明显降低烧结砖的体积密度,但也同时增加烧结砖的收缩。通过测定不同污泥掺量和不同烧成温度下的烧结砖收缩率变化,同时采用SEM进行微观结构分析,结果表明污水污泥掺入后,较低温度下页岩烧结砖的微观结构从致密的块状转为较为分散的层片状结构,密实程度较低,随着温度升高到900℃时,颗粒堆积紧密程度明显增加,但温度过度升高则产生的液相完全浸润包裹固体颗粒,微观上表现为致密的板状结构,宏观上表现非常大的体积收缩。因此,污水污泥掺入后控制页岩烧结砖的烧成温度非常重要。对污水污泥页岩砖性能分析还发现当污泥掺量过高时会出现比较严重的泛霜。
本文重点研究了污水污泥用于页岩陶粒的烧制,通过改变污水污泥掺量、预热温度和时间、焙烧温度和时间等因素,研究了陶粒的颗粒表观密度、强度和吸水率等性能。结果显示,污水污泥将明显提高页岩陶粒的烧胀性能,含水率80%左右的污水污泥掺量为20%~30%,烧胀温度达到1150℃时,可获得颗粒表观密度500kg/m3左右的超轻陶粒。还进一步研究烧制工艺参数对陶粒性能的影响,结果表明预热时适当降低温度和缩短时间,焙烧时适当提高温度和延长时间有利于获得轻质污泥页岩陶粒。
为了更好了解污水污泥在页岩陶粒烧胀过程中的作用,本文还采用SEM、XRD、IR和TG-DTA手段,研究了掺加污水污泥的页岩陶粒的内部结构、矿物组成、Si-O四面体聚合度以及高温焙烧熔融变化情况。结果显示,污水污泥页岩陶粒的主要矿物为α-石英(α-SiO2)、蓝晶石(Al2O3·SiO2)及钙长石(CaO·2Al2O3·2SiO2)等,随着污水污泥掺量增加时,陶粒中Fe的价态由赤铁矿(Fe2O3)向方铁矿(FeO)转变,反映了陶粒料球焙烧时还原环境的增强,此时,陶粒矿物中的Si-O对称伸缩振动波数降低明显,Si-O四面体的聚合度明显降低,架状结构的桥氧大量断裂,从而表现为焙烧时陶粒的熔融温度降低和熔融程度增加;污水污泥能促使陶粒内部产生大量孔结构,污泥掺量过多时会出现孔结构的连通和坍缩,随预热温度提高,陶粒表层壳结构增厚,焙烧温度越高,焙烧时间越长,陶粒内部孔结构尺寸变大,并逐渐由孤立到连通,最后合并成大孔。
本文最后研究了污水污泥中的重金属在陶粒和烧结砖烧制过程中的挥发情况以及在使用过程中的浸出情况。考虑到污水污泥中重金属可能的含量范围,选取具有代表性的重金属Zn、Cu、Cr、Pb、Ni,通过外掺重金属化合物以扩大污水污泥中的重金属含量,研究最为不利条件下污水污泥页岩建筑材料生产和使用过程中的环境特性。结果显示,在相同烧成温度下,与纯污水污泥焚烧相比,污水污泥页岩陶粒和烧结砖的重金属挥发量明显降低;另外,污水污泥页岩陶粒和烧结砖中的重金属浸出浓度都非常低,符合浸出毒性的安全标准;相比而言,陶粒比烧结砖对污水污泥中的重金属有更好的固化能力。
可以认为高含水率的污水污泥与页岩混合制备陶粒和烧结砖不仅可以充分消纳污水污泥,还能提高页岩建筑材料制品的性能,是污水污泥资源化最为有效和最为环保的技术途径;本研究条件下,污水污泥用于烧制页岩陶粒优势更为明显。
The great amount of sewage sludge with high water content, which comes from municipal sewage treatment process, has already become one of the critical environmental problems in rapid urbanization. The sewage sludge treatment methods, landfilling, composting, incination, etc., are either unthorough in harmless treatment or high in costs, thus, it is hard to handle all the surging sewage sludge. Therefore, it is critical to develop new ways of utilization. In this paper, the property requirements of raw materials to make shale building materials and their burning characteristics were fully considered. High water content sewage sludge was well mixed with widely available shale, and the water in sewage sludge can be used as the imperative water source of making shale building material. Meanwhile, the organics in sewage sludge can act as extra heat supplier in the manufacture process. Both these factors make it technically, economically and environmently advantageous of using sewage sludge to produce shale building materials.
According to the property requirements of raw materials used in manufactures of expanded shale and sintered brick, the pressure dewatered sludges of high water content from different sewage treatment plants were used. The particle size distribution, chemical and mineral compositions of the sludge were investigated and compared with those of shale. The plasiticity index of the mixture prepared with sludge and shale was also studied. In addition, the heat value of the sludge was examined by TG-DTA. The results shown that the sewage sludge has a similar chemical and mineral compositions with shale, and its particle size is very small - most of which are smaller than 0.15mm, and it has a high plasticity index. The plasticity of shale can be significantly improved. When sewage sludge was mixed in, the mix will be suitable for the balling of expanded shale and the preparation of adobe brick. It also shown that the impact resistance of expanded shale can be obviously improved. Meanwhile, the sewage sludge has a large potential of heat release, releasing more than 3000J/g during the heating process from 250℃to 550℃.
The investigation of sewage sludge shale sintered brick was performed. The influence of sintering temperature, heating rate and heat preservation time on the performance of the solid and porous bricks were investigated at a constant sewage dosage. The results shown that the solid brick with a bulk density of about 1600 kg/m3 and compressive strength of up to 10MPa can be obtained when 30% sewage sludge was added. The presence of sewage sludge could significantly decrease the bulk density. On the contrary, the sintering contraction will be strengthened as the increase of sludge dosage. The determinations of SEM microstructure analysis and changes in sintering contraction occurred under different sludge dosages and sintering temperatures shown that the densified block structure turned into a loose layer structure. When the temperature was up to 900℃, the microstructure tended to be significantly denser. But when the temperature was extensively high, the solid paticals would be thoroughly trapped by liquid phase, which will result in a high contraction of the product. Therefore, it is very important to fix sintering temperature when sewage sludge is added into shale sintered brick. Further study on the influence of sludge dosage on the property of sintered brick revealed that a high sludge dosage will cause a very severe scumming.
The calcining of expanded shale was priorally investigated. The relations of bulk density, particle strength and water absorption ration of expanded shale with factors such as sewage sludge dosage, preheating temperature and preheating time, calcining temperature and calcining time were studied. Results shown that sewage sludge will significantly improve the calcining expantion property of expanded shale. The ultra-light expanded shale with a bulk density of about 500kg/m3 can be obtained at the calcining expantion temperature of 1150℃when 20%~30% of sewage sludge with a water contend of 80% were added. The influence of calcining parameters on properties of expanded shale were further studied, the results revealed that a proper lowing of preheating temperature and preheating time and a moderate raising of calcining temperature and calcining time would benefit for the formation of light sewage sludge expanded shale.
To understand the effects of sewage sludge plays in the calcining expansion process of the expanded shale, SEM, XRD, IR and TG-DTA were used to analyze the internal structure, mineral compositions, polymerization degree of Si-O tetrahedron and high temperature sintering/melting changes of sewage sludge expanded shale. It shown that main mineral compositions of the sewage sludge expanded shale wereα-quartz(α-SiO2), kyanite(Al2O3·SiO2), anorthite(CaO·2Al2O3·2SiO2) and so on. With the increase of sewage sludge, the valency of Fe in adobe particle converted from hematite(Fe2O3)to wustite(FeO), which reflected that the reducing atmosphere was strengthened during the calcining process. At this time, the Si-O symmetric stretching vibration wave number and the Si-O tetrahedron polymerization degree were significantly decreased and a large number of bridging oxygen bindings in framework structure was disruptured. All these factors contributed to the lowering of sintering temperature and strengthening of melting degree. The sewage sludge is beneficial for the formation of large quantity of pore structure, while an excessive dosage will result in a connective pore structure and a collapse of the structure. The shell of the expanded shale will become thicker when the preheating temperature was raised; a higher calcining temperature and a longer calcining time will enlarge the size of the inner pore structure of expanded shale, which will eventually form a big pore from the isolated ones.
Finally, this paper investigated the volatility and leachability of heavy metal in sewage sludge during the burning and in-situ using processes of expanded shale and sintered brick. Regarding the possible content of heavy metals contained in the sewage sludge, we studied several representive heavy metals, i.e., Zn、Cu、Cr、Pb、Ni, to study the environmental characteristics of manufacture and utilization of building materials from sewage sludge and shale in the most severe condition. And the results shown that the amount of volatilization duiring burning processes of sintered brick and expanded shale made of sewage sludge, compared to that of pure sewage sluge, decreased obviously. Besides, the leaching amount of heavy metals in both materials was very small, and it could meet the corresponding leaching toxicity security standards. Comparatively, expanded shale can solidify heavy metals more efficiently than sintered brick.
It is believed that using high water content sewage sluge and shale to produce expanded shale and sintered brick could not only consume sewage sluge sufficiently, but also improve the performance of shale building materials. This is the best techenic method of recyling sewage sludge due to its advantages in effectiveness and environment protection. The advantage is more obvious to produce expanded shale in the presented condition of this paper.
本文研究首先根据页岩陶粒和烧结砖制备对于原材料的要求,选择了不同处理工艺的污水处理厂经过压滤脱水后得到的高含水率污水污泥,研究了污泥粒径分布范围、化学与矿物组成等,并与页岩进行对比,还研究了污水污泥与页岩混合后的塑性指数,另外,还采用TG-DTA对污水污泥的热值进行了分析。结果显示污水污泥的化学、矿物组成与页岩比较接近,颗粒非常细小,主要集中0.15mm以下,且具有较高的塑性指数,与页岩混合后可以明显改善页岩的塑性,适合页岩陶粒的成球和页岩烧结砖坯的制备,页岩陶粒料球抗冲击性能明显增强。另外,污水污泥放热量较大,在250℃~550℃的升温过程放出热量可超过3000J/g。
本文进行了污水污泥页岩烧结砖的研究,先固定污泥掺量,变化烧成温度、升温速率和保温时间等因素,进行实心和多孔污泥页岩烧结砖的烧制。结果表明污泥掺量30%时可以烧制出体积密度1600 kg/m3左右,抗压强度10MPa以上的实心砖,掺加污水污泥可明显降低烧结砖的体积密度,但也同时增加烧结砖的收缩。通过测定不同污泥掺量和不同烧成温度下的烧结砖收缩率变化,同时采用SEM进行微观结构分析,结果表明污水污泥掺入后,较低温度下页岩烧结砖的微观结构从致密的块状转为较为分散的层片状结构,密实程度较低,随着温度升高到900℃时,颗粒堆积紧密程度明显增加,但温度过度升高则产生的液相完全浸润包裹固体颗粒,微观上表现为致密的板状结构,宏观上表现非常大的体积收缩。因此,污水污泥掺入后控制页岩烧结砖的烧成温度非常重要。对污水污泥页岩砖性能分析还发现当污泥掺量过高时会出现比较严重的泛霜。
本文重点研究了污水污泥用于页岩陶粒的烧制,通过改变污水污泥掺量、预热温度和时间、焙烧温度和时间等因素,研究了陶粒的颗粒表观密度、强度和吸水率等性能。结果显示,污水污泥将明显提高页岩陶粒的烧胀性能,含水率80%左右的污水污泥掺量为20%~30%,烧胀温度达到1150℃时,可获得颗粒表观密度500kg/m3左右的超轻陶粒。还进一步研究烧制工艺参数对陶粒性能的影响,结果表明预热时适当降低温度和缩短时间,焙烧时适当提高温度和延长时间有利于获得轻质污泥页岩陶粒。
为了更好了解污水污泥在页岩陶粒烧胀过程中的作用,本文还采用SEM、XRD、IR和TG-DTA手段,研究了掺加污水污泥的页岩陶粒的内部结构、矿物组成、Si-O四面体聚合度以及高温焙烧熔融变化情况。结果显示,污水污泥页岩陶粒的主要矿物为α-石英(α-SiO2)、蓝晶石(Al2O3·SiO2)及钙长石(CaO·2Al2O3·2SiO2)等,随着污水污泥掺量增加时,陶粒中Fe的价态由赤铁矿(Fe2O3)向方铁矿(FeO)转变,反映了陶粒料球焙烧时还原环境的增强,此时,陶粒矿物中的Si-O对称伸缩振动波数降低明显,Si-O四面体的聚合度明显降低,架状结构的桥氧大量断裂,从而表现为焙烧时陶粒的熔融温度降低和熔融程度增加;污水污泥能促使陶粒内部产生大量孔结构,污泥掺量过多时会出现孔结构的连通和坍缩,随预热温度提高,陶粒表层壳结构增厚,焙烧温度越高,焙烧时间越长,陶粒内部孔结构尺寸变大,并逐渐由孤立到连通,最后合并成大孔。
本文最后研究了污水污泥中的重金属在陶粒和烧结砖烧制过程中的挥发情况以及在使用过程中的浸出情况。考虑到污水污泥中重金属可能的含量范围,选取具有代表性的重金属Zn、Cu、Cr、Pb、Ni,通过外掺重金属化合物以扩大污水污泥中的重金属含量,研究最为不利条件下污水污泥页岩建筑材料生产和使用过程中的环境特性。结果显示,在相同烧成温度下,与纯污水污泥焚烧相比,污水污泥页岩陶粒和烧结砖的重金属挥发量明显降低;另外,污水污泥页岩陶粒和烧结砖中的重金属浸出浓度都非常低,符合浸出毒性的安全标准;相比而言,陶粒比烧结砖对污水污泥中的重金属有更好的固化能力。
可以认为高含水率的污水污泥与页岩混合制备陶粒和烧结砖不仅可以充分消纳污水污泥,还能提高页岩建筑材料制品的性能,是污水污泥资源化最为有效和最为环保的技术途径;本研究条件下,污水污泥用于烧制页岩陶粒优势更为明显。
The great amount of sewage sludge with high water content, which comes from municipal sewage treatment process, has already become one of the critical environmental problems in rapid urbanization. The sewage sludge treatment methods, landfilling, composting, incination, etc., are either unthorough in harmless treatment or high in costs, thus, it is hard to handle all the surging sewage sludge. Therefore, it is critical to develop new ways of utilization. In this paper, the property requirements of raw materials to make shale building materials and their burning characteristics were fully considered. High water content sewage sludge was well mixed with widely available shale, and the water in sewage sludge can be used as the imperative water source of making shale building material. Meanwhile, the organics in sewage sludge can act as extra heat supplier in the manufacture process. Both these factors make it technically, economically and environmently advantageous of using sewage sludge to produce shale building materials.
According to the property requirements of raw materials used in manufactures of expanded shale and sintered brick, the pressure dewatered sludges of high water content from different sewage treatment plants were used. The particle size distribution, chemical and mineral compositions of the sludge were investigated and compared with those of shale. The plasiticity index of the mixture prepared with sludge and shale was also studied. In addition, the heat value of the sludge was examined by TG-DTA. The results shown that the sewage sludge has a similar chemical and mineral compositions with shale, and its particle size is very small - most of which are smaller than 0.15mm, and it has a high plasticity index. The plasticity of shale can be significantly improved. When sewage sludge was mixed in, the mix will be suitable for the balling of expanded shale and the preparation of adobe brick. It also shown that the impact resistance of expanded shale can be obviously improved. Meanwhile, the sewage sludge has a large potential of heat release, releasing more than 3000J/g during the heating process from 250℃to 550℃.
The investigation of sewage sludge shale sintered brick was performed. The influence of sintering temperature, heating rate and heat preservation time on the performance of the solid and porous bricks were investigated at a constant sewage dosage. The results shown that the solid brick with a bulk density of about 1600 kg/m3 and compressive strength of up to 10MPa can be obtained when 30% sewage sludge was added. The presence of sewage sludge could significantly decrease the bulk density. On the contrary, the sintering contraction will be strengthened as the increase of sludge dosage. The determinations of SEM microstructure analysis and changes in sintering contraction occurred under different sludge dosages and sintering temperatures shown that the densified block structure turned into a loose layer structure. When the temperature was up to 900℃, the microstructure tended to be significantly denser. But when the temperature was extensively high, the solid paticals would be thoroughly trapped by liquid phase, which will result in a high contraction of the product. Therefore, it is very important to fix sintering temperature when sewage sludge is added into shale sintered brick. Further study on the influence of sludge dosage on the property of sintered brick revealed that a high sludge dosage will cause a very severe scumming.
The calcining of expanded shale was priorally investigated. The relations of bulk density, particle strength and water absorption ration of expanded shale with factors such as sewage sludge dosage, preheating temperature and preheating time, calcining temperature and calcining time were studied. Results shown that sewage sludge will significantly improve the calcining expantion property of expanded shale. The ultra-light expanded shale with a bulk density of about 500kg/m3 can be obtained at the calcining expantion temperature of 1150℃when 20%~30% of sewage sludge with a water contend of 80% were added. The influence of calcining parameters on properties of expanded shale were further studied, the results revealed that a proper lowing of preheating temperature and preheating time and a moderate raising of calcining temperature and calcining time would benefit for the formation of light sewage sludge expanded shale.
To understand the effects of sewage sludge plays in the calcining expansion process of the expanded shale, SEM, XRD, IR and TG-DTA were used to analyze the internal structure, mineral compositions, polymerization degree of Si-O tetrahedron and high temperature sintering/melting changes of sewage sludge expanded shale. It shown that main mineral compositions of the sewage sludge expanded shale wereα-quartz(α-SiO2), kyanite(Al2O3·SiO2), anorthite(CaO·2Al2O3·2SiO2) and so on. With the increase of sewage sludge, the valency of Fe in adobe particle converted from hematite(Fe2O3)to wustite(FeO), which reflected that the reducing atmosphere was strengthened during the calcining process. At this time, the Si-O symmetric stretching vibration wave number and the Si-O tetrahedron polymerization degree were significantly decreased and a large number of bridging oxygen bindings in framework structure was disruptured. All these factors contributed to the lowering of sintering temperature and strengthening of melting degree. The sewage sludge is beneficial for the formation of large quantity of pore structure, while an excessive dosage will result in a connective pore structure and a collapse of the structure. The shell of the expanded shale will become thicker when the preheating temperature was raised; a higher calcining temperature and a longer calcining time will enlarge the size of the inner pore structure of expanded shale, which will eventually form a big pore from the isolated ones.
Finally, this paper investigated the volatility and leachability of heavy metal in sewage sludge during the burning and in-situ using processes of expanded shale and sintered brick. Regarding the possible content of heavy metals contained in the sewage sludge, we studied several representive heavy metals, i.e., Zn、Cu、Cr、Pb、Ni, to study the environmental characteristics of manufacture and utilization of building materials from sewage sludge and shale in the most severe condition. And the results shown that the amount of volatilization duiring burning processes of sintered brick and expanded shale made of sewage sludge, compared to that of pure sewage sluge, decreased obviously. Besides, the leaching amount of heavy metals in both materials was very small, and it could meet the corresponding leaching toxicity security standards. Comparatively, expanded shale can solidify heavy metals more efficiently than sintered brick.
It is believed that using high water content sewage sluge and shale to produce expanded shale and sintered brick could not only consume sewage sluge sufficiently, but also improve the performance of shale building materials. This is the best techenic method of recyling sewage sludge due to its advantages in effectiveness and environment protection. The advantage is more obvious to produce expanded shale in the presented condition of this paper.
引文
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