Fired clay bricks synergistically valorizing hazardous nickel chrome-plating sludge and fly ash: Performance assessment

Abstract

Nickel Chrome Plating Sludge (NCPS) is a hazardous waste containing 25%-30% nickel and chromium. Previous attempts to immobilize NCPS into fired clay bricks resulted in weakened strength due to porosity and microstructure deterioration. This study introduces co-valorization of NCPS and fly ash in fired clay bricks to address these issues. Factory-scale firing of green bricks, alongside conventional clay bricks, assessed the commercialization potential. The optimal proportion of NCPS, fly ash, and clay was found to be as 12.5:37.5:50.0, respectively. Fly ash addition significantly improved brick properties, causing compressive strength to increase from 3.2 MPa to 11.6 MPa for a NCPS content of 12.5%. Microstructural analysis highlighted fluxing oxides in NCPS, amorphous silica-alumina in fly ash, synergistic ceramic bond formation, enhanced sintering and pore filling during vitrification. The study also demonstrated substantial fuel savings of 40%-50% due to NCPS's high heat of combustion causing internal firing of green bricks. The developed bricks exhibited almost double linear attenuation coefficients, indicating enhanced gamma radiation shielding. Leaching tests confirmed successful heavy metal immobilization. This co-valorization approach not only overcomes previous drawbacks but also offers significant environmental and economic benefits in utilizing NCPS in brick production.