Application of the Taguchi Method for Optimizing the Process Parameters of Producing Lightweight Aggregates by Incorporating Tile Grinding Sludge with Reservoir Sediments

This study aimed to apply the Taguchi optimization technique to determine the process conditions for producing synthetic lightweight aggregate (LWA) by incorporating tile grinding sludge powder with reservoir sediments. An orthogonal array L16(45) was adopted, which consisted of five controllable four-level factors (i.e., sludge content, preheat temperature, preheat time, sintering temperature, and sintering time). Moreover, the analysis of variance method was used to explore the effects of the experimental factors on the particle density, water absorption, bloating ratio, and loss on ignition of the produced LWA. Overall, the produced aggregates had particle densities ranging from 0.43 to 2.1 g/cm3 and water absorption ranging from 0.6% to 13.4%. These values are comparable to the requirements for ordinary and high-performance LWAs. The results indicated that it is considerably feasible to produce high-performance LWA by incorporating tile grinding sludge with reservoir sediments.

[1]  Nader Yaghi,et al.  Enhancement of phosphorus sorption onto light expanded clay aggregates by means of aluminum and iron oxide coatings. , 2013, Chemosphere.

[2]  田口 玄一,et al.  Introduction to quality engineering : designing quality into products and processes , 1986 .

[3]  C. Butler,et al.  A primer on the Taguchi method , 1992 .

[4]  Chao-Wei Tang,et al.  Reuse of incineration fly ashes and reaction ashes for manufacturing lightweight aggregate , 2010 .

[5]  S. Mishra,et al.  Development of synthetic aggregate using off-ASTM specification ashes , 2013 .

[6]  K. Ramamurthy,et al.  Identification of design parameters influencing manufacture and properties of cold-bonded pond ash aggregate , 2014 .

[7]  Ralph W. Kluge,et al.  Lightweight Aggregate Concrete , 1949 .

[8]  C. S. Poon,et al.  Production of lightweight concrete using incinerator bottom ash , 2008 .

[9]  A. Bahrami,et al.  Design of experiments using the Taguchi approach: Synthesis of ZnO nanoparticles , 2012 .

[10]  V. Ducman,et al.  Lightweight aggregate based on waste glass and its alkali–silica reactivity , 2002 .

[11]  Chung-Ho Huang,et al.  Application of water treatment sludge in the manufacturing of lightweight aggregate , 2013 .

[12]  Christopher R. Cheeseman,et al.  Properties and microstructure of lightweight aggregate produced from lignite coal fly ash and recycled glass , 2010 .

[13]  R. Cioffi,et al.  Coal Combustion Wastes Reuse in Low Energy Artificial Aggregates Manufacturing , 2013, Materials.

[14]  A. Sivakumar,et al.  Accelerated curing effects on the mechanical performance of cold bonded and sintered fly ash aggregate concrete , 2015 .

[15]  C. M. Riley,et al.  Relation of Chemical Properties to the Bloating of Clays , 1951 .

[16]  Januarti Jaya Ekaputri,et al.  A Review on the Manufacturing of Lightweight Aggregates Using Industrial By-Product , 2016 .

[17]  Y. Liao,et al.  Lightweight aggregates from water reservoir sediment with added sodium hydroxide , 2013 .

[18]  O. Kayali.  Fly ash lightweight aggregates in high performance concrete , 2008 .

[19]  Barbara Liguori,et al.  Recycled polyolefins waste as aggregates for lightweight concrete , 2016 .

[20]  Chao-Wei Tang.  Producing synthetic lightweight aggregates by treating waste TFT-LCD glass powder and reservoir sediments , 2014 .

[21]  Romina D. Farías,et al.  Effects of Wastes from the Brewing Industry in Lightweight Aggregates Manufactured with Clay for Green Roofs , 2017, Materials.

[22]  Mohd Zamin Jumaat,et al.  A Review on the Use of Agriculture Waste Material as Lightweight Aggregate for Reinforced Concrete Structural Members , 2014 .

[23]  Rui Liu,et al.  Lightweight Aggregate Made from Dredged Material in Green Roof Construction for Stormwater Management , 2016, Materials.

[24]  Raffaele Cioffi,et al.  Recycling of non-metallic automotive shredder residues and coal fly-ash in cold-bonded aggregates for sustainable concrete , 2017 .

[25]  A. Korjakins,et al.  Pore structure of lightweight clay aggregate incorporate with non-metallic products coming from aluminium scrap recycling industry , 2012 .

[26]  Madhan Shridhar Phadke,et al.  Quality Engineering Using Robust Design , 1989 .

[27]  Ö. Cizer,et al.  Properties and pozzolanic reactivity of flash calcined dredging sediments , 2016 .

[28]  Chao-Wei Tang,et al.  Production of synthetic lightweight aggregate using reservoir sediments for concrete and masonry , 2011 .

[29]  R. Roy.  A Primer on the Taguchi Method , 1990 .

[30]  K. Wiik,et al.  Mechanical properties of lightweight aggregates , 2013 .

[31]  P. K. Mehta,et al.  Concrete: Microstructure, Properties, and Materials , 2005 .

[32]  K. Mun,et al.  Development and tests of lightweight aggregate using sewage sludge for nonstructural concrete , 2007 .

[33]  Christopher R. Cheeseman,et al.  Recycling and recovery routes for incinerated sewage sludge ash (ISSA): a review. , 2013, Waste management.

[34]  P. Wainwright,et al.  Synthetic aggregates from combustion ashes using an innovative rotary kiln. , 2001, Waste management.

[35]  K. Youm,et al.  Evaluation of the anisotropy of the void distribution and the stiffness of lightweight aggregates using CT imaging , 2013 .

[36]  Ravindra K. Dhir,et al.  Civil Engineering Materials , 2017 .

[37]  M. Franus,et al.  Mechanical and Physical Properties of Hydrophobized Lightweight Aggregate Concrete with Sewage Sludge , 2016, Materials.

[38]  Eric Mayer,et al.  Properties Of Concrete , 2016 .

[39]  J. Douglas Barrett,et al.  Taguchi's Quality Engineering Handbook , 2007, Technometrics.

[40]  Ing-Jia Chiou,et al.  Lightweight aggregate made from sewage sludge and incinerated ash. , 2006, Waste management.

[41]  Najiah Nadir,et al.  Improvement of one factor at a time through design of experiments , 2012 .

[42]  Christopher R. Cheeseman,et al.  Properties and microstructure of lightweight aggregate produced from sintered sewage sludge ash , 2005 .

[43]  Raffaele Cioffi,et al.  Use of Cement Kiln Dust, Blast Furnace Slag and Marble Sludge in the Manufacture of Sustainable Artificial Aggregates by Means of Cold Bonding Pelletization , 2013, Materials.

[44]  Svetlana N. Sokolova,et al.  Characteristics of lightweight aggregates from primary and recycled raw materials , 2008 .

[45]  Ming-Der Yang,et al.  Producing synthetic lightweight aggregates from reservoir sediments , 2012 .

[46]  Raffaele Cioffi,et al.  Recycling of MSWI fly ash by means of cementitious double step cold bonding pelletization: Technological assessment for the production of lightweight artificial aggregates. , 2015, Journal of hazardous materials.

[47]  Christopher R. Cheeseman,et al.  PROPERTIES OF LIGHTWEIGHT AGGREGATE PRODUCED BY RAPID SINTERING OF INCINERATOR BOTTOM ASH , 2005 .