Materials Today: Proceedings 46 (2021) 5666–5674

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Materials Today: Proceedings

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Recycling of fly ash for development of value added products

Kanchapogu Suresh
Department of Chemical Engineering, Maulana Azad National Institute of Technology Bhopal, Bhopal, 462003, India

a r t i c l e i n f o a b s t r a c t

Article history: The present work addressed the maximum quantity of fly ash utilization in raw materials composition to
Received 24 August 2020 fabricate fly ash based ceramic membranes and bricks. The fly ash, TiO2 and CaCO3 materials were iden-
Received in revised form 16 September tified as new composition for the preparation of membrane with fly ash as the major quantity. The slip
2020
casting method was employed for the preparation of both the membrane and bricks. The properties
Accepted 24 September 2020
Available online 31 October 2020
(porosity, chemical and mechanical stability and water absorption capacity) of the membrane and bricks
were estimated and found stable in acidic and basic medium. Mechanical stability of the membrane was
found to be 1.98 MPa. Surface morphology of membrane was identified as defect free and porosity of 39%.
Keywords:
Fly ash
The parametric optimization study was carried out by response surface methodology only for the fly ash
Bricks bricks. The optimal raw material compositions used for bricks fabrication were 59.24 mass % fly ash,
Ceramic membrane 20.76 mass % Cement and 5 mass % sand and at which identified optimal responses of mechanical
Slip casting method strength and water absorption capacity were 9.745 N/mm2 and 10.9%, respectively.
Response surface methodology Ó 2020 Elsevier Ltd. All rights reserved.
Compressive strength Selection and peer-review under responsibility of the scientific committee of the International Confer-
ence on Innovations in Clean Energy Technologies.

1. Introduction mum discharge values to restrict concentration of oil in industrial

Coal burning in the thermal power plants for electrical power
generation that produces the millions of tons of fly ash and related
by-products [1].The produced fly ash storage and identification of
effective recycling method for usage was the current problems
faced by the entire world today [2–4]. Therefore, it is urgent need
to recycle the fly ash to solve environment problems. Hence, indus-
trialists are looking for various viable alternative ways for fly ash
utilization [5–9]. Fly ash has good properties such as ease of han-
dling, low carbon content good shear strength, pozzolanic proper-
ties, low alkali content, spherical texture, low cost, consistent
quality and moisture insensitivity this merit caused to effective
usage of fly ash for value added production preparation [10–13].
Therefore, the primary objective of the present work is develop-
ment of fly ash membranes and fly ash bricks by slip casting
method.
The human life is in threat because of highly concentrated
waste disposal of oil–water emulsions (500–1000 mg/L) into envi-
ronment [14]. Aquatic life is also gets into danger with this effect.
In order to protect the environment and ecosystems from this
destructive impact, it is necessary to separate oil waste from water.
Government agencies like pollution control board have set maxi-
E-mail address: ksuresh@manit.ac.in
effluents [15]. Therefore, many researches are suggested effective
technologies like electrocoagulation, de-emulsification process,
coagulation, skimming, dissolved air floatation method, which
are extensively developed and used for this purpose [16]. Though,
many of these methods are not efficient to achieve the standards
set by pollution control agencies. In the past few years, scientists
were developed ceramic membrane technology for industrial
applications of effluent treatment [17]. Ceramic membranes pro-
vide promising features like chemical, thermal, mechanical stabil-
ity, de-fouling characteristics, longer shelf life, membrane flux,
susceptibility, and separation efficiency [18]. They are widely used
in pharmaceutical, dairy, food, refinery, beverages, electronic
industries [19–21].
Recently, it has been proved that separation of oil from wastew-
ater is effective with membrane-based technology [14–18]. Rev-
erse osmosis is employed when high pressure is required. In this
case, we will encounter problems like fouling, low permeability.
Other methods like nanofiltration, ultrafiltration also have low per-
meability flux problem. On the other hand, microfiltration is effec-
tive for the separation and treatment of oil–water emulsions owing
to its low-pressure requirements, higher water permeability. The
membranes used in this method should have good pore size distri-
butions and decent average pore sizes. Generally, the cost of mem-
branes is significantly high due to the higher costs of the raw

https://doi.org/10.1016/j.matpr.2020.09.653
2214-7853/Ó 2020 Elsevier Ltd. All rights reserved.
Selection and peer-review under responsibility of the scientific committee of the International Conference on Innovations in Clean Energy Technologies.
K. Suresh
materials and their sintering temperatures. Therefore, from eco-
nomic perspective, membranes produced from Alumina and Tita-
nia are not viable for environmental process engineering
applications. As an alternative for their economic infeasibility, cur-
rent research proposed fly ash utility to reduce the cost. The main
objectives designed for the present work are (i) effective use of fly
ash for development of membranes and bricks, and (ii) optimiza-
tion of bricks making raw materials composition by d-optimal mix-
ture model in Response Surface Methodology.
2. Materials and methods
2.1. Membrane manufacturing and testing methods
The amount of fly ash, TiO2, and CaCO3 materials used for the fab-
rication of the membrane was presented in the table 1 and these
constituents are directly taken without any processing. The binder
used in this work was prepared by mixing 1 gm of poly vinyl alcohol
in the 100 ml of water under constant heating and mixing with a
magnetic stirrer for 10 min. After that, the obtained binder solution
was filtered with whatman filter paper to remove any foreign parti-
cles present in it. Finally, the 5 ml of binder was added to powder
mixture. In addition, some water was also added so that the whole
mixture was maintained thick enough to make membrane as shown
in the Fig. 1. The required care was taken for the mixture not to dry
when it was in the form of paste. The paste was casted with a definite
shape on a non-stick cover of alumina foil and placed a chocolate
wrapper between paste and support.
Then the whole setup was exposed to the sunlight by placing it
where the sunlight at richly available (see Fig. 1). It was recom-
mended to place in the midday sunlight because the sunlight pen-
etrates whole membrane paste. It was dried until all the moisture
present in it goes out and dried completely. Finally, the dried mem-
brane was obtained after completion of continuous three days of
drying. After drying, the paper was removed then membrane was
placed in a glass plate. Thereafter, the membrane was placed in a
muffle furnace and sintered at 800 °C for 5 hrs. This was done to
get hardened membrane and for pore formation. Then the mem-
brane was taken out once the furnace cooled down to room tem-
perature. In this way, ceramic membrane is prepared and same
as shown in Fig. 1.
Chemical stability is the property of the membrane that deter-
mines whether a substance (membrane) reactive towards chemi-
cals, especially in acidic and basic medium. This test was
conducted with a strong acid and base solutions. The average
weight loss of membrane was estimated before and after placing
the membrane in the solutions of the base NaOH (14 pH) once
and with acid H2SO4 (1 pH) for one week each. After one week,
membrane was taken out and weighed to note the value. The
weight loss data for membranes was used to express its sts stabil-
ity. Experimental setup for finding the chemical stability of the
membrane was depicted in Fig. 2.
The chemical stability of the membranes were estimated by
considering the change in weight of the membrane after being kept
in a particular solution for a week. The formula used for the weight
loss calculations was expressed as


W1  W2
Weight lossð%Þ ¼  100
W1
Table 1
The raw materials used for the preparation membrane.
Basis (g) Fly ash (g) Titanium dioxide (g)
100 50 20
Materials Today: Proceedings 46 (2021) 5666–5674
Where W1 is the Initial weight of the membrane; W2 is the final
weight of the membrane after keeping in solution. It should be less
than 1% to have good chemical stability.
The surface morphology of the fabricated membrane was ana-
lyzed using micro scope image analysis. The micro scope images
are obtained at different magnifications and these images are char-
acterized to find any holes, cracks and defects on surface of mem-
brane. Microscopy is conducted to examine the surface
morphology using the Microscope instrument. Image software-
based microscope image analysis is further carried out to deter-
mine the average membrane pore size. A small piece of membrane
is placed in a microscope. It is adjusted by viewing it carefully.
Then, recorded the surface image by connecting it with computer.
The resulted surface image obtained in the microscope is shown in
the Fig. 3. Surface morphology includes the features of surface
roughness, surface porosity, pore shape, thickness and contact
angle. Strong influence of such parameters on the wetting beha-
viour of the membranes is found to prove that membrane structure
does play a role in membrane wetting. The results suggest prefer-
able characteristics that can help increase the LEP (Liquid Entry
Pressure) in hydrophobic membranes. Obviously, the pore size
and the pore size distribution will have a direct influence on the
selectivity and the permeation rate of Nanofiltration, Ultrafiltra-
tion, and Microfiltration membranes, where pores are most visible.
The roughness parameters are related to the fouling tendency of
the Reverse Osmosis/Nanofiltration and Ultrafiltration membranes.
2.2. Fly ash brick manufacturing procedure and testing methods
The mixture of composition for bricks manufacturing was taken
accordingly the compositions amount mentioned in the Table 2.
After that, the homogeneous mixture was prepared by mixing of
feed and water in the pan. The process of brick preparation was
described in Fig. 4. After preparing the homogeneous mixture of
the fly ash brick, then the mixture is fed into the mould and then
entire setup was kept for 2–3 days of normal drying. The same
was shown in Fig. 4. The green bricks was placed inside the muffle
furnace for sintering at 800 °C. The fly ash bricks after furnace heat-
ing became hard and possessed good solid structure as shown in
the Fig. 4. The same procedure was repeated for all the given 16
composition of fly ash bricks fabrication in Table 2.
To obtain the mechanical strength of fly ash brick then applied
certain load on the brick using compression testing machine for
checking the mechanical strength of the fly ash bricks. The testing
process illustration was demonstrated in the Fig. 5.
Further for checking the chemical stability of the fly ash bricks,
initially the bricks were weighed and then placed in the HCl (pH1)
solution and NaOH solution (pH14) for physical contact in acidic
and basic medium Fig. 6.
The test specimen was physical contacted with acidic and basic
solutions for 7 days. Thereafter, the specimens were taken out from
solutions and measured their final weight. The weight loss
obtained from test was reported as chemical stability of the bricks.
If weight loss (%) value is decreases then brick chemical stability
increase.
The following equation is used for calculating the weight loss (%)


W initial  W final
ð1Þ Weight lossð%Þ ¼  100 ð2Þ
W initial
Calcium Carbonate (g) Polyvinyl alcohol (ml)
30 5
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K. Suresh
Fig. 1. The experimental steps involved in the fabrication of membrane (a) composition mixing (b) casting (c) drying in sunlight (d) sauntering (e) sintered shaped
membrane.
Fig. 2. Images of chemical stability analysis (a) membrane dipped in NaOH solution
(pH 14) (b) membrane immersed in H2SO4 solution (pH1).
Where, Winitial is the weight of initial fly ash brick; Wfinal is the
weight of final fly ash brick after physical contact.
Fly ash brick initial weight measured (W1) it is dry weight of
brick before it placed in water. Then the brick is placed in water
for observing the water absorbing capacity. Then weighed its mois-
ture absorbing weight (W2). These values used for measurement of
water absorption ratio. Water absorption ratio of the bricks is cal-
culated by using following equation


W1  W2
Water absorptionð%Þ ¼  100
W1
Materials Today: Proceedings 46 (2021) 5666–5674
Fig. 3. Surface morphology of the membrane.
Where, W1- is the weight of initial fly ash brick, W2 – is the weight
of brick after absorbing moisture
In present work used the design expert software for validation
of results and analysis of fly ash bricks. Compressive strength
and water absorption are the main two responses on which these
fly ash bricks made composition mixture were checked at various
input parameters range. Less compressive strength means it will
have less strength to bear the weight of high buildings. Hence,
prior to recommend the bricks for construction purposes then
should be insure about its strength and water absorption quantity.
Applied RSM involved d-optimal design mixture model for design
of experiments. Initially, set the raw materials (Fly ash, cement
and sand) three input parameters then the corresponding desired
two responses considered as the compressive strength and water
ð3Þ absorption. Experimental results corresponding run of the two
responses were noted. After that checked the predicted values by
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K. Suresh Materials Today: Proceedings 46 (2021) 5666–5674

Table 2
Experimental results at various input parameters and corresponding responses.

Run Component 1 A: Fly ash (%) Component 2B: Cement (%) Component 3C: Sand % Response 1: Compressive Response 2: Water
Strength (N/mm2) absorption (%)
Experimental Predicted Experimental Predicted
1 53.69 26.31 5.00 10.09 10.09 18.10 17.90
2 40.01 30.00 14.99 3.21 3.48 15.10 16.12
3 45.28 30.00 9.72 8.52 8.32 18.70 18.78
4 59.99 20.01 5.00 9.36 9.58 13.30 12.99
5 53.06 20.00 11.94 4.06 5.15 15.60 15.69
6 50.00 30.00 5.00 9.44 9.49 15.70 14.22
7 47.16 22.84 15.00 6.25 7.63 10.90 11.27
8 55.42 22.05 7.53 10.09 8.62 17.90 17.02
9 50.11 25.50 9.39 8.45 9.40 19.50 20.72
10 50.11 20.00 14.89 5.63 4.99 16.20 16.58
11 50.00 30.00 5.00 9.37 9.49 12.63 14.22
12 40.01 30.00 14.99 3.35 3.48 16.80 16.12
13 44.02 26.83 14.14 8.93 7.66 17.60 16.73
14 59.99 20.01 5.00 9.46 9.58 12.40 12.99
15 45.28 30.00 9.72 8.42 8.32 19.20 18.78
16 50.11 20.00 14.89 5.64 4.99 17.10 16.58

Fig. 4. Experimental steps in bricks processing (a) Raw materials mixing (b) Paste formation (c) Slip casting (d) Un-sintered bricks (e) Sintering in furnace (f) Shaped sintered
bricks.

different analysis given in the software. Similarly, validation of Then, it was immersed in water for 24 h. Subsequently, membrane
experimental and predicted values are analyzed by using various taken out then the outer surface water was wiped using tissue
available model fit. paper. Finally, measured wet weight of the membrane (W2). These
weights were considered for measuring the porosity (e) of the
3. Results and discussion membrane using the following relation.

3.1. Fly ash based ceramic membrane analysis " #

ðw2  w1 Þ  4
e¼ ð4Þ
Archimedes’ principle was adopted to calculate porosity of the qw  p  d2  T
membrane. Initially measured the dry membrane weight (W1).
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K. Suresh
Fig. 5. The steps involved in testing of compressive strength for bricks.
Fig. 6. The bricks immersed in acidic and basic solution for chemical stability.
Where, W1 is the dry weight of membrane, W2 is the wet weight
and qw is the water density, T is the membrane thickness, e is the
membrane volumetric porosity; d is the diameter of the membrane
(volume p(d/2)2  T).
The porosity of the membrane was obtained as 39%. The pres-
ence of the calcium carbonate vulnerable for the high porosity of
the membrane because during the sintering process the CaCO3
was converted to CaO and CO2. The evolved CO2 forms pores in
the membrane and increase the void volume of the membrane
hence increase porosity.
The microscopic image of the membrane surface is depicted in
Fig. 3. It reveals that the membrane does not have any defects,
cracks and pinholes. ImageJ software used and analyzed the mem-
brane pores size, then found pore size as 1.47 mm.
Universal testing machine (Make: Mechatronic Control systems,
India, Model: Mech.CS.UTE, 40 T, specifications as 1 mm of resolu-
tion, 25–50 mm range gauge length with 2 mm extension) was
used to evaluate the mechanical stability of the membrane. The
rectangular bar specimen (Specimen Length: 50 mm, Specimen
Thickness: 5 mm, Specimen Width: 5 mm) was undergone bending
method (three point) and measured mechanical strength value as
1.98 MPa.
The estimated cost of the membrane was Rs. 6.15 for 100 g sam-
ple, which was determined on the basis of individual raw material
cost consideration (Fly Ash = Rs. 2, TiO2 = Rs. 3.4 and CaCO3 = Rs.
0.75). The price values were according to the market values in
2019–2020. Therefore, it was economically feasible to prepare a
fly ash-based membrane.
Chemical stability of the membrane was measured in the acidic
medium as 0.29% and in the case of basic medium was determined
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Materials Today: Proceedings 46 (2021) 5666–5674
as 0.40%. The results confirmed that the membrane was stable in
the corrosion environment. Therefore this membrane effectively
used for industrial effluent treatment process application.
3.2. Fly ash based bricks analysis
The D-optimal mixture design model was employed for the
optimization of the bricks precursor composition by using Design
Expert software 7. The fly ash, cement and sand were used as the
raw materials for the production of bricks. The weight percentage
of these precursor components was taken as input variables and
optimized the mixture composition in terms of compressive
strength and water absorption as desired responses. The reason
for the selection of D-optimal model was feasibility of variation
of constraints in the total composition range (1–100%). The compo-
nents in the mixture can be expressed as either in the weight frac-
tion or weight percentage then the individual components of
mixture composition was varied in the range of 1 to 100%. Hence
the present study was focused on the optimization of components
in mixture by using three parametric with one level D-optimal
design models. As a result of this RSM design model total 16 exper-
imental runs was planned with 6 model points. The lack of fit for
the model was estimated using experimental data among the
selected 5 data points with corresponded 5 replicate points. The
response equations for the compressive strength and water
absorptions were expressed as function of input variables. The gen-
eralized expression for the responses were as follows
Y ¼ f ðX1; X2; X3 . . . :XnÞ ð5Þ
Where, Y is the response, X1, X2, X3. . . Xn are the input variables.
The boundary conditions for the input parameters involved in
the RSM analysis were set the range of compositional variation
for the individual component as fly ash (40–60%), cement (20–
30%) and sand (5–15%), respectively. In this manner, the total
amount of the mixture composition was set as 85% and added
remaining amount as water to make total mixture 100%. The tar-
geted objectives of the RSM analysis was completed in two steps.
In the initial step, the optimization of raw material composition
(fly ash, cement and sand) by considering compressive strength
and water absorption as the desired response variables. Finally,
the data obtained from the design expert software was used for
conducting the further optimization studies on responses. The data
obtained for the desired responses from the experimental analysis
were presented in the Table 2.
K. Suresh
Design study analysis was carried out by using d optimal design
mixture model in RSM approach and generated 16 run data sets.
The experimental studies was carried out to estimate the compres-
sive strength and water absorption of the bricks and the data sets
generated through these runs was tabulated in Table 2. The
obtained data reproducibility and impart confidence of the value
were evaluated at lower standard deviation. The set of data for
the compressive strength and water absorption considered
response variables chosen for model fitting analysis and tested
and compared the responses at various model present in the soft-
ware. Among available alternate models, the suitable model was
selected on the basis of F-value (high as possible) and p-value
(low as possible) [22]. The special cubic model was well fitted
model for compressive strength response case and cubic model
was considered as best suitable model in water absorption
response variables. Desirable model was decided by the model F-
value and p-value of responses analyzed then F-value 13.63
implies the model is significant. Lowest p-value (<0.0500) indicate
model terms are significant. The Lack of Fit F-value of 492.10
implies the Lack of Fit is significant.
For the case of water absorption considered as response vari-
able then among all the models then identified the best model
Fig. 7. Contour plots for compressive strength analysis (a) Normal residual plot (b) experimental vs predicted (c) 2D analysis plot (d) 3D analysis plot.
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Materials Today: Proceedings 46 (2021) 5666–5674
was cubic model fitness was analysed (F value = 5.76 and
p < 0.0500). The Lack of Fit F-value of 2.38 implies the Lack of Fit
is not significant relative to the pure error. Non-significant lack
of fit is good. This is the desired the model to fit.
3.3. Strength analysis of fly ash bricks
The strength of fly ash bricks were estimated at various input
parameters and correspond changes in mixture composition was
observed. The obtained results revealed that the strength and com-
position mixture of three raw materials strongly effect the strength
of brick. Raw material quantity and particle size also place a role in
improve the strength of brick. Fly ash quantity increases the
strength value increases up to a certain value later on then
strength decreased. The variation in strengths values with compo-
sition was described in the Fig. 7.
The RSM analysis revealed that special cubic model was signif-
icant model for compressive strength response variable analysis,
the factors AB, AC, AB and ABC were considered as important vari-
ables in this model analysis. Considering the primacy of special
cubic model, used these model parameters, the variation in the
compressive strength of the brick with variation in fly ash (A),
K. Suresh
cement (B) and sand (C) raw material compositions was expressed
as the equation:
 
Compressive Strength N=mm2
¼ 0:6734A þ 1:14943B þ 13:1675C  0:03882AB
 0:3112AC  0:5537BCE þ 0:0126ABC
The model analysis results obtained adequate precision was
10.108 and adjusted R-Squared and predicted R-Squared values
were 0.8348 and 0.6898 respectively. Similar values were obtained
for the water absorption case (adjusted value = 0.8962, adequate
precision 9.0432 and Predicted value = 0.7405).
Data analysis plots (Fig. 7(a) and Fig. 8(a)) of normal distribu-
tion revealed that normal distribution of data points which are
near to the diagonal straight line confirmed that no non-
normality of the data points in compressive strength and water
absorption cases. Predicted vs experiment plots (Fig. 7(b) and
Fig. 8(b)), confirms the similarity of the data points of predicted
and experimental results were observed and suitable of the model
fit was confirmed for the represent of response variables in terms
input variables composition of fly ash, cement and sand.
Fig. 8. contour plots for water absorption analysis (a) Normal residual plot (b) experimental vs predicted (c) 2D analysis plot (d) 3D analysis plot.
Materials Today: Proceedings 46 (2021) 5666–5674
3.4. Absorption of water
Water absorption ratio of bricks decreased by increasing of fly
ash quantity in mixture up to 59.24 mass%. Where kept the
other raw materials in mixture at cement 20.76 mass% and sand
5 mas%. The variation of fly ash components effects the water
ð6Þ
absorption capacity of the bricks. The effect of fly ash quantity
on water absorption ratio of bricks are depicted in Fig. 8. The
optimal mix percentage of fly ash 59.24 mass%, cement-20.76
mass% and sand- 5 mass%, and rest water then obtained strength
of brick as 9.745 N/mm2 and water absorption as 10.9%,
respectively.
ANOVA analysis results confirms that cubic model was best fit-
ted model for water absorption as response variable. The results
obtained from ANOVA analysis conveyed that the water absorption
variation was complex function of input variables A, B and C. The F
values of the variables point out that interaction between all con-
stituents combination was strong for AB, AC, BC, ABC, AB(A–B), AC
(A–C) and BC(B–C), respectively. The response of water absorption
in the function of input variables were expressed in below
equation
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K. Suresh
Fig. 9. The variation of strength with water absorption.
Water absorptionð%Þ ¼ 13:9246A  229:878B þ 414:887Cþ
4:79082AB  7:78934AC  3:03624BC  0:0151ABC
0:0444ABðA  BÞ þ 0:0411ACðA  CÞ þ 0:0904BCEðB  CÞ
ð7Þ
The Model F-value of 5.76 implies the model is significant. P-
values less than 0.0500 indicate model terms are significant.
Values greater than 0.1000 indicate the model terms are not signif-
icant. If there are many insignificant model terms (not counting
those required to support hierarchy). The Lack of Fit F-value of
2.38 implies the Lack of Fit is not significant relative to the pure
error. Non-significant lack of fit is good.
The change in the response variables (compressive strength and
water absorption) with variation in the raw material compositions
of materials fly ash (A), cement (B) and sand (C) in the mixture
were denoted with 2D plots (Fig. 7(c) and Fig. 8(c)) and 3D
response plots (Fig. 7(d) and Fig. 8(d)). With an increase in fly
ash (A) quantity, the compressive strength increased, which was
not the case for decrease in cement (B) and sand content (C)
(Fig. 7(d) and Fig. 8(d)). The increment of fly ash content in the
raw material composition mixture facilitates a decrease in water
absorption capacity because the sintering helps strengthening of
bonds between components in the mixture composition and
enhance the hardness of brick. Therefore compressive strength
increased and water absorption decreased. In contrast, with an
increase in cement content, water absorption increases as a result
of greater contribution of pozzolanic property of cement. The
water absorption with an increase in cement (B) and sand (C)
(Fig. 7(c & d) and Fig. 8(c & d)). And also, sand (C) variation exhibit
significant effect on mechanical strength, by increasing sand con-
tent the strength of brick decreased. Whereas, the water absorp-
tion increased with increase of sand content in composition
mixture. The optimal set of brick fabricated raw material composi-
tion was produced subsequently as to maximize the compressive
strength and minimize water absorption capacity of the brick.
The design analysis suggested that, the optimum raw material
mixture composition was estimated as 59.24 mass % fly ash,
20.76 mass % cement and 5 mass % sand. At this condition, the
average compressive strength and water absorption of brick were
expected to be 9.745 N/mm2 and 10.9% respectively.
The variation of water absorption with compressive strength of
brick was depicted in Fig. 9. The mechanical strength of the mem-
branes decreases with increase of water absorption (%). This due to
the fly ash content increment in bricks composition, ANOVA anal-
ysis confirmed that compressive strength was increased when the
fly content increased in bricks fabricating compositions. The
results obtained water absorption for optimal mixture composition
was 10.9%.
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4. Conclusions
For the first time, the current work deliberated d optimal mix-
ture model based RSM design method for the optimization of raw
material composition of brick to achieve maximum compressive
strength. The investigation in the work drawn significant conclu-
sions. The d optimal model was effective in determination of opti-
mal composition of mixture in design of bricks by using fly ash,
cement and sand as raw materials. The comparison of various
model fit and identified the best model for the desired responses
variables based on the variation in input variable compositions.
Present work confirms that d optimal mixture model is an effective
tool to organise RSM based experimental investigations and
ANOVA analysis to determine the best model fit for the predicted
vs experimental values validation. Identified fly ash has one of
the raw materials for making membranes and bricks. Slip casting
method successfully applied for membrane and brick manufactur-
ing and identified low sintering temperature as 800OC. The fabri-
cated membrane exhibited high thermal, chemical stability and
defect free surface. For experimental study, the brick specimen of
size 230 mm  110 mm  90 mm were cast for different mixture
composition of fly ash (40 to 60%), cement (20 to 30%), sand(5 to
15%), and rest water. The specimens have been tested for sixteen
mixture proportions. ANOAVA analysis inferred that, among the
sixteen proportions the maximum compressive strength
(9.745 N/mm2) and minimum water absorption (10.9%) was
obtained for optimal mixture composition of flyash-59.24 mass%,
cement-20.76 mass%, sand-5 mass% and rest water.
CRediT authorship contribution statement
Kanchapogu Suresh: Conceptualization, Methodology, Valida-
tion, Writing - original draft, Writing - review & editing, Visualiza-
tion, Supervision, Project administration, Formal analysis,
Investigation, Resources, Data curation.
Declaration of Competing Interest
The authors declare that they have no known competing finan-
cial interests or personal relationships that could have appeared
to influence the work reported in this paper.
Acknowledgement
The author thankfully acknowledge the Department of Chemi-
cal Engineering for providing necessary facilities for carrying out
this research, and the author also would like to thank Maulana
Azad National Institute of Technology for providing the financial
assistance from SEED money grant to carry out this study.
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