RECYCLING PAINT SLUDGE WITH CEMENT

& LIME FOR LIGHTWEIGHT MORTAR

PRASHANTH PRABHAKAR
16MS60D04
MATERIALS SCIENCE CENTRE
https://www.getty.edu/conservation/publications_resources/teac
hing/case/olita/building/construction_building.html
IIT KHARAGPUR 1
 BACKGROUND
• PAINT SLUDGE
A industrial hazardous waste produced by
Background
industries involved in metal dyeing such as
Source automotive, appliance & manufacturing
industries.
Materials &
Method

Results &
• GENERATION
Discussions A. 20 to 60 percent paint is wasted and
Conclusion
collected outside paint shops in sludge pits
with regular flowing water. India alone
generates 65,000 K.litrs. of PS every year.
B. Thousands of Litres of paints expires in
industries and turn into unusable form
https://www.process- 2
worldwide.com/index.cfm?pid=9890&pk=387426&fk=525889&type=article
 BACKGROUND
• PROBLEM
Background  Toxicity class 2
Source  Presence of VOCs like benzene, toluene
Materials &
etc causes health problems.
Method  Presence of toxic and heavy metals
Results & Pollution of ground water
Discussions
Damage to flora and fauna
Conclusion

3
http://particlecounting.tumblr.com/post/105818344169/does-carbon-really-work
https://www.raleighnc.gov/safety/content/PWksStormwater/Articles/WaterPollution.html
 BACKGROUND
• CURRENT METHODS

http://www.process-worldwide.com/turning-paint-sludges-into-
Background  Landfill – a. Paying fees for transportation,
disposal and treatment of waste.
Source
b. Requires huge space
Foul Release c. May cause water pollution.
Coatings

Materials for
Foul Release
 Incineration – a. Needs Fuel for burning
Coatings b. Generation of hazard gas.

valueable-products-a-387426/
Plan of work
 Second grade Paint – a. Risks acceptability in
market.
b. Higher residual waste
Existing generated 4
Patents
 BACKGROUND
• EXISTING PATENTS
Background  Sealant Industry
Source  PS with cement as reactive expansion
additives in shrinkage compensating
Materials &
Method concrete.
Results &  Co processing method to cement kiln
Discussions structure for destruction of paint sludge.
Conclusion Recovery of organic and inorganic
components from paint sludge.

Back
5
www.process-worldwide.com
 SOURCE

Background

Source

Materials &
Method

Results &
Discussions

Conclusion

6
 MATERIALS & METHOD
• Paint Sludge
Background – Technocryl 2k acrylic paint inox 552
Source – Zinc yellow as primer
Materials &
– Moonlight new metallic grey topcoat
Method
• Cement
Results &
Discussions
– CEM 1 42.5R with standard TS EN 197-1
with CEN standard Sand
Conclusion
• Slaked Lime
– CL 80-S with standard TS EN459-1
Huseyin, Hamed, Ilker and Nurbas: “Investigation and recycling of paint sludge
Composition with cement and lime for producing lightweight construction mortar ", Journal
8/11/2019 7
of environmental chemical engineering, 2017
 MATERIALS & METHOD

Background

Source

Materials &
Method

Results &
Discussions

Conclusion

Back
8/11/2019 8
 PREPARATION OF SPECIMENS
• SPECIMEN 1 (PS-CEMENT)
– Sand partially replaced by PS at 0, 2, 6, 8 & 10% wt
Background
Series Specimen Cement Water Sand PS
Source 1 Control 450 400 1350 -
2 PS(2%) 450 400 1323 27
Materials &
3 PS(4%) 450 400 1296 54
Method
4 PS(6%) 450 400 1269 81
Results & 5 PS(8%) 450 400 1242 108
Discussions 6 PS(10%) 450 400 1215 135

Conclusion • SPECIMEN 2 (PS-Lime)

– PS added in Lime by 0, 10,20, 30% wt.

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 TESTS CONDUCTED
• Expansion analysis
– Absolute digimatic digital callipers
Background • Mechanical Properties
Source – Flexural test- Michaelis Tester
– Compressive test- Hydraulic concrete press
Materials &
Method
• Capillary absorption test
– Water absorbed checked (after 1 hr) with &
Results & without PS
Discussions • Heavy metal analysis
Conclusion – Atomic absorption spectroscopy to test presence of
heavy metals in specimens (after 72 hrs in water).
• Thermo- Gravimetric Analysis
– To investigate hydraulic properties by weight loss at
temperature range from 30°C to 1000°C.
8/11/2019 10
 SPECIMEN EXPANSION RATE (%) REMARKS
PS (2%)-Cement
EXPANSION
17

PS (4%)-Cement 18
Background
PS
Source (6%)-Cement 19

Materials &
PS (8%)-Cement
Method 19.5

Results &
PS (10%)-Cement
Discussions 19.8

Conclusion
PS (10%)-Lime 20.5

PS(20%)-Lime 21.3

PS(30%)- Lime 22.3

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 MECHANICAL PROPERTIES
S.No PS % ratio in Cement PS% ratio in Lime

Flexural Compressive Flexural Compressive

Background
1. Highest at Highest at PS
Source PS(2%) 2(%)
Materials & 2. Strength
Method nearly 0 at
PS(30%)
Results &
Discussions 3. Strength Strength 54%
25% more more than
Conclusion than PS(lime PS(lime 10%)
10%)
4. Does not Decreases linearly
linearly
decrease
REQUIREMENT FOR STRUCTURAL APPLICATION – 17 MPa to 28 MPa;
8/11/2019 12
OBTAINED : Above 25 MPa in addition to thermal & sound insulation
 RESULTS & DISCUSSIONS
• Capillary absorption test
Background – Both PS(lime) & PS(cement) showed similar
Source
linear increase in water absorption due to
PS.
Materials &
Method • Heavy Metals analysis
Results &
Specimen Cu(II) (mg/L) Zn(II) (mg/L) Fe(III) (mg/L) Pb(II) (mg/L)
Discussions
PS 0.0091 0.0058 0.0391 0.0071
Conclusion PS-Cement 0.0303 0.0392 0.7767 0.0433
Control 0.0255 0.0309 0.6841 0.0108
WHO 0.5 3 3 0.01

* use cement, sand and water with low levels of lead concentration
8/11/2019 13
 MICROSTRUCTURE
– Porous structure in shape and surface texture smooth.
– PS acts as a filler material, however, excess porosity of PS
Background creates free space and decreases mechanical strength.
Source

Materials &
Method

Results &
Discussions

Conclusion

8/11/2019 14
 THERMO-GRAVIMETRIC ANALYSIS

Background

Source

Materials &
Method

Results &
Discussions
PS
Conclusion
(a) 200-500C : loss of chemically bound water of products
(b) Above 600: release of C02 during decomposition of carbonates.
PS-Lime
(a) First peak: dehydroxylation of hydraulic products
(b) Second peak: decomposition of carbonated lime
PS-Cement
8/11/2019 (a) Relatively lower loss. 15
 CONCLUSION
– Adding PS causes reduction in weight and
increase in unit volume of structures.
Background
– Flexural and compressive strength relatively
Source
decreased with increase of PS content.
Materials &
Method
– Economic value in certain applications with
reduced harmful effect on environment.
Results &
Discussions – Good compressive strength along with high
Conclusion
expansion and improved thermal and sound
insulation.

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