Industry-Government-University Cooperative Research Program for the Development of Structural Materials from Sulfate-Rich FGD Scrubber Sludge

The main aim of our project was to develop technology, which converts flue gas desulfurization (FGD) sulfate-rich scrubber sludge into value-added decorative materials. Specifically, we were to establish technology for fabricating cost effective but marketable materials, like countertops and decorative tiles from the sludge. In addition, we were to explore the feasibility of forming siding material from the sludge. At the end of the project, we were to establish the potential of our products by generating 64 countertop pieces and 64 tiles of various colors. In pursuit of our above-mentioned goals, we conducted Fourier transform infrared (FTIR) and differential scanning calorimetry (DSC) measurements of the binders and co-processed binders to identify their curing behavior. Using our 6-inch x 6-inch and 4-inch x 4-inch high pressure and high temperature hardened stainless steel dies, we developed procedures to fabricate countertop and decorative tile materials. The composites, fabricated from sulfate-rich scrubber sludge, were subjected to mechanical tests using a three-point bending machine and a dynamic mechanical analyzer (DMA). We compared our material's mechanical performance against commercially obtained countertops. We successfully established the procedures for the development of countertop and tile composites from scrubber sludge by mounting our materials on commercial boards. We fabricated more than 64 pieces of countertop material in at least 11 different colors having different patterns. In addition, more than 100 tiles in six different colors were fabricated. We also developed procedures by which the fabrication waste, up to 30-weight %, could be recycled in the manufacturing of our countertops and decorative tiles. Our experimental results indicated that our countertops had mechanical strength, which was comparable to high-end commercial countertop materials and contained substantially larger inorganic content than the commercial products. Our moisture sensitivity test suggested that our materials were non-water wettable and did not disintegrate on submerging the product in water for at least two months. Countertop polishing techniques were also established