Assessing the Effects of Refuse-Derived Fuel (RDF) Incorporation on the Extrusion and Drying Behavior of Brick Mixtures

Abstract

This study explores the potential benefits of incorporating Recycled Demolition Waste (RDF) as an additive in ceramic mass for the brick industry, with a focus on applications such as thermoblocks. The research underscores the significance of sustainable waste management practices and environmental conservation by diverting waste from landfills. RDF, exhibiting combustion properties above 550 °C, emerges as a valuable candidate for enhancing clay-based materials, particularly in the brick production process where firing temperatures exceed 850 °C. Conducted in two phases, the research initially concentrated on RDF preparation, RDF integration with clay materials, and its influence on extrusion and drying phases. Employing innovative techniques involving brick and tile industry machinery coupled with sand incorporation yielded promising results. The grounding of RDF particles to less than 1 mm not only facilitated the mixing process but also ensured stable grinding temperatures within the hammer mill, reducing operational costs. During extrusion, challenges associated with unprocessed RDF material were addressed by utilizing ground RDF, leading to a more efficient and cost-effective process with enhanced plasticity and reduced water requirements. Practical implications for brick plant operations were identified, promoting resource and energy savings. Drying behavior analysis revealed the positive impact of RDF integration, showcasing reduced sensitivity, decreased drying linear shrinkage, and improved density properties. RDF’s role as an inert additive resulted in a 5% reduction in density, enhancing porosity and thermal insulation properties, particularly in thermoblock applications. In the brick industry, where durability, thermal performance, and cost-efficiency are paramount, this study emphasizes the potential benefits of incorporating RDF into clay-based materials. While further research is needed to address the firing procedure of RDF as a brick mass additive, the initial findings underscore the promise of this approach for sustainable and environmentally responsible brick production. This study contributes to the literature by shedding light on the advantages and challenges of integrating RDF into clay-based products, supporting sustainability and waste reduction in construction and manufacturing. The findings provide valuable insights into the performance and feasibility of these mixtures, offering crucial information for industries striving to adopt eco-conscious production methods. This article not only outlines the applied methodology and experimental setup but also presents results related to the behavior of RDF-inclusive clay block mixtures in the production environment. Anticipated to exert considerable influence on future practices and policies, this research contributes to the growing body of knowledge concerning eco-friendly and sustainable manufacturing processes.