Reuse of lead glass sludge in the fabrication of thermally insulating foamed glass with outstanding properties and high Pb-stabilization

This study represents the sustainable/safe consumption of lead glass sludge (LGS) in the fabrication of thermally insulating foamed glass via sintering (750-950o C) and chlorination processes. The impact of selected additives including calcium chloride (CaCl2) and sodium hydroxide (NaOH) on the foaming efficiency and Pb-stabilization has been deeply investigated. LGS is mainly lead silicate material with considerable content of calcium carbonate, which acts as foaming agent during sintering process. The newly developed foamed-materials exhibited thermal conductivity of 0.054-0.136 W/m.K, density of 0.23-1.10 g/cm(3), porosity of 63.3-92.6%, and compressive strength of 0.10-2.69 MPa. X-ray diffraction proved that the immobilization mechanism was attributed to the transformation of free Pb within LGS into insoluble ganomalite Pb9Ca5MnSi9O33 phase. Adding NaOH enhanced the foaming process accompanied by a significant reduction in Pb-leaching. Incorporating CaCl2 has resulted in a retardation in Pb-leaching, which associated with Pb-stabilization and Pb-vaporization. In an attempt to reduce CO2-emission, the potential use of alkali-rich-wastewater (AW) as eco-friendly alkali source in lieu of NaOH was studied. Regardless of the variation in Pb-concentrations in leachates, all samples recorded Pb-concentrations lower than the safe limit (<= 5 mg/l), achieving Pb-immobilization of 95.98-99.87%. The significantly reduced thermal conductivity and enhanced Pb-immobilization efficiency along with the reasonable compressive strength summarize the major innovation presented in this study.