Preparation of Ecological Refractory Bricks from Phosphate Washing By-Products

This research is to assess the potential use of phosphate sludge from the Gafsa (Tunisia) phosphate laundries as an alternative raw material for the manufacture of ecological refractory bricks. Feasibility was evaluated through comprehensive physico-chemical and mineralogical characterizations of the raw materials using X-ray diffraction (XRD), X-ray fluorescence (XRF), Fourier transform infrared spectroscopy (FTIR), and thermal analysis (TGA-DTA). Bricks were formulated by substituting phosphate sludge with clay and diatomite, then activated with potassium silicate solution to produce geopolymeric materials. Specific formulations showed remarkable mechanical performances of approximately 7 MPa to 26 MPa, highlighting the importance of composition and minimal water absorption value of approximately 17.8% and 7.7%. The thermal conductivity of the bricks was found to be dependent on the proportions of diatomite and clay, reflecting their insulating potential. XRD analysis indicated the formation of an amorphous aluminosilicate matrix, while FTIR spectra confirmed the development of new chemical bonds characteristic of geopolymerization. Thermal analysis revealed good stability of the materials, with mass losses mainly related to dehydration and dehydroxylation processes. Environmental assessments showed that most samples are inert or non-hazardous, though attention is required for those with elevated chromium content. Overall, these findings highlight the viability of incorporating phosphate sludge into fired brick production, offering a sustainable solution for waste valorization in accordance with circular economy.