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<p>This study investigates the incorporation of petroleum sludge as a partial substitute for raw materials in fired clay brick production, with the aim of promoting industrial waste valorization while maintaining essential material properties. A full 2³ factorial design was employed to evaluate the effects of petroleum sludge content (PSC), water-to-clay ratio (W/C), and firing temperature (FT) on linear variation (LV), porosity (PO), and compressive strength (CS). First-order models were developed and validated, demonstrating excellent predictive accuracy (R² &gt; 0.99 for all responses). The results indicate that increasing PSC significantly raises porosity and reduces compressive strength, while the W/C ratio primarily governs linear variation. FT consistently enhances all properties, particularly mechanical strength. Notable interactions were observed: PSC-FT significantly affects both CS and LV, and W/C-FT influences PO. Interestingly, PSC acts as a shrinkage-reducing agent at 600&#xa0;°C but contributes to expansion at 900&#xa0;°C due to vitrification, especially under high W/C conditions. A novel multi-objective optimization approach was introduced through abacus charts developed for 600&#xa0;°C and 900&#xa0;°C. These tools enable precise formulation adjustments based on end-use requirements (e.g., load-bearing walls, partitions), in compliance with current standards. Optimal brick performance—balancing mechanical strength, dimensional stability, and porosity is achieved by minimizing PSC and W/C at 900&#xa0;°C. These findings highlight the potential of petroleum sludge valorization in brick manufacturing, and the proposed abacus charts offer an innovative decision-making tool for managing multiple formulation constraints simultaneously.</p> Graphical Abstract <p></p>

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Valorization and optimization of petroleum sludge waste in building bricks: an experimental design approach

  • 期刊论文

  • 发表日期：

    2026年4月22日

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  • Djamel Benyessad,
  • Yassine Bounouri,
  • Hamid Arkoub,
  • Atmane Djermoune

摘要

This study investigates the incorporation of petroleum sludge as a partial substitute for raw materials in fired clay brick production, with the aim of promoting industrial waste valorization while maintaining essential material properties. A full 2³ factorial design was employed to evaluate the effects of petroleum sludge content (PSC), water-to-clay ratio (W/C), and firing temperature (FT) on linear variation (LV), porosity (PO), and compressive strength (CS). First-order models were developed and validated, demonstrating excellent predictive accuracy (R² > 0.99 for all responses). The results indicate that increasing PSC significantly raises porosity and reduces compressive strength, while the W/C ratio primarily governs linear variation. FT consistently enhances all properties, particularly mechanical strength. Notable interactions were observed: PSC-FT significantly affects both CS and LV, and W/C-FT influences PO. Interestingly, PSC acts as a shrinkage-reducing agent at 600 °C but contributes to expansion at 900 °C due to vitrification, especially under high W/C conditions. A novel multi-objective optimization approach was introduced through abacus charts developed for 600 °C and 900 °C. These tools enable precise formulation adjustments based on end-use requirements (e.g., load-bearing walls, partitions), in compliance with current standards. Optimal brick performance—balancing mechanical strength, dimensional stability, and porosity is achieved by minimizing PSC and W/C at 900 °C. These findings highlight the potential of petroleum sludge valorization in brick manufacturing, and the proposed abacus charts offer an innovative decision-making tool for managing multiple formulation constraints simultaneously.

Graphical Abstract