Effect of Ion Water Washing of Neutralized Sludge
Contaminated by High Concentrations of Chloride
Chiharu Tokoro
1,+, Yuji Oda
1, Shuji Owada
1and Hiroshi Hayashi
21Department of Resources and Environmental Engineering, School of Creative Science and Engineering,
Faculty of Science and Engineering, Waseda University, Tokyo 169-8555, Japan 2Central Research Institute, Mitsubishi Materials Corporation, Iwaki 971-8101, Japan
The effects of NO3¹and SO42¹ions on chloride ion removal from neutralized sludge were investigated to determine if removal of chloride
ions enabled the use of sludge for cement production. An artificial sludge prepared from iron, calcium and chloride that primarily consisted of two-line ferrihydrite was prepared. Chloride ions in the sludge were easily washed out by distilled water, NO3¹water or SO42¹water to levels
below those specified in the standard for Eco-cement production (1,000 mg/kg), but the washed sludges did not meet the standard for ordinary Portland cement (350 mg/kg). Conversely, artificial sludge prepared from aluminum, calcium and chloride mainly consisted of low crystalline boehmite with other minor components. Chloride ions in this sludge were only reduced to below those specified in the standard for the ordinary cement production if SO42¹water was used to wash the sludge. Thefiltration rate during washing using SO42¹water was faster than when
distilled water or NO3¹water was used because SO42¹ions were adsorbed onto the sludge particles and the absolute value of the zeta potential of
the sludge particles decreased. Overall, sludge washing using SO42¹water was the best process for chloride ion removal and efficientfiltration. [doi:10.2320/matertrans.M2013001]
(Received January 7, 2013; Accepted April 2, 2013; Published June 25, 2013)
Keywords: sludge recycling, chloride removal, two-line ferrihydrite, low crystalline boehmite,filtration rate
1. Introduction
Minimizing resource consumption and waste generation is a frequent topic of discussion worldwide that is especially
important in Japan because of a shortage of landfill sites
for disposal as well as a stable supply of resources. In 2010, a total of 389.746 million tons of industrial waste was discharged, while the total discharge of sludge was 173.629
million tons, which accounted for 44.5% of the industrial
waste.1)Accordingly, more efficient recycling and a reduction
of the quantity of sludge generated are necessary in Japan. Several waste and by-products are utilized by the cement industry as row materials or thermal sources for cement
production.25) However, sludge contaminated with high
quantities of chloride cannot be utilized for cement production because the chloride ions decrease the quality of cement and make the operation unstable. As a result, the
concentration of chloride in cement is limited to 350 mg/kg
in ordinary Portland cement6) and 1,000 mg/kg in
Eco-cement (Eco-cement in which municipal waste combustion ash
and sewage sludge are utilized as the main raw materials).7)
Neutralized sludge from industrial wastewater sometimes
contains high quantities of chloride and requires efficient
washing of chloride for utilization in cement production.8)
Many researchers have reported that when metal hydroxides are the main component of the sludge chloride ions cannot be removed from the sludge by washing with water alone due
to the chemical affinity between chloride ions and sludge
components.911) However, the mechanism for uptake of
chloride ions by sludge components and their removal during sludge washing have not been described in detail to date.
This study was conducted to investigate chloride ion removal from neutralized sludge using several types of ionic
water. Specifically, the mechanism of chloride ion removal
during the washing process was evaluated to determine if the use of ionic water for the removal of chloride ions from sludge to be used in cement production was feasible. To
study the uptake/removal mechanism of chloride ions in
sludge in detail, we used two types of artificial sludge that
were neutralized using calcium hydroxide, one prepared from
ferric and chloride ions solution (FeCaCl sludge) and
another prepared from aluminum and chloride ions solution
(AlCaCl sludge). These ferric and aluminum ions are the
main components in actual neutralized sludge and calcium hydroxide is also the most commonly used neutralizer owing
to its good performance and effective solid/liquid separation.
This study was conducted to compare the removal of
chloride ions from FeCaCl sludge or AlCaCl sludge
washed with distilled water, nitric acid (NO3¹) water and
sulfuric acid (SO42¹) water, and to discuss the mechanism
by which the uptake/removal of chloride ions occurred. To
accomplish this, we repeated batch washing experimentsfive
times and then quantitatively analyzed the concentration of chloride ions in washing water and sludge. We also evaluated
the sludge before/after washing by X-ray diffraction (XRD)
and Fourier transformed infrared spectrometry (FT-IR). In general, several researches have proposed that
adsorp-tion affinity to hydroxides is SO42¹º NO3¹>Cl¹in high
concentration of acid solution.12)Additionally, high
concen-tration of SO42¹ sometimes promotes dissolution of sludge
containing Cl¹ because it products new precipitation with
metallic ions in the sludge. Therefore, SO42¹or NO3¹water
has potential to remove Cl¹ from the sludge consisting of
hydroxides. After washing using these ion water, effluent is
consisted of several acid and dissolved components from the sludge and additional neutralization is needed. However, it is expected that the amount of new precipitated sludge from
effluent treatment is small.
During washing of sludge, good solid/liquid separation is
required in addition to efficient chloride removal. Therefore,
+Corresponding author, E-mail: tokoro@waseda.jp
we also compared the filtration rate during the washing process and evaluated differences among sludges based on
the zeta potential of the sludge before/after washing.
2. Experimental Procedure
2.1 Standard and reagents
All chemicals and solutions used in this study were of analytical grade and were purchased from Wako Pure Chemicals, Inc., Japan. The ferric, aluminum and chloride
solutions were prepared from FeCl3·6H2O, AlCl3·6H2O and
12N HCl, respectively. Ca(OH)2 was used as neutralizer.
The NO3¹ washing water and SO42¹ washing water were
prepared from NaNO3and Na2SO4, respectively. All
experi-ments were conducted at 25°C. In addition, all experiexperi-ments were performed at least in triplicate and the error was
confirmed to be within 1%.
2.2 Preparation of artificial sludge
Artificial FeCaCl sludge and AlCaCl sludge were
prepared as follows. Briefly, 0.6 dm3of 0.1 M Fe(III) or 0.1 M
Al(III) and 1 M Cl(-I) were initially prepared in 1 dm3beakers
and neutralized by the addition of about 0.1 dm3of 20 mass%
Ca(OH)2slurry to give a pH of 7. After agitation at 5000 rpm
for 30 min using a magnetic stirrer, the suspension was
filtered through a 0.45 µm membrane filter (Advantec,
Japan).
2.3 Washing experiments
Freshly prepared artificial sludge was prepared for all
washing experiments conducted in this study. Three types of washing water, deionized (DI) water, water containing
2000 mg/dm3 NO
3¹ and water containing 2000 mg/dm3
SO42¹were used.
A total of 80 cm3 of artificial sludge suspension was
filtered through a 0.45 µm membrane filter and the residue
was then re-dispersed in 40 cm3 of washing water in a
100 cm3 conical beaker and stirred at 1000 rpm using a
magnetic stirrer. The suspension was then passed through a
0.45 µm membranefilter again. The re-dispersion in washing
water andfiltration were repeatedfive times, after which the
concentration of Cl¹, NO3¹or SO42¹infiltrate were analyzed
by ion chromatography (IC-2001, Tosoh, Japan) and the concentration of chloride ions in the residue were analyzed
by the Volhard method.13) The concentration of iron,
aluminum, calcium and sodium in the residue was analyzed
by X-ray fluorescence (XRF) (PW1480/1404, PANalytical,
Japan).
2.4 XRD analysis
The chemical forms of the sludge were evaluated by XRD
analysis (Geigerflex RAD-IR, Rigaku, Japan). XRD patterns
of the sludge before/after washing were obtained using a
copper target (Cu K¡), a crystal graphite monochromator,
and a scintillation detector. The equipment was operated at
40 kV and 30 mA by step-scanning from 2° to 80° 2ª at
increments of 0.02° 2ªand a scan speed of 2°/min. A crystal
sample holder was used and the diffractograms were not
corrected by background diffraction. The filter residue was
freeze-dried at¹45°C for 24 h prior to analysis.
Two-line ferrihydrite and low crystalline boehmite were synthesized as reference materials. Two-line ferrihydrite was
synthesized from 10 mg/dm3Fe(III) solution prepared using
Fe(NO3)3·9H2O at pH 5 and an ionic strength of 0.05 using
1 M HNO3 and 1 M KOH to regulate the pH and ionic
strength, respectively. Low crystalline boehmite was
synthe-sized from 20 mg/dm3 of Al(III) solution prepared using
Al(NO3)3·9H2O at pH 9 and an ionic strength of 0.05 using
1 M HNO3 and 1 M KOH to regulate the pH and ionic
strength, respectively.
2.5 FT-IR analysis
The sludge was also analyzed during the washing experi-ments after freeze-drying using FT-IR spectroscopy (FT-IR 4200, JASCO, Japan). Pellets for FT-IR were prepared by compression molding with KBr. The mixing ratio of the
sample to KBr was fixed at 0.3 mass% and FT-IR spectra
were obtained using transmission FT-IR spectroscopy.
2.6 Zeta potential measurement
Measurement of the zeta potential was conducted using an electrophoresis light scattering spectrophotometer (ELS-8000, Otsuka Electronics, Japan). To accomplish this, suspensions of the sludge prepared during the washing
exper-iments prior tofiltration were dispersed in an ultrasonic bath
for 5 min and then rapidly analyzed by spectrophotometry.
2.7 Measurement offiltration rate
The quantity offiltrate and time offiltration were measured
during suctionfiltration of a suspension of the sludge under
0.005 MPa. For filtration, a filter holder with a 250 dm3
funnel (Sartorius, Germany) and 0.45 µm membrane filter
were used. Thefiltration rate was determined as follows:
V ¼QS ; ð1Þ
where Q(m3/h) is the flow rate and S (m2) is the filtration
area. In this study, the effective area of the filtration
equipment was 1.25©10¹3m2.
3. Results and Discussion
3.1 Effect of ionic water on removal of chloride from the sludge
The concentrations of chloride ions in the artificial FeCa
Cl sludge and AlCaCl sludge before/after washing using
distilled water, NO3¹ water and SO42¹ water are shown in
Figs. 1 and 2. The concentrations of iron and calcium in the
sludge are shown in Table 1. For the artificial FeCaCl
sludge, there was little difference in chloride removal by
distilled water, NO3¹ water and SO42¹ water, and most of
the chloride ions were removed from the sludge during the
first washing process. Salingaret al.also proposed that 92%
of the chloride ions in a sludge in which Fe(III) was the main component could be removed by a single wash using
water.14) As shown in Table 1, the residual concentration
of chloride in the sludge after five washes was less than
900 mg/kg, which did not meet the standard for ordinary
Portland cement (350 mg/kg), but did meet the standard for
For AlCaCl sludge, there was a large difference in
chloride removal between distilled water, NO3¹ water and
SO42¹ water. A large amount of chloride (33,000 mg/kg)
remained in the sludge when distilled water was used, while removal of additional chloride from the sludge was achieved when ionic water was used. Following washing
with NO3¹ water, the residual concentration of chloride
was 4,400 mg/kg, which exceeded the standard for cement
production. In contrast, when SO42¹ water was used, the
residual concentration of chloride was less than 300 mg/kg,
which met the standards for both ordinary Portland cement and Eco-cement.
NO3¹or SO42¹concentration taken in sludge during five
times washing was shown in Fig. 3. Both for FeCaCl and
AlCaCl sludge, more SO42¹ ion was uptake than NO3¹
ion. Especially for AlCaCl sludge, in thefirst washing by
SO42¹ ion water, a lot of SO42¹ was uptake to the sludge.
This result suggests that new precipitates could be formed
between AlCaCl sludge and SO42¹ ion water during the
first washing. In any case, these residual SO42¹ or NO3¹
concentration in the sludge after washing have no problem for cement utilization.
In addition, pH was decreased until around 6.5 at thefirst
washing, while it was increased gradually during following washing up to 7.5.
3.2 Mineralogical changes in sludge following washing Figure 4 shows a comparison of the XRD patterns of
artificial FeCaCl sludge before/after washing five times
using distilled water, NO3¹ water and SO42¹ water. All
XRD patterns showed two broad bands at 34° 2ª and 61°
2ª, which were the same positions as observed for two-line
ferrihydrite.14)These results suggest that artificial FeCaCl
sludge mainly consisted of two-line ferrihydrite, and that the mineral form was not changed by washing with ionic water. Chloride ions generally form outer-sphere complexes with hydro ferric oxide, and not many chloride ions can be
taken up by ferrihydrite.12,15)However, as shown in Table 1,
residual chloride ions that exceeded the standard for ordinary Portland cement production were left behind in
FeCaCl sludge after washing with any type of water.
These findings suggest that some amorphous component
other than two-line ferrihydrite strongly bound the chloride
ions into the sludge. As shown in Table 1, the artificial Fe
CaCl sludge contained 0.28%calcium, and that the amount
of calcium did not change after washing. In this study,
calcium ferrite (CaFe2O4) was thermodynamically saturated
in an artificial FeCaCl formation16) as shown in Table 2.
Moreover, there was the potential for formation of CaFe
hydrotalcites, which could take up chloride ions in the Fe
CaCl sludge.
0 50 100 150 200
0 1 2 3 4 5 6
Cl Conc. in Sludge (g/kg)
Washing Cycle Number (-) Pure water
Nitrate ion water
Sulfate ion water
Fe
Fig. 1 Concentration of chloride in FeCaCl sludge after washing with distilled water, NO3¹water and SO42¹water.
0 50 100 150 200
0 1 2 3 4 5 6
Cl Conc. in Sludge (g/kg)
Washing Cycle Number (-) Pure water
Nitrate ion water
Sulfate ion water
Al
Fig. 2 Concentration of chloride in AlCaCl sludge after washing with distilled water, NO3¹ion water and SO42¹ion water.
Table 1 Concentration of chloride, calcium and iron in sludge before/after washing.
Cl (mg/kg)
Ca (mg/kg)
Fe or Al (mg/kg)
FeCaCl sludge Fe
Before washing 1.0©105 2.8©104 5.7©105
After washing with pure water 8.9©102 2.1©104 5.6©105
After washing with NO3¹water 8.6©102 1.9©104 5.6©105
After washing with SO42¹water 8.8©102 2.0©104 5.7©105
AlCaCl sludge Al
Before washing 1.8©105 7.7©104 3.7©105
After washing with pure water 3.3©104 6.1©102 3.6©105
After washing with NO3¹water 4.4©103 3.7©103 3.5©105
After washing with SO42¹water 2.8©102 1.3©104 2.9©105
0 0.05 0.1 0.15 0.2
0 1 2 3 4 5 6
NO
3
or SO
4
Conc. in Sludge (mg/kg)
Washing Cycle Number (-) Nitrate ion water (Fe) Nitrate ion water (Al) Sulfate ion water (Fe) Sulfate ion water (Al)
Figure 5 shows a comparison of the XRD patterns of
artificial AlCaCl sludge before/after washing five times
with distilled water, NO3¹water and SO42¹water. Thisfigure
also shows the XRD patterns of low crystalline boehmite,
which has broad bands at 29° 2ª, 39° 2ª and 48° 2ª.17)
Although the artificial AlCaCl sludge had broader and
weaker peaks at the same positions before washing as observed for low crystalline boehmite, these peaks became
sharper and clearer after five washes with distilled water or
NO3¹ water. These results suggest that artificial AlCaCl
sludge mainly consisted of low crystalline boehmite and other minor components that could easily be washed out by
distilled water or NO3¹water. These trends coincided with a
reduction in residual calcium concentration in the sludge after
washing using distilled water or NO3¹water (Table 1). Many
wastes consist of aluminum, calcium and chloride in the form
of Friedel’s salt (Ca2Al(OH)6(Cl, OH)·2H2O), which
immo-bilizes chloride ions onto the solid. Although the Friedel’s
salt was not thermodynamically saturated in this study, there was the potential for adsorption of chloride ions to boehmite
because of high chemical affinity between Al, Ca and Cl.
Conversely, when samples were washed with SO42¹water,
the XRD patterns became broader and weaker. As shown
in Table 1, the aluminum concentration in the sludge was
reduced as well as the chloride ion concentration, while 17%
of calcium remained in the sludge after washing. These results suggest that a portion of the sludge dissolved and minor new components formed in the sludge after washing
with SO42¹water. In this study, gypsum (CaSO4·2H2O) and
aluminum sulfate were thermodynamically saturated during
SO42¹ water washing16) as shown in Table 3. Additionally,
ettringite (Ca6Al2(SO4)3(OH)12·26H2O) is also known to be
a stable component in AlCaSO4 aqueous systems.
Although ettringite was thermodynamically unsaturated in
this study, there was the potential for adsorption of Ca or SO4
ions to boehmite because of high chemical affinity between
Al, Ca and SO4.
To evaluate mineralogical changes in the AlCaCl sludge
after washing, we also analyzed the FT-IR spectrum (Fig. 6).
The band at approximately 600 cm¹1 could be assigned to a
mixed contribution of AlO stretching and bending for AlO6,
which has one particularly long AlO bond with respect to
the other five bonds.18) Prior to washing, this band shifted
toward a low wavenumber, which suggests that the structure of low crystalline boehmite was ambiguous in the sludge
before washing. The band at 950 cm¹1 corresponds to the
0
20
40
60
80
Relati
v
e Intensity (-)
Cu
Κα
Κα
(
°
)
Two-line ferrihydrite
Before washing
Pure water
Nitrate ionwater
Sulfate ion water
Fig. 4 XRD patterns of tow-line ferrihydrite (as reference material) and FeCaCl sludge before washing and after washing five times with distilled water, NO3¹ion water and SO42¹ion water.
Table 2 Saturation indices duringfirst washing for FeCaCl sludge using SO4¹water.
Fe (mol/L)
Ca (mol/L)
Cl (mol/L)
SO4
(mol/L)
pH (¹)
Saturation Index (¹)
Goethite CaFe2O4 Gypsum
1.5©10¹1 1.0©10¹2 4.2©10¹2 2.1©10¹2 6.8 10.5 11.6 ¹0.19
0
20
40
60
80
Relati
v
e Intensity (-)
Cu
Κα
Κα
(
°
)
Poorly crystalline boehmite
Before washing
Pure water
Nitrate ionwater
Sulfate ion water
Fig. 5 XRD patterns of low crystalline boehmite (as reference material) and AlCaCl sludge before washing and after washingfive times with distilled water, NO3¹ion water and SO42¹ion water.
Table 3 Saturation indices duringfirst washing for AlCaCl sludge using SO4¹water.
Al (mol/L)
Ca (mol/L)
Cl (mol/L)
SO4
(mol/L)
pH (¹)
Saturation Index (¹)
Boehmite Al4(OH)10SO4 AlOHSO4 Gypsum Ettringite
stretching mode of AlO,1820) which is observed in both
aluminum hydroxide and low crystalline boehmite. This band could be clearly distinguished in the sludge before and
after washing with SO42¹ water, while it shifted or became
smaller after washing using distilled water or NO3¹ water.
The small band at approximately 1050 cm¹1 corresponds to
the stretching mode of AlO, which is only observed in low
crystalline boehmite.21)This band was unclear in the sludge
before washing or after SO42¹ water washing, while it was
clear in the sludge after washing using distilled water or
NO3¹ water. The band at approximately 1060 cm¹1 and
1400¹1corresponds to the bond angle bending mode of SO
and the stretching mode of NO, respectively.22)These bands
suggest that adsorption of NO3¹ or SO42¹ occurred during
washing with NO3¹water or SO42¹water.
All of the FT-IR spectra suggest that components of the
AlCaCl sludge before washing or after washing with
SO42¹consisted of combinations of aluminum hydroxide and
low crystalline boehmite, which had a structure that became
clearer after washing with distilled water or NO3¹ water.
Overall, the results of FT-IR analysis coincide with those of XRD analysis.
3.3 Effect of washing with ionic water onfiltration rate
The filtration rate of the FeCaCl sludge and AlCaCl
sludge during five washes with distilled water, NO3¹water
and SO42¹water are shown in Figs. 7 and 8. In the cases of
FeCaCl sludge and AlCaCl sludge, thefiltration rate was
largest during SO42¹water washing, followed by NO3¹water
washing and distilled water washing.
Thefiltration rate generally depends on the crystallinity or
particle size of the components in the sludge and the surface
electric potential at the solid/liquid interface between the
sludge and the washing water. As shown in Figs. 9 and 10, the zeta potential of the sludge decreased considerably after
washing with SO42¹water, which suggests that many SO42¹
ions were adsorbed onto the surface of the sludge particles.
In the case of NO3¹water washing, the zeta potential of the
sludge also decreased because of the adsorption of NO3¹ions
onto the sludge; however, this decrease was not as great as
that observed during washing with SO42¹water. Conversely,
the zeta potential showed increases or decreases during
washing with distilled water owing to the desorption of chloride, calcium and aluminum ions from the sludge.
The relationship between the zeta potential and the
filtration rate was found to be negatively correlated
(Fig. 11), which suggests that when the absolute value of the zeta potential was small, particles of sludge were agglomerated together and the pathway of the washing water could form inside the sludge.
Before washing
Pure water
Nitrate ionwater
Sulfate ion water SO4
NO3
Al-O in boehmite
Al-O
AlO6
H2O
Fig. 6 FT-IR patterns of AlCaCl sludge before washing and after washingfive times with distilled water, NO3¹water and SO42¹water.
0 0.0002 0.0004 0.0006 0.0008 0.001 0.0012 0.0014 0.0016
0 1 2 3 4 5 6
Filtration Rate (m/h)
Washing Cycle Number (-) Pure water Nitrate ion water Sulfate ion water Fe
Fig. 7 Filtration rate of FeCaCl sludge during washing with distilled water, NO3¹water and SO42¹water.
0 0.0002 0.0004 0.0006 0.0008 0.001 0.0012 0.0014 0.0016
0 1 2 3 4 5 6
Filtration Rate (m/h)
Washing Cycle Number (-) Pure water Nitrate ion water Sulfate ion water Al
Fig. 8 Filtration rate of AlCaCl sludge during washing with distilled water, NO3¹water and SO42¹water.
0 10 20 30 40 50 60
0 1 2 3 4 5 6
Zeta P
otential (mV)
Washing Cycle Number (-) Pure water
Nitrate ion water Sulfate ion water
Fe
4. Conclusion
The effects of NO3¹or SO42¹on removal of chloride ions
from sludge during washing were investigated. Artificial
sludge prepared from iron, calcium and chloride mainly consisted of two-line ferrihydrite and chloride ions at levels exceeding the standards for cement utilization. However, the
chloride ions in the FeCaCl sludge were easily removed
to levels below the standard for Eco-cement production
(1,000 mg/kg) by washing with distilled water, NO3¹water
or SO42¹water, although they did not meet the standard for
ordinary Portland cement (350 mg/kg).
The artificial sludge prepared from aluminum, calcium and
chloride mainly consisted of low crystalline boehmite with other minor components and chloride ions at levels exceed-ing the standards for cement utilization. Washexceed-ing with
distilled water or NO3¹ water removed a portion of the
chloride ions as well as minor components of the sludge, but the concentration of chloride remained above the standards
for cement utilization. However, when SO42¹water was used
for washing, the chloride levels were reduced to below the standard for ordinary cement production.
The effects of NO3¹ or SO42¹ ions on the filtration rate
during washing of sludge were also investigated. During
washing using SO42¹water, thefiltration rate was faster than
that of distilled water or NO3¹ water because SO42¹ ions
were adsorbed onto the sludge particles and the absolute value of the zeta potential of the sludge particles decreased.
Overall, sludge washing using SO42¹water produced the best
results for chloride ion removal andfiltration.
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0 0.0002 0.0004 0.0006 0.0008 0.001 0.0012 0.0014 0.0016
0 10 20 30 40 50 60
Filtration Rate (m/h)
Zeta Potential (mV)
Fe-pure water Fe-nitrate ion water Fe-sulfate ion water Al-pure water Al-nitrate ion water Al-sulfate ion water
Fig. 11 The relationship betweenfiltration rate and zeta potential for Fe CaCl sludge and AlCaCl sludge before/after washing with distilled water, NO3¹water and SO42¹water.
0 10 20 30 40 50 60
0 1 2 3 4 5 6
Zeta P
otential (mV)
Washing Cycle Number (-)
Pure water Nitrate ion water Sulfate ion water
Al