Cement-bonded boards use sludge

MABALACAT, Pampanga – Cement-bonded boards (CBB), manufactured from paper mill sludge can be utilized for construction purposes.

Proof is a model house constructed in the sprawling complex here of the Trust International Paper Corp. (TIPCO), a major newsprint manufacturer for various media and book publishers.

"The pilot production of cement-bonded boards from sludge is technically and economically feasible," averred research team headed by Dr. Elvira C. Fernandez of the UP Los Baños College of Forestry and Natural Resources-Department of Forest Products and Paper Science (UPLB-CFNR-DFPPS).

Members of the team were Clevan Reyve Lamason, Dr. Margaret Calderon, and Engr. Teodulfo Delgado.

The research, entitled "Production of cement-bonded boards from wastewater treatment sludge of a recycled papermill," was conducted to assess and evaluate the suitability of sludge as an aggregate of CBB.

The model house was inaugurated recently with Sen. Ramon Magsaysay, Jr. as guest speaker.

Among those present were Science and Technology Secretary Estrella F. Alabastro, DOST- Region 3 director Dr. Conrado Oliveros, UPLB Vice Chancellor August Sumalde, UPLB-CFNR Dean Lucrecio Rebugio, former UPLB-CFNR Dean Dr. Virgilio A. Fernandez, UPLB Foundation executive director Abraham Caoili, Mabalacat local government officials, and TIPCO officials and employees headed by George Chua (president) and Willy Chua (vice president).

The project is a joint undertaking of TIPCO, UPLB-CFNR, UPLB foundation, and the DOST-Philippine Council for Industry and Energy Research and Development (PCIERD).

In his speech, Magsaysay extolled the project, saying it reflected the ingenuity of the research sector in converting what would have been a waste into something useful, in this particular case as construction material.

The senator specifically lauded the research team headed by Dr. Fernandez as a proof that "Filipinos can really be competitive."

Sludge, or fiber clay, is the final solid waste or residue recovered after the treatment of paper mill effluent (wastewater). The cement-bonded boards made from these residues are good materials for interior and exterior walls, partitions, and ceiling, as exemplified by the model house built in the TIPCO complex to showcase the technology.

Portland cement to fiber clay ratio of 60:40 was used to product boards of different thickness (six mm, 12 mm and 18 mm).

The researchers averred that CBBs with sludge as the main ingredient have comparable mechanical and physical properties compared to other CBBs abundant nowadays.

"The utilization of fiber clay as a component in cement-bonded board production cannot just alleviate most of the pulp and paper industry’s problem in disposing of their waste materials but also provide new alternative materials for low-cost housing," TIPCO also emphasized.

In the market feasibility study undertaken, it was found that the project is feasible.

"The projected market demand for panelboards in the next 10 years far exceeds the projected supply, indicating the excellent market potential of sludge cement-bonded boards," the researchers stressed. They added: "The product can be priced competitively because of the low production costs."

The results of the financial study also indicated that the proposed pilot plant is financially feasible.

"Positive net income can be expected beginning year 2 until year 16. The return on investments (ROI) for year 2 and years 3 to 16 are 52 percent and 65 percent, respectively.

"The imply that the proposed pilot plant for sludge cement-bonded boards is highly profitable," the researchers concluded.