Sewage sludge is a high-volume and low-cost waste commonly generated worldwide, so its utilization is a vital issue. The application of this waste in the manufacturing of lightweight aggregates was investigated. The process was performed using intensive mixers with volumes of 5 and 30 L, as well as the industrial 500 L mixer. Then, granulates were sintered in a tube furnace. The influence of composition and mixer size on the particle size, microstructure, mechanical performance, and stability of lightweight aggregates in different environments was analyzed. The best results were obtained for a 500 L mixer, enhancing the industrial potential of the presented process. Increasing the share of sewage sludge in the composition of aggregates enhanced their porosity and reduced the specific weight, which caused a drop in compressive strength. Nevertheless, for all analyzed materials, the mechanical performance was superior compared to many commercial products. Therefore, sewage sludge can be efficiently applied as a raw material for the manufacturing of lightweight aggregates. The presented results confirm that a proper adjustment of composition allows easy the tailoring of aggregates' performance and cost.
Keywords: granulation; lightweight aggregate; recycling; sewage sludge; sintering.