Synergic effect of recycled paper sludge and expanded perlite on the engineering properties of porous clay bricks: A new mathematical modelling approach.

• Combined effects of extruded brick compositions with paper sludge and expanded perlite were characterized. • The use of additives in bricks has significantly affected their thermo-physical and mechanical properties. • The effects of process parameters on brick properties were investigated with a new mathematical modeling approach. • Fired brick samples showed good thermal insulation performance. • Produced exruded bricks have good potential for energy saving. Lightweight bricks produced with addition of different additive materials such as expanded perlite (EP) and recycling paper sludge (RPS) waste have been accomplished by a pug mill. Porous fired bricks were produced by using organic and inorganic additives such as paper waste and expanded perlite as pore-makers. In the experimental study, the seventeen mixture sets were prepared with Box-Behnken experimental design procedure of two additive ratios and firing temperatures. The brick samples were produced with shaping by extrusion method and firing at 850, 950 and 1050 °C for two hours after drying. Physical characteristics such as bulk density, apparent porosity and water absorption, and also, compressive strength, thermal conductivity and microstructural properties of brick samples were studied. Influences of process parameters on brick properties were investigated with a detailed neuro-regression analysis. In conclusion, the best brick composition (10 % EP + 10 %RPS by weight) in terms of thermal conductivity corresponding to acceptable mechanical properties was optimized. Accordingly, the compressive strength values of all samples are around 10 to 27 MPa. Also, the samples with high additive content (especially 10 %RPS + 5 %EP sample) exhibited the lowest thermal conductivity value (0.432 W/mK) due to the low firing temperature. [ABSTRACT FROM AUTHOR]