How does AAK process scheduled waste into raw material for cement bricks?

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AAK Transforms Scheduled Waste into Cement Brick Raw Material Through a Multi-Stage Process

AAK processes scheduled waste, specifically alum sludge from water treatment plants, into raw material for cement bricks by first dewatering the residue to recover water and then chemically treating the remaining solids to produce aggregates. These aggregates are subsequently used in a proprietary formulation for cement brick manufacturing. This innovative approach makes Penang Water Supply Corporation (PBAPP) the first water operator in Malaysia to adopt a circular economy model for managing such residue, with AAK being the first facility in the country to process SW204 into raw material for cement bricks.
Dewatering and Water Recovery

The process commences at the Sungai Dua Dewatering Plant (SDDP), where water treatment residue, classified as scheduled waste (SW204), is subjected to belt press dewatering technology. This technology effectively separates water from the solid sludge. The recovered water is then reintegrated into PBAPP’s water supply system, potentially yielding approximately nine million litres of water daily, sufficient for 10,000 to 12,000 households.
Chemical Treatment to Produce Aggregates

Following the dewatering stage, the alum sludge is transported to AAK’s manufacturing facility. Here, the sludge undergoes a chemical treatment process designed to convert it into usable aggregates. These aggregates form the primary raw material for the subsequent production of cement bricks.
Cement Brick Manufacturing

The aggregates produced from the chemically treated sludge are then utilised in conventional cement brick production methods. AAK employs a proprietary formulation, developed through nearly five years of research and development, to ensure the final product meets industry quality standards. The plant has the capacity to produce up to 150,000 bricks daily, with current production ranging between 70,000 and 100,000 bricks.
Product Commercialisation and Certification

The cement bricks produced through this process have been commercialised and are currently being used in construction projects and sold through hardware stores in Penang. The product has achieved ISO 9001 certification and is undergoing further certification by the Standards and Industrial Research Institute of Malaysia (Sirim) and the Fire and Rescue Department of Malaysia (JBPM). The bricks have also demonstrated better fire resistance compared to conventional cement bricks.

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How does AAK process scheduled waste into raw material for cement bricks?

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