Investigation of the Innovative Combined Reuse of Phosphate Mine Waste Rock and Phosphate Washing Sludge to Produce Eco-Friendly Bricks

Phosphate mining generates substantial quantities of waste rock during the extraction of sedimentary ores, leading to significant environmental concerns as these wastes accumulate around mining sites. The industry is under increasing pressure to adopt more sustainable practices, necessitating considerable financial investments in remediation and technological advancements. Addressing these challenges requires a holistic strategy that balances social responsibility, environmental preservation, and economic viability. This study proposes an innovative, cost-effective, and environmentally friendly method to manufacture compressed stabilized earth bricks by combining the valorization of phosphate waste rock (PWR) and phosphate washing sludge (PWS). These bricks offer numerous advantages, including low embodied energy, robust mechanical performance, and excellent insulation and thermal properties. Initially, a Toxicity Characteristic Leaching Procedure (TCLP) test and radiometric surface contamination measurement, carried out on raw materials (PWR and PWS), showed that the results were below the permissible limits. Then, the chemical, mineralogical, and geotechnical properties of the raw materials were characterized. Subsequently, various mixtures were formulated in the laboratory using PWR and PWS, with and without cement as a stabilizer. Optimal formulations were identified and scaled up for pilot production of solid bricks with dimensions of 250 × 125 × 75 mm3. The resulting bricks exhibited thermal conductivity and water absorption coefficients that satisfied standard requirements. This method not only addresses the environmental issues associated with phosphate mining waste but also provides a sustainable solution for building materials production.