The main objective of this research was to evaluate the effects of process variables which were forming ability, flow displacement, effective stress, effective strain, fluid vector and products defects on manufactured artificial lightweight aggregate made of both incinerated sewage sludge ash and clay by means of the numerical analysis of a rigid-plastic finite element method. CATIA (3D CAD program) was used for an extrusion metal mold design that was widely used in designing aircraft, automobile and metallic molds. A metal forming analysis program (ATES Co.) had a function of a rigid-plastic finite element method was used to analyze the program. The result of extrusion forming analysis indicated clearly that a shape retention of the manufactured artificial lightweight aggregate could be maintained by increasing the extrusion ratio (increasing compressive strength inside of extrusion die) and decreasing the die angle. The stress concentration of metal mold was increased by increasing an extrusion ratio, and it was higher in a junction of punch and materials, friction parts between a bottom of the punch and inside of a container, a place of die angle and a place of die of metal mold. Therefore, a heat treatment as well as a rounding treatment for stress distribution in the higher stress concentration regions were necessary to extend a lifetime of the metallic mold. A deformity of the products could have made from several factors which were a surface crack, a lack of the shape retention and a crack of inside of the products. Specially, the surface crack in the products was the most notably affected by the extrusion ratio.

The objectives of this study have been carried out to investigate the solubilization of municipal sewage sludge by single and dual frequency ultrasonic pretreatment, and the methane production characteristics of pretreated sewage sludge by specific methanogenic activity test for sewage sludge reduction. The waste activated sludge was collected from thickened tank of Suyoung sewage treatment plant in Busan city, and its concentration was adjusted to 1.0% total solids. Ultrasonic frequency was varied 15, 20, 15+20 kHz, and acoustic density was used a maximum 176W/L. The dual frequency ultrasonic pretreatment was found to be more effective than single frequency ultrasonic in the solubilization rate and methane production. The SCODCr/TCODCr rate were 15.2%, 13.9%, 17.0% with single frequency of 15 kHz, 20 kHz, dual frequency of 15+20 kHz, respectively. The application of dual frequency ultrasound for sewage sludge pretreatment can be interest for sewage treatment plants having problems in sludge treatment and disposal.