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A special issue of Materials (ISSN 1996-1944). This special issue belongs to the section "Manufacturing Processes and Systems".

Deadline for manuscript submissions: closed (10 October 2024) | Viewed by 12115

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Special Issue Editors

Dr. Isabel Padilla

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Guest Editor

Eduardo Torroja Institute for Construction Sciences, IETcc, CSIC, 28033 Madrid, Spain
Interests: solid waste characterization; concentrated solar radiation; recycling; zeolites; effluents depuration; adsorption process; chemical analysis
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Dr. Maximina Romero

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Guest Editor

MEDES Group, Eduardo Torroja Institute for Construction Sciences, IETcc-CSIC, C/ Serrano Galvache 4, 28033 Madrid, Spain
Interests: glasses; ceramics; waste valorization; microstructure; mullite; porcelain stoneware; glazes; concentrated solar radiation
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Dr. Aurora López-Delgado

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Guest Editor

MEDES Group, Eduardo Torroja Institute for Construction Sciences, IETcc-CSIC, C/Serrano Galvache 4, 28033 Madrid, Spain
Interests: waste valorization; concentrated solar radiation; zeolites; inorganic synthesis processes; environmental engineering
Special Issues, Collections and Topics in MDPI journals

Special Issue Information

Dear Colleagues,

As you know, the UN Sustainable Development Goals are a call to action by all countries to promote prosperity while protecting the planet. The economic and social progress of the last century has unfortunately been accompanied by environmental degradation that threatens the actual systems on which our future growth is built. In this contest, the SDG 12 “Responsible consumption and production” commits, among other things, to achieve by 2030 a substantial reduction in waste generation through prevention, reduction, recycling, and reuse. In the achievement of this objective, the scientific community can play a key role by generating knowledge and developing technologies that allow the transformation of industrial waste into secondary raw materials for the manufacture of sustainable materials. This is the aim of this Special Issue, in which works related to the synthesis of materials from industrial wastes are welcome.

We would to finish with the words of the UN Secretary-General António Guterres “We need to turn the recovery into a real opportunity to do things right for the future.”

Dr. Isabel Padilla
Dr. Maximina Romero
Dr. Aurora López-Delgado
Guest Editors

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Keywords

solid industrial waste
synthesis of sustainable materials, ceramics, glasses, zeolites, refractories, composites, construction materials, adsorbents, etc.

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Published Papers (9 papers)

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Research

16 pages, 4606 KiB

Open AccessArticle

Analysis of the Impact of Waste Fly Ash on Changes in the Structure and Thermal Properties of the Produced Recycled Materials Based on Polyethylene

by Renata Caban and Adam Gnatowski

Materials 2024, 17(14), 3453; https://doi.org/10.3390/ma17143453 - 12 Jul 2024

Viewed by 692

Abstract

This paper presents the results of the research on the structure and thermal properties of materials made from fly ash based on high-density polyethylene (HDPE). Composites based on a polyethylene matrix with 5, 10, and 15 wt% fly ash from hard coal combustion content were examined. Fourier transform infrared spectroscopy with attenuated total reflectance (FTIR-ATR) was used to identify characteristic functional groups present in the chemical structure of polyethylene and the composites based on its matrix. Structural analysis was performed using X-ray diffraction (XRD), a differential scanning calorimeter (DSC), and microscopic examinations. Mechanical properties were also examined. Analysis of the thermal effect values determined by the DSC technique, XRD, and FTIR-ATR allowed the evaluation of the crystallinity of the tested materials. Polyethylene is generally considered to be a two-phase system consisting of crystalline and amorphous regions and is a plastic characterized by a significant crystalline phase content. Based on the FTIR-ATR spectra, DSC curves, and XRD, the effect of the filler and the changes occurring in the materials studied resulted in a decrease in the degree of crystallinity and a change in the melting point and crystallization temperature of the polymer matrix were established. Microscopic examinations were carried out to analyze the microstructure of the composites to collect information on the distribution and shape of the filler particles, indicating their size and distribution in the polymer matrix. Furthermore, the use of scanning electron microscopy combined with energy-dispersive X-ray spectroscopy (SEM-EDS) allowed for the microanalysis of the chemical composition of the filler particles. Full article

(This article belongs to the Special Issue Sustainable Materials from Industrial Waste)

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19 pages, 7118 KiB

Open AccessArticle

Enhancing the Performance of Hemihydrate Phosphogypsum by the Collaborative Effects of Calcium Hydroxide and Carbonation

by Jiawen Huang, Zanqun Liu, Xiangsong Wei, Xiaojiang Ding, Jiahui Zhu, Yilin Zhao, Babar Iqbal and Shulai Guo

Materials 2024, 17(10), 2204; https://doi.org/10.3390/ma17102204 - 8 May 2024

Cited by 1 | Viewed by 904

Abstract

Normally, the acidic impurities in hemihydrate phosphogypsum (HPG) must be neutralized when HPG is utilized, and a little amount of calcium hydroxide (CH) is the best choice. In this paper, the effects of excessive CH (5 wt.%, 10 wt.%, 15 wt.% and 20 wt.% of HPG) for carbonation curing on the performance of hardened HPG paste were studied. According to the results of macro tests and microanalyses of XRD, TG, SEM-EDS, MIP and N₂ physisorption, it could be verified that CaF₂, Ca₃(PO₄)₂ and a large amount of nanoscale CaCO₃ crystals were produced as a result of neutralization and carbonation, and the compressive strength and the water resistance of carbonated HPG + CH paste were significantly improved due to the effects of nanoscale CaCO₃ crystals on pore refinement and the coverage on the surfaces of gypsum crystals of the hardened paste. Therefore, this study suggests a feasible and green method for recycling HPG/PG, with the collaborative effects of neutralization, performance enhancement and reductions in CO₂ emissions. Full article

(This article belongs to the Special Issue Sustainable Materials from Industrial Waste)

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16 pages, 4063 KiB

Open AccessArticle

Study of a Fire-Resistant Plate Containing Fly Ashes Generated from Municipal Waste Incinerator: Fire and Mechanical Characteristics and Environmental Life Cycle Assessment

by Begoña Peceño, Yolanda Luna-Galiano, Fabiola Varela, Bernabé Alonso-Fariñas and Carlos Leiva

Materials 2024, 17(8), 1813; https://doi.org/10.3390/ma17081813 - 15 Apr 2024

Cited by 3 | Viewed by 861

Abstract

The recycling of fly ash from municipal solid waste incineration is currently a global issue. This work intends to examine the viability of a novel recycling alternative for fly ashes as a component of fire-resistant plates. To lessen the quantity of heavy metal leaching, the fly ash was utilized after being washed using a water/fly ash ratio of 2 for one hour. Subsequently, an inexpensive, straightforward molding and curing process was used to create a plate, with a composition of 60%wt of MSWI-FA, 30%wt of gypsum, 0.5%wt of glass fiber and 9.5%wt of vermiculite. The plate exhibited high fire resistance. Furthermore, it demonstrated compression, flexural strength and surface hardness slightly lower than the requirements of European Standards. This allows for manufacturing plates with a high washed MSWI-FA content as fire protection in firewalls and doors for homes and commercial buildings. A Life Cycle Assessment was carried out. The case study shows that a 60% substitution of gypsum resulted in an environmental impact reduction of 8–48% for all impact categories examined, except four categories impacts (marine eutrophication, human toxicity (cancer), human non-carcinogenic toxicity and water depletion, where it increased between 2 and 718 times), due to the previous washing of MSWI-FA. When these fly ashes are used as a raw material in fire-resistant materials, they may be recycled and offer environmental advantages over more conventional materials like gypsum. Full article

(This article belongs to the Special Issue Sustainable Materials from Industrial Waste)

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18 pages, 7243 KiB

Open AccessArticle

Processing of Thin Films Based on Cellulose Nanocrystals and Biodegradable Polymers by Space-Confined Solvent Vapor Annealing and Morphological Characteristics

by Lacrimioara Senila, Ioan Botiz, Cecilia Roman, Dorina Simedru, Monica Dan, Irina Kacso, Marin Senila and Otto Todor-Boer

Materials 2024, 17(7), 1685; https://doi.org/10.3390/ma17071685 - 7 Apr 2024

Viewed by 1144

Abstract

L-poly(lactic acid), poly(3-hydroxybutyrate), and poly-hydroxybutyrate-co-hydroxyvalerate are biodegradable polymers that can be obtained from renewable biomass sources. The aim of this study was to develop three types of environmentally friendly film biocomposites of altered microstructure by combining each of the above-mentioned polymers with cellulose nanocrystal fillers and further processing the resulting materials via space-confined solvent vapor annealing. Cellulose was previously obtained from renewable biomass and further converted to cellulose nanocrystals by hydrolysis with the lactic acid. The solutions of biodegradable polymers were spin-coated onto solid substrates before and after the addition of cellulose nanocrystals. The obtained thin film composites were further processed via space-confined solvent vapor annealing to eventually favor their crystallization and, thus, to alter the final microstructure. Indeed, atomic force microscopy studies have revealed that the presence of cellulose nanocrystals within a biodegradable polymer matrix promoted the formation of large crystalline structures exhibiting fractal-, spherulitic- or needle-like morphologies. Full article

(This article belongs to the Special Issue Sustainable Materials from Industrial Waste)

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19 pages, 7133 KiB

Open AccessArticle

Development of Eco-Mortars with the Incorporation of Municipal Solid Wastes Incineration Ash

by Inês S. Vilarinho, Gonçalo Guimarães, João A. Labrincha and Maria P. Seabra

Materials 2023, 16(21), 6933; https://doi.org/10.3390/ma16216933 - 28 Oct 2023

Cited by 1 | Viewed by 1118

Abstract

The cement sector is the second largest contributor to anthropogenic CO₂ emissions, and several efforts have been made to reduce its environmental impact. One alternative that has gained interest in recent years involves the use of municipal solid waste incineration (MSWI) bottom ash (BA) as clinker/cement replacement. This paper studies the application of MSWI BA in three different ways: (i) aggregate (0 to 100 v/v %), (ii) partial binder substitute (0 to 30 v/v %), and (iii) filler (5 v/v %). It stands out for its approach in characterizing seven distinct BA particle sizes and for the development and analysis of eco-cement mortars with only mechanically pre-treated BA. Hardened state properties showed that the use of BA as aggregate leads to deterioration and efflorescence formation on the surface of the mortars, making this application unfeasible. The replacement of 15 v/v % of OPC (Ordinary Portland Cement) by BA and the use of finer (<63 μm) BA as filler caused a decrease in the compressive strength of the mortar, from 15.8 to 9.3 and 11.0, respectively. However, these materials are suitable for use in walls where the minimum required mechanical resistance is 5 MPa. Furthermore, these mortars demonstrated resilience against freeze–thaw cycles and even exhibited increased compressive strength after 25 cycles. Thus, this work showed that MSWI BA can be used as an OPC substitute (up to 15 v/v %) and as a filler, promoting circular economy principles and reducing CO₂ emissions related to the construction industry. Full article

(This article belongs to the Special Issue Sustainable Materials from Industrial Waste)

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12 pages, 2316 KiB

Open AccessArticle

Development of Lightweight Mortars Using Sustainable Low-Density Glass Aggregates from Secondary Raw Materials

by Maximina Romero, Isabel Padilla, José Luis García Calvo, Pedro Carballosa, Filipe Pedrosa and Aurora López-Delgado

Materials 2023, 16(18), 6281; https://doi.org/10.3390/ma16186281 - 19 Sep 2023

Cited by 2 | Viewed by 1195

Abstract

In this study, different lightweight expanded glass aggregates (LEGAs) were produced from glass cullet and various carbonated wastes, through a thermal impact process. The effects of LEGA microstructure and morphology on both the adherence to the cement paste and the mechanical properties of mortars after 28 days of curing were studied. The properties of lightweight mortars made of either LEGAs or expanded clay aggregates were compared. The results demonstrated the feasibility of using LEGAs to produce glass lightweight aggregate mortar, with flexural and compressive strength values ranging from 5.5 to 8.2 MPa and from 28.1 to 47.6 MPa, respectively. The differences in mechanical properties were explained according to the microstructures of the fracture surfaces. Thus, arlite-type ceramic aggregates presented surface porosities that allowed mortar intrusion and the formation of an interconnected interface; although the surfaces of the vitreous aggregates were free from porosity due to their vitreous nature, the mortars obtained from different wastes presented compressive and flexural strengths in the range of lightweight mortars. Full article

(This article belongs to the Special Issue Sustainable Materials from Industrial Waste)

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16 pages, 2737 KiB

Open AccessArticle

Use of a Waste-Derived Linde Type-A Immobilized in Agarose for the Remediation of Water Impacted by Coal Acid Mine Drainage at Pilot Scale

by Cristiano Luiz Chostak, Aurora López-Delgado, Isabel Padilla, Flávio Rubens Lapolli and María Ángeles Lobo-Recio

Materials 2023, 16(11), 4038; https://doi.org/10.3390/ma16114038 - 29 May 2023

Cited by 2 | Viewed by 1164

Abstract

A new adsorbent based on an immobilized waste-derived LTA zeolite in agarose (AG) has proven to be an innovative and efficient alternative for removing metallic contaminants from water impacted by acid mine drainage (AMD) because the immobilization prevents the solubilization of the zeolite in acidic media and eases its separation from the adsorbed solution. A pilot device was developed containing slices of the sorbent material [AG (1.5%)–LTA (8%)] to be used in a treatment system under an upward continuous flow. High removals of Fe²⁺ (93.45%), Mn²⁺ (91.62%), and Al³⁺ (96.56%) were achieved, thus transforming river water heavily contaminated by metallic ions into water suitable for non-potable use for these parameters, according to Brazilian and/or FAO standards. Breakthrough curves were constructed and the corresponding maximum adsorption capacities (mg/g) (Fe²⁺, 17.42; Mn²⁺, 1.38; Al³⁺, 15.20) calculated from them. Thomas mathematical model was well fitted to the experimental data, indicating the participation of an ion-exchange mechanism in the removal of the metallic ions. The pilot-scale process studied, in addition to being highly efficient in removing metal ions at toxic levels in AMD-impacted water, is linked to the sustainability and circular economy concepts, due to the use as an adsorbent of a synthetic zeolite derived from a hazardous aluminum waste. Full article

(This article belongs to the Special Issue Sustainable Materials from Industrial Waste)

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18 pages, 9363 KiB

Open AccessArticle

Characterization of Volcano-Sedimentary Rocks and Related Scraps for Design of Sustainable Materials

by Luisa Barbieri, Fabiana Altimari, Fernanda Andreola, Bruno Maggi and Isabella Lancellotti

Materials 2023, 16(9), 3408; https://doi.org/10.3390/ma16093408 - 27 Apr 2023

Cited by 8 | Viewed by 1675

Abstract

This work started as a joint academia and company research project with the aim of finding new applications for domestically sourced volcanic products and related waste (pumice, lapillus, zeolitic tuff and volcanic debris from Tessennano and Arlena quarry) by creating a database of secondary volcanic raw materials and their intrinsic characteristics to help industry replace virgin materials and enhance circularity. In this context, accurate chemical, mineralogical, morphological, granulometric and thermal characterizations were performed. Based on the results presented, it can be concluded that due to their lightness, these materials can be used in the design and preparation of lightweight aggregates for agronomic purposes or in the construction field. Furthermore, due to their aluminosilicate nature and amorphous fraction, pumice and lapillus can play the role of precursor or activator for geopolymer preparation. With its porous nature, zeolitic tuff can be exploited for flue gas treatment. Due to the presence of feldspathic phase (sanidine), these materials can be used in tile production as a fluxing component, and with their pozzolanic activity and calcium content, they have application in the binder field as supplementary cementitious material or as aggregates. Full article

(This article belongs to the Special Issue Sustainable Materials from Industrial Waste)

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19 pages, 6434 KiB

Open AccessArticle

Reuse of Oil Refining Sludge Residue Ash via Alkaline Activation in Matrices of Chamotte or Rice Husk Ash

by Almudena García-Díaz, Salvador Bueno-Rodríguez, Luis Pérez-Villarejo and Dolores Eliche-Quesada

Materials 2023, 16(7), 2801; https://doi.org/10.3390/ma16072801 - 31 Mar 2023

Cited by 1 | Viewed by 2079

Abstract

The aim of this work is to investigate the possibility of reusing ashes obtained by the calcination of industrial sludge from the oil refining industry (ORSA) as a secondary raw material in the manufacture of alkaline activated cements or geopolymers. The incorporation behavior of 5–20 wt.% of residue in binary mixtures with rice husk ash (RHA) or chamotte (CHM) was evaluated. The cements were activated with a sustainable alternative activating solution obtained from NaOH (10 M) and diatomaceous earth. The specimens were cured at room temperature. Physical and mechanical properties were determined, and the reaction products were characterized by X-ray diffraction (XRD), Fourier transform infrared spectroscopy (FTIR) and scanning electron microscopy–energy dispersive X-ray spectroscopy (SEM-EDX). The results indicate that the addition of ORSA (5–20 wt.%) to RHA and CHM improves the mechanical strength of alkaline activated cements with maximum compressive strengths of 30.6 MPa and 15.7 MPa, respectively, after 28 days of curing, with the incorporation of 20 wt.% waste. In these mixtures, the sludge acts as a source of aluminum, promoting the formation of a higher amount of geopolymer gel N-A-S-H in materials using RHA as a precursor and also (N)-(C)-A-S-H gel in cements using CHM. Full article

(This article belongs to the Special Issue Sustainable Materials from Industrial Waste)

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