Search Results (36)

Silica/alumina composite particles were synthesized via the sol–gel method to promote fine dispersion and homogenous mixing. Aluminum chloride hydroxide served as the alumina precursor, while amorphous silica, obtained from rice husk, was directly incorporated into the alumina sol. Following synthesis, the material was calcined at 1000 °C, yielding an α-cristobalite form of silica and corundum-phase alumina. These hybrid particles were introduced into polymer composites at reinforcement levels of 1 wt.%, 3 wt.%, and 5 wt.%. Mechanical behavior was evaluated through three-point bending tests, Shore D hardness measurements, and controlled-energy impact testing. Among the formulations, the 3 wt.% composite exhibited optimal performance, displaying the highest flexural modulus and strength, along with enhanced impact resistance. Hardness increased with rising particle content. Fractographic analysis revealed that the 3 wt.% loading produced a notably rougher fracture surface, correlating with improved energy absorption. In contrast, the 5 wt.% composite, although harder than the matrix and other composites, exhibited diminished toughness due to particle agglomeration. Full article

Laterite soil is widely found in various tropical and subtropical regions. This study focuses on the physical and chemical properties of laterite soil as a precursor for geopolymer synthesis. The characteristics of the soil were determined through experimental analyses, including XRF, XRD, SEM, EDS, FTIR, TGA/DTA, and pH measurements. XRF analysis revealed that the primary chemical oxides are silica, alumina, and iron oxide, which are very essential for geopolymer production. Both XRD and FTIR assessments revealed that the calcination process applied to laterite diminishes its crystallinity while enhancing its amorphous nature, thereby improving its reactivity. TGA and DTA results confirmed significant weight loss and dihydroxylation between 400 °C and 700 °C, while temperatures above 700 °C showed minimal weight loss and no further dihydroxylation. The pH of the tested laterite soil was measured at 5.35, indicating strong acidic behaviour. Based on these combined chemical and physical analyses, this study concludes that laterite soil is a viable precursor material for geopolymer synthesis. Full article

The accumulation and improper management of mining tailings represent significant environmental and public health challenges globally, due to their potential for water contamination and the presence of heavy metals. In recent years, various studies have explored the feasibility of using mining wastes, such as tailings sludge, as partial replacements for cement in concrete mixes. The literature highlights the pozzolanic properties of mining tailings attributable to their silica and alumina content, which contribute to the improved structural characteristics, chemical resistance, and enhanced durability of concrete. This research evaluates the specific potential of gold mining tailings sludge (REMI) from the municipality of Vetas, Santander, Colombia, as a sustainable substitute in cementitious materials. Characterization methodologies including X-ray fluorescence (XRF), X-ray diffraction (XRD), and scanning electron microscopy (SEM) confirmed the pozzolanic behavior of REMI due to its high content of silica- and alumina-rich amorphous phases and verified negligible contamination levels (Hg and cyanide below detectable limits). Concrete mixes with varying cement substitution levels (0% to 50%) were formulated and systematically evaluated to determine optimal substitution ranges based on criteria such as density, workability, setting time, and compressive strength. Consistent with previous studies, the results revealed an optimal replacement rate between 10% and 20%, with a particular emphasis on the 20% substitution achieving mechanical strengths comparable to traditional concrete. These findings underscore the technical viability and environmental benefits of using mining tailings sludge, contributing both to sustainable waste management and the advancement of eco-efficient concrete technologies. Full article

Coal fly ash (CFA) is a commercially viable source of alumina comparable to traditional bauxite deposits. Due to its high silica content and alumina in the refractory mullite phase, the most suitable processing technique is the sinter-H₂SO₄ leach process. However, this process is energy-intensive, has low selectivity for Al, and generates a secondary solid waste residue. To develop a sustainable process that is economically attractive, Al can be extracted with REEs, Ti, and Fe as saleable products, while secondary solid waste is regenerated for further applications to achieve high-value and high-volume utilisation of CFA. This study focused on the potential extraction of selected REEs (Ce, La, Nd, Y, and Sc), Al, Ti, and Fe, using dry magnetic separation and the sinter-H₂SO₄ leach process. XRD analysis showed that CFA is predominantly amorphous with crystalline mullite, quartz, and magnetite/hematite. Further analysis using SEM-EDS and TIMA showed Al-Si-rich grains as the predominant phase, with discrete REE-bearing grains (phosphates and silicates) and Fe-oxide (magnetite/hematite) grains. Traces of REEs, Ti, Ca, Si, and Fe were also found in the Al-Si-rich grains. Discrete Fe-oxide was recovered using dry magnetic separation, and up to 65.9% Fe was recovered at 1.05 T as the magnetic fraction (MF). The non-magnetic fraction (non-MF) containing quartz, mullite, and amorphous phase was further processed for preliminary leaching studies. The leaching behaviour of Al, Ti, Fe, and the selected REEs was investigated using the direct H₂SO₄ and sinter-H₂SO₄ leaching processes. The maximum extraction efficiency was observed using the sinter-H₂SO₄ leach process at 6 M H₂SO₄, a 1:5 solid-to-liquid ratio, 70 °C, and a residence time of 10 h, yielding 77.9% Al, 62.1% Fe, 52.3% Ti, and 56.7% Sc extractions. The extraction efficiencies for Ce, La, Nd, and Y were relatively lower at 23.2%, 27.6%, 11.3%, and 11.2%, respectively. Overall, the results demonstrate that the extraction of REEs using the sinter-H₂SO₄ leach process is strongly influenced by the complex CFA phase composition and the possible formation of insoluble calcium sulphates. Appreciable extraction of Al, Fe, Ti, and Sc was also observed, suggesting a potential two-step leaching process for the extraction of REEs as a feasible option for the industrial recovery of multiple saleable products. Full article

Coal tar naphtha is produced from coal carbonization, moving bed coal gasification, and thermal liquefaction of coal. The naphtha can contain up to 60% aromatics and 15% olefins, as well as nitrogen-, oxygen-, and sulfur-containing compounds. Usually only hydrotreating is considered, but when producing motor gasoline, olefin–aromatic alkylation could reduce the associated octane number loss due to olefin hydrogenation by converting olefins to alkylated phenols and aromatics. The plausibility of using acid-catalyzed alkylation with coal tar naphtha, which contains nitrogen bases, was investigated by studying a model system comprising phenol and 1-hexene in the absence and presence of pyridine. It was found that pyridine only inhibited conversion over a range of amorphous silica–alumina catalysts. The most effective catalyst was Siral 30 (30% silica, 70% alumina) and at 315 °C, 0.05 wt% pyridine caused a 35% inhibition of phenol conversion compared to conversion in the absence of pyridine. Catalyst activity could be restored by rejuvenating the catalyst with clean feed at a higher temperature. The results supported a description of phenol alkylation with olefins that took place by at least two pathways, one involving protonation of the olefin (typical for Friedel–Crafts alkylation) and one where the olefin is the nucleophile. Full article

The utilization of silicomanganese slag (SiMnS) as a precursor for alkali-activated materials (AAMs) is considered as an efficient approach for sustainable and eco-friendly large-scale resource utilization. However, sodium silicate solutions account for more than 50% of the production costs and carbon emissions of AAMs. In this study, AAM activators were prepared by silica-containing waste (acid leaching residue of boron mud, BM-AR) and NaOH as raw materials, and were successfully substituted for commercial sodium silicate-NaOH activators. Results indicated that the NaOH dosage had a great effect on the concentration and modulus of the activator. With the appropriate dosage of NaOH (NaOH: BM-AR = 0.4–0.7), suitable moduli of AAM activators can be produced at a wide range of solid/liquid ratios (L/S = 3–4.5) under mild conditions (80–100 °C). The compressive strength of the SiMnS AAM specimens prepared by this activator can reach 68.58 MPa, and its hydration products were mainly hydrated calcium silicate and amorphous silica–alumina gel, indicating the successful preparation of AAM. Calculation showed that the carbon emission of the AAMs prepared in this study was 12.4% and 37.6% of that of OPC and commercial water glass/NaOH-activated AAMs, and the cost was only 67.14% and 60.78% of them. The process achieves the use of waste materials to replace commercial activators, and is expected to be extended to a variety of AAMs raw materials and silica-containing waste. This makes it a highly promising alternative method for the production of AAMs, particularly the ‘just add water’ AAMs. Full article

Nanocrystalline mullite was synthetized by annealing a highly porous 3D structure consisting of nanofibrous aluminum oxyhydroxides treated with ethoxysilanes. The chemical, structural, and phase transformations in the aluminosilicate nanosystem were studied in the temperature range between 100 and 1600 °C. The features of the solid-phase synthesis of mullite at the interface of crystalline alumina with a liquid silica layer are discussed. It was established that chemical modification of the alumina surface with ethoxysilanes significantly limits the interphase mass transport and delays the phase transformation of the amorphous oxide into γ-Al₂O₃, which begins at temperatures above 1000 °C, while the basic structural nanofibrils are already crystallized at ~850 °C. The formation of mullite was completed at temperatures ≥ 1200 °C, where the fraction of γ-Al₂O₃ sharply decreased. Full article

In the search for alternative cementitious materials, the alkali activation of aluminosilicates has been found to be a mechanically effective binder. Among precursors, metakaolin is most frequently used, with a primary source, kaolin, distributed globally in varying compositions. This variability may indicate potential compositional limitations for the large-scale production of such binders. Thus, four types of commercial calcined clays, activated under identical conditions, were evaluated, and their physicochemical characteristics were correlated with the mechanical properties of the resulting binder. Different characterization methods were used for the raw material and for each alkali-activated system. Anhydrous metakaolin was assessed through particle size distribution, specific surface area, zeta potential, vitreous phases, Fourier transform infrared spectroscopy (FTIR), X-ray diffraction (XRD), amorphism, and pozzolanic activity. The pastes were evaluated in the fresh state through apparent activation energy progression and isothermal conduction calorimetry, and in the hardened state through compressive strength and dilatometry. Compressive strength values ranged from 7 to 42 MPa. From these results, a mathematical model was developed to estimate mechanical performance based on key variables, specifically amorphism, the pozzolanic index, and the silica-to-alumina ratio. This model allows for performance predictions without the need to prepare additional pastes. Interestingly, it was found that while some systems displayed low initial reactivity, their relative reactivity over time increased more significantly than those with higher early-stage reactivity, suggesting their potential for reconsideration in long-term applications. Full article

The application of geopolymers has recently been given significant attention to address climate change and the growing scarcity of construction materials in the 21st century. Researchers have utilized industrial waste or supplementary cementitious materials containing high levels of silica and alumina as precursors along with different alkaline activators. Furthermore, the technical challenges associated with waste brick management or recycling include both land use changes and financial implications. The existence of amorphous aluminosilicates in waste clay bricks, which can be used as geopolymer binders, has drawn attention recently. This paper reviews the recent advancements of the integration of clay brick wastes in geopolymer applications, individually as well as its use with other alternative materials. Prior studies suggest that waste clay bricks can effectively serve as the primary source material in geopolymer applications. This review covers various aspects, including the assessment of fresh, mechanical, microstructure, and durability-related properties. It specifically focused on enhancing these properties of waste clay bricks through mechanical and thermal treatments, through varying curing conditions, utilizing different types of alkaline activators, and considering their properties and corresponding ratios in the development of geopolymer products using waste brick powder. Furthermore, this paper portrays a critical review of the sustainability implications of the utilization of clay brick waste in geopolymer applications. Conclusively, this review provided the lessons learnt, research gaps, and the future direction for investigation into the feasibility of geopolymers derived from waste clay brick powder. Full article

This study investigates how different sodium silicate SiO₂/Na₂O MS ratios (0.75, 0.9, and 1.2) affect the hydration behavior of amorphous wollastonitic hydraulic (AWH) binders containing various amounts of Al₂O₃ content (4, 7, 10, and 12%wt). The effects of and interaction between the MS ratio of the activator and the Al₂O₃ content of the sample on the hydration reaction and paste performance were investigated. The reaction was followed by calorimetry, and the pastes’ compressive strength performances were tested at different curing times (2, 7, and 28 days). The hydrated pastes were characterized by FTIR, thermogravimetry analysis, and X-ray diffraction. The calorimetric results show that a higher Al₂O₃ cContent and a higher MS ratio result in a longer induction period. In terms of paste performance, an increase of the Al₂O₃ coupled with an activation with a 1.2 MS ratio results in a lower compressive strength after 28 days of hydration; the results range from 76 to 52 MPa. A decrease of the MS ratio to 0.9 allowed the obtention of a narrower range of results, from 76 to 69 MPa. Even though a decrease of the MS ratio to 0.75 led to higher hydration kinetics and high compressive strength results at early ages, at 28 days of curing, a decrease in compressive strength was observed. This may be a consequence of the fast kinetic of the mixture, since the rapid growth of hydration products may inhibit the dissolution at later ages and increase the porosity of the paste. Moreover, the high Al intake in the hydration product, facilitated by the high sodium content of the activator, promotes the formation of a higher number of calcium aluminate silicate hydrate structures (C-A-S-H) to the detriment of calcium silicate hydrate structures (C-S-H), decreasing the compressive strength of the samples. The TGA results indicate that the samples hydrated with the MS075 solution resulted in a higher number of hydrated products at early ages, while the samples hydrated with the MS09 and MS1.2 solutions exhibit a steady increase with curing time. Hence, an equilibrium in the hydration kinetic promoted by Si saturation–undersaturation appears to be fundamental in this system, which is influenced by both the MS ratio and the Al(OH)⁴⁻ content in solution. The results of this study suggest that for this type of binder, optimal performance can be achieved by decreasing the MS ratio to 0.9. This composition allows for a controlled kinetic and overall higher compressive strength results in pastes produced with this AWH precursor. Full article

The efficiency of the vapor phase crystallization (VPC) process in zeolite formation using mixtures of a natural source (obsidian) and common waste materials (red mud and fly ash) was analyzed. The aim was to demonstrate that water molecules available during this treatment control mainly the synthesis of sodalite, regardless of the raw material used, as long as it is rich in amorphous silica and alumina pre-fused with NaOH. The data indicate that increasing the temperature to generate steam from distilled water during the VPC process results in the continuous transformation of amorphous material into sodalite and, subordinately, cancrinite. The formation of the newly formed phases was monitored by powder XRD and SEM. Full article

Thin, supported inorganic mesoporous membranes are used for the removal of salts, small molecules (PFAS, dyes, and polyanions) and particulate species (oil droplets) from aqueous sources with high flux and selectivity. Nanofiltration membranes can reject simple salts with 80–100% selectivity through a space charge mechanism. Rejection by size selectivity can be near 100% since the membranes can have a very narrow size distribution. Mesoporous membranes have received particular interest due to their (potential) stability under operational conditions and during defouling operations. More recently, membranes with extreme stability became interesting with the advent of in situ fouling mitigation by means of ultrasound emitted from within the membrane structure. For this reason, we explored the stability of available and new membranes with accelerated lifetime tests in aqueous solutions at various temperatures and pH values. Of the available ceria, titania, and magnetite membranes, none were actually stable under all test conditions. In earlier work, it was established that mesoporous alumina membranes have very poor stability. A new nanofiltration membrane was made of cubic zirconia membranes that exhibited near-perfect stability. A new ultrafiltration membrane was made of amorphous silica that was fully stable in ultrapure water at 80 °C. This work provides details of membrane synthesis, stability characterization and data and their interpretation. Full article

Coal bottom ash is used globally in various applications in the construction industry to reduce its negative environmental impacts. In this study, the potential utilization of lignite bottom ash from four power plants in Greece in concrete manufacturing was evaluated through granulometric, chemical, and mineralogical analyses. The particle-size distribution of bottom ash obtained from dry sieving resembles that of sand, making bottom ash suitable for replacing fine aggregates in the production of concrete. Its chemical composition, determined with selective point analyses energy dispersive spectroscopy (EDS), reveals high amounts of silica and alumina indicating pozzolanic properties, and high calcium contents suggesting hydraulic/cementitious character. Mineralogical characterization, obtained from powder X-Ray diffraction analyses (XRD), displays the prevalence of amorphous matter, calcite, quartz, aluminosilicate minerals, and portlandite, implying a beneficial pozzolanic and hydraulic activity in concrete manufacturing. Full article

Fluidized catalytic cracking of vacuum gas oil is considered a promising factor in enhancing the gasoline yield to fulfill global energy demands. In this study, a series of FCC catalysts with a zeolite to matrix ratio varying from 18 to 50 was prepared using USY zeolite and amorphous matrix. The matrix was composed of amorphous silica-alumina, kaolin, and silica sol binder. All fresh catalysts were subjected to hydrothermal deactivation treatment at 750 °C for 5 h. The performance evaluation of FCC catalysts was conducted in a fixed bed microactivity test unit, with vacuum gas oil as feed at 550 °C. Comparing a steamed CAT01 sample with a fresh CAT01, the surface area of the steamed sample was 23.3% less. Similarly, the fresh sample CAT05 acidity increased by 102% when compared with the fresh CAT01 sample. As the zeolite to matrix ratio increased, the selectivity of dry gas, LPG, and coke increased, associated with a consistent decrease in gasoline and heavy ends (LCO and HCO). The combined selectivity of product gasoline and LCO with low-zeolite steamed catalyst (CAT01) was 82%, and that of high-zeolite steamed catalyst (CAT05) was 76%. Furthermore, coke selectivity for the steamed CAT01 was 2.1%, whereas 3.7% was observed for the steamed CAT05 sample. The effect of the zeolite to matrix ratio was less pronounced in steamed catalysts as compared with fresh catalysts. Full article

Colloidal bonds are realized by sol–gel technology. The binder system of the refractory castable belongs to the Al₂O₃–SiO₂ binary diagram. Mullite is the most thermally stable mineral in this system. This work was motivated by an attempt to maximize the mullite content in the NCC binder system, because a high content of mullite is a guarantee of the long service life of refractories. Initially, the mineralogical composition of the pure gel was tested after drying and firing at temperatures between 1000 °C and 1600 °C. The behavior of the gel during drying was described. Subsequently, a method of minimizing gel shrinkage during drying was sought. To this aim, fine fillers (microfillers) of alumina and silica were tested. In particular, the reactivity of the microfillers, the ability of the microfillers to react with the sol to form mullite, and the drying shrinkage of the microfiller-doped gel were evaluated. The study showed that the least suitable source of Al₂O₃ in terms of its reactivity is tabular corundum, which produces the lowest amount of mullite. The internal structure of the prepared binder system when using different microfillers was described. Based on the results from the second stage of the work, several complete matrixes of the binder system were designed and the degree of their mullitization at different firing temperatures was studied. During this stage, it was shown that the degree of mullitization of the binder system depends mainly on the microsilica content. In the binder system, the maximum mullite content recorded was 76%. The effect of amorphous SiO₂ on the bulk density and internal structure of the binder system was also described. Full article