Search Results (28)

This study explores the potential of using sustainable materials in brick manufacturing by designing a novel brick mix in the laboratory, incorporating sand, lime kiln dust (LKD) waste, tyre rubber, and ground granulated blast furnace slag (GGBFS) waste. These cementless bricks blended LKD–GGBFS wastes as the binder agent and fine crumb rubber from waste tyres as a partial replacement for sand in measured increments of 0%, 5%, and 10% by volume of sand. Ordinary Portland cement (OPC) and fired clay bricks were sourced from the industry, and their properties were compared to those of the laboratory bricks. Tests performed on the industry and laboratory bricks included compressive strength (CS), freeze-thaw (F-T), and water absorption (WA) tests for comparison purposes. Additionally, scanning electron microscopy (SEM) and energy-dispersive X-ray spectroscopy (EDS) analyses were performed on the bricks to assess the morphological and mineralogical changes responsible for the observed strengths and durability. The CS and WA values of the engineered bricks were 12, 6, and 4 MPa, and 7, 12, and 15%, respectively, for 0, 5, and 10% crumb rubber replacements. The industry bricks’ average CS and WA values were 13 MPa and 8%, respectively. From the results obtained, the green laboratory bricks passed the minimum strength requirements for load-bearing and non-load-bearing bricks, which can be used to construct small houses. Lastly, the engineered bricks demonstrated strength and durability properties comparable to those of the industry-standard bricks, indicating their potential as a sustainable alternative to help divert waste from landfills, reduce the pressure on natural fine sand extraction, and support eco-conscious brick production for a sustainable environment. Full article

The iron and steel industry generates large quantities of iron-bearing dust (IBD), contributing to resource inefficiency and environmental concerns. This study investigates heating methods and the use of organic solid waste, specifically waste tire carbon (WTC), as a reductant for the recovery of Fe from sintering machine tail dust (SMTD) and steelmaking gravity dust. The results indicate that the optimal reduction conditions occurred at 1000 °C, with a 2:1 ratio of SMTD to WTC, and 0% O₂ holding for 45 min. WTC is the best material, and heating methods affect it limitedly. The leaching behavior of seven metals was measured, showing an increase in the leaching of Ca and Al compared to the raw materials. The study shows that WTC provides a promising alternative reductant for IBD reduction, offering an energy-saving and low-carbon alternative to conventional fossil fuel injections in blast furnaces. The risk of Cr leaching should be paid attention to while enhancing Fe recovery. Full article

Using solid waste-based materials, such as recycled building aggregate (RCA), preparing 3D-printed materials can reduce costs but increase the water–cement ratio of the printed material, which reduces its mechanical performance. In order to solve the problem of mechanical properties decline caused by an increase in the w/c ratio, this experiment found that adding calcined salt mud (CSM) to the printing materials and changing the water-to-cement ratio from 0.37 to 0.4 CSM can ensure that the compressive strength of the printing materials remains basically unchanged. Moreover, through TG, SEM, and other microscopic data, it can be seen that calcium hydroxide in CSM can not only participate in the synergistic reaction of ethylene/vinyl acetate copolymer (EVA) and dust ash (DA), produce more NaOH, and promote the hydration of granulated blast furnace slag (GBFS) but also promote the formation of ettringite together with SO₄²⁻ in solution, optimizing pore size distribution. Full article

Steel metallurgical dust, characterized by a substantial output, minute particle size, and intricate composition, poses a considerable risk of environmental contamination while simultaneously embodying an exceptionally high potential for recycling. To achieve its resource utilization, chemical analysis, particle size analysis, X-ray diffraction (XRD), scanning electron microscopy (SEM), Mössbauer spectroscopy, and water leaching methods were employed to investigate the chemical compositions, particle size distributions, phase compositions, and microscopic morphologies of blast furnace bag dust, sintering dust, converter fine dust, and electric arc furnace dust from steel plants. The results indicate that the four types of dust have extremely fine particle sizes, with the main distribution range of particle size being less than 100 μm. The main constituent element is Fe (19–56%), and it also contains Zn (1.4–33.5%), Pb, K, C, and other valuable elements. Alkali metals in blast furnace bag dust and sintering machine head dust existed mainly in the form of chloride. The zinc phases in sintering machine head dust and converter fine dust were ZnFe₂O₄, and the zinc phases in blast furnace bag dust were ZnCl₂ and ZnFe₂O₄. Zinc in electric furnace dust was composed of ZnO and ZnFe₂O₄, accounting for 70.31% and 23.12%, respectively. There are significant differences in the types and contents of valuable elements among various dusts, making it difficult to achieve full-scale recovery through a single process. In view of this, a process of “in-plant recycling of harmless dusts—collaborative treatment of harmful dusts” has been proposed. Based on the characteristics of metallurgical dusts, multiple processes are used for collaborative treatment (using hydrometallurgical and pyrometallurgical methods), which can not only directly recover iron resources from dusts within the plant, but also avoid the waste of valuable elements such as Zn, Pb, K, Na, etc. It is hoped that the above work can provide a reference for steel enterprises to achieve full-scale and high value-added treatment of metallurgical dusts. Full article

A technology was developed for managing Zn-bearing dust, facilitating the recycling of hazardous solid waste and the production of porous carbon materials. In the one-step process, Zn-bearing dusts were employed not only as raw materials to prepare reduced Zn-bearing dust pellets but also as activators to prepare K, Na-embedded activated carbon. In the process, the Fe, C, Zn, K, and Na in the dusts were rationally utilized. Under optimal conditions, the reduced pellets and porous carbon materials were simultaneously produced and characterized using XRD, SEM/EDS, FTIR, and adsorption of nitrogen techniques. The results indicated that the reduced pellets, with low levels of harmful elements and high iron grade and strength, could be directly used as burden for enhancing blast furnace operation without additional agglomeration. Meanwhile, the K and Na-embedded porous carbon material demonstrated superior SO₂ and NO adsorption capacities compared to the commercial activated carbon, making it suitable for purifying SO₂ and NO-bearing flue gas. The hazardous solid wastes were effectively used to treat flue gases through this technology. The mechanism in the synergistic reduction and activation process was elucidated. The coupling effect between the reduction reactions of Fe₂O₃, Fe₃O₄, FeO, MgFe₂O₄, CaFe₂O₄, ZnFe₂O₄, KFeO₂, and NaFeO₂ in the dusts and activation reaction of C in the coal promoted the synchronous reduction and activation process. Full article

This study reports an alkali-activated binder including blast furnace slag (BFS) together with marble waste (MW). Cement is an industrial product that emits a significant amount of CO₂ during its production and incurs high energy costs. MW is generated during the extraction, cutting, and processing of marble in production facilities, where dust mixes with water to form a settling sludge. This sludge is an environmentally harmful waste that must be disposed of in accordance with legal regulations. In this study, a substantial amount of MW, a by-product with considerable environmental and economic impacts worldwide, was utilized in the production of a binder through the alkaline activation of BFS. In doing this, different experimental parameters were tested to obtain the best binder samples according to workability and mechanical properties. Then, some experiments such as drying shrinkage determination, strength testing, and microstructure analyses were fulfilled through samples with the best values. The findings supported the improvement of the rapid-setting property of BFS by means of the addition of MW. MW reduced the time-dependent drying shrinkage values of BFS by 55%, especially in slag alkaline activation systems with a low or moderate alkali activator content. The substitution of MW (≤50%) in BFS increased flexural and compressive strengths (4.5 and 61.7 MPa), while a reference sample contained BFS only. Although the use of MW did not create a new phase, it contributed to a C-S-H bonding structure during the alkali activation of BFS in a microstructure analysis. Full article

This study aimed to investigate the behavior of accelerated carbonation-cured laboratory specimens using the ultrasonic non-destructive testing (UNDT) method and compare the results with the destructive testing (DT) method. The materials used in the study included a blend of lime kiln dust and ground granulated blast furnace slag (LKD-GBFS) wastes, natural fine aggregate (sand), and alternative fine aggregates from waste tires. The chemical analysis of the LKD and GBFS samples highlighted them as suitable alternatives to OPC, hence their utilization in the study. A 60:40 (LKD-GBFS) blending ratio and a 1:2 mix design (one part LKD-GBFS blend and two part sand) was considered. The natural fine aggregate was partially replaced with fine waste tire rubber crumbs (TRCs) in stepped increments of 0, 5, and 10% by the volume of the sand. The samples produced were cured using three curing regimens: humid curing (HC), accelerated carbonation curing (ACC) with no water curing (NWC) afterwards, and water curing after carbonation (WC). From the results, an exponential model was developed, which showed a direct correlation between the UNDT and DT results. The developed model is a useful tool that can predict the CS of carbonated samples when cast samples are unavailable. Lastly, a total CO₂ uptake of 15,912 g (15.9 kg) was recorded, which underscores ACC as a promising curing technique that can be utilized in the construction industry. This technique will bring about savings in terms of the time required to produce masonry units while promoting a change in the basic assumptions of a safer and cleaner environment. Full article

The main purpose of this research is to develop a solid waste-based cementitious material (SWC) instead of cement for solidifying a large amount of marine soft soil with high water content and low bearing capacity in coastal areas. This aims to solve the problems encountered in the practical application of cement soil, such as slow strength growth and poor durability. The SWC includes ground granulated blast furnace slag (GGBS), dust ash (DA), and activated cinder powder (ACP), with admixtures of naphthalene sulfonate formaldehyde condensate (NS) and compound salt early strength agent (SA). Both the 7 d and 28 d compressive strength values of the SWC formulations G4 and G7 are about twice as strong as those of cement soil (GC), even when mixed with seawater. Immersion tests revealed that stabilized soil had superior resistance to seawater corrosion compared to cement soil. X-ray diffraction, scanning electron microscopy, infrared spectroscopy, and thermogravimetric analysis explained that the main hydration products in cement soil are C-S-H and CH, while in stabilized soil, SWC generates a large amount of C-A-S-H with gelling properties and AFt with filling properties. These hydration products have better effects on strength and seawater erosion resistance. Full article

The global challenge faced due to the impact of the construction industry on climate change, along with the issues surrounding sustainable waste disposal, has necessitated various research on using waste products as eco-friendly alternatives in construction. In this study, the avoidance of waste disposal through landfills in Australia was encouraged by incorporating lime kiln dust (LKD) and tire rubber waste (TRW) into masonry mixes to manufacture green bricks. Furthermore, the investigations in this article highlight the use of mercury intrusion porosimetry (MIP) to determine the durability of the LKD-TRW bricks when exposed to freeze–thaw (F-T) cycles by examining the pore size distribution within the bricks. The LKD waste was blended with ground granulated blast furnace slag (GGBFS) at a 70:30 blending ratio and combined with the TRW in stepped increments of 5% from 0 to 20% to produce these eco-friendly bricks. The compressive strength (CS), flexural strength (FS), frost resistance (FR), pore size distribution according to mercury intrusion porosimetry (MIP), and the water absorption (WA) properties of the bricks were assessed. The CS and FS values at 28 days of curing were recorded as 6.17, 5.25, and 3.09 MPa and 2.52, 2, and 1.55 MPa for 0, 5, and 10% TRW contents, respectively. Durability assessments using the F-T test showed that the bricks produced with 0% TRW passed as frost-resistant bricks. Furthermore, the results from the MIP test showed a total pore volume of 0.033 mL/g at 3 µm pore size for the 0% TRW content, further confirming its durability. Hence, the 0% LKD-TRW bricks can be utilized in cold regions where temperatures can be as low as −43 °C without deteriorating. Lastly, WA values of 7.25, 11.76, and 14.96% were recorded for the bricks with 0, 5, and 10% TRW, respectively, after the 28-day curing period. From all of the results obtained from the laboratory investigations, the LKD-TRW bricks produced with up to 10% TRW were within the satisfactory engineering requirements for masonry units. Full article

Blast furnace dust waste (BFDW) proved efficient as a photocatalyst for the decolorization of methylene blue (MB) dye in water. Structural analysis unequivocally identified α-Fe₂O₃ as the predominant phase, constituting approximately 92%, with a porous surface showcasing unique 10–30 nm agglomerated nanoparticles. Chemical and thermal analyses indicated surface-bound water and carbonate molecules, with the main phase’s thermal stability up to 900 °C. Electrical conductivity analysis revealed charge transfer resistance values of 616.4 Ω and electrode resistance of 47.8 Ω. The Mott-Schottky analysis identified α-Fe₂O₃ as an n-type semiconductor with a flat band potential of 0.181 V vs. Ag/AgCl and a donor density of 1.45 × 10¹⁵ cm⁻³. The 2.2 eV optical bandgap and luminescence stem from α-Fe₂O₃ and weak ferromagnetism arises from structural defects and surface effects. With a 74% photocatalytic efficiency, stable through three photodegradation cycles, BFDW outperforms comparable waste materials in MB degradation mediated by visible light. The elemental trapping experiment exposed hydroxyl radicals ($\mathrm{O}\mathrm{H}_{•}^{}$) and superoxide anions (${\mathrm{O}}_2^{-}_{•}^{}$) as the primary species in the photodegradation process. Consequently, iron oxide-based BFDW emerges as an environmentally friendly alternative for wastewater treatment, underscoring the pivotal role of its unique physical properties in the photocatalytic process. Full article

This paper presents a comprehensive study in which non-destructive testing utilizing ultrasonic pulse velocity (UPV), considering both pressure (P) waves and shear (S) waves, was used to assess the compressive strength (CS) of rubberized bricks. These innovative bricks were manufactured by blending lime kiln dust (LKD) waste with ground granulated blast furnace slag (GGBFS), sand, and fine waste tire crumb rubber (WTCR). This study introduces mathematical models to explain the relationships between the results of destructive tests (DTs), specifically compression strength (CS) tests, and non-destructive tests (NDTs) employing UPV. These models were subsequently used to conduct validation exercises to accurately predict the strength of the rubberized bricks produced. The outcomes of the validation tests underscore the effectiveness of the UPV method in predicting the CS of rubberized eco-friendly bricks produced using an LKD-GGBFS blend. Importantly, the prediction using the power model exhibited minimal errors, confirming the utility of the UPV method as a reliable tool for assessing the compressive strength of such sustainable construction materials. This research contributes to advancing the field of eco-friendly construction materials and highlights the practical applicability of non-destructive ultrasonic testing in assessing their structural properties. Full article

The demand for materials with improved properties and less negative impact on the environment is growing. Artificial stones are examples of these materials produced with up to 90% of particulate material joined by a binder. This article evaluates the physical and mechanical properties of two artificial stones produced with processing steel residue (blast furnace dust waste) and quartz powder. Two binders were used: pure epoxy resin, denoted as ASPB100, or a mixture of 70 wt% epoxy resin with 30 wt% cashew nut shell oil, denoted as ASPB7030. The process took place under vibration, compression (3 MPa/20 min and 90 °C) and vacuum (80 Pa). ASPB100 showed water absorption of 0.07%, while for ASPB7030, it was 0.54%. They were classified as having high mechanical strength associated with bending stress values equal to 32 and 25 MPa, respectively. Stain resistance indicated that both artificial stones had their stains removed with the tested cleaning agents. In this way, the novel artificial stones produced are sustainable alternatives for the application of blast furnace waste and cashew nut shell oil, reducing their negative impacts on the environment. Full article

This work presents an experimental study on the physico-mechanical and microstructural characteristics of stabilised soils and the effect of wetting and drying cycles on their durability as road subgrade materials. The durability of expansive road subgrade with a high plasticity index treated with different ratios of ground granulated blast furnace slag (GGBS) and brick dust waste (BDW) was investigated. Treated and cured samples of the expansive subgrade were subjected to wetting–drying cycles, California bearing ratio (CBR) tests, and microstructural analysis. The results show a gradual reduction in the California bearing ratio (CBR), mass, and the resilient modulus of samples for all subgrade types as the number of cycles increases. The treated subgrades containing 23.5% GGBS recorded the highest CBR value of 230% under dry conditions while the lowest CBR value of 15% (wetting cycle) was recorded for the subgrade treated with 11.75% GGBS and 11.75% BDW at the end of the wetting–drying cycles, both of which find useful application in road pavement construction as calcium silicate hydrate (CSH) gel was formed in all stabilised subgrade materials. However, the increase in alumina and silica content upon the inclusion of BDW initiated the formation of more cementitious products due to the increased availability of Si and Al species as indicated by EDX analysis. This study concluded that subgrade materials treated with a combination of GGBS and BDW are durable, sustainable and suitable for use in road construction. Full article

Magnetosensitive biochars were prepared with mechanochemical ball-milling of lignin and blast furnace dust with further pyrolysis at 800 °C under an inert gas atmosphere. The physicochemical and sorption characteristics of the materials were analyzed using several techniques: low-temperature nitrogen adsorption–desorption, X-ray powder diffraction, Raman spectroscopy, elemental analysis, potentiometric titration, and thermal analysis. All the synthesized biocarbons were characterized by their specific surface areas (S_BET) in the range of 290–330 m²/g and microporous structures with certain contribution of mesopores in the total porosity. Equilibrium adsorption studies revealed the potential applicability of the materials in water remediation from hazardous organic substances modelled with methylene blue (MB) dye. Generally, this study illustrates the effective conversion of sustainable waste into a functional carbon material. Full article

Self-compacting concrete (SCC) is a special, highly fluid type of concrete that is produced using chemical additives. It is easier to pour and reduces defects arising from workability. Waste marble dust is generated during the production of marble using different methods, or during the cutting of marble in processing plants; however, the uncontrolled disposal of waste marble dust in nature is associated with some environmental problems. Cement and concrete technology is a field with potential for the utilization of these large amounts of waste. The present study explores the use of marble dust (MD) (an industrial waste generated in abundance around the province of Bilecik) and granulated blast furnace slag (GBFS) (another industrial waste product) in the production of SCC. In this study, MD and GBFS are used as fine materials in SCC mixtures, and the rheological and workability properties and other hardened concrete properties of the produced SCC specimens are tested. Additional tests are conducted to identify the durability of the specimens to sulfate attack, as well as their freeze–thaw and abrasion resistance, followed by microstructure tests to identify the effects of MD and GBFS on bond structure. The late-age performances of MD and GBFS were then examined based on the results of the durability tests. The presented results revealed improvements in the fresh and hardened properties of SCC produced using MD and GBFS. Full article