Search Results (512)

Ceramic pastes used in additive manufacturing offer several advantages, including low production costs due to the availability of raw materials and efficient processing methods, as well as a reduced environmental footprint through minimized material waste, optimized resource use, and the inclusion of recyclable or sustainably sourced components. This study evaluates the effect of diatomite content in a ceramic paste composed of carboxymethyl cellulose, kaolinite, and feldspar on its extrusion behavior and thermal conductivity, with additional analysis of its implications for microstructure, mechanical properties, and thermal performance. Four ceramic pastes were prepared with diatomite additions of 0, 10, 30, and 60% by weight. Thermal conductivity, extrusion behavior, morphology, and distribution were examined using scanning electron microscopy (SEM), while thermal degradation was assessed through thermogravimetric analysis (TGA) and differential scanning calorimetry (DSC). The results show that increasing diatomite content leads to a reduction in thermal conductivity, which ranged from 0.719 W/(m·°C) for the control sample to 0.515 W/(m·°C) for the 60% diatomite sample, as well as an improvement in extrusion behavior. The ceramic paste demonstrated adequate extrusion performance for 3D printing at diatomite contents above 30%. These findings lay the groundwork for future research and optimization in the development of functional ceramic pastes for advanced manufacturing applications. Full article

The stabilization of heavy metal elements, such as zinc, in the form of ions within the glass-ceramics represents a valuable approach to addressing environmental pollution caused by heavy metals. This study investigates the feasibility and physicochemical properties of diopside-based glass-ceramics synthesized from zinc-containing smelting slag. The zinc-rich smelting slag is abundant in SiO₂, Al₂O₃, CaO, and other constituents, thereby providing cost-effective and efficient raw materials for glass-ceramic production. The conversion of zinc-containing smelting slag into glass-ceramics was achieved through a melting process. We analyzed the effects of varying doping levels on the properties of the resulting glass-ceramics. The results indicated that as the doping level of smelting slag increases, the crystallization temperature of the glass-ceramics decreases while the crystal phases of diopside and anorthite progressively increase, significantly enhancing both mechanical strength and chemical stability. Notably, when the doping level reaches 60%, these glass-ceramics exhibit remarkable physical properties, including high density (3.12 g/cm³), Vickers hardness (16.60 GPa), and excellent flexural strength (150.75 MPa). Furthermore, with increasing amounts of doped smelting slag, there are substantial improvements in acid resistance, alkali resistance, and corrosion resistance in these materials. Raman spectroscopy and EDS analysis further verified a uniform distribution of the crystal phase and effective immobilization of heavy metal zinc. Full article

Electrostatic separation is a promising technology for the recovery of valuable metals from electronic waste, particularly from printed circuit boards (PCBs). This study explores the application of electrostatic separation for the selective recovery of metallic and non-metallic fractions from crushed PCBs (PCBs). The process exploits the differences in electrical properties between conductive metals and non-conductive polymers and ceramics, facilitating their separation through applied electric fields. The raw materials were pre-treated via mechanical comminution using shredders and hammer mills to achieve an optimal particle size distribution (<3 mm), which enhances separation efficiency. Ferrous materials were removed prior to electrostatic separation to improve process selectivity. Key operational parameters, including particle size, charge accumulation, environmental conditions, and separation efficiency, were systematically analysed. The results demonstrate that electrostatic separation effectively recovers high-value metals such as copper and gold while minimizing material losses. Additionally, the process contributes to the sustainability of e-waste recycling by enabling the recovery of non-metallic fractions for potential secondary applications. This work underscores the significance of electrostatic separation as a viable technique for e-waste management and highlights optimization strategies for enhancing its performance in large-scale recycling operations. Full article

Traditional stabilization techniques, such as lime and cement, widely used for their effectiveness, albeit with economic and environmental limitations, are leading to the search for sustainable approaches that utilize agricultural and industrial waste, such as rice husk ash, bagasse, and natural fibers. These have been shown to improve key geotechnical properties, even under saturated conditions, significantly. In particular, the combination of rice husk ash and recycled ceramics has shown notable results in Ecuadorian coastal soils. The article emphasizes the importance of selecting techniques that balance effectiveness, cost, and sustainability and identifies existing limitations, such as the lack of long-term data (ten years) and predictive models adapted to the Ecuadorian climate. From a bibliographic perspective, this article analyzes the challenges posed by expansive soils in the western coastal region of Ecuador, whose high plasticity and instability to moisture negatively affect civil works such as roads and buildings. The Ecuadorian clay contained 30% kaolinite and only 1.73% CaO, limiting its chemical reactivity compared to soils such as Saudi Arabia, which contained 34.7% montmorillonite and 9.31% CaO. Natural fibers such as jute, with 85% cellulose, improved the soil’s mechanical strength, increasing the UCS by up to 130%. Rice husk ash (97.69% SiO₂) and sugarcane bagasse improved the CBR by 90%, highlighting their potential as sustainable stabilizers. All of this is contextualized within Ecuador’s geoenvironmental conditions, which are influenced by climatic phenomena such as El Niño and La Niña, as well as global warming. Finally, it is proposed to promote multidisciplinary research that fosters more efficient and environmentally responsible solutions for stabilizing expansive soils. Full article

The sustainable valorization of electrolytic manganese residue (EMR) and fly ash (FA) presents critical environmental challenges. This study systematically investigates the performance optimization of EMR-FA ceramic composites through the coordinated regulation of raw material ratios, sintering temperatures, and additive effects. While the composite with 85 g FA exhibits the highest mechanical strength, lowest porosity, and minimal water absorption, the formulation consisting of 45 wt% EMR, 40 wt% FA, and 15 wt% kaolin is identified as a balanced composition that achieves an effective compromise between mechanical performance and solid waste utilization efficiency. Sintering temperature studies revealed temperature-dependent property enhancement, with controlled sintering at 1150 °C preventing the over-firing phenomena observed at 1200 °C while promoting phase evolution. XRD-SEM analyses confirmed accelerated anorthite formation and the morphological transformations of FA spherical particles under thermal activation. Additive engineering demonstrated that 8 wt% CaO addition enhanced structural densification through hydrogrossular crystallization, whereas Na₂SiO₃ induced sodium-rich calcium silicate phases that suppressed anorthite development. Contrastingly, ZrO₂ facilitated zircon nucleation, while TiO₂ enabled progressive performance enhancement through amorphous phase modification. This work establishes fundamental phase–structure–property relationships and provides actionable engineering parameters for sustainable ceramic production from industrial solid wastes. Full article

The sustainable utilization of solid waste is crucial for environmental protection. This work investigates the fabrication of foamed ceramics from Cr slag and municipal solid waste incineration (MSWI) fly ash, focusing on the effects of three inhibitors—NH₂SO₃H, ZnO·TiO₂, and (NH₄)₂HPO₄—on material properties and Cr leaching behavior. Experimental analysis, chemical thermodynamic calculations, and material characterization were all employed. Results show that the prepared foamed ceramics meet the JG/T 511-2017 standard for building materials, exhibiting excellent physical properties but significant Cr leaching. Among the inhibitors, (NH₄)₂HPO₄ with a molar ratio of n(P)/n(Cr) = 1 shows the best performance, achieving a bulk density of 205 kg/m³, compressive strength of 0.850 MPa, Cr leaching concentration of 188 μg/L, and a 70.0% of Cr leaching inhibition rate. The improvement is attributed to the AlPO₄ formation that enhancing the strength, and Ca₂P₂O₇ that stabilizing Cr during sintering. This work provides a feasible method for the safe resource utilization of Cr-containing waste. Full article

Using innovative and sustainable materials has become crucial for developed countries. Reusing waste as a secondary raw material in industrial processes central to the circular economy could enhance environmental sustainability and support local economies. Building materials such as Portland cement have a significant environmental impact due to greenhouse gas emissions and construction and demolition waste (CDW), which is challenging to recycle. Research into sustainable alternatives is, therefore, essential. The European Union has set ambitious targets to reduce greenhouse gas emissions by 55% by 2030 and achieve climate neutrality by 2050. The National Recovery and Resilience Plan (PNRR) supports the green transition in Italy by promoting sustainable materials like geopolymers. These ceramic-like materials are based on aluminosilicates obtained through the chemical activation of waste rich in silica and aluminosilicate compounds. Though promising, these materials require further research to address challenges like long-term durability and chemical variability. Collaboration between scientific research and industry is essential to develop specific protocols and suitable infrastructures. This article provides a critical review of the advancements and challenges in using alkali-activated waste as construction binders, focusing on Italy, and encourages the exploration of alternative sustainable materials beyond conventional Portland cement. Full article

Nowadays, there is wide advocacy for a transition to circular economic models. Fly Ash (FA) in particular is a major by-product of coal combustion and its annual waste has reached one million tonnes. Cenospheres (CSs) are considered as possibly the most valuable element within FA. Thus, in this research, polymeric foam replication was employed to fabricate ceramic foams based on a CS matrix, for potential biomedical applications. For the fabrication of foams, four types of natural marine sponges were used as templates along with a binder agent. The specimens were sintered at 1200 °C for 1 h. The results were encouraging as the specimens obtained retained the given shape and geometry. Further research will enhance the potential of such materials for future use in biomedical engineering. Full article

The storage of sewage sludge in landfills is still the primary method of their disposal in many countries. Therefore, finding sustainable solutions for the reuse of this waste is an important issue to be addressed. This paper presents the results of research on processing sewage sludge generated at the wastewater treatment plants of Almaty, Kazakhstan, for use in the manufacturing of ceramic bricks. The chemical composition of the sewage sludge was determined, showing the presence of 35.7% silicon dioxide, 7.3% aluminum oxide, 11.2% iron oxide, and 10.6% calcium oxide. Experimental studies established that adding sewage sludge to clay reduces the compressive strength of ceramic bricks while increasing their flexural strength. Furthermore, as the proportion of sewage sludge in the clay mixture increases, the average density of the ceramic bricks decreases, while water absorption increases. It was also found that ceramic bricks made from a mixture of 90% clay and 10% sewage sludge demonstrated the best physico-mechanical properties. This composition showed increased flexural strength and a simultaneous reduction in the average density by 15.4%, indicating the improved structural quality of the manufactured bricks. Full article

Membrane distillation (MD) has attracted increasing attention as a thermally driven separation process for water purification, desalination, and wastewater treatment. Its primary advantages include high rejection of non-volatile solutes, compatibility with low-grade or waste heat sources, and operation at ambient pressure. Despite these benefits, large-scale implementation remains limited due to the lack of membrane materials capable of withstanding harsh operating conditions and maintaining their hydrophobic character. Polymeric membranes have traditionally been used in MD applications; however, their limited thermal and chemical stability compromises long-term performance and reliability. In contrast, ceramic membranes are emerging as a promising alternative, offering superior mechanical strength, chemical resistance, and thermal stability. Nevertheless, their broader adoption in MD is hindered by several challenges, including high thermal conductivity, surface wettability, high fabrication costs, and limited scalability. This review provides a critical assessment of current developments, key opportunities, and ongoing challenges associated with the use of ceramic membranes in MD. Particular emphasis is placed on advances in surface modification techniques and the emerging applications in advanced MD configurations. Full article

Ceramic tiles classified as non-biodegradable are made from fired clay, silica, and other natural materials for several construction applications. Waste ceramic tiles (WCTs) are produced from several sources, including manufacturing defects; surplus, broken, or damaged tiles resulting from handling; and construction and demolition debris. WCTs do not decompose easily, leading to long-term accumulation in landfills and occupying a significant amount of landfill space, which has substantial environmental impacts. Recycling WCTs offers several critical ecological benefits, including reducing landfill waste and pollution, conserving natural resources, lowering energy consumption, and supporting the circular economy, which in turn contributes to sustainable construction and waste management practices. In green concrete manufacturing, WCTs are widely utilized as replacements for cement, fine, and coarse aggregates, and the recycling level in the concrete industry is an increasingly explored practice aimed at promoting sustainability and reducing construction waste. From this view, this paper reports the innovative technologies, advancements in green concrete performance, and development trends in the reuse of WCTs in the production of systems. The effects of WCTs on fresh, engineering, microstructural, and durable properties, as well as their environmental performance, are reviewed. In conclusion, the use of technologies for recycling WCTs has demonstrated potential in promoting sustainability and supporting the transition toward a more environmentally friendly construction industry. This approach offers a practical contribution to sustainable development and represents significant progress in closing the recycling loop within the construction sector. Full article

The use of construction and demolition waste (CDW) as an alternative binder to ordinary Portland cement presents a promising solution through alkaline activation. This study evaluates the physical, mechanical, and microstructural behaviour of pastes and mortars produced with CDW—specifically concrete (RH) and ceramic (RC) waste—activated with NaOH and Na₂SiO₃ (SS) solutions. Mortars were prepared with NaOH/SS ratios of 0.2 and 0.3 and an activator-to-precursor (AA/P) ratio of 0.2. Results showed that higher NaOH content accelerated alkaline activation, reducing setting times from 6.2 h to 3.7 h for RC and from 4.6 h to 3.2 h for RH. Conversely, increasing Na₂SiO₃ content led to greater drying shrinkage, from −0.42% to −0.49% in RC and from −0.46% to −0.52% in RH. Compressive strength values at 28 days ranged from 7.6 to 8.2 MPa. X-ray diffraction (XRD) revealed the presence of non-reactive crystalline phases in both precursors, while Fourier transform infrared (FTIR) spectroscopy indicated the formation of CASH, CSH, and/or (N)CASH gels. This study highlights the potential of CDW as a sustainable alternative binder and the usefulness of the proposed method for optimising alkali-activated systems, contributing to circular economy strategies in the construction sector. Full article

Mining activities generate large volumes of tailings with significant environmental impact but also the potential for sustainable reuse in construction materials. This study evaluates the production of ceramic aggregates from mixtures of clay, sand, and iron ore waste subjected to thermal treatment at temperatures ranging from 600 to 1100 °C. The influence of calcination temperature on mineralogical transformations and mechanical integrity was investigated using X-ray diffraction (XRD) and the $\alpha$-Treton parameter, derived from standardized impact resistance testing. The results indicate that the formation of metakaolinite between 700 and 900 °C enhances mechanical resistance, while higher temperatures (>900 °C) lead to structural degradation, followed by partial recovery due to mullite crystallization. The $\alpha$-Treton curve exhibited clear correlation with the phase changes identified by XRD, demonstrating its applicability as a low-cost, sensitive proxy for optimizing thermal activation. A simplified methodology is proposed to optimize the thermal activation of such materials by correlating firing temperature with mineralogical evolution and mechanical integrity, contributing to the development of sustainable ceramic aggregates for pavement applications. Full article

Microstructural, mechanical and qualitative phase identification of durable mullite-based ceramics obtained by utilization of waste clay–diatomite has been studied. Mullite-based ceramics were fabricated using waste clay–diatomite from the Baroševac open-cast coal mine, Kolubara (Serbia). The raw material consists mainly of SiO₂ (70.5 wt%) and a moderately high content of Al₂O₃ (13.8 wt%). In order to achieve the stoichiometric mullite composition (3Al₂O₃-2SiO₂), the raw material was mixed with an appropriate amount of Al(NO₃)₃·9H₂O. After preparing the precursor powder, the green compacts were sintered at 1300, 1400 and 1500 °C for 2 h. During the process, rod-shaped mullite grains were formed, measuring approximately 5 µm in length and a diameter of 500 nm (aspect ratio 10:1). The microstructure of the sample sintered at 1500 °C resulted in a well-developed, porous, nest-like morphology. According to the X-ray diffraction analysis, the sample at 1400 °C consisted of mullite, cristobalite and corundum phases, while the sample sintered at 1500 °C contained mullite (63.24 wt%) and an amorphous phase that reached 36.7 wt%. Both samples exhibited exceptional compressive strength—up to 188 MPa at 1400 °C. However, the decrease in compressive strength to 136 MPa at 1500 °C is attributed to changes in the phase composition, the disappearance of the corundum phase and alterations in the microstructure. This occurred despite an increase in bulk density to 2.36 g/cm³ (approximately 82% of theoretical density) and a complete reduction in open porosity. The residual glassy phase (36.7 wt% at 1500 °C) is probably the key factor influencing the mechanical properties at room temperature in these ceramics produced from waste clay–diatomite. However, the excellent mechanical stability of the samples sintered at 1400 and 1500 °C, achieved without binders or additives and using mined diatomaceous earth, supports further research into mullite-based insulating materials. Mullite-based materials obtained from mining waste might be successfully used in the field of energy-efficient refractory materials and thermal insulators. for high-temperature applications Full article

When there are several different types of heat-storage ceramic bricks (checkers) that can be arranged in a regenerative combustion system, one must find an optimal arrangement (with the highest long-term Waste Heat Recovery Ratio) of these checkers, possibly of different types, in this regenerative combustion system. However, the number of possible arrangements of checkers in a heat regenerator could be huge. For example, when 5 different types of checkers are available for each of 14 positions in a heat regenerator, the total number of possible arrangements of checkers is 6,103,515,625. It is impractical to completely evaluate the efficiency of each of the 6,103,515,625 arrangements of checkers by 3D CFD simulations on Ansys Fluent. Here, we propose an optimization algorithm by tree search to tackle this optimization problem. This tree search method is motivated by the recent applications of Artificial Intelligence, based on combination of Deep Learning with Monte-Carlo Tree Search, to the incredibly complicated board game Go. Empirical evidence shows that this simple tree search algorithm leads to fast convergence of an optimization search and successfully suggests the optimal arrangement of checkers. This simple tree search method/algorithm may effectively enhance the thermal efficiency of a regenerative combustion system. Full article