Search Results (30)

The global escalation of organic waste generation, coupled with rising protein demand and environmental pressure, necessitates innovative, circular approaches to resource management. Hermetia illucens (Black Soldier Fly, BSF) has emerged as a leading candidate for integrated waste-to-resource systems. This review examines BSF biological and genomic adaptations underpinning waste conversion efficiency, comparative performance of BSF bioconversion versus traditional treatments, nutritional and functional attributes, techno-economic, regulatory, and safety barriers to industrial scale-up. Peer-reviewed studies were screened for methodological rigor, and data on life cycle traits, conversion metrics, and product compositions were synthesized. BSF larvae achieve high waste reductions, feed-conversion efficiencies and redirect substrate carbon into biomass, yielding net CO₂ emissions as low as 12–17 kg CO₂ eq ton⁻¹, an order of magnitude below composting or vermicomposting. Larval biomass offers protein, lipids (notably lauric acid), micronutrients, chitin, and antimicrobial peptides, with frass serving as a nutrient-rich fertilizer. Pathogen and antibiotic resistance gene loads decrease during bioconversion. Key constraints include substrate heterogeneity, heavy metal accumulation, fragmented regulatory landscapes, and high energy and capital demands. BSF systems demonstrate superior environmental and nutritional performance compared to conventional waste treatments. Harmonized safety standards, feedstock pretreatment, automation, and green extraction methods are critical to overcoming scale-up barriers. Interdisciplinary innovation and policy alignment will enable BSF platforms to realize their full potential within circular bio-economies. Full article

This study investigates the chemical stability and leaching behavior of two environmentally sustainable EPDM elastomers filled with circular carbon black (CCB) and recycled carbon black (RCB) when exposed to acidic, fuel cell-like environments. Accelerated aging tests were conducted in sulfuric acid solutions of varying concentrations (1 M, 0.1 M, and 0.001 M) at 90 °C for 1000 h to simulate long-term degradation in proton exchange membrane fuel cell (PEMFC) sealing applications. Complementary hot water extraction tests (HWET) were performed at 80 °C for up to 168 h to evaluate ionic leaching via conductivity measurements. HPLC-DAD analysis was used to assess organic leachates, while surface changes were examined by SEM and thermal transitions by DSC. Results revealed lower leaching and improved surface preservation in the CCB-filled EPDM, which remained below the critical 5 µS/cm ionic conductivity threshold for longer durations than its RCB counterpart. HPLC results showed filler-dependent trends in organic compound release, with CCB EPDM exhibiting higher leaching only under strong acid exposure. SEM confirmed greater surface damage and porosity in RCB EPDM. Overall, both materials demonstrated adequate chemical resistance, but the CCB formulation exhibited superior long-term stability, supporting its use in sustainable PEMFC sealing applications. Full article

This study proposes a novel integrated biorefinery approach that combines Hermetia illucens (Black Soldier Fly) larvae treatment, anaerobic digestion (AD), and hydrothermal carbonization (HTC) to enhance the valorisation of fat-rich food residues. The process was designed to improve biogas yields while mitigating the inhibitory effects of lipid accumulation in AD systems. Results from larval bioconversion showed effective fat removal and a promising potential for protein and biomass valorisation. Downstream integration with AD and HTC enabled thermal self-sufficiency, enhanced energy recovery, and improved digestate dewaterability. Additionally, HTC process water recirculation to the AD unit was evaluated, considering its acidic nature and impact on biomethane production. A thermally integrated process flow was proposed, enabling efficient heat exchange and reduced external energy input. The overall system allows for multi-product recovery—including biogas, hydrochar, and larval biomass—offering a sustainable pathway for circular bioeconomy applications. This study illustrates the feasibility of a synergetic process chain that maximises energy recovery and resource efficiency from food industry waste streams. Full article

Sustainable ethylene propylene diene monomer (EPDM) elastomers are gaining traction as eco-friendly sealing materials in fuel cell applications. This study evaluates the mechanical degradation behavior of two ECO EPDM formulations—one reinforced with circular carbon black (CCB EPDM), and the other with recycled carbon black (RCB EPDM)—under conditions representative of acidic fuel cell environments. The samples underwent thermal aging at 90 °C for 1000 h, and were immersed in aqueous H₂SO₄ solutions of varying concentrations (1 M, 0.1 M, and 0.001 M) for 1000 h at the same temperature. Gravimetric and volumetric swelling measurements revealed that RCB EPDM experienced significantly higher mass and volume uptake, particularly at intermediate acid concentration, indicating greater susceptibility to fluid ingress. Mechanical testing, including measurement of tensile strength, Shore A hardness, and IRHD microhardness, showed that while RCB EPDM exhibited higher initial strength, it degraded more severely under thermal and acidic exposure. SEM-EDS analysis revealed microstructural damage and compositional changes, with RCB EPDM displaying more pronounced oxidation and surface erosion. In contrast, CCB EPDM demonstrated greater retention of mechanical integrity, greater dimensional stability, and lower variability across aging conditions. These findings highlight the advantages of circular carbon black in enhancing the durability of ECO EPDM compounds in acidic and thermally dynamic fuel cell environments. Full article

Achieving net-zero carbon emissions, this study introduces a sustainable pathway for reducing strontium sulfate (SrSO₄) and celestite ore to strontium sulfide (SrS) using biofuels (biomethane, bioethanol) derived from agro-industrial waste and green hydrogen. Traditional SrSO₄ reduction methods, which rely on fossil-derived reductants like coal and operate at energy-intensive temperatures (1100–1200 °C), generate significant greenhouse gases and toxic byproducts, highlighting the need for eco-friendly alternatives. Experimental results demonstrate that bioethanol outperformed other reductants, achieving 97% conversion of synthetic SrSO₄ at 950 °C within 24 min and 74% conversion of natural celestite ore over 6 h. Remarkably, this bioethanol-driven process matches the energy efficiency of the conventional black ash method while enabling carbon neutrality through renewable feedstock utilization, reducing CO₂ emissions by 30–50%. By valorizing agro-industrial waste streams, this strategy advances circular economy principles and aligns with Mexico’s national agenda for sustainable industrial practices, including its commitment to decarbonizing heavy industries. This study contributes to sustainable development goals and offers a scalable solution for decarbonizing strontium compound production in the chemical industry. Full article

This study investigates graphite separation from Lithium-Ion Battery (LIB) black mass (which is a mixture of anode and cathode materials) via froth flotation coupled with an open-loop recycling approach for the graphite (froth) product. Black mass samples originating from different LIB types were used to produce a carbon-poor and a carbon-enriched fractions. The optimization of the flotation parameters was carried out depending on the black mass chemistry, i.e., the number of flotation stages and the dosing of flotation agents. The carbon-enriched product (with a carbon content of 92 wt.%, corresponding to a recovery of 89%) was subsequently used as a secondary carbon source for refractory material (magnesia carbon brick). Analyses of brick chemistry, as well as thermo-mechanic properties in terms of density, porosity, cold crushing strength (CCS), hot modulus of rupture (HMOR—the maximum bending stress that can be applied to a material before it breaks), and thermal conductivity showed no negative influence on brick quality. It could be demonstrated that flotation graphite can principally be used as a secondary source for non-battery applications. This is a highly valuable example that contributes to a more complete closure of a battery’s life cycle in terms of circular economy. Full article

The clean energy transition is a paradigm shift from a carbon-intensive energy system to a renewable energy one. The new energy system requires large amounts of critical minerals, including lithium. However, the mining and extraction of these minerals introduces environmental challenges. Recycling critical minerals, a critical step for a circular economy, is a potential solution that could reduce the need for new mining, lowering the overall environmental impact. In this experimentally based work, we evaluate the lithium recycling labor- and cost-intensive preprocessing stage that is currently performed by large-scale recycling systems, reducing the efficiency and raising the costs of the downstream stages. We investigate multiple inexpensive and distributed alternatives to the preprocessing tasks that produce black mass (separation, grinding, and shredding techniques) in order to identify methods that improve the efficiency of the downstream recycling process. This work finds that shredding and grinding end-of-life batteries with equipment that can be purchased for under USD 1000 produces viable black mass for a fraction of the cost. Therefore, this work contributes toward the goal of a circular economy for battery energy storage by identifying the technical requirements and measuring the efficacy of redistributing the labor- and time-intensive preprocessing tasks to small-scale recyclers in order to enhance the efficiency of the downstream stages in the lithium-ion battery recycling reverse supply chain. Full article

Herbal dust, a waste byproduct from filter-tea production, was annealed to form ash that can be incorporated into natural rubber as an eco-friendly filler. Three types of herbal dust ash (HDA), green tea, hibiscus, and lemon balm, were added at two different contents, 2.5 and 5 phr, into the rubber compound, while the content of carbon black, as a filler, was maintained at 50 phr in all samples. The impact of HDA type and content on the rheological and mechanical properties of rubber products was evaluated. Rheological analysis showed that HDA samples exhibited slightly lower maximum torque values (around 11.6 dNm) than ash-free samples (13.53 dNm), yet maintained vulcanization effectiveness with minimal impact on torque or cure rate metrics. Mechanical testing found that samples with 2.5 phr of lemon balm ash achieved comparable properties to samples without added ash, while samples with added hibiscus preserved crosslinking density and hardness. The addition of HDA led to decreases in tensile strength, elongation at break, and hardness values, with slight changes suggesting its applicability in similar industrial contexts. The findings highlight HDAs potential as a cost-effective, sustainable filler for rubber production, contributing to circular economy practices by repurposing significant amounts of tea waste into high-quality rubber materials. Full article

Driving a car at extreme speeds, road holding, and sustainability do not go together well. Formula 1 racing is exciting but is not an example of sustainability. The aim of this work was to use materials, suitable for the treads of high-performance racing tyres, that can favour both high performance and sustainability. In particular, the objective was to achieve high dynamic rigidity at high temperatures (>100 °C) and a stable crosslinking network. A copolymer from an industrial waste such as sulphur and a comonomer from a circular biosourced material were used as the crosslinking agent of an elastomer composite based on poly(styrene-co-butadiene) from solution anionic polymerization and a carbon black with a high surface area. The biosourced circular material was 1,6-bis(2,5-dimethyl-1H-pyrrol-1-yl)hexane (HMDP), the di-pyrrole derivative of hexamethylenediamine. Two poly(S-co-HMDP) copolymers, with different S/HMDP ratios (6 and 8.9, Copolymer 1 and Copolymer 2) were carefully characterized by means of ¹H-, ¹³C-, 2D¹H-¹H-COSY and 2D ¹H-¹³C HSQC NMR. The comparison of the spectra highlighted the substitution with sulphur of the β-position of the pyrrole ring: mono-substitution largely prevailed in Copolymer 1 and also bi-substitution in Copolymer 2. The copolymers were used as additives in the vulcanization system. Compared with a reference composite, they allowed us to achieve more efficient vulcanization, a higher density of the crosslinking network, higher dynamic rigidity, better ultimate tensile properties, and better stability of the crosslinking network at high temperatures. Compared with a traditional oil-based crosslinking agent for elastomer composites with high rigidity and a stable structure at high temperatures, such as the perthiocarbamate 6-((dibenzylcarbamothioyl)disulfaneyl)hexyl 1,3-diphenylpropane-2-sulfinodithioate, the poly(S-co-HMDP) copolymers led to higher dynamic rigidity and better ultimate tensile properties. These improvements occurring simultaneously are definitely unusual. This work paves the way for the upcycling of circular materials in a large-scale application such as in tyres. Full article

Bearing steel (GCr15) is widely used in key parts of mechanical transmission for its excellent mechanical properties. Electrochemical machining (ECM) is a potential method for machining GCr15, as the machining process is the electrochemical dissolution of GCr15 regardless of its high hardness (>50 HRC). In ECM, NaNO₃ solution is a popular electrolyte, as it has the ability to help in the nonlinear dissolution of many metallic alloy materials, making it useful for precision machining. However, due to high carbon content of GCr15, the electrochemical dissolution of GCr15 is unique, and there is always a black layer with high roughness on the machined surface, reducing the surface quality. In order to improve the electrochemical machining of GCr15 with a high surface quality, the surface characteristics of GCr15 in ECM were investigated. The anodic polarisation curve in the NaNO₃ electrolyte was measured and electrochemical dissolution experiments were conducted with different current densities. SEM, XRD, and XPS were employed to analyse the surface morphology and composition formed on the machined surface at different current densities. The initial results showed that there were two parts (black part and bright part) formed on the machined surface when a short circuit occurred, and the test results suggested that the black part contained a mass of Fe₃O₄ while the bright part was composed of mainly Fe and Fe₃C. Further investigation uncovered that a black flocculent layer (Fe₃O₄) always formed in a low current density (32 A/cm²) with high roughness. With the current density increased, the amount of black flocculent layer was reduced, and Fe₃C particles appeared on the machined surface. When the current density reached 81 A/cm², the entire flocculent oxide layer was removed, only some spherical Fe₃C particles were inserted on the machined surface, and the roughness was reduced from Ra7.743 μm to Ra1.783 μm. In addition, due to exposed Fe₃C particles on the machined surface, the corrosion resistance of the machined surface was significantly improved. Finally, circular arc grooves of high quality were well manufactured with current density of 81 A/cm² in NaNO₃ electrolyte. Full article

High production rates and the constant expansion of production capacities for lithium-ion batteries will lead to large quantities of production waste in the future. The desired achievement of a circular economy presupposes that such rejects could be recovered. This paper presents a two-staged process route that allows one to recover graphite and conductive carbon black from already coated negative electrode foils in a water-based and function-preserving manner, and it makes it directly usable as a particle suspension for coating new negative electrodes. In a first step, coating residues, which accumulate in production (as offcuts or rejects for example), are decoated in an aqueous ultrasonic bath. The ultrasonic bath also serves as a pre-thickener. As a result, high mass concentrations of active material can already be achieved in the water after the first process step. Water is then removed from the negative electrode suspension in a subsequent step by applying dynamic cross-flow filtration. With this unit operation, it is possible to concentrate the slurry residue to a solid content similar to that of the new electrode slurries used for coatings. An important criterion for the direct utilization of production waste is that the particle properties are affected as little as possible so that the suspension can be used directly for coating new films. This work presents the individual recycling process steps and their influence on the particle and slurry properties. The aim is to assess whether the recyclate is suitable for a coating of new negative electrodes and thus also for manufacturing batteries from 100% recycled material. Full article

In this study, a flash pyrolysis process is developed using an entrained flow reactor for recycling of waste tires. The flash pyrolysis system is tested for process stability and reproducibility of the products under similar operating conditions when operated continuously. The study is performed with two different feedstock materials, i.e., passenger car (PCT) and truck tire (TT) granulates, to understand the influence of feedstock on the yield and properties of the pyrolysis products. The different pyrolytic products i.e., pyrolytic carbon black (pCB), oil, and pyro-gas, are analyzed, and their key properties are discussed. The potential applications for the obtained pyrolytic products are discussed. Finally, a mass and energy balance analysis has been performed for the developed pyrolysis process. The study provides insight into the governing mechanisms of the flash pyrolysis process for waste tires, which is useful to optimize the process depending on the desired applications for the pyrolysis products, and also to scale up the pyrolysis process. Full article

Polymer waste is currently a big and challenging issue throughout the world. Waste tires represent an important source of polymer waste. Therefore, it is highly desirable to recycle functional fillers from waste tires to develop composite materials for advanced applications. The primary theme of this review involves an overview of developing polystyrene (PS) composites using materials from recycled tires as fillers; waste tire recycling in terms of ground tire rubbers, carbon black, and textile fibers; surface treatments of the fillers to optimize various composite properties; and the mechanical, fire retarding, acoustic, and electromagnetic field (EMI) shielding performances of PS composite materials. The development of composite materials from polystyrene and recycled waste tires provides a novel avenue to achieve reductions in carbon emission goals and closed-loop plastic recycling, which is of significance in the development of circular economics and an environmentally friendly society. Full article

Composites revolutionize material performance, fostering innovation and efficiency in diverse sectors. Elastomer-based polymeric composites are crucial for applications requiring superior mechanical strength and durability. Widely applied in automotives, aerospace, construction, and consumer goods, they excel under extreme conditions. Composites based on recycled rubber, fortified with reinforcing fillers, represent a sustainable material innovation by repurposing discarded rubber. The integration of reinforcing agents enhances the strength and resilience of this composite, and the recycled polymeric matrix offers an eco-friendly alternative to virgin elastomers, reducing their environmental impact. Devulcanized rubber, with inherently lower mechanical properties than virgin rubber, requires enhancement of its quality for reuse in a circular economy: considerable amounts of recycled tire rubber can only be applied in new tires if the property profile comes close to the one of the virgin rubber. To achieve this, model passenger car tire and whole tire rubber granulates were transformed into elastomeric composites through optimized devulcanization and blending with additional fillers like carbon black and silica–silane. These fillers were chosen as they are commonly used in tire compounding, but they lose their reactivity during their service life and the devulcanization process. Incorporation of 20% (w/w) additional filler enhanced the strength of the devulcanizate composites by up to 15%. Additionally, increased silane concentration significantly further improved the tensile strength, Payne effect, and dispersion by enhancing the polymer–filler interaction through improved silanization. Higher silane concentrations reduced elongation at break and increased crosslink density, as it leads to a stable filler–polymer network. The optimal concentration of a silica–silane filler system for a devulcanizate was found to be 20% silica with 3% silane, showing the best property profile. Full article

In a circular economy, the efficient utilization of all materials as valuable resources, with a focus on minimizing waste, is paramount. This study shows the possibilities of upgrading the lowest-valued residuals from the forest industry into a new product with both liming and fertilizing properties on forest soil. Hydrothermal carbonized sludge mixed with bark and ash in the proportions of 45:10:45 was densified into fertilizer pellets that meet the nutrient requirements of 120 kg N per hectare when 7 tons of pellets is spread in forests. The pellets met a high-quality result according to durability and density, which were above 95% and 900 kg/m³. However, pellets exposed to wet and cold conditions lost their hardness, making the pellets dissolve over time. Small amounts, <5‰, of nutrients, alkali ions, and heavy metals leached out from the pellets under all conditions, indicating good properties for forest soil amendment. The conclusion is that it is possible to close the circle of nutrients by using innovative thinking around forest industrial residual products. Full article