Search Results (314)

Recycling of 6xxx aluminum alloys, which are used extensively in the automotive industry, is important for ensuring a carbon-neutral future and the efficient use of resources on Earth. The sustainability of recycling in aluminum alloys is directly proportional to the correct classification of the scrap to be used. In this study, scrap stream from a novel scrap-sorting technology called MULTI-PICK has been used to validate. The 6063 and 6082 alloys produced with scrap stream, which are commonly used for structural parts in the automotive sector, are analyzed with hydrogen analysis and PREFIL. Cast billets are evaluated considering extrusion. After extrusion, microstructures of the profiles are investigated with scanning electron microscopy (SE), transmission electron microscopy (TE) and electron backscatter diffraction (EBSD). Their mechanical properties and anisotropic behaviors are investigated with tensile testing in different orientations. Additionally, an alternative alloy called 6111 has been studied to replace the target alloys with low critical raw material (CRM) content. According to the findings, highly recycled 6xxx alloys can be used in the automotive industry without losing their existing properties. Furthermore, using alternative feedstock and retrofitted systems can decrease carbon footprint below 4 kgCeq/kgAl. Full article

Polyurethanes (PUs) are indispensable polymeric materials widely employed across diverse industrial sectors due to their excellent thermal stability, chemical resistance, adhesion, and mechanical durability. However, the intrinsic three-dimensional crosslinked network that underpins their performance also presents a fundamental barrier to reprocessing and recycling. Consequently, most end-of-life PU waste is currently managed through landfilling or incineration, resulting in significant resource loss and environmental impact. To address these challenges, this review presents an integrated perspective on sustainable PU systems by unifying green synthesis strategies with closed-loop recovery approaches. First, recent advances in bio-based polyols and phosgene-free isocyanate synthesis derived from renewable resources—such as plant oils, carbohydrates, and lignin—are discussed as viable means to reduce dependence on petrochemical feedstocks and mitigate toxicity concerns. Next, emerging chemical recycling methodologies, including acidolysis and aminolysis, are reviewed with a focus on the selective recovery of high-purity monomers. Finally, PU vitrimers and dynamic covalent polymer networks (DCPNs) based on urethane bond exchange reactions are examined as reprocessable architectures that combine thermoplastic-like processability with the mechanical robustness of thermosets. By integrating synthesis, recovery, and reuse within a unified framework, this review aims to outline a coherent pathway toward establishing a sustainable circular economy for PU materials. Full article

Biodiesel, which is a blend of fatty acid methyl esters (FAME), has garnered significant attention as a promising alternative to petroleum-based diesel fuel. Nevertheless, the commercial production of biodiesel faces challenges due to the high costs associated with feedstock and the non-recyclable homogeneous catalyst system. To address these issues, a solid catalyst derived from construction industry waste cement was synthesized and utilized for biodiesel production from waste cooking oil (WCO). The catalyst’s surface and physical characteristics were analyzed through various techniques, including Scanning Electron Microscopy-Energy Dispersive Spectroscopy (SEM-EDS), X-ray diffraction (XRD), X-ray photoelectron spectroscopy (XPS), and Fourier Transform Infrared Spectroscopy (FTIR). The waste-cement catalyst demonstrated remarkable catalytic performance and reusability in the transesterification of WCO with methanol for biodiesel synthesis. A maximum biodiesel yield of 98.1% was obtained under the optimal reaction conditions of reaction temperature 65 °C; methanol/WCO molar ratio 16:1; calcined cement dosage 3 g; and reaction time 8 h. The apparent activation energy (Ea) from the reaction kinetic study is 35.78 KJ·mol⁻¹, suggesting that the transesterification reaction is governed by kinetic control rather than diffusion. The biodiesel produced exhibited high-quality properties and can be utilized in existing diesel engines without any modifications. This research presents a scalable, environmentally benign pathway for WCO transesterification, thereby contributing significantly to the economic viability and long-term sustainability of the global biodiesel industry. Full article

Agricultural biomass has potential as a renewable and versatile carbon feedstock for developing eco-friendly and biodegradable polymers capable of replacing conventional petrochemical plastics. To address the growing environmental concerns associated with plastic waste and carbon emissions, lignocellulosic residues, edible crop by-products, and algal biomass were utilized as sustainable raw materials. These biomasses provided carbohydrate-, lipid-, and lignin-rich fractions that were deconstructed through optimised physical, chemical, and enzymatic pretreatments to yield fermentable intermediates, such as reducing sugars, organic acids, and fatty acids. The intermediates were subsequently converted through tailored microbial fermentation processes into biopolymer precursors, primarily polyhydroxyalkanoates (PHAs) and lactate-based monomers. The resulting monomers underwent polymerization via polycondensation and ring-opening reactions to produce high-performance biodegradable plastics with tunable structural and mechanical properties. Additionally, the direct extraction and modification of naturally occurring polymers, such as starch, cellulose, and lignin, were explored to develop blended and functionalized bioplastic formulations. Comparative evaluation revealed that these biomass-derived polymers possess favourable physical strength, thermal stability, and biodegradability under composting conditions. Life-cycle evaluation further indicated a significant reduction in greenhouse gas emissions and improved carbon recycling compared to fossil-derived counterparts. The study demonstrates that integrating agricultural residues into bioplastic production not only enhances waste valorization and rural bioeconomy but also supports sustainable material innovation for packaging, farming, and consumer goods industries. These findings position agriculture-based biodegradable polymers as a critical component of circular bioeconomy strategies, contributing to reduced plastic pollution and improved environmental sustainability. Full article

Cross-linked polyethylene (PEX) is very stable, both chemically and mechanically. This makes its waste difficult to process. A very promising approach is slow pyrolysis catalyzed by hematite (α-Fe₂O₃). Such pyrolysis was carried out on a large scale (feedstock of 38 kg, catalyst amount of 2 wt.%, heating rate of 4 K min⁻¹, end temperature of 435 °C, delay at the end temperature several hours) and provided an oil containing both liquid (up to C₁₇) and solid hydrocarbons (>C₁₇). Thus, the oil obtained can be a source of valuable chemicals, solvents, and paraffin, and/or used as a clean liquid fuel and/or as a source of lubricants. Pyrolysis of PEX also yielded energy gas (12 wt.%) and solid carbonaceous residue (15 wt.%) for further use. The process mass balance and parameters (temperature, heating rate, dwell time, catalyst amount), composition, and chemical (elemental analysis, XRF, GC-MS, GC, distillation curve) and physical (viscosity, density, higher and lower heating value) properties of the oil, gas, and solid carbonaceous residue obtained are presented and discussed. The main product of the proposed technology is oil with a yield of almost 73 wt.%. The by-products are energy gas (12 wt.%) and solid carbonaceous residue (15 wt.%). The results obtained showed that the proposed technology successfully recycles difficult-to-process PEX with a process efficiency of 70%. Full article

As a widely sourced solid waste rich in metallic elements such as Fe, Zn, Mn and Ca, electric furnace dust serves as a crucial raw material for preparing catalytic materials. This study employed a three-step process—“acid/alkali modification–impregnation–calcination”—to synthesise an electric furnace dust-based magnetic heterogeneous catalyst for biodiesel production. The catalyst prepared via CH₃ONa modification combined with Na₂CO₃ impregnation achieved stable cycling performance at low temperatures, with 14 cycles yielding a consistent conversion exceeding 93.44 wt%, demonstrating exceptional catalytic activity. The CH₃ONa modification generates abundant reactive oxygen species on the furnace dust surface, facilitating the binding of hydroxyl oxygen from the active component (Na⁺) to the modified surface (EFD/CH₃ONa) and thereby anchoring the active species. However, the decline in catalytic performance of the Na₂CO₃&(EFD/CH₃ONa) catalyst after calcination at 600 °C (yield decreasing to 69.77 wt% after 11 stable cycles) was attributed to the detachment and agglomeration of the active component sodium at elevated temperatures. This paper employed electric furnace dust as feedstock to synthesise highly active and stable magnetic multiphase catalysts, thereby not only providing an environmentally sound pathway for industrial solid waste recycling but also offering novel insights for the industrial-scale production of biodiesel. Full article

Despite the positive dynamics of biogas and biomethane production in Poland, the country still lags behind Western European leaders per capita. With the ongoing phaseout of coal and the growing demand for power system flexibility, the importance of alternative solutions, with particular emphasis on renewable gases, is growing. Furthermore, capturing methane from manure and food waste offers a significant opportunity to significantly reduce the release of harmful gases into the atmosphere, as well as to recycle nutrients, which in turn translates into enhanced environmental performance (ESG). This places biogas production in Poland among the current and important issues of the energy transition. The available research relates to a limited extent to the conditions of biogas production and processes, particularly in the Polish market. With this in mind, the challenge was taken up to provide up-to-date knowledge on the management challenges of the biogas sector in Poland—today’s situation, conditions and development potential until 2030 and beyond. The analysis draws on regulatory reports, official records, EU policy documents, and industry data, offering practical insights for policymakers, investors, and researchers. The review’s methodology is based on economic analysis and evaluation techniques. The analysis revealed that management challenges in Poland’s biogas sector differ in severity and systemic impact. The priority ranking of barriers is as follows: policy and regulatory barriers, economic barriers, technological barriers, and social barriers. Moreover, the analysis confirms that feedstock price volatility and revenue instability are core components of the economic barrier category, directly affecting managerial decision-making, risk perception, and the overall investment climate in the Polish biogas industry. Full article

The methanol-to-olefins (MTO) process offers a viable alternative to traditional naphtha cracking for producing light olefins, providing flexibility in feedstock sources and the potential for reduced energy consumption. This study presents a detailed plant-wide design of an MTO process, developed and optimized to increase ethylene and propylene yields while reducing energy consumption. The methodology includes comprehensive reactor modeling of a fast fluidized-bed reactor–regenerator system, accounting for coke formation kinetics, along with rigorous process simulation for the subsequent separation and purification of products. A six-column distillation train has been designed and optimized for the recovery of polymer-grade ethylene and propylene, while dual-stage CO₂ absorption units ensure complete removal of carbon dioxide. Pinch analysis is used to identify opportunities for heat integration, resulting in an optimized heat-exchanger network that significantly reduces the need for external heating and cooling utilities. The results show that the optimized MTO design achieves a methanol conversion rate of over 99.9% and produces a propylene-rich product stream with a propylene-to-ethylene ratio of approximately 1.8, while maintaining a high purity level exceeding 99.5%. By implementing heat integration and recycling by-products, including using off-gas methane as furnace fuel and repurposing waste heat for steam generation, the plant reduces utility requirements by more than 85%, significantly improving energy efficiency. An economic evaluation shows a favorable payback period of approximately 5.4 years and an internal rate of return of 15–16%, confirming the viability and industrial potential of the integrated MTO process for sustainable olefin production. Full article

Lithium-ion batteries (LIBs) have become the leading energy storage technology because of their high specific energy, excellent efficiency, and longer lifespan. This review offers a comprehensive overview of the lithium battery industry, covering lithium materials and the global supply chain, as well as examining traditional and sustainable extraction methods. The discussion includes the technical and environmental challenges of each extraction method, with particular emphasis on feedstock selection, which greatly influences lithium recovery efficiency, yield, and ecological impact, and capital and operating expenditures. It also investigates the growth of the global battery recycling industry and provides an outlook on innovations in this area. These innovations include recycling systems, a case study on Biomass Energy Systems Inc., and the battery chemistries needed to support a circular economy. The review highlights industrial applications of LIBs in sectors such as automotive, consumer electronics, and aerospace. Finally, it addresses supply chain and recycling challenges related to LIBs, positioning cost, environmental footprint, and regulatory compliance as central considerations for the future of the battery industry. Full article

The incorporation of cattle slurry in soil in short-rotation-cycle poplar cultivations can be a win–win strategy, insofar as a main feedstock derived from local intensive dairy cattle breeding can be used as a natural fertilizer and in bioenergy produced in the same region. The circularity of this process can contribute to boosting local socio-economic value. In this context, this work involved the installation of a poplar SRC plantation with a density of 5330 trees ha⁻¹ in a 4000 m² moderately fertile flat site, which was formerly used as a vineyard. Mechanical dosages of slurry of 0, 26.6, 53.2, and 106.5 Mg ha⁻¹, designated as treatments T0, T1, T2, and T3, were applied three times per year during 2019, 2020, and 2021. The variables quantified were related to plant growth, biomass productivity and mass balances of K, P, Cu, Zn, Mg, and N, and organic matter in the whole soil, plant, and slurry system during the first rotation cycle. For treatments T0 and T1, all these seven chemical components showed positive balances in the system, with cumulative demand by soil and biomass being higher than cumulative supply by slurry. Negative balances occurred for P with T2 and T3 and for Zn with T3, so that an overall condition of nutrient saturation of the whole system was not achieved. A no-slurry application, or at most a moderate application equivalent to T1, in the second rotation cycle should therefore be prescribed to allow a nutrient equilibrium status to be achieved through internal seasonal recycling mechanisms. The biomass average productivities ranged from 6.1 to 11.8 Mg ha⁻¹ y⁻¹, peaking under treatment T2, and are within the typical values for a first rotation cycle for poplar SRCs. The biomass fuel quality was not affected by the slurry treatments. A good performance of plant total height and growth in diameter at breast height suggested that poplar trees were not stressed by the applied slurry. Only treatment T1 could assure that cattle CO₂-eq methane emissions were overall equilibrated by the carbon sequestration from poplar cultivation, with an absence of climatic-warming impacts. Treatments T2 and T3 could only partially minimize that impact, which would always exist. Globally, this site-specific analysis showed that, under moderately fertile conditions, controlled cattle slurry fertilization of poplar SRC cultivations, which would assure a long-term steady-state equilibrium, can be a viable option to contribute to decentralized production of bioenergy in rural communities. Full article

The growing scarcity of natural renewable resources has accelerated interest in producing nanomaterials from waste streams. Nanomaterials offer exceptional reinforcement capabilities for advanced composites, driving the need for sustainable and scalable production routes. While prior reviews have broadly examined nanomaterial synthesis from biomass or industrial residues, they often overlook textile waste as a strategic feedstock. This review uniquely focuses on the upcycling of textile waste—one of the most abundant yet underutilized waste streams—into high-value nanomaterials, thereby advancing circular economy principles. Unlike earlier studies that primarily discuss energy recovery or generic recycling, this work systematically explores mechanical, chemical, and thermal conversion routes tailored for textiles, leading to the production of cellulose nanofibers, cellulose nanocrystals, and carbon nanoparticles, which represent a significant class of biodegradable nanomaterials. Furthermore, a comprehensive analysis of the physicochemical properties of the nanomaterials and their emerging applications in water purification and environmental remediation is provided. An alternative pathway for nanomaterial synthesis from waste rather than renewable sources, providing information on the effective extraction of nanomaterials from mixed fiber compositions and dye residues present in textile waste, is also highlighted. By addressing current challenges and outlining future research directions, this review establishes a roadmap for sustainable textile waste valorization, marking a critical step toward eco-friendly nanomaterial production. Full article

The rapid accumulation of plastic and textile waste, particularly polyethylene terephthalate (PET), has emerged as a global challenge for sustainable resource management. Conventional recycling methods, including mechanical and chemical routes, recover limited value and often degrade material quality while consuming substantial energy. Biocatalytic recycling, by contrast, offers a resource-efficient alternative that transforms post-consumer PET into high-purity monomers under mild and environmentally benign conditions. This review examines advances in enzymatic PET depolymerization, focusing on hydrolases such as cutinases, PETases, MHETases, and lipases. The discussion highlights enzyme engineering, reactor design, and process integration that improve kinetics, thermostability, and yield. From a resource perspective, biocatalytic recycling redefines PET waste as a renewable carbon feedstock capable of re-entering industrial cycles, thereby reducing reliance on virgin petrochemicals and mitigating greenhouse gas emissions. Ultimately, this review positions biocatalytic PET recycling as a cornerstone technology for achieving circularity and advancing global resource sustainability. Full article

Capsicum residue generated from industrial capsaicin extraction is rich in nutrients and represents a significant fraction of solid waste in the food processing industry. Despite its potential value, limited efforts have been devoted to its resource recovery, leading to considerable resource loss and environmental burdens. This study systematically evaluates the applicability of existing food waste recycling technologies for capsicum residue and assesses its valorization potential through comprehensive characterization. The results indicate that capsicum residue holds promise as a feedstock for pectin extraction and as a component in animal feed. Regarding anaerobic fermentation for acid production, the maximum volatile fatty acids (VFAs) yield and VFAs/SCOD ratio reached 462.09 mg·L⁻¹ and 3.16%, respectively, suggesting moderate potential for acidogenic conversion but limited suitability for methanogenesis. Fluorescence spectroscopy of dissolved organic matter revealed that microbial humic-like substances (C1) were the dominant fluorophore, accounting for 42.64% of the total fluorescence, followed by terrestrial humic-like (C2, 19.28%), fulvic-like (C3, 19.12%), and tryptophan-like (C4, 18.95%) components. The favorable C/N ratio of amino acids and humic substances supports the feasibility of composting. Additionally, trace levels of residual capsaicin may confer antibacterial benefits and enhance soil fertility, further supporting the potential of capsicum residue as a value-added resource. Full article

Municipal solid waste (MSW) recycling is constrained by contamination, heterogeneity, and infrastructure built around material-specific pathways. We introduce effectiveness-normalized greenhouse gas (GHG) emissions as a system-level metric that adjusts reported process burdens by feedstock eligibility (Effectiveness Fraction, EF) and carbon recovery efficiency (CRE) to reflect real-world MSW conditions. Using published LCA data and engineering estimates, we benchmark six pathways, mechanical recycling, PET depolymerization, enzymatic depolymerization, pyrolysis, supercritical water gasification (SCWG), and Regenerative Robust Gasification (RRG), at the scale of mixed MSW. Normalizing for EF and CRE reveals large differences between process-level and system-level performance. Mechanical recycling and PET depolymerization show low process intensities yet high normalized impacts because they can treat only a small share of plastics in MSW. SCWG performs well at broader eligibility. RRG, a plasma-assisted molten-bath approach integrated with methanol synthesis, maintains the lowest normalized impact (~1.6 t CO₂e per ton of recycled polymer) while accepting virtually all organics in MSW and vitrifying inorganics. Modeled methanol yields are ~200–300 gal·t⁻¹ without external hydrogen and up to ~800 gal·t⁻¹ with renewable methane reforming. The metric clarifies trade-offs for policy and investment by rewarding technologies that maximize diversion and carbon retention. We discuss how effectiveness-normalized results can be incorporated into LCA practice and Extended Producer Responsibility (EPR) frameworks and outline research needs in techno-economics, regional scalability, hydrogen sourcing, and uncertainty analysis. Findings support aligning infrastructure and procurement with robust, scalable routes that deliver circular manufacturing from heterogeneous MSW. Full article

Large-format additive manufacturing (LFAM) is an enabling manufacturing technology capable of producing large parts with highly complex geometries for a wide variety of applications, including automotive, infrastructure/construction, and aerospace mold and tooling. In the past decade, the LFAM industry has seen widespread use of bio-based, glass, and/or carbon fiber reinforced thermoplastic composites which, when printed, serve as a lower-cost alternative to metallic parts. One of the highest-volume materials utilized by the industry is carbon fiber (CF)-filled polycarbonate (PC), which in out-of-autoclave applications can achieve comparable mechanical performance to metal at a significantly lower cost. Previous work has shown that if this material is recovered at various points throughout the manufacturing process for both the lab and pilot scale, it can be mechanically recycled with minimal impacts on the functional performance and printability of the material while significantly reducing the feedstock costs. End-of-life (EOL) CF-PC components were processed through industrial shredding, melt compounding, and LFAM equipment, followed by evaluation of the second-life material properties. Experimental assessments included quantitative analysis of fiber length attrition, polymer molecular weight degradation using gel permeation chromatography (GPC), density changes via pycnometry, thermal performance using dynamic mechanical analysis (DMA), and mechanical performance (tensile properties) in both the X- and Z-directions. Results demonstrated a 24.6% reduction in average fiber length compared to virgin prints, accompanied by a 21% decrease in X-direction tensile strength and a 39% reduction in tensile modulus. Despite these reductions, Z-direction tensile modulus improved by 4%, density increased by 6.8%, and heat deflection temperature (HDT) under high stress retained over 97% of its original value. These findings underscore the potential for integrating mechanically recycled CF-PC into industrial LFAM applications while highlighting the need for technological innovations to mitigate fiber degradation and enhance material performance for broader adoption. This critical step toward circular material practices in LFAM offers a pathway to reducing feedstock costs and environmental impact while maintaining functional performance in industrial applications. Full article