Search Results (44)

Geopolymers are a new breed of construction materials that are environmentally friendly and replace old Portland cement. These materials are produced through the alkaline activation of industrial and agricultural waste rich in aluminosilicates. The growing interest in sustainable building solutions has driven research into their development. Palm oil fuel ash (POFA) and waste ceramic tile powder (WTCP) are both highly rich in reactive aluminosilicates and widely recommended for the production of sustainable geopolymers. This study aims to evaluate the suitability of POFA and WTCP as sustainable alternatives to conventional binders and to identify the potential advantages of each waste material in developing eco-friendly, high-performance geopolymers. The results indicate that specimens prepared with a high content (50 wt%) of POFA or WTCP, incorporating fly ash and slag, can achieve compressive strengths of up to 50 MPa after 28 days of curing. However, increasing the proportion of POFA or WTCP from 50% to 60% and 70% resulted in a significant reduction in compressive strength. In contrast, specimens containing higher proportions of POFA and WTCP demonstrated superior durability when exposed to aggressive environments. In summary, the findings indicate that WTCP is more suitable than POFA for producing geopolymers as eco-friendly construction materials. Its superior reactivity, workability, early-age strength development, and durability make it a promising precursor for sustainable applications in the construction sector. Full article

Ladle slag (LF slag) is a by-product of secondary steelmaking that presents unique valorization challenges compared to BOF or EAF slags due to its distinctive chemical composition (high Al₂O₃ and CaO content) and uncontrolled hydraulic activity. While other steelmaking slags can be reused as supplementary cementitious materials or aggregates, LF slag is predominantly landfilled, with over 2 million tons discarded annually in Europe alone. This study introduces a novel pyrometallurgical valorization strategy that, unlike conventional approaches focused solely on mineral recovery, simultaneously recovers both metallic and mineral value through aluminothermic reduction. This process utilizes end-of-waste aluminum scrap rather than virgin materials to reduce Fe and Si oxides, creating a circular economy solution that addresses two waste streams simultaneously. The process generates two valuable products with low liquidus temperatures: a ferrosilicon alloy (FeSi15-50 grade) and a residual oxide rich in calcium and magnesium aluminates suitable for cementitious or ceramic applications. Through the integration of FactSage thermodynamic simulations with experimental validation, it is possible to predict and control phase evolution during equilibrium cooling, an approach not previously applied to LF slag valorization. Experimental validation using industrial slags confirms the theoretical predictions and demonstrates the process operates in a near-energy-neutral, self-sustaining mode by recovering both chemical and sensible thermal energy (50–100 kWh per ton of slag). This represents approximately 90% lower energy consumption compared to conventional ferrosilicon production. The work provides a comprehensive and scalable approach to transform a problematic waste material into valuable products, supporting circular economy principles and low-carbon metallurgy objectives. Full article

High-performance geopolymer concrete (HPGC) is an eco-friendly type of concrete that is traditionally made of slag, silica fume (SF), and quartz sand. Recycling industrial waste in HPGC presents an eco-friendly approach for maximizing sustainability in the construction sector. This study evaluates the impact of incorporating recycled fine aggregates like crumb rubber (CR), glass waste (GW), and ceramic waste (CW) as partial replacements for quartz sand in HPGC at 10%, 20%, and 40% by volume. GW and CW were also used in binder size as full replacements for SF. The novelty of this research lies in its comprehensive evaluation of waste-integrated HPGC under diverse conditions, including mechanical performance, durability (water absorption, sulfate/chloride/acid resistance), thermal stability (up to 600 °C), and microstructure analysis, while addressing critical gaps in eco-friendly construction materials. The results indicate that CW significantly enhanced compressive strength, increasing by 24–29% at 10% and 40% replacement levels, whereas CR reduced strength by 69.2–83.5%. GW effectively decreases water absorption by 66–72% compared to CW and CR. Both CW and GW improved chemical resistance, reducing compressive strength loss by 15–33% under sulfate and acid attacks. CW exhibited superior residual strength at 600 °C, reaching 96.4 MPa, compared to 54.5 MPa for GW. However, fully replacing SF with GW or CW as a binder resulted in performance deterioration, making it unsuitable. This study demonstrates that incorporating recycled waste materials in HPGC enhances its mechanical and durability properties, making it a viable option for sustainable construction. The findings support the integration of CW and GW as eco-friendly alternatives in HPGC applications. Full article

The escalating global water crisis, coupled with the unsustainable accumulation of industrial and urban waste, demands innovative solutions that align with circular economy principles. This review explores the transformative potential of waste-derived ceramic membranes as a sustainable strategy for water purification, simultaneously addressing waste valorization and clean water scarcity. Ceramic membranes, traditionally fabricated from high-purity inorganic materials, are renowned for their superior chemical resistance, thermal stability, and durability. Recent advances demonstrate that industrial byproducts, such as red mud, coal fly ash, blast furnace slag, coal gangue, and kiln roller waste, can be effectively repurposed into cost-effective, high-performance filtration materials. This paper critically examines fabrication techniques, material properties, and performance metrics of waste-derived ceramic membranes. By transforming industrial waste into functional filtration materials, this approach not only mitigates environmental pollution but also contributes to sustainable water security. Full article

Electric arc furnace slag is a major by-product of steelmaking, yet its industrial utilization remains limited due to its complex chemical and mineralogical composition. This study presents a hydrogen-based approach to recover metallic components from EAF slag for potential reuse in steelmaking. Laboratory experiments were conducted by melting 50 g of industrial slag samples at 1600 °C and injecting hydrogen gas through a ceramic tube into the liquid slag. After cooling, both the slag and the metallic phases were analyzed for their chemical and phase compositions. Additionally, the reduction process was modeled using a combination of approaches, including the thermochemical software FactSage 8.1, models for density, surface tension, and viscosity, as well as a diffusion model. The injection of hydrogen resulted in the reduction of up to 40% of the iron oxide content in the liquid slag. In addition, the fraction of reacted hydrogen gas was calculated. Full article

The expansion of the construction sector has contributed to the depletion of raw materials and an increased demand for resources; therefore, sustainable approaches are required to satisfy the construction demand. The present study explores the development of geopolymers by utilizing industrial by-products from mining, ceramics, olive oil production, and steel manufacturing. Specifically, slate stone cutting sludge (SSCS) and chamotte (CH) are used as aluminosilicate precursors, with olive biomass bottom ash (OSBA) acting as an alkaline activator, along with sodium silicate, and steel granulated slag (SGS) incorporated as an aggregate. Novel geopolymers were prepared with consistent proportions of SSCS and OSBA while varying the CH content from 10 to 2 wt.%. The SGS proportion was adjusted from 35 to 50 wt.%, and different Na₂SiO₃/OSBA ratios (0.35, 0.31, 0.19, and 0.08) were examined. To identify the optimal mix, a series of physical and mechanical tests was conducted, complemented by FTIR and SEM analysis to evaluate the chemical and microstructural changes. The best-performing formulation achieved a compressive strength of 42.8 MPa after 28 days of curing. FTIR analysis identified quartz and carbonate phases, suggesting that quartz did not fully dissolve and that carbonates formed during the heating process. SEM examination of the optimal mixture indicated that the incorporation of SGS (up to 45 wt.%) facilitated the creation of a compact, low-porosity structure. EDX results revealed the presence of Ca-, Na-, Si-, Al-, and K-enriched phases, supporting the formation of (N, C)-A-S-H gel networks. These results demonstrate the potential of utilizing SSCS, CH, OSBA, and SGS to create geopolymer concretes, showcasing the viability of using industrial by-products as eco-friendly substitutes for traditional construction materials. Full article

Foundries generate millions of tons of waste annually, posing a challenge to companies that generate it and to the environment due to landfill disposal. Meanwhile, the construction sector contributes heavily to global resource consumption. Adopting a circular economy approach by integrating foundry wastes into construction materials offers two main benefits: reducing landfill accumulation and preserving natural reserves of raw materials while also supporting the UN’s Sustainable Development Goals. This paper presents a review of recent studies on the use of foundry wastes in construction materials and provides an overview of the foundry industry, including its background, waste management, and statistics. Furthermore, a bibliometric analysis highlights the evolution of research in this area, showing a 182% increase in publications over the last 10 years. Key findings include that waste foundry sand is the most widely utilized foundry waste in construction materials, while ceramic mold shells and paraffin waxes remain underexplored. Concrete is the primary material incorporating foundry waste. The incorporation of foundry waste into construction materials improves durability and mechanical strength when used in appropriate proportions. The replacement content can reach up to 100%. These results underscore the feasibility of foundry waste as a sustainable alternative in construction, building circularity, and reducing environmental impact. Full article

Steel slag and waste clay bricks are two prevalent solid waste materials generated during industrial production. The complex chemical compositions of these materials present challenges to their utilization in conventional alumina silicate ceramics manufacturing. A new type of ceramic tile, which utilizes steel slag and waste clay brick as raw materials, has been successfully developed in order to effectively utilize these solid wastes. The optimal composition of the ceramic material was determined through orthogonal experimentation, during which the effects of the sample molding pressure, the soaking time, and the sintering temperature on the ceramic properties were studied. The results show that the optimal ceramic tile formula was 45% steel slag, 35% waste clay bricks, and 25% talc. The optimal process parameters for this composition included a molding pressure of 25 MPa, a sintering temperature of 1190 °C, and a soaking time of 60 min. The prepared ceramic tile samples had compositions in which solid waste accounted for more than 76% of the total material. Additionally, they possessed a modulus of rupture of more than 73.2 MPa and a corresponding water absorption rate of less than 0.05%. Full article

Steel slag and waste clay brick are two common solid wastes in industrial production, and their complex chemical compositions pose challenges to the production of traditional alumina silicate ceramics. To investigate the influence of steel slag and waste clay brick on the performance of CaO–SiO₂–MgO ceramic materials, this study examined their effects on the mechanical properties, crystal composition, and microstructure of the ceramics through single-factor experiments. The results demonstrate that when keeping the dosage of waste clay brick and talcum powder constant, a 43% dosage of steel slag yields optimal performance for the ceramic materials with a modulus of rupture of 73.01 MPa and a water absorption rate as low as 0.037%. Similarly, when maintaining a constant dosage of steel slag and talcum powder, a 41% dosage of waste clay brick leads to superior performance of the ceramic materials, with a modulus of rupture reaching 82.17 MPa and a water absorption rate only at 0.071%. Furthermore, when keeping the dosage of steel slag and waste clay brick constant, employing a talcum powder dosage of 24% results in excellent performance for the ceramic materials with a modulus of rupture measuring 73.01 MPa while maintaining an extremely low water absorption rate at only 0.037%. It is noteworthy that steel slag contributes to akermanite phase formation while talcum powder and waste clay brick contribute to diopside phase formation. Full article

The production of iron castings in cupola furnaces is a significant industrial process that has a notable impact on the environment. This paper examines and describes the environmental impact of this process, specifically focusing on the generation, characterization, and utilization of waste materials through data analysis and collection. Approximately one hundred and two million metric tons of castings are produced worldwide each year, with approximately one ton of foundry waste generated for every ton of castings. The slag from this waste can amount to as much as 7.14 million metric tons annually. Most of the slag ends up in landfills, which is expensive and represents a waste of this potential secondary raw material. Therefore, it is necessary to find ways to utilize this waste in other processes or industrial sectors. Cupola slag, given its high phosphorus content, can be used as agricultural fertilizer or in the production of ceramic foam used in foundries as filters during casting. In the construction industry, slag can be used in the production of concrete as a partial substitute for fine aggregate. This concept not only mitigates the environmental impact of waste disposal, but also aligns with the circular economy concept, promoting resource efficiency. Full article

Promoted by carbon neutrality and solid iste policies, iron- and steelmaking iste slag (ISWS)-based glass-ceramics have drawn attention because of their contribution to achieving the net-zero carbon emissions goal for the iron- and steelmaking industry. However, a holistic estimation of the preparation, property and GHG (greenhouse gas) emission abatement of ISWS-based glass-ceramics is still under exploration. In this paper, research progress on preparing glass-ceramics from ISWS discharged from the traditional iron- and steelmaking industry is reviewed. Then, the influence of ISWS’s chemical characteristics on the preparation of glass-ceramics and the products’ performance are discussed. In addition, the potential of GHG emission reduction related to the promotion of ISWS-based glass-ceramics is measured. It is found that ISWS-based glass-ceramics can avoid 0.87–0.91 tons of CO₂ emissions compared to primary resource routes. A scenario simulation is also conducted. If the technology could be fully applied in the ironmaking and steelmaking industries, the results suggest that 2.07 and 0.67 tons of indirect CO₂ reductions can be achieved for each ton of crude steel production from blast furnace–basic oxygen furnace (BF-BOF) and electric arc furnace (EAF) routes, respectively. Finally, a “dual promotion” economic mode based on national policy orientation and the high demands on metallurgical iste slag (MWS)-based glass-ceramics is proposed, and the application prospects of MWS-based glass-ceramics are examined. These application prospects will deepen the fundamental understanding of glass-ceramic properties and enable them to be compounded with other functional materials in various new technologies. Full article

Various designs of furnaces for melting alloys are used in the foundry industry. Regardless of their design, they have one common detail, which is the lining of their interiors with refractory materials. This component in the design of a metal-melting furnace has a very important task—to protect the rest of the furnace assemblies from thermal and mechanical damage. Continuous technical progress and the quality requirements of casting production produce increasingly higher demands for refractory materials in connection with their development as well. The article presents the results of an innovative method of vibratory compaction of refractory material (high-alumina aluminosilicate) using reduced pressure. The analysis presents a comparative study of two methods used for forming refractory materials, i.e., the application of the mentioned innovative method and the classical (standard) method of compaction by vibration only. The effects of the introduced modification in the manufacture of ceramic shapes were evaluated by means of the material’s resistance to thermal shock, linear expansion, and dimensional change due to firing, apparent density, open porosity, and apparent specific gravity, determination of total pore volume and pore size distribution by mercury porosimetry, and slag resistance. The tests performed indicate that the procedure of lowering the pressure during the vibratory compaction of the refractory material creates a more homogeneous structure with a smaller number and size of pores. This makes it possible to improve most of the parameters that determine the quality of the refractories used for the linings of the foundry furnace. Full article

The preparation of glass–ceramics with red mud and steel slag can not only solve the pollution problem caused by industrial waste slag but also produce economic benefits. It is difficult to analyze the high-temperature melt with the existing test methods, so the simulation experiment with molecular dynamics calculation becomes an important research method. The effects of steel slag content on the microstructure of red mud glass–ceramics were studied by molecular dynamics method. The results show that the binding ability of Si-O, Al-O, and Fe-O decreases with the increase in steel slag content. The number of Si-O-Si bridge oxygen increased gradually, while the number of Al-O-Al, Al-O-Fe, and Fe-O-Fe bridge oxygen decreased significantly. The number of tetrahedrons [SiO₄] increased, the number of tetrahedrons [FeO₄] and [AlO₄] decreased, and the total number of three tetrahedrons decreased. The mean square displacement value of Si⁴⁺ and O²⁻ increases first and then decreases, resulting in the viscosity of the system decreasing first and then increasing. The molecular dynamics method is used to analyze the structure of red mud–steel slag glass–ceramics on the microscopic scale, which can better understand the role of steel slag and has guiding significance for the experiment of this kind of glass–ceramics. Full article

In order to reduce the manufacturing cost of foamed ceramics and expand the application scope of industrial solid waste, in this study, a new type of environment-friendly foamed ceramics was prepared using direct high-temperature foaming with waste silicomanganese slag (SMS) and fly ash (FA) as raw materials and silicon carbide (SiC) as a foaming agent. The influence of SMS content, SiC content, and sintering temperature on the characteristics and microstructure of the specimen were explored. More concretely, the compressive strength, pore morphology, bulk density, and crystalline composition of the foamed ceramics were discussed. The foaming mechanism was also further analyzed. The results showed that including 20% SMS significantly reduced the melt’s viscosity and stimulated bubble expansion. This, in turn, facilitated the creation of a porous structure. Moreover, it was noted that samples containing 20% SMS exhibited an anorthite phase when sintered at 1110 °C, resulting in enhanced compressive strength. The bulk density and compressive strength of the foamed ceramics decreased with an increase in the sintering temperature and SiC content. This trend was primarily attributed to the higher total porosity and the insufficient support of the pore wall to the matrix. The best all-around performance was achieved with 20 wt% SMS, 80 wt% FA as raw material, SiC addition of 1.0 wt%, and a sintering temperature of 1100 °C. Under these conditions, the compressive strength, bulk density, and total porosity of the foamed ceramics were 8.09 MPa, 0.57 g/cm³, and 71.04%, respectively. Taken together, the outstanding porous structure and mechanical properties of this foamed ceramic make it suitable for use as insulation or for building partition materials. Full article

Because of their excellent properties, glass-ceramics have been widely developed and applied in many fields, and there are many potential application values to be disseminated. The preparation of glass-ceramics from industrial slag and metallurgical waste provides a new way for the comprehensive utilization of solid waste. Coal gangue is the largest of all kinds of industrial waste slag, while iron tailings and high-carbon ferrochrome slag also occupy a large proportion of China’s industrial solid waste. With cheap industrial solid waste as the main raw material, the production of high-value-added glass-ceramics can reduce pollution, protect the ecological environment, and have good economic and social benefits. Cordierite glass-ceramics were prepared using the sintering method with coal gangue, iron tailings, and high-carbon ferrochrome slag as the main raw materials. Meanwhile, an iron silicon alloy containing chromium was obtained. The heat treatment system of basic glass was determined by differential scanning calorimetry (DSC), and the sintered product was analyzed by X-ray diffraction (XRD) and scanning electron microscopy (SEM). An orthogonal test was used to analyze the effects of the mass of basic glass powder, molding pressure, and holding time on the grain size and crystallinity of the samples. The hardness, acid and alkali resistance, density, and water absorption of the sintered products were determined. The results show that the main crystal phase of the prepared glass-ceramics is cordierite. The optimal combination for the green body is “basic glass powder mass 6 g, molding pressure 35 MPa, holding time 10 min”. The properties of glass-ceramics are good. At the crystallization temperature of 970 °C, the Vickers hardness is up to 866 HV, and the bulk density is up to 2.99 g/cm³. This study may provide a useful reference for the treatment of industrial solid waste. Full article