Search Results (476)

In this work, the characteristic temperatures (solidus and liquidus) of selected lead blast furnace slags were investigated using in situ high-temperature optical microscopy. The effects of the basicity of the slag (CaO/SiO₂), the Fe/SiO₂ ratio, and the Zn content were investigated. The deformation temperature associated with the rounding of the sample edges and the temperature at which 75% of the sample height decreases were experimentally considered as the solidus and liquidus temperatures, respectively. The pseudoternary phase diagrams CaO-SiO₂-Fe_0.63Zn_0.37O and FeO-Ca_0.54Si_0.46O_1.46-ZnO were calculated, along with the crystallization curves, using the thermodynamic software FactSage to estimate the characteristic temperatures and phase evolution during the cooling of the slag. The difference between the calculated and experimental solidus and liquidus temperatures was about 70 °C. The results of XRD, SEM, and DSC analysis at high temperatures showed that spinel (ZnFe₂O₄), melilite (Ca₂ZnSi₂O₇), and andradite (Ca₃Fe₂Si₃O₁₂) were the base crystals for all slag samples. The liquidus temperature increases with decreasing slag basicity (CaO/SiO₂), while the liquidus temperature increases with increasing Fe/SiO₂ ratio or Zn content. Full article

Phosphorus is an essential resource for numerous industrial applications. However, its uneven global distribution makes Europe heavily dependent on imports. Recovering phosphorus from waste streams is therefore crucial for improving resource security. The FlashPhos project addresses this challenge by developing a process to recover phosphorus from sewage sludge, in which phosphorus-rich slag is produced in a flash reactor and subsequently reduced in a Submerged Arc Furnace (SAF). In this process, approximately 250 kg/h of sewage sludge is converted into slag, which is further processed in the SAF to recover about 8 kg/h of white phosphorus. This work focuses on the development of a computational model of the SAF, with particular emphasis on slag behaviour. Due to the extreme operating conditions, which severely limit experimental access, a numerically efficient three-dimensional CFD model was developed to investigate the internal flow of the three-phase, AC-powered SAF. The model accounts for multiphase interactions, dynamic bubble generation and energy sinks associated with the reduction reaction, and Joule heating. A temperature control loop adjusts electrode currents to reach and maintain a prescribed target temperature. To further reduce computational cost, a novel simulation approach is introduced, achieving a reduction in simulation time of up to 300%. This approach replaces the solution of the electric potential equation with time-averaged Joule-heating values obtained from a preceding simulation. The system requires transient simulation and reaches a pseudo-steady state after approximately 337 s. The results demonstrate effective slag mixing, with gas bubbles significantly enhancing flow velocities compared to natural convection alone, leading to maximum slag velocities of 0.9–1.0 m/s. The temperature field is largely uniform and closely matches the target temperature within ±2 K, indicating efficient mixing and control. A parameter study reveals a strong sensitivity of the flow behaviour to the slag viscosity, while electrode spacing shows no clear influence. Overall, the model provides a robust basis for further development and future coupling with the gas phase. Full article

Liquefaction in urban areas has repeatedly caused severe damage to infrastructure, including manhole uplift, road subsidence, and failure of buried utility lines, as evidenced by reports during major earthquakes such as the 1964 Niigata earthquake and the 2011 Great East Japan Earthquake. Although natural sand has been widely used as backfill, excess pore water pressure leads to rapid loosening. This study evaluates slag–dried sludge mixed soil as a new liquefaction-resistant backfill that improves disaster mitigation while promoting resource recycling. Compaction, cone penetration, and shaking table tests were conducted with sludge mixing ratios of 0–30%, identifying 20% as optimal. Liquefaction in slag-only soil occurred at 1013 s (7 m/s²), whereas the 20% mixture delayed it to 1380 s (11 m/s²), increasing the acceleration threshold by 1.5 times and extending the onset time by 36%. Therefore, the acceleration required for liquefaction to begin was approximately 1.5 times higher, and the occurrence time was extended by approximately 36%. Also, the cone index reached 7750 kPa, exceeding the traffic load requirement of 1200 kN/m², while still allowing for sufficient permeability and workability compared to the use of natural clay particles. The improved backfill material proposed is promising as a sustainable urban infrastructure technology that simultaneously reduces liquefaction damage, improves the resilience of urban infrastructure, and reduces environmental impact through waste recycling. Full article

In Mediterranean cities, high solar radiation combined with limited shading and vegetation intensifies the urban heat island (UHI) phenomenon. As the road network often covers a large portion of the cities’ surfaces and is mostly constructed using asphalt pavements, it can significantly affect the urban microclimate, leading to low thermal comfort and increased energy consumption. Recycled and waste materials are increasingly used in the construction of pavements in accordance with the principle of sustainability for minimizing waste and energy to produce new materials based on a circular economy. The scope of this study is to evaluate the effect of recycled or waste materials used in road pavements on the urban microclimate. The surface and ambient temperature of urban pavements constructed with conventional asphalt and recycled/waste-based mixtures are assessed through simulation. Two study areas comprising large street junctions near metro stations in the city of Thessaloniki, in Greece, are examined under three scenarios: a conventional hot mix asphalt, an asphalt mixture containing steel slag, and a high-albedo mixture. The results of the research suggest that the use of steel slag could reduce the air temperature by 0.9 °C at 15:00, east European summer time (EEST), while the high-albedo scenario could reduce the ambient temperature by 1.6 °C at 16:00. The research results are useful for promoting the use of recycled materials, not only as a means of sustainably using resources but also for the improvement of thermal comfort in urban areas, the mitigation of the UHI effect, and the reduction of heat stress for human health. Full article

Interactions between alkaline solutions and the surface of pyrolytically coated graphite tubes (PCGTs) with/without a platform for determination of vanadium using high-resolution continuum source graphite furnace atomic absorption spectrometry (HR CS GFAAS) are discussed. Changes on the surface of tubes, lifetime of tubes, and formation of memory effect in the determination of vanadium in alkaline solutions (NaOH, Na₂CO₃, and real alkaline slag leachates) were investigated. Based on the results obtained, it is possible to state that HR CS GFAAS determination of vanadium content in alkaline solutions reveals that PCGTs with a platform are more susceptible than those without a platform to the formation of deposits and degradation of the platform surface, especially after the application of hydroxide environments. More marked and faster formation of deposits leads to shortening of the analytical lifetime of PCGTs with a platform (approx. 70 atomization/analytical cycles (ACs)) compared to PCGTs without a platform (approx. 290 ACs). The mechanical life of both types of tubes is comparable (approx. 500 ACs). Deposits formed on the internal surface of PCGTs can be removed in the presence of a carbonate environment and higher temperatures. Damage to the PCGT surface leads to the formation of scaled shapes and cavities, which can result in decreased absorbance due to losses of vanadium in the cavities (negative measurement error), or in increased absorbance by washing out of vanadium from the cavities (positive measurement error, and formation of memory effect). It was found that more frequent cleaning of PCGTs by performing ACs in an environment of 4 mol L⁻¹ HNO₃ can eliminate these unfavourable phenomena. Our results have shown that in the case of samples analysed with different sample environments (acidic vs. alkaline), the surface material of the tube/platform wears out more quickly, and therefore it is necessary to include a cleaning stage after changing the nature of the environment. Full article

This study prepares solid-waste-based alkali-activated material (AAM) concrete using ground granulated blast furnace slag (GGBFS), fly ash (FA), steel slag (SS), and desulfurized gypsum (DG) as primary raw materials, with Na₂SiO₃ as the activator. Taking the GGBFS content (X₁), Na₂SiO₃ content (X₂), and water-to-binder ratio (X₃) as independent variables and the 3-day, 7-day, and 28-day compressive strengths and slump as response values, it investigates the influence of each factor and their interactions, constructs a response surface prediction model, screens for the optimal mix proportion with comprehensive performance, and explores the microstructural characterization and strength formation mechanism of the AAM concrete via SEM and EDS. The results indicate the following: (1) compared with binary and ternary mixtures, the use of the quaternary solid waste mixture not only enhances strength and optimizes the microstructure but also increases the utilization rate of low-quality solid wastes; (2) the regression coefficients (R²) of the response surface models are all greater than 0.98, exhibiting good goodness of fit and rationality. Experimental validation confirms that each model shows excellent predictive capability; (3) AAM concrete exhibits comprehensively superior mechanical properties to ordinary cement, with leading early- and late-stage compressive strengths and splitting strengths, albeit with a slightly lower slump; (4) the performance synergy is prominent. Combined with microscopic analysis (highly polymerized C-S-H gels and a dense structure), the superiority of its macroscopic mechanical properties stems from the optimization of the microstructure, reflecting the intrinsic correlation of the “microscopic densification-macroscopic high strength. Full article

In hydraulic structures such as water control projects, spillway tunnels, and overflow dams that are subjected to high-velocity flow erosion, Concrete is required to exhibit high resistance to abrasion and cracking. While low water-to-binder ratio concrete can meet strength requirements, its inherent high shrinkage propensity often leads to cracking, seriously compromising long-term safety and durability under severe operating conditions. To address this engineering challenge, this study focuses on optimizing concrete performance through the synergistic combination of slag (GGBS) and silica fume (SF). This study systematically investigated the effects of incorporating GGBS (20–24%) and SF (6–10%) in a low water-to-binder ratio system with a fixed 70% cement content on key concrete properties. The evaluation was conducted through comprehensive tests including compressive strength, drying shrinkage, autogenous shrinkage, and hydration heat analysis. The results demonstrate that the blended system successfully achieves a synergistic improvement in both “high strength” and “low cracking risk.” Specifically, the incorporation of silica fume significantly enhances the compressive strength at all ages, providing a solid mechanical foundation for resisting high-velocity flow erosion. More importantly, compared to the pure cement system, the blended system not only delays the onset but also reduces the rate of early-age shrinkage, and lowers its ultimate autogenous shrinkage value. This characteristic is crucial for controlling the combined effects of thermal and shrinkage stresses from the source and preventing early-age cracking. Simultaneously, hydration heat analysis reveals that the blended system retards the heat release process, which helps mitigate the risk of thermal cracking. This study elucidates the regulatory mechanism of the GGBS-SF combination and provides a critical mix design basis and theoretical support for producing high-strength, high-abrasion-resistant, and low-shrinkage concrete in high-velocity flow environments, offering direct practical implications for engineering applications. Full article

The disposal of industrial waste poses a significant environmental challenge, often leading to pollution and degradation of surrounding and terrestrial ecosystems. This study investigates the sustainable valorization of such wastes through the development of one-part geopolymer mortars. Solid sodium silicate was employed as a dry alkali activator for binary blends comprising ground granulated blast-furnace slag (GGBS), clay brick powder (CBP), steel slag (SS), and fly ash (FA), with all mixtures cured under ambient conditions. The mortars were evaluated in terms of fresh properties (flow and setting time) and hardened characteristics, including compressive strength, density, water absorption, and porosity. Durability performance was assessed through mass loss, visual degradation, and compressive strength retention following exposure to acidic (H₂SO₄, HCl) and sulfate environments. Microstructural characterization using XRD, SEM, and FTIR provided insight into the mechanisms of gel formation and degradation in aggressive media. The results revealed that incorporating 5% FA into GGBS-based mortars enhanced 28-day compressive strength by 21.7% compared with the control mix. The inclusion of industrial by-products promoted the formation of C–S–H and C–(A)–S–H gels, contributing to a denser and more refined microstructure. Overall, the findings demonstrate that one-part geopolymer mortars offer a promising, eco-efficient, and durable alternative to traditional cementitious systems, while also addressing safety and handling concerns associated with liquid alkaline activators used in conventional two-part geopolymer formulations. Full article

Biomass gasification serves as a key carbon-neutral technology. To effectively address the challenge of tar treatment during biomass gasification, the National Institute of Clean and low-carbon Energy developed a fluidized bed coupled with an entrained-flow bed. A steady-state Aspen Plus V12 model was designed to assess the compatibility between the two beds and optimize operating parameters. The model divides the process into three main zones: fluidized bed gasification, entrained-flow bed gasification, and bottom slag treatment, employing a reaction-restricted equilibrium assumption. Simulation results indicate that an increase in pressure leads to a reduction in the concentration of syngas components (CO and H₂), an insignificant rise in gas low heating value (LHV), and a notable decline in cold gas efficiency (η). A higher equivalence ratio (ER) results in decreased syngas components, along with a significant reduction in both LHV and η. The introduction of carbon dioxide reduces syngas components and lowers LHV. Similarly, the addition of steam reduces the CO content of the syngas and decreases its LHV. When the fluidized bed temperature exceeds 900 °C, changes in LHV and gas yield become negligible, while variations remain minimal when the entrained-flow bed temperature exceeds 1200 °C. Full article

The depletion of natural resources remains a major global challenge, emphasizing the need to develop sustainable processes that enable both metal recovery and waste recycling. This study investigates the leaching of valuable metals from lead smelting slag using methanesulfonic acid (MSA), a biodegradable and environmentally benign reagent. Batch experiments were performed under different MSA concentrations (0.35–1.4 M) and temperatures (22–80 °C). Metal dissolution increased nearly linearly with acid concentration up to 1 M, with maximum recoveries after 60 min of 85% Zn, 64% Pb, 75% Cu, and 68% Fe. Copper dissolution was governed by the oxidation of Cu₂S, while Fe leaching was affected by pH variations that promoted re-precipitation. Kinetic modeling indicated mixed chemical–diffusion control mechanisms, with activation energies of 22.6 kJ mol⁻¹ for Zn and 31–33 kJ mol⁻¹ for Pb, Cu, and Fe. Beyond efficient metal extraction, the process generated a leach residue with reduced concentrations of base metals and a mineralogical composition dominated by stable calcium-silicate phases, improving its potential suitability for reuse in construction or mining backfill applications. Overall, methanesulfonic acid proved to be an effective and sustainable lixiviant, combining high metal recovery with the generation of recyclable slag, thereby contributing to circular metallurgical practices. Full article

Cement production is a significant global source of CO₂ emissions, leading to a demand for sustainable concrete alternatives. This study investigates the use of various additives to partially replace cement and assesses their effects on compressive strength and fire resistance, particularly spalling. Seven concrete mixes were tested for their initial and post-fire compressive strength, mass loss, and cracking. The cement-only reference mix (R1) achieved the highest initial strength (53.3 MPa) but experienced severe explosive spalling. In contrast, the mix with slag and polypropylene (PP) fibers (R4) offered the best balance, maintaining substantial strength after fire while completely preventing spalling. Biochar additions consistently lowered strength and increased spalling risk, whereas hydrochar notably enhanced spalling resistance, especially at higher replacement levels. The results demonstrate that sustainable additives, such as slag with PP fibers or high-dose hydrochar, can effectively improve fire safety and reduce cement use, though there is an initial trade-off in mechanical performance. Ultimately, choosing the optimal mix depends on whether environmental benefits, fire resistance, or structural strength is the highest priority. Full article

Geopolymers, as sustainable alternatives to traditional cementitious materials, offer superior mechanical and durability properties; however, they face challenges with rapid setting, particularly in fly ash–slag systems. Retarders play a crucial role in tailoring the setting behavior and workability of geopolymers, especially in applications where extended setting time or placement under challenging conditions is required. Geopolymers, unlike traditional Portland cement, undergo a rapid alkali-activation process involving dissolution, polymerization, and hardening of aluminosilicate materials. This can lead to very short setting times, particularly at elevated temperatures. In this scenario, the present study investigates the effect of different retarders-including cellulose, starch, borax, and their different combinations the setting time. The effectiveness of a retarder depends on the geopolymer formulation, including the type of precursor, activator, and curing conditions. The initial and final setting times improved by the addition of retarders, whereas most of the retarders had a negative effect on compressive strength. The optimum retarder combination was starch and borax, with a remarkable improvement in setting time and a positive result on the compressive strength, while maintaining reasonable workability. The retarder was equally effective under both ambient and oven-cured conditions and for different mix proportions of fly ash (FA) and slag, indicating that its effectiveness depends only on the type of precursors used. The study reveals the use of borax along with cellulose- or sugar-based compounds, which balances the reaction kinetics, resulting in balanced mechanical characteristics. Full article

The cement industry’s significant carbon footprint has driven research into sustainable alternatives like alkali-activated materials (AAMs). This study investigates the synergistic effect of blending copper–nickel slag (CNS) with fly ash (FA) to produce high-performance AAMs. Mechanically activated mixtures of CNS and FA, with FA content varying from 0 to 100%, were alkali-activated with sodium silicate. A distinct synergy was observed, with the blend of 80% CNS and 20% FA (AACNS–80) achieving the highest compressive strength (99.9 MPa at 28 days), significantly outperforming the single-precursor systems. Analytical techniques including thermogravimetry, FTIR spectroscopy, and SEM–EDS were used to elucidate the mechanisms behind this enhancement. The results indicate that the AACNS–80 formulation promotes a greater extent of reaction and forms a denser, more homogeneous microstructure. The synergy is attributed to an optimal particle packing density and the co-dissolution of precursors, leading to the formation of a complex gel that incorporates magnesium and iron from the slag. This work demonstrates the potential for valorizing copper–nickel slag in the production of high-strength, sustainable binders. Full article

The effects of Ce₂O₃ and CaF₂ on the microstructure of silicate-based mold flux were investigated using an integrated approach combining molecular dynamics (MD) simulations with viscosity testing, SEM-EDS, and XRD analysis. The structural origin of changes in viscosity and crystallization behavior was revealed. It was found that the joint addition of CaF₂ and Ce₂O₃ to the silicate melt leads to a synergistic effect; CaF₂ acts as a diluent within the silicate network, while O²⁻ introduced by Ce₂O₃ promotes the depolymerization of the complex [SiO₄]⁴⁻ network. As a result, highly polymerized structural units (Q², Q³, and Q⁴) transform into less polymerized ones (Q⁰ and Q¹), reducing the overall degree of polymerization and enhancing slag fluidity. Moreover, the preferential formation of [SiO₄]⁴⁻–Ce³⁺–F⁻ and [SiO₄]⁴⁻–Ca²⁺–F⁻ coordination structures replaces the original [SiO₄]⁴⁻–Ce³⁺ and [SiO₄]⁴⁻–Ca²⁺ linkages. This structural rearrangement facilitates the formation of low-melting-point phases during cooling, thereby suppressing the crystallization tendency and improving the stability of viscous properties of the mold flux. These findings provide theoretical insight for the design of high-performance fluxes used in rare earth-containing steel continuous casting. Full article

Waste stone powder, as a solid waste resource, is characterized by its large volume, wide distribution, and low utilization rate. Its resource utilization is one of the important approaches to achieving closed-loop recycling development in the stone industry. This study aims to utilize waste stone powder as a mineral admixture in the preparation of alkali-activated cementitious materials, investigating the influence of parameters such as waste stone powder content, water-binder ratio, and Na₂O content on the mechanical properties, fluidity, setting time, and shrinkage behavior of the cementitious materials. The results indicate that both waste stone powder and the water-binder ratio can effectively improve the setting time and fluidity of the paste. However, higher waste stone powder content leads to more severe shrinkage, and a calculation model for material shrinkage was established. The optimal mechanical properties for alkali-activated slag samples were achieved with a Na₂O content of 8%, waste stone powder content of 16%, and a water-binder ratio of 0.45. For alkali-activated metakaolin samples, a waste stone powder content of 16% resulted in superior mechanical performance. Furthermore, the failure of all material samples was brittle, primarily exhibiting typical splitting failure. Based on damage theory, a calculation model for the load–displacement curve of the material was developed, providing reference and support for further research and application of this material Full article