Search Results (369)

The conventional recycling processes for waste sand with inorganic binder (WSIB) in aluminum alloy casting involve washing, heat treatment, and mechanical grinding. However, this process is complex and inefficient for removing the residual binder on the surface of WSIB. This study proposes a simplified and effective recycling process using ultrasound treatment to more efficiently remove residual binder on the surface of WSIB. To evaluate its effectiveness, we characterized ultrasonically recycled sand (URS), conventionally recycled sand (CRS), and virgin sand (VS). The evaluation consisted of the following three steps: (1) characteristics of sand, such as residual binder content, particle size distribution, surface morphology, and specific surface area; (2) measuring the properties of sand cores, including bending strength and the volume of gas evolved during the pouring of A356 Al melts; and (3) measurement of porosity level at the interface between the sand core and A356 Al castings. These results indicate that the ultrasonic recycling process can achieve a technically efficient and simplified recycling process for WSIB. Full article

We present a comprehensive study of LED-based optical sensing systems for the classification of waste materials, analyzing recent developments in the field. Accurate identification of materials such as plastics, glass, aluminum, and paper is a crucial yet challenging task in waste management for recycling. The first approach uses short-wave infrared reflectance spectroscopy with commercial Germanium photodetectors and selected LEDs to keep data complexity and cost at a minimum while achieving classification accuracies up to 98% with machine learning algorithms. The second system employes a voltage-tunable Germanium-on-Silicon photodetector that operates across a broader spectral range (400–1600 nm), in combination with three LEDs in both the visible and short-wave infrared bands. This configuration enables an adaptive spectral response and simplifies the optical setup, supporting energy-efficient and scalable integration. Accuracies up to 99% were obtained with the aid of machine learning algorithms. Across all systems, the strategic use of low-cost LEDs as light sources and compact optical sensors demonstrates the potential of light-emitting devices in the implementation of compact, intelligent, and sustainable solutions for real-time material recognition. This article explores the design, characterization, and performance of such systems, providing insights into the way light-emitting and optoelectronic components can be leveraged for advanced sensing in waste classification applications. Full article

Asphalt plant reclaimed powder is a common solid waste in road engineering. Reusing reclaimed powder as filler holds significant importance for environmental protection and resource conservation. The key factors affecting the feasibility of reclaimed powder reuse are its acidity/alkalinity and cleanliness. Traditional evaluation methods, such as the methylene blue test and plasticity index, can assess reclaimed powder properties to guide its recycling. However, these methods suffer from inefficiency, strong empirical dependence, and high variability. To address these limitations, this study proposes a rapid and precise evaluation method for reclaimed powder properties based on Fourier transform infrared spectroscopy (FTIR). To do so, five field-collected reclaimed powder samples and four artificial samples were evaluated. Scanning electron microscopy (SEM), X-ray fluorescence spectroscopy (XRF), and X-ray diffraction (XRD) were employed to characterize their microphase morphology, chemical composition, and crystal structure, respectively. Subsequently, FTIR was used to establish correlations between key acidity/alkalinity, cleanliness, and multiple characteristic peak intensities. Representative infrared characteristic peaks were selected, and a quantitative functional group index (Is) was proposed to simultaneously evaluate acidity/alkalinity and cleanliness. The results indicate that reclaimed powder primarily consists of tiny, crushed stone particles and dust, with significant variations in crystal structure and chemical composition, including calcium carbonate, silicon oxide, iron oxide, and aluminum oxide. Some samples also contained clay, which critically influenced the reclaimed powder properties. Since both filler acidity/alkalinity and cleanliness are affected by clay (silicon/carbon ratio determining acidity/alkalinity and aluminosilicate content affecting cleanliness), this study calculated four functional group indices based on FTIR absorption peaks, namely the Si-O-Si stretching vibration (1000 cm⁻¹) and the CO₃²⁻ asymmetric stretching vibration (1400 cm⁻¹). These indices were correlated with conventional testing results (XRF for acidity/alkalinity, methylene blue value, and pull-off strength for cleanliness). The results show that the Is index exhibited strong correlations (R² = 0.89 with XRF, R² = 0.80 with methylene blue value, and R² = 0.96 with pull-off strength), demonstrating its effectiveness in predicting both acidity/alkalinity and cleanliness. The developed method enhances reclaimed powder detection efficiency and facilitates high-value recycling in road engineering applications. Full article

The current paper presents a comprehensive intelligent system designed to optimize the performance of a barrier eddy current separator (BECS), comprising a conveyor belt, a vibration feeder, and a magnetic drum. This system was trained and validated on real-world industrial data gathered directly from the working separator under 81 different operational scenarios. The intelligent models were used to recommend optimal settings for drum speed, belt speed, vibration intensity, and drum angle, thereby maximizing separation quality and minimizing energy consumption. the smart separation module utilizes YOLOv11n-seg and achieves a mean average precision (mAP) of 0.838 across 7163 industrial instances from aluminum, copper, and plastic materials. For shape classification (sharp vs. smooth), the model reached 91.8% accuracy across 1105 annotated samples. Furthermore, the thermal monitoring unit can detect iron contamination by analyzing temperature anomalies. Scenarios with iron showed a maximum temperature increase of over 20 °C compared to clean materials, with a detection response time of under 2.5 s. The architecture integrates a Digital Twin using Azure Digital Twins to virtually mirror the system, enabling real-time tracking, behavior simulation, and remote updates. A full connection with the PLC has been implemented, allowing the AI-driven system to adjust physical parameters autonomously. This combination of AI, IoT, and digital twin technologies delivers a reliable and scalable solution for enhanced separation quality, improved operational safety, and predictive maintenance in industrial recycling environments. Full article

This study investigates the effectiveness of geopolymer-based binders for the stabilization of silty sand, aiming to improve its strength and durability under cyclic environmental conditions. A composite binder consisting of Ground Granulated Blast-furnace Slag (GGBS) and Recycled Glass Powder (RGP), modified with nano poly aluminum silicate (PAS), was used to treat the soil. The long-term performance of the stabilized soil was evaluated under cyclic wetting–drying (W–D) conditions. The influence of PAS content on the mechanical strength, environmental safety, and durability of the stabilized soil was assessed through a series of laboratory tests. Key parameters, including unconfined compressive strength (UCS), mass retention, pH variation, ion leaching, and microstructural development, were analyzed using field emission scanning electron microscopy (FE-SEM) and energy-dispersive X-ray spectroscopy (EDS). Results revealed that GGBS-stabilized specimens maintained over 90% of their original strength and mass after eight W–D cycles, indicating excellent durability. In contrast, RGP-stabilized samples exhibited early strength degradation, with up to an 80% reduction in UCS and 10% mass loss. Environmental evaluations confirmed that leachate concentrations remained within acceptable toxicity limits. Microstructural analysis further highlighted the critical role of PAS in enhancing the chemical stability and long-term performance of the stabilized soil matrix. Full article

With the continuous exploitation of bauxite mineral resources, Guangxi bauxite faces many difficulties in alumina production due to its characteristics of high silicon content, high iron content, and a low Al-Si ratio. In view of this, this study is closely related to the key link of bauxite pre-desiliconization and strives to break free from the status quo to improve the aluminum/silicon ratio and help optimize the subsequent alumina-refining process. In the work presented in this paper, the unique mineralogy of Guangxi bauxite was comprehensively considered, covering its complex mineral composition and fine distribution characteristics. The barium hydroxide pre-desilication technology was first used for in-depth experimental exploration, and the silicon removal efficiency under different working conditions was systematically compared. The system compared the silicon removal effect and the associated aluminum loss under different working conditions. The results of this study will lay a solid foundation for the rational and efficient development of bauxite in Guangxi, which is expected to reduce the cost of alumina production, improve the economic benefits for the Guangxi aluminum industry, simultaneously strengthen the efficiency of resource recycling, accelerate the sustainable development of the industry, and provide a useful reference example for subsequent similar studies. Full article

Introducing and compacting lignocellulosic biomass in aluminum structures, though recommendable in terms of higher sustainability, the potential use of agro-waste and significant weight reduction, still represents a challenge. This is due to the variability of biomass performance and to its limited compatibility with the metal. Another question may concern possible moisture penetration in the structure, which may reduce environmental resistance and result in local degradation, such as wear or even corrosion. Despite these limitations, this hybridization enjoys increasing success. Two forms are possibly available for this: introduction into metal matrix composites (MMCs), normally in the form of char from biomass combustion, or laminate reinforcement as the core for fiber metal laminates (FMLs). These two cases are treated alongside each other in this review, first because they may represent two combined options for recycling the same biomass into high-profile structures, aimed primarily at the aerospace industry. Moreover, as discussed above, the effect on the aluminum alloy can be compared and the forces to which they are subjected might be of a similar type, most particularly in terms of their hardness and impact. Both cases considered, MMCs and FMLs involved over time many lignocellulosic residues, starting from the most classical bast species, i.e., flax, hemp, sisal, kenaf, etc., and extending also to less diffuse ones, especially in view of the introduction of biomass as secondary, or residual, raw materials. Full article

The conventional spent lithium-ion batteries (LIBs) recycling method suffers from complex processes and excessive chemical consumption. Hence, this study proposes an electrochemical strategy for achieving reductant-free leaching of high-valence transition metals and efficient separation of valuable components from spent cathode sheets (CSs). An innovatively designed sandwich-structured electrochemical reactor achieved efficient reductive dissolution of cathode materials (CMs) while maintaining the structural integrity of aluminum (Al) foils in a dilute sulfuric acid system. Optimized current enabled leaching efficiencies exceeding 93% for lithium (Li), cobalt (Co), manganese (Mn), and nickel (Ni), with 88% metallic Al foil recovery via cathodic protection. Multi-scale characterization systematically elucidated metal valence evolution and interfacial reaction mechanisms, validating the technology’s tripartite innovation: simultaneous high metal extraction efficiency, high value-added Al foil recovery, and organic removal through single-step electrochemical treatment. The process synergized the dissolution of CM particles and hydrogen bubble-induced physical liberation to achieve clean separation of polyvinylidene difluoride (PVDF) and carbon black (CB) layers from Al foil substrates. This method eliminates crushing pretreatment, high-temperature reduction, and any other reductant consumption, establishing an environmentally friendly and efficient method of comprehensive recycling of battery materials. Full article

Recyclable aluminum-containing industrial solid waste can be used as supplementary cementitious materials (SCMs) to replace cement (30–50%), thereby reducing CO₂ emissions during cement production and improving the mechanical properties and durability of concrete. Therefore, the use of SCMs in building materials presents significant potential. Due to the presence of the aluminum phase in the SCMs, the hydration products of cements blended with SCMs are changed. Compared to the primary hydration product of conventional cement, calcium silicate hydrate (CSH), the main hydration product of cement blended with SCMs is calcium aluminosilicate hydrate (CASH), which exhibits a more complex molecular structure. Understanding the role of Al in C-A-S-H at the atomic scale facilitates mechanistic insights and promotes the sustainable utilization of SCMs in eco-friendly construction. Molecular dynamics enables the rapid and accurate structural analysis and property prediction of materials. Therefore, this paper presents a systematic review of molecular dynamics simulations of CASH and discusses the role of Al in the molecular structure, dynamic, and mechanical behavior of CASH. It also analyzes the interfacial properties of CASH composites, the immobilization and transport of ions in CASH, and the temperature effect on the structure and properties of CASH. Finally, the challenges and perspectives for molecular dynamics simulation of CASH are presented. Full article

Pyrometallurgical recycling of lithium-ion batteries presents distinct advantages including streamlined processing, simplified pretreatment requirements, and high throughput capacity. However, its industrial implementation faces challenges associated with high energy demands and lithium loss into slag phases. This investigation develops an integrated reduction smelting–chloridizing volatilization process for the comprehensive recovery of strategic metals (Li, Mn, Cu, Co, Ni) from spent ternary lithium-ion batteries; calcium chloride was selected as the chlorinating agent for this purpose. Thermodynamic analysis was performed to understand the phase evolution during reduction smelting and to design an appropriate slag composition. Preliminary experiments compared carbon and aluminum powder as reducing agents to identify optimal operational parameters: a smelting temperature of 1450 °C, 2.5 times theoretical CaCl₂ dosage, and duration of 120 min. The process achieved effective element partitioning with lithium and manganese volatilizing as chloride species, while transition metals (Cu, Ni, Co) were concentrated into an alloy phase. Process validation in an induction furnace with N₂-O₂ top blowing demonstrated enhanced recovery efficiency through optimized oxygen supplementation (four times the theoretical oxygen requirement). The recovery rates of Li, Mn, Cu, Co, and Ni reached 94.1%, 93.5%, 97.6%, 94.4%, and 96.4%, respectively. This synergistic approach establishes an energy-efficient pathway for simultaneous multi-metal recovery, demonstrating industrial viability for large-scale lithium-ion battery recycling through minimized processing steps and maximized resource utilization. Full article

Recycled aluminum–silicon alloys provide significant environmental benefits by reducing the consumption of raw materials and lowering carbon emissions. However, their industrial application is limited by the presence of iron-based intermetallic compounds and the insufficient investigation in the literature regarding their effects on mechanical behavior. This study focuses on a recycled EN 42000 alloy, comprising 95% recycled aluminum, with a focus on the effect of its elevated iron content (0.447 wt%) on aging behavior and mechanical performance. Laboratory-scale specimens were produced through gravity die casting and subjected to T6 heat treatment, consisting of solution, quenching, and artificial aging from 160 °C to 190 °C for up to 8 h. To investigate overaging, analyses were conducted at 160 °C and 170 °C for durations up to 184 h. Tensile tests were conducted on specimens aged under the most promising conditions. Based on innovative quality indices and predictive modeling, aging at 160 °C for 4.5 h was identified as the optimal condition, providing a well-balanced combination of strength and ductility (YS = 258 MPa, UTS = 313 MPa, and e% = 3.9%). Mechanical behavior was also assessed through microstructural and fractographic analyses, highlighting the capability of EN 42000 to achieve properties suitable for high-performance automotive components. Full article

This study signifies the development and characterization of a composite material with a metallic matrix of aluminum reinforced with a steel mesh, utilizing centrifugal casting technology. An evaluation was conducted to ascertain the influence of the formulation process and the presence of the insert on the mechanical behavior with regard to tensile strength. The aluminum matrix was obtained from commercial and scrap alloys, elaborated by advanced methods of degassing and chemical modification. Meanwhile, the steel mesh reinforcement was cleaned, copper plated, and preheated to optimize wetting and, consequently, adhesion. The structural characterization was performed by scanning electron microscopy (SEM) and energy dispersive X-ray spectroscopy analyses (EDX), which highlighted a well-defined interface and uniform copper distribution. The composite was produced by means of horizontal-axis centrifugal casting in a fiberglass mold, followed by cold rolling to obtain flat specimens. A total of eight tensile specimens were examined, with measured ultimate tensile strengths ranging from 78.5 to 119.8 (MPa). A thorough examination of the fractured specimens revealed a brittle fracture mechanism, devoid of substantial plastic deformation. The onset of failures was frequently observed at the interface between the aluminum matrix and the steel mesh. The use of SEM and EDX investigations led to the confirmation of the uniformity of the copper coating and the absence of significant porosity or interfacial defects. A bimodal distribution of tensile strength values was observed, a phenomenon that is likely attributable to variations in mesh positioning and local differences in solidification. A correlation was established between the experimental results and an analytical polynomial model, thereby confirming a reasonable fit. In sum, the present study provides a substantial foundation for the development of metal matrix composites with enhanced performance, specifically designed for challenging structural applications. This method also demonstrates potential for recycling aluminum scrap into high-performance composites with controlled microstructure and mechanical integrity. Full article

Energy conversion and infrastructure facilities consist of large amounts of metal and have lifetimes of several decades. When recycling metals, the methods of allocation play a decisive role in evaluating how primary and secondary materials, as well as the products that are produced with them, are to be evaluated ecologically. So-called credits for recycling are the subject of a particularly controversial discussion. This article shows that the current practice of giving credits for long-lasting products leads to a significant distortion of the actual emissions. Using the examples of steel, aluminum, and copper, prospective LCA data is used to show how the carbon footprint actually behaves. When credits are applied, the time dependency of emissions must be taken into account; otherwise, burden shifting into the future occurs, which can hardly be considered sustainable. The increase compared to the conventional time-independent practice lies, depending on the metal, at 70 to 300%. It is recommended that the cutoff approach be used conservatively when allocating recycling cascades in order to optimize environmental impact and avoid greenwashing. Full article

The growing demand for sustainable materials has driven significant interest in composites reinforced with organic fibers, due to their mechanical performance, availability, and reduced environmental impact. This study investigates the mechanical behavior of two composite configurations: a cross-woven fabric and a sandwich-type panel, both made from totora (Schoenoplectus californicus) and low-density polyethylene–aluminum (LDPE–Al). Our experimental results show that the cross-woven variant achieved higher impact resistance (2.51 J), tensile strength (5.82 MPa), and greater deformation capacity (6.76%), making it more suitable for applications requiring energy absorption and flexibility, such as interior cladding and modular furniture. In contrast, the sandwich configuration exhibited superior stiffness (910 MPa), favoring structural panels and low-load roofing uses. This research distinguishes itself by integrating biodegradable totora fibers with recycled LDPE–Al to fabricate sustainable construction components, advancing circular economy principles while addressing limitations in previous composite formulations through improved mechanical balance and application-specific performance. Full article

Fused filament fabrication (FFF) is a 3D printing technology that has been successfully demonstrated aboard the International Space Station (ISS), proving its suitability for space applications. In this study, we aimed to apply FFF to the 3D printing of recycled space beverage packaging, made of LDPE and a PET-Aluminum-LDPE (PAL) trilaminate. To minimize material waste and optimize the experimental process, we first conducted numerical simulations of additive manufacturing. Using Digimat-AM 2021.1 software, we analyzed residual stresses and warpage in an LDPE/PAL composite with a 10 wt% filler content, processed through the FFF technique. Three key printing parameters, including printing speed and infill pattern, were varied across different levels to assess their impact. Once the optimal combination of parameters for minimizing residual stresses and warpage was identified, we proceeded with the experimental phase, printing objects of increasing complexity to validate the correlation between numerical predictions and the 3D-printed models. The successful fabrication of all geometries under optimized conditions confirmed the numerical predictions, particularly the reduction in warpage and residual stress, validating the material’s viability for additive manufacturing. These findings support the potential application of the LDPE/PAL composite for in situ resource utilization strategies in long-term space missions. Full article