Search Results (181)

Rhenium is one of the rarest and most strategically important metals, indispensable in high-temperature superalloys and platinum–rhenium catalysts used across the aerospace and petrochemical industries. Owing to its limited primary reserves, recovering rhenium from secondary sources, such as spent catalysts, superalloy residues, and metallurgical dusts, has become vital to ensuring supply security. This review examines technological developments between 1998 and 2025, focusing on how operational parameters, including temperature, leaching time, reagent concentration, and solid-to-liquid ratio, govern dissolution kinetics and overall process efficiency. Comparative evaluation of hydrometallurgical, alkaline, and hybrid processes indicates that modern systems can achieve recovery rates exceeding 98% through selective oxidation, alkaline activation, or combined pyro and hydrometallurgical mechanisms. Acid–chlorine leaching facilitates rapid, low-temperature dissolution; alkaline sintering stabilises rhenium as soluble perrhenates; and hybrid smelting routes enable the concurrent separation of rhenium and osmium. Sustainable aqueous systems employing nitric and ammonium media have also demonstrated near-complete recovery at ambient temperature under closed-loop recycling conditions. Collectively, these findings highlight a technological transition from energy-intensive, acid-based pathways towards low-impact, recyclable, and digitally optimised hydrometallurgical processes. The integration of selective oxidants, phase engineering, circular reagent management, and artificial intelligence-assisted modelling is defining the next generation of rhenium recovery, combining high extraction yields with reduced environmental impact and alignment with global sustainability goals. 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

The removal of topsoil from agricultural land and the use of low-quality fuel to produce fired clay bricks affect the environment, disturbing the ecological balance and contributing to climate change. This study has attempted to produce sustainable concrete hollow blocks by replacing OPC with a combination of supplementary cementitious materials (SCMs) (5–25% fly ash) optimally (10% silica fume and 5% recycled aggregate fine dust). Furthermore, 100% of the developed sustainable sand was added instead of natural sand. Based on the results, the highest compressive strength, 7.6 MPa, was achieved in the mix 15FASFRAHB with the combination SCMs (15% fly ash + 10% silica fume + 5% recycled aggregate fine dust), slightly higher (2.7%) than that of the reference mix NAHB*’s value of 7.4 MPa. All hollow block mixes also satisfied the tensile strength criterion (10–15% of f’c of NAHB*). This showed that they reached the acceptable strength limit for building hollow blocks. In addition, the SCMs effectively reduce the permeability coefficient (k) of sustainable concrete hollow block mixes. However, a direct correlation between the permeability coefficient (k) and compressive strength was not maintained. Finally, the best overall mix from this study, 15FASFRAHB, was with an optimal 30% SCMs and 100% sustainable sand. By using developed sustainable concrete hollow blocks in place of fired clay bricks (6.48 × 10⁷ tons of CO₂ emission), 1.2 × 10⁹ tons of natural sand can be saved. Full article

This study investigates the potential of alkali bypass dust (ABD) as a supplementary material to partially replace cement in paste and mortar formulations. The selection of ABD is motivated by the dual objectives of utilizing an industrial waste product to promote sustainable construction and reducing the carbon footprint associated with cement production. The chemical and mineralogical composition of ABD was characterized using X-ray fluorescence (XRF) and X-ray diffraction (XRD), revealing a composition similar to Portland cement but with a notably lower CaO content (44.32%) and the presence of calcite, portlandite, quartz, and free lime. The incorporation of ABD as a cement replacement significantly influenced the fresh and hardened properties of the mixtures. In paste mixtures, results demonstrated a proportional increase in water demand and setting times with higher ABD content, attributed to its lower reactivity and higher water absorption. Mechanical properties were adversely affected; compressive and flexure strengths in paste mixtures decreased substantially, with a 40% reduction observed at just 10% replacement. This was corroborated by a decrease in density, an increase in water absorption, and a significant drop in ultrasonic pulse velocity (UPV), indicating a more porous and less dense microstructure. In mortar mixtures, a 30% cement replacement with ABD yielded compressive and flexure strengths that remained within acceptable ranges for plastering and masonry applications, despite a reduction in workability. The findings suggest that while high-volume ABD replacement negatively impacts performance, a 30% replacement level presents a viable, sustainable alternative for specific non-structural applications, contingent upon further durability assessments. Full article

This paper presents the investigation of the effect of electron radiation or the combined action of this radiation and triallyl isocyanurate (TAIC) on the structural, thermal, and mechanical properties of epoxy resin filled with a fraction of dust fibers (DFs) from recycled wind turbine blades. The resin containing 20 wt% of DF was irradiated with doses of 40, 80, 120, and 160 kGy. The results showed that electron radiation had only a slight effect on the properties of the studied composite, mainly on its glass transition temperature. More significant changes were observed with the combined action of radiation and TAIC. The main effect that occurred after the TAIC addition was the plasticization of the polymer matrix. With its participation, the glass transition temperature, thermal stability, and the hardness of the material and its flexural modulus were significantly reduced. The degree of change in these properties was regulated by the radiation dose. Furthermore, no significant changes in the composite structure were observed after radiation treatment, while the introduction of TAIC into the polymer matrix caused the formation of gas cells, probably due to the partial decomposition of TAIC. Full article

An integrated approach to waste management is based on efficient and safe methods for waste prevention, recycling, and safe waste treatment. In accordance with these principles, in this study, non-hazardous aluminosilicate waste (dust and sand) was used in the solidification/stabilization (S/S) treatment of hazardous waste (coating, emulsion, and sludge) from the automotive industry. Also, the oily component of the waste was valorized and investigated for energy recovery through co-incineration. The two S/S processes were proposed and their sustainability was assessed by utilizing all types of waste generated in the same plant, obtaining stabilized material suitable for safe disposal and oil phases for further valorization, and by techno-economic analysis. The efficiency of the S/S processes was evaluated by measuring unconfined compressive strength, hydraulic conductivity, density, and the EN 12457-4 standard leaching test of S/S products, along with XRD, SEM-EDS, and TG-DTG analyses. The possibility of using the oil phase was assessed based on its calorific value. The techno-economic assessment compared the investments, operating costs, and potential savings of both treatment scenarios. The results show that an integrated approach enables safe waste immobilization and resource recovery, contributing to environmental protection and economic benefits. Full article

This paper reviews various emerging alternative SCMs derived from minerals and biomass sources, industrial byproducts, and underutilized waste streams. The paper compiles and evaluates physicochemical properties, reaction mechanisms in cementitious systems, resource availability, supply chain dynamics, technology readiness, the impact on concrete performance, and environmental and cost factors for each candidate SCM. Specifically, the review examines wood ash from bioenergy plants, volcanic and sedimentary natural pozzolans, and construction and demolition waste. This includes recycled concrete fines, asphalt plants’ rock dust (baghouse fines), aggregate production fines, and post-consumer waste, particularly municipal solid waste incinerator ash and wastewater sludge ash. Additionally, the paper explores innovative additives such as cellulose and chitin nanomaterials and calcium–silicate–hydrate nanoseeds to address challenges of slower strength development and rheological changes. The key contribution of this review is a multifactor framework for assessing alternative SCMs, emphasizing availability, supply chain, market readiness, and environmental performance, combined with an engineering performance review. Full article

The electric arc furnace (EAF) is a key technology in the steel production industry, particularly for recycling scrap iron. It plays a crucial role in the shift to low-carbon metallurgy, responding to the growing demand for more sustainable production methods. Alongside its environmental and energy benefits, the EAF process generates significant amounts of solid by-products, including dust (EAFD) and slag (EAFS). These wastes are not only rich in base metals but also contain critical elements, which have attracted increasing scientific and industrial interest. Depending on the waste type, key metals such as zinc (from EAFD) and chromium, vanadium, and titanium (from EAFS) are targeted for recovery. This review examines the chemical and phase compositions of these wastes, various leaching techniques (often combined with pretreatment stages), and methods for final metal recovery, either in their pure form or as compounds. Key challenges in hydrometallurgical routes include chloride contamination, the dissolution of refractory zinc ferrite, and impurity management. Despite current limited industrial adoption, hydrometallurgical approaches show significant promise as efficient and environmentally friendly solutions for resource recycling, offering high-purity metal recovery. Full article

In the process of producing ferroalloys, a large amount of secondary raw materials is formed, including slag, aspiration dusts and sludge. The recycling of secondary raw materials can create resources and bring environmental and economic benefits. Wet secondary raw materials (WSRMs) are characterized by a high chromium oxide content (averaging 24%), but due to their high moisture levels, they cannot be directly used in arc furnaces. As a strategic approach, mixing WSRMs with drier, more chromium-rich dusts (up to 45% Cr₂O₃) has been proposed. This not only reduces the overall moisture content of the mixture but also enhances the metallurgical value of the charge material. This paper presents the results of laboratory studies on the agglomeration of secondary wet raw materials using briquetting, extrusion and pelletizing methods. The main factors influencing the quality of the resulting product were analyzed, including the method of agglomeration, the composition of the mixture, as well as the type and dosage of the binder component. The strength characteristics of the finished agglomerated samples were evaluated in terms of resistance to splitting, impact loads and falling. Notably, the selected binders are organic and polymer substances capable of complete combustion under metallurgical smelting conditions. 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

Carbon fiber (CF) and carbon fiber-reinforced polymers (CFRPs) are widely used in the aerospace, automotive, and energy sectors due to their high strength, stiffness, and low density. However, significant waste is generated during manufacturing and after the use of CFRPs. Traditional disposal methods like landfilling and incineration are unsustainable. CFRP machining processes, such as drilling and milling, produce fine chips and dust that are difficult to recycle due to their heterogeneity and contamination. This study investigates the oxidation behavior of CFRP drilling waste from two types of materials (tube and plate) under oxidative (non-inert) conditions. Thermogravimetric analysis (TGA) was performed from 200 °C to 800 °C to assess weight loss related to polymer degradation and carbon fiber integrity. Scanning electron microscopy (SEM) was used to analyze morphological changes and fiber damage. The optimal range for removing the polymer matrix without significant fiber degradation has been identified as 500–600 °C. At temperatures above 700 °C, notable surface and internal fiber damage occurred, along with nanostructure formation, which may pose health and environmental risks. The results show that partial fiber recovery is possible under ambient conditions, and this must be considered regarding the harmful risks to the human body if submicron particles are inhaled. This research supports sustainable CFRP recycling and fire hazard mitigation. Full article

The 1.9 billion metric tons of steel globally manufactured in 2023 justify the steel industry’s pivotal role in modern society’s growth. Considering the rapid development of countries that have not fully taken part in the global market, such as Africa, steel production is expected to increase in the next decade. However, the environmental burden associated with steel manufacturing must be mitigated to achieve sustainable production, which would align with the European Green Deal pathway. Such a burden is associated both with the GHG emissions and with the solid residues arising from steel manufacturing, considering both the integrated and electrical routes. The valorisation of the main steel residues from the electrical steelmaking is the central theme of this work, referring to the steel electric manufacturing in the Dalmine case study. The investigation was carried out from two different points of view, comprising the action of a plasma electric reactor and a RecoDust unit to optimize the recovery of iron and zinc, respectively, being the two main technologies envisioned in the EU-funded research project ReMFra. This work focuses on those preliminary steps required to detect the optimal recipes to consider for such industrial units, such as thermodynamic modelling, testing the mechanical properties of the briquettes produced, and the smelting trials carried out at pilot scale. However, tests for the usability of the dusty feedstock for RecoDust are carried out, and, with the results, some recommendations for pretreatment can be made. The outcomes show the high potential of these streams for metal and mineral recovery. Full article

Quarry dust (QD) landfill causes environmental issues that cannot be ignored. In this study, we systematically explore its potential application as a supplementary cementitious material (SCM) in cemented paste backfill (CPB), revealing the activated mechanism of modified QD (MQD) and exploring the hydration process and workability of CPB containing QD/MQD. The experimental results show that quartz, clinochlore and amphibole components react with CaO to form reactive dicalcium silicate (C₂S) and amorphous glass phases, promoting pozzolanic reactivity in MQD. QD promotes early aluminocarbonate (M_c) formation through CaCO₃-derived CO₃²⁻ release but shifts to hemicarboaluminate (H_c) dominance at 28 d. MQD releases active Al³⁺/Si⁴⁺ due to calcination and deconstruction, significantly increasing the amount of ettringite (AFt) in the later stage. With the synergistic effect of coarse–fine particle gradation, MQD-type fresh backfill can achieve a 161 mm flow spread at 20% replacement. Even if this replacement rate reaches 50%, a strength of 19.87 MPa can still be maintained for 28 days. The good workability and low carbon footprint of MQD-type backfill provide theoretical support for—and technical paths toward—QD recycling and the development of low-carbon building materials. Full article

Circulating fluidized bed fly ash (CFBFA) stockpiles release alkaline dust, high-pH leachate, and secondary CO₂/SO₂—an environmental burden that exceeds 240 Mt yr⁻¹ in China alone. Yet, barely 25% is recycled, because the high f-CaO/SO₃ contents destabilize conventional cementitious products. Here, we presents a pressurized flue gas heat curing (FHC) route to bridge this scientific deficit, converting up to 85 wt% CFBFA into structural lightweight gravel. The gypsum dosage was optimized, and a 1:16 (gypsum/CFBFA) ratio delivered the best compromise between early ettringite nucleation and CO₂-uptake capacity, yielding the highest overall quality. The optimal mix reaches 9.13 MPa 28-day crushing strength, 4.27% in situ CO₂ uptake, 1.75 g cm⁻³ bulk density, and 3.59% water absorption. Multi-technique analyses (SEM, XRD, FTIR, TG-DTG, and MIP) show that FHC rapidly consumes expansive phases, suppresses undesirable granular-ettringite formation, and produces a dense calcite/needle-AFt skeleton. The FHC-treated CFBFA composite gravel demonstrates 30.43% higher crushing strength than JTG/TF20-2015 standards, accompanied by a water absorption rate 28.2% lower than recent studies. Its superior strength and durability highlight its potential as a low-carbon lightweight aggregate for structural engineering. A life-cycle inventory gives a cradle-to-gate energy demand of 1128 MJ t⁻¹ and a process GWP of 226 kg CO₂-eq t⁻¹. Consequently, higher point-source emissions paired with immediate mineral sequestration translate into a low overall climate footprint and eliminate the need for CFBFA landfilling. Full article

Many components in industry are subjected to high loads during operation and therefore often do not reach their intended service life. Conventional steels frequently do not provide sufficient protection against wear and corrosion. One solution is to coat these components using methods like thermal spraying to apply cermet coatings such as Cr₃C₂-NiCr or WC-Co-Cr. In light of increasingly strict environmental regulations, more eco-friendly alternatives are needed, especially ones that use little or no Cr, Ni, Co, or W. Another alternative is the recycling of powder materials, which is the focus of this research project. This study investigated whether filter dust from an HVOF system could be used to develop a new coating suitable for use in applications requiring resistance to wear and corrosion. This is challenging as the filter dusts have heterogeneous compositions and irregular particle sizes. Nevertheless, this recycled material, referred to as “Green Cermets” (GCs), offers previously untapped potential that may also be of ecological interest. An established WC-Co-Cr coating served as a reference. In addition to friction wear and corrosion resistance, the study also examined particle size distribution, hardness, microstructure, and susceptibility to crack formation at the interface and inside the coating. Even though the results revealed a diminished performance of the GC coatings relative to the conventional WC-CoCr, they may still be applicable in various industrial applications. Full article