Search Results (163)

High-temperature sintering for ceramsite preparation is a safe and effective approach to recycle solid waste. Flux components are critical in ceramsite sintering, as they can reduce sintering temperature, modulate the viscosity and content of the liquid phase, and ultimately optimize ceramsite performance. However, existing studies on lead–zinc tailings (LZTs) and coal gangue (CG)-based ceramsite lack systematic exploration of key fluxes (Na₂O, MgO, CaO, Fe₂O₃), limiting the high-value utilization of these wastes. Under fixed sintering conditions (preheating at 400 °C for 30 min, sintering at 1250 °C for 30 min, heating rate of 10 °C/min), this work systematically investigated the effects of these fluxes (in the forms of carbonates, except for Fe₂O₃) on LZTs-CG ceramsite. The mechanical properties, mineral composition, microstructure and heavy metal leaching of samples were analyzed using various methods, including uniaxial compression, X-ray diffraction (XRD), scanning electron microscopy (SEM), and inductively coupled plasma optical emission spectrometry (ICP-OES). Results showed that, while Fe₂O₃ exerted a non-monotonic influence, Na₂O, MgO, and CaO improved apparent density and compressive strength, concurrently reducing water absorption, with these effects enhancing in a dose-dependent manner. Na₂O, MgO and Fe₂O₃ facilitated the formation of labradorite, cordierite and hematite, respectively. All fluxes weakened the diffraction peaks of quartz and mullite. ICP-OES results indicated that the fluxes slightly increased Pb and Zn leaching, yet the highest values (0.1975 mg/L for Pb, 0.0485 mg/L for Zn) were well below the limits specified in the Chinese national standard GB 5086.2-1997 (Leaching Toxicity of Solid Waste—Horizontal Vibration Extraction Procedure). This work shows optimized flux composition enables high-performance, eco-safe LZTs-CG ceramsite, supporting LZTs and CG high-value utilization and sustainable development. Full article

Aviation’s sustainability discourse often centres on flight emissions, but production and end-of-life phases also carry material, energy, and pollution impacts that are large enough to merit systematic intervention. With ~13,000 aircraft projected to retire over the next two decades—roughly 44% of the global fleet—the sector must scale responsible dismantling and material recovery to avoid lost opportunities for meeting future sustainability goals and to harness economic value from secondary parts and recycled feedstocks. Embedding major sustainability and circular economy principles into aircraft design, operations, and retirement can reduce waste, conserve critical materials, and lower lifecycle emissions while contributing directly to multiple SDGs. Furthermore, when considering particular aircraft types, thousands of narrow-body aircraft such as the Airbus A320 and Boeing 737 are due to reach their end of life over the next two decades. This research evaluates the economic and environmental feasibility of aluminium recycling from these aircraft, integrating material flow analysis, cost–benefit modelling, and a lifecycle emissions assessment. An economic assessment framework is developed and applied, with the results showing that approximately 24.7 tonnes of aluminium can be recovered per aircraft, leading to emissions savings of over 338,000 kg of CO₂e, a 95% reduction compared to primary aluminium production. However, scrap value alone cannot offset dismantling costs; the break-even scrap price is over USD 4200 per tonne. When additional revenue streams such as component resale and carbon credit incentives are incorporated, the model predicts a net profit of over USD 59,000 per aircraft. The scenario analysis confirms that aluminium recycling only becomes financially viable through multi-stream revenue models, supported by Extended Producer Responsibility (EPR) and carbon pricing. While barriers remain, aluminium recovery is a strategic opportunity to align aviation with circular economy and decarbonisation goals. 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

Recently, environmental issues have compelled people worldwide to pursue sustainability and adopt circular economy practices across all engineering sectors, including polymer engineering and composite fabrication. A transition towards fabric-reinforced thermoplastics (FRTPs), a greener solution, has been recommended in recent years. On the other hand, utilizing recovered reinforcing phases, such as recycled carbon fiber (rCF), has attracted tremendous attention. In this framework, the aim of this research is to investigate the performance of acrylic-based FRTPs (Elium^® resin developed by Arkema). Woven virgin carbon fiber (vCF) and non-woven recycled carbon fiber (rCF) fabrics were used as reinforcement architectures for the fabrication of composites via resin infusion. The optimized formulation selected for the matrix showed flexural modulus and flexural strength of 5 GPa and 78 MPa, respectively. Composites prepared with woven vCF reached 36 GPa and 620 MPa values of flexural modulus and strength, respectively. The study of non-woven fabric is of particular interest, because the web is composed of recycled carbon fibers obtained from end-of-life (EoL) thermoset composite components. The results were promising; the flexural modulus reached 8 GPa, and the flexural strength was 113 MPa. Improvements are anticipated, especially in the parameters and conditions of the molding process. Full article

The acquisition of high-purity impurities is pivotal for structural identification and an origin analysis, thereby laying a critical foundation for subsequent toxicological evaluation, quality standard development, and process optimization. This study investigated the feasibility of using a solvent gradient twin-column recycling chromatography technique for the separation and purification of multiple trace impurities in iohexol. In this approach, a modifier with a weaker elution strength than the mobile phase is introduced between two chromatographic columns to form a step gradient solvent system. This gradient slows down the leading edge of the elution band relative to the rear edge, inducing a band compression effect that counteracts band broadening and enhances the chromatographic resolution. By optimizing parameters such as the mobile phase composition, elution mode, and modifier flow rate, three trace impurities were successfully separated and purified from iohexol. Their respective purities were improved from initial concentrations of 0.36%, 0.35%, and 0.15% to 97.82%, 91.56%, and 81.56%, respectively. Leveraging the band compression effect on the target components, the impurities were simultaneously purified and concentrated. These results demonstrate that the proposed method is highly effective for the rapid isolation and preparation of trace pharmaceutical impurities. 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

The accelerated industrialization in China has precipitated a dramatic surge in solid waste generation, causing severe land resource depletion and posing substantial environmental contamination risks. Simultaneously, the cement industry has become characterized by the intensive consumption of natural resources and high carbon emissions. This review aims to investigate the current technological advances in utilizing industrial solid waste for cement production, with a focus on promoting resource recycling, phase transformations during hydration, and environmental management. The feasibility of incorporating coal-based solid waste, metallurgical slags, tailings, industrial byproduct gypsum, and municipal solid waste incineration into active mixed material for cement is discussed. This waste is utilized by replacing conventional raw materials or serving as active mixed material due to their content of oxygenated salt minerals and oxide minerals. The results indicate that the formation of hydration products can be increased, the mechanical strength of cement can be improved, and a notable reduction in CO₂ emissions can be achieved through the appropriate selection and proportioning of mineral components in industrial solid waste. Further research is recommended to explore the synergistic effects of multi-waste combinations and to develop economically efficient pretreatment methods, with an emphasis on balancing the strength, durability, and environmental performance of cement. This study provides practical insights into the environmentally friendly and efficient recycling of industrial solid waste and supports the realization of carbon peak and carbon neutrality goals. Full article

Batteries are used as energy storage devices in various equipment. Today, research is focused on solid-state batteries (SSBs), replacing the liquid electrolyte with a solid separator. The solid separators provide electrolyte stability, no leakage, and provide mechanical strength to the battery. Separators are mostly manufactured by either traditional processes or 3D printing technologies. These processes involve making a slurry of plastic, active and conductive material and usually adding a plasticizer when making thin films or filaments for 3D printing. This study investigates the additive manufacturing of solid-state electrolytes (SSEs) by employing fused deposition modeling (FDM) with recyclable, bio-derived polylactic acid (PLA) filaments. Precise control of macro-porosity is achieved by systematically varying key process parameters, including raster orientation, infill percentage, and interlayer adhesion conditions, thereby enabling the formation of tunable, interconnected pore networks within the polymer matrix. Following 3D printing, these engineered porous frameworks are infiltrated with lithium hexafluorophosphate (LiPF₆), which functions as the active ionic conductor. A tailored thermal sintering protocol is then applied to promote solid-phase fusion of the embedded salt throughout the macro-porous PLA scaffold, resulting in a mechanically robust and ionically conductive composite separator. The electrochemical ionic conductivity and structural integrity of the sintered SSEs are characterized through electrochemical impedance spectroscopy (EIS) and standardized mechanical testing to assess their suitability for integration into advanced solid-state battery architectures. The solid-state separator achieved an average ionic conductivity of 2.529 × 10⁻⁵ S·cm⁻¹. The integrated FDM-sintering process enhances ion exchange at the electrode–electrolyte interface, minimizes material waste, and supports cost-efficient, fully recyclable component fabrication. Full article

The limited understanding of intermolecular interactions in deep eutectic solvents (DESs) has restricted their rational design and broader application. In this study, a series of hydrophobic DESs (HDESs) were prepared using lidocaine as the hydrogen bond acceptor and various carboxylic acids as hydrogen bond donors. Their physicochemical properties, including density, viscosity, and thermal stability, were systematically characterized. Interactions between components were evaluated through excess molar volume, viscosity deviation, and Grunberg–Nissan parameters. Strong hydrogen bonding between lidocaine and carboxylic acids was confirmed, which weakened with increasing alkyl chain length of the acids. Furthermore, as the acid content in the mixture increased, lidocaine’s ability to disrupt the intrinsic hydrogen-bonding network of the carboxylic acids decreased, thereby weakening the hydrogen bonding interactions between the components. The extraction capability of the HDESs for cobalt ions was evaluated in aqueous systems. Cobalt, a key material in lithium-ion batteries and advanced alloys, is in rising demand due to clean energy development. The lidocaine/decanoic acid (1:2) system exhibited nearly 100% extraction efficiency, surpassing conventional extractants. The hydrophobic nature of the HDESs facilitated effective phase separation and reduced solvent loss. These findings provide theoretical insights and design principles for developing high performance HDESs tailored for environmentally friendly metal recovery, particularly in battery recycling and treatment of industrial wastewater. Full article

The increasing accumulation of plastic waste—especially from packaging and post-consumer sources—calls for the development of sustainable recycling strategies. Due to the challenges associated with sorting mixed waste, directly processing waste streams offers a practical approach. Polyethylene terephthalate (PET) and high-density polyethylene (HDPE) are common consumer plastics, but they are difficult to recycle together due to immiscibility and degradation. In mixed waste, recycled HDPE (r-HDPE) often contaminates the recycled PET (r-PET) stream. Additive manufacturing (AM) offers a promising solution to upcycle these mixed polymers into functional products with minimal waste. This study investigates the processing and characterization of r-PET/r-HDPE blends for AM, focusing on the role of compatibilizers in enhancing their properties. Blends were melt-compounded using a twin-screw extruder to improve dispersion, followed by direct pellet-based 3D printing. A compatibilizer (0–7 php) was incorporated to improve miscibility. Rheological testing showed that the 5 php compatibilizer optimized viscosity and elasticity, ensuring smoother extrusion. Thermal analysis revealed a 30 °C increase in crystallization temperature and a shift in decomposition temperature from 370 °C to 400 °C, indicating improved thermal stability. Mechanical testing showed a tensile strength of 35 MPa and 17% elongation at break at optimal loading. Scanning electron microscopy (SEM) confirmed reduced phase separation and improved morphology. This work demonstrates that properly compatibilized r-PET/r-HDPE blends enable sustainable 3D printing without requiring polymer separation. The results highlight a viable path for the conversion of plastic waste into high-value, customizable components, contributing to landfill reduction and advancing circular economy practices in polymer manufacturing. Full article

Polyimine-based composites have emerged as a promising class of dynamic covalent thermosets, combining high mechanical strength, thermal stability, self-healing, recyclability, and reprocessability. This review systematically summarizes recent advances in polyimine synthesis, highlighting dynamic covalent chemistry (DCC) strategies such as imine exchange and reversible Schiff base reactions. Structural customization can be achieved by incorporating reinforcing phases such as carbon nanotubes, graphene, and bio-based fibers. Advanced fabrication methods—including solution casting, hot pressing, and interfacial polymerization—enable precise integration of these components while preserving structural integrity and adaptability. Mechanical performance analysis emphasizes the interplay between dynamic bonds, interfacial engineering, and multiscale design strategies. Polyimine composites exhibit outstanding performance characteristics, including a self-healing efficiency exceeding 90%, a tensile strength reaching 96.2 MPa, and remarkable chemical recyclability. Emerging engineering applications encompass sustainable green materials, flexible electronics, energy storage devices, and flame-retardant systems. Key challenges include balancing multifunctionality, enhancing large-scale processability, and developing low-energy recycling strategies. Future efforts should focus on interfacial optimization and network adaptivity to accelerate the industrial translation of polyimine composites, advancing next-generation sustainable materials. Full article

Rapid progress in lithium-ion batteries and AI-powered autonomous driving is poised to propel electric vehicles to a 50% share of the global automotive market by the year 2035. Today, there is a major focus on recycling electric vehicle motors, particularly on extracting rare earth elements (REEs) from NdFeB permanent magnets (PMs). This research is based on a single-furnace process concept designed to separate metal components within PM motors by exploiting the varying melting points of the constituent materials, simultaneously extracting REEs present within the PMs and transferring them into the slag phase. Thermodynamic modeling, via Factsage Equilib stream calculations, optimized the experimental process. Simulated materials substituted the PM motor, which optimized modeling-directed melting within an induction furnace. The 2FeO·SiO₂ fayalite flux can oxidize rare earth elements, resulting in slag. The neodymium oxidation reaction by fayalite exhibits a ΔG° of −427 kJ when subjected to an oxygen partial pressure ($P_{O_2}$) of 1.8 × 10⁻⁹, which is lower than that required for FeO decomposition. Concerning the FeO–SiO₂ system, neodymium, in Nd³⁺, exhibits a strong bonding with the ${\mathrm{S}\mathrm{i}\mathrm{O}}_4^{4^{-}}$ matrix, leading to its incorporation within the slag as the silicate compound, Nd₂Si₂O₇. When 30 wt.% fayalite flux was added, the resulting experiment yielded a neodymium extraction degree of 91%, showcasing the effectiveness of this fluxing agent in the extraction process. Full article

The construction sector faces growing pressure to adopt sustainable alternatives amid the global plastic-waste crisis. This study presents a novel use of mechanically recycled high-density polyethylene (HDPE) and polypropylene (PP) to manufacture full-scale plastic rebars for mortar-free, light-load construction applications. A total of 48 samples, plain and ribbed, across three diameters (12 mm, 19 mm, and 25 mm) were fabricated and tested. Due to the absence of standardized protocols for recycled plastic rebars, tensile testing was conducted in reference to ASTM A615. Characterization techniques such as X-ray diffraction (XRD), and Scanning Electron Microscopy (SEM) confirmed the material’s structural features and polymer integrity. XRD confirmed the crystalline phases of HDPE and PP, while SEM revealed ductile fracture in HDPE and brittle failure in PP. The 25 mm ribbed PP rebars demonstrated superior performance, achieving a maximum load capacity of 12.2 ± 0.6 kN, a toughness index of 19.3 ± 1.0, and energy absorption of 101.6 ± 5.0 N-m × 10. These results affirm their suitability for lightweight structural components such as boundary walls, partition panels, and mortar-free interlocking systems. Unlike prior studies that confined recycled plastics to filler roles in composites, this work validates their direct application as full-section, load-bearing members. Additionally, a polynomial-based empirical model was formulated to predict the tensile behavior of the recycled rebars. The findings underscore the potential of mechanical extrusion as a low-emission, scalable solution to convert plastic waste into durable construction materials that support circular economic principles. Full article

The pyrolysis of non-recyclable construction, renovation, and demolition (CRD) wood waste is a complex thermochemical process involving devolatilization, diffusion, phase transitions, and char formation. CRD wood, a low-ash biomass containing 24–32% lignin, includes both hardwood and softwood components, making it a viable heterogeneous feedstock for bioenergy production. Thermogravimetric analysis (TGA) of CRD wood residues was conducted at heating rates of 10, 20, 30, and 40 °C/min up to 900 °C, employing model-fitting (Coats–Redfern (CR)) and model-free (Ozawa–Flynn–Wall (OFW), Kissinger–Akahira–Sunose (KAS), and Friedman (FM)) approaches to determine kinetic and thermodynamic parameters. The degradation process exhibited three stages, with peak weight loss occurring at 350–400 °C. The Coats–Redfern method identified diffusion and phase interfacial models as highly correlated (R² > 0.99), with peak activation energy (E_a) at 30 °C/min reaching 114.96 kJ/mol. Model-free methods yielded E_a values between 172 and 196 kJ/mol across conversion rates (α) of 0.2–0.8. Thermodynamic parameters showed enthalpy (ΔH) of 179–192 kJ/mol, Gibbs free energy (ΔG) of 215–275 kJ/mol, and entropy (ΔS) between −60 and −130 J/mol·K, indicating an endothermic, non-spontaneous process. These results support CRD wood’s potential for biochar production through controlled pyrolysis. Full article

Ferrosilicon (FeSi) is a commercially important material with multiple uses in metallurgical processes. Recently, in an attempt to reduce the carbon impact of the FeSi production process, researchers have proposed using recycled Si recovered from electronic waste in the production of FeSi. However, Si recovered from electronic waste usually contains Al, Cu, and Sn as impurities. Hence, FeSi alloys produced with recycled Si from electronic waste may contain all these elements in varying proportions. Al, Cu, and Sn have been explored as alloying elements to produce alloys with Fe. FeSiAl alloys have also been studied recently for their superior properties. In this work, a multicomponent FeSiAlCuSn alloy is produced, and the phases formed at different temperatures are analyzed using different phase identification techniques. We also analyze the hardness of the multicomponent alloy to find any deviation from the standard FeSi alloy without the additional alloying elements. Understanding the phases and the composition of such alloys may help design future multi-component or high-entropy alloys involving Fe, Si, Al, Cu, and Sn for specific applications. Full article