No full-text available
To read the full-text of this research,
you can request a copy directly from the authors.
Environment friendly ceramics from hazardous industrial wastes
Abstract
This paper reports on recycling mixed industrial wastes (exhaust metallurgical dust, spent foundry sands, galvanic glass microspheres, and acid inertization salt) into environmentally friendly composite ceramic materials. The only natural component of the compositions developed is clay and sand mixture, which is a traditional raw material of local brick factories. All industrial wastes under study have high contents of heavy metals, such as Pb, Br, Sr and Cr. The main goal of this research is development of eco-friendly construction materials based on hazardous industrial wastes to reduce waste disposal at dumps that chemically contaminate the environment. This would prolong service life of industrial landfills and essentially reduce exploitation of natural raw materials. Samples containing 75-85% of industrial wastes fabricated at 950-1010 °C have flexural strength values of up to 14 MPa. The values of leaching and solubility of the heavy metals are hundreds of times less than those permitted the national standards of Brazil. Physicochemical studies of the samples confirm the formation of a glassy structure with inclusion of newly formed minerals (Sodium Anortite, Thenardite, Hematite and Mullite). This structure can explain the mechanical and chemical characteristics of the new ceramic materials.
... Upon a review of the literature related to mitigation of pollution produced by the accumulation of galvanic sludge, it was seen that it can be divided into two fields: barrier processes (for clays, cements, asphalts, etc.), prevent the mobility of toxic elements towards the environment, and processes of industrial benefit, in which the sludge is exploited, either by extracting the metals contained in it or by using the sludge itself as raw material in other processes. With respect to the clay barrier processes for producing bricks and ceramics, several studies have been conducted (Mymrin et al., 2014). The ceramic material is sintered from the mixture of heavy metal-laden residues and mixed with clay and sand, and then sintering tests at different times and temperatures are performed (Wiemes et al., 2016). ...
... It was found that the value obtained for the mixtures was less than about 0.02 MPa compared to that obtained for the clays. These results are contradictory to those obtained in tests on the laboratory level by Mymrin et al. (2014) and Pérez-Villarejo et al. (2015), who assert that the flexural strength of samples with added galvanic sludge is higher than that required by the 3 MPa standard. ...
... The color changes from a cream tone in the pattern to a greenish tone in the samples dosed with sludge. Of the studies consulted, none presents results of color measurement for the samples (Mymrin et al., 2014;Wiemes et al., 2016;Mymrine et al., 2013;Pérez-Villarejo et al., 2015;Magalhães et al., 2004;Karlovic et al., 2008). ...
... For the pieces formed by dry pressing, the variations with respect to the control are 13.29%, 34.78%, and 54.83%, for 2%, 5%, and 8% of sludge, respectively, and for those formed by extrusion, the variations with respect to the standard are 8.52%, 29.48%, and 51.09% for the same sludge concentrations. The results obtained are consistent with those presented by [37,38], which show that the increase in calcination losses is directly proportional to the increase in sludge dosage. Regardless of the forming and sintering process, the result shows the same trend. ...
... In the case of those formed by extrusion, the variations with respect to the control are 2.37%, 13.00%, and 22.48%. These results agree with those reported in different studies [17,37,38], which show that without taking into account the process variables, the addition of galvanic sludge to the clay decreases the flexural strength of the samples. ...
This study aimed to scale the process of encapsulation in clay of the heavy metals Ni, Cr, and Cu, traditionally carried out at the laboratory level, up to industrial conditions. For this purpose, sludge from the galvanic industry, considered highly polluting, was mixed with the clay used to make traditional ceramics. The sludge concentrations were 2%, 5%, and 8% by weight. Two shaping processes traditionally used in the ceramic industry were used: extrusion and dry pressing, and the sintering was carried out in industrial gas kilns at 2 firing cycles: fast, lasting 34 min in a roller gas kiln, and slow, lasting 42 h in a tunnel gas kiln. The specimens thus obtained were characterized in terms of mechanical and esthetic properties. In the first case, the following characteristics were evaluated: flexural strength at three points, shrinkage, calcination losses, and water absorption. In the second, the color change obtained in the finished product generated by the presence of sludge was evaluated. Additionally, by means of the toxicity characteristic leaching procedure (TCLP) method, the impact that the finished product would have on the environment by leaching was determined. The results showed that the two processes of forming and sintering are viable for the treatment of galvanic sludge contaminant.
... Os elevados teores de alumínio (Al 2 O 3 ) e de sílica (SiO 2 ) são justificados pela origem mineralógica dos materiais em estudo (argilominerais do solo e areia quartzosa da ADF). Tais valores também corroboram os resultados citados por outros autores (Siddique et al., 2010;Mymrin et al., 2014). Deve-se destacar a redução no teor de óxidos de ferro de 14% para 4%, respectivamente, para a amostra de solo e para a mistura de solo+70%ADF. ...
... Ao comparar os resultados da presente pesquisa com os de outros autores, verifica-se que os metais pesados também excederam o limite da legislação (Mymrin et al., 2014), sem causarem contaminação das águas subterrâneas (Guney et al., 2006). ...
Este artigo apresenta uma análise numérica de solos não saturados colapsíveis, utilizados em uma pequena barragem de terra localizada no município de Quixadá, Estado do Ceará, Brasil. A estrutura colapsível foi resultado da aplicação de baixa energia de compactação e baixa umidade. São apresentados resultados dos ensaios de caracterização, compactação e adensamento duplo para o material oriundo da jazida empregada na construção da pequena barragem, com o objetivo de identificar as amostras analisadas e estudar o fenômeno do colapso. Através dos resultados dos ensaios, foi realizada uma análise numérica de fluxo e equilíbrio, com os programas Slide 6.0 e UNSTRUCT, de forma associada, para previsão do comportamento tensão x deformação (colapso) da barragem experimental. A seção transversal da barragem é constituída de núcleo com material compactado na umidade ótima e energia de Proctor Normal, e de espaldares no ramo seco. O objetivo é verificar a eficiência do maciço construído com redução de custos (por diminuição de terraplenagem) e redução do consumo de água, tornando-a uma importante solução construtiva para pequenas barragens em regiões semiáridas. Os estudos experimentais e numéricos da obra com estas características apontaram condições de estabilidade, tendo em vista que a barragem não apresentou ruptura durante o monitoramento.
... Yaghoubi studied waste foundry sand's bearing capacity and physical properties, et al. 2020 [35]; waste foundry sand was found suitable as an engineered fill and road embankment fill material. Mymrin, et al. [36] suggested foundry sand along with the addition of other industrial wastes for the sintering of environmentally-safe ceramics at 950-1050°C with samples' flexural strength values of up to 14 MPa. Coppio, et al. [37] experimentally proved that the concrete electrical resistivity changes according to the FS composition This brief review of the scientific and technical literature on the methods of methanol synthesis catalyst waste, bauxite processing waste, and waste foundry sand shows the lack of information on the possibility of a complete replacement of traditional natural materials with these industrial wastes. ...
Methanol synthesis catalyst (MSC) waste was applied as the principal component (till 70 wt.%) of sustainable ceramics in composites with bauxite processing waste (RM), and waste foundry sand (FS). The results of the initial components' chemical interaction studies by a complex of methods (XRD, SEM/EDS/mapping, AAS and LAMMA) during heating demonstrated the synthesis of amorphous glasslike new formation, their filling of pores and compaction of the ceramic’s structure. In this case, a strong chemical and mechanical binding of all heavy metals and other hazardous elements of the initial industrial waste occurs with their transfer to an insoluble in an acidic environment. The materials with the highest MSC contents have the highest axial resistance values ill 25.98 MPa after firing at 1050°C.
... ABM waste containing predominantly silica and/or alumina with low levels of metal contaminants can be processed thermally to form glass or ceramic products, or be used as raw materials in ceramic manufacturing (Mymrin et al., 2014;Rodriguez et al., 2016). A sandblasting waste, mainly composed of Al 2 O 3 , was recycled into the water-retention porous ceramics by co-sintering with waste diatomite at 1000-1270 • C with a sandblasting waste replacement level of up to 20% (Ho et al., 2019). ...
Solid blasting waste generated from coating removal during ship repair and maintenance poses environmental challenges. This paper presents a review of the generation, characterization, and treatment of blasting waste in the ship repair industry. The quantities, properties, and environmental impacts of the generated blasting waste are summarized and analyzed, and the results indicate that blasting waste has a high generation rate and/or high toxicity. As alternatives to landfill, available blasting waste treatment methods include hydrometallurgical leaching, physical/physicochemical separation, thermal treatment, and direct utilization in the production of building materials. The advantages and disadvantages of these treatments are reviewed and compared. The production of building materials from blasting waste is currently attractive owning to its economic benefits and technical simplicity, whereas recycling blasting waste for high-value applications is gradually gaining research interest. The high dependence of the choice and performance of treatment methods on the waste type and characteristics is highlighted. The results emphasize the interest in conducting more research on physiochemical and thermal properties and the environmental effects of blasting waste. This review suggests that future research should focus more on paint waste management because of the restricted application of dry abrasive blasting and the development of nonabrasive blasting methods in the ship repair industry.
... In the last years, synergy of various mixtures of industrial wastes containing useful oxides has been under investigation for the fabrication of construction products including ceramics, glass-ceramics and cement-based materials [14,15]. Limited data are reported, however, regarding synergistic utilization of fly ash with steel-industry solid residues in the formation of fired clay ceramics, although appropriate mixture combinations of industrial residues of these categories can be attractive starting materials for ceramics development, taking advantage from differences in their chemical and mineralogical composition [16]. ...
In the present work, the utilization of two by-products from Greek industries, as 100% the raw material mixture for the sustainable development of ceramics is examined, a challenge with both environmental and economic benefits. Specifically, fly ash derived from lignite-fed power station and electric arc furnace-carbon slag (EAFC) from steelmaking plant, were used as secondary resources. For that purpose, these powdery materials were mixed in various proportions (0-70%wt. EAFC content), cold compacted at 20tn load using an automated hydraulic press to form a series of 5cm diam. disc-shaped specimens, and then sintered at three different peak temperatures (1000 o C, 1100 o C and 1140 o C) for 3h. The microstructures produced were studied via SEM-EDS, and specimen physico-mechanical properties were evaluated. For a 50-50%wt. fly ash-EAFC mixture, the experimental data show that as the firing temperature is increased from 1000 o C up to 1140 o C, the produced specimens remain integral and not deformed during the sintering process. For that mixture, the diametral tensile strength (DTS) increases from approx. 1.5 MPa at 1000 o C and 1100 o C up to 7.4 MPa at 1140 o C. The coefficient of thermal conductivity also remains practically constant up to 1100 o C, attaining its max. value at 1140 o C. At this peak temperature, max. DTS was recorded for the 100% fly ash specimens (11.6 MPa). Nevertheless, mixtures containing up to 60%wt. EAFC (at 1140 o C) seem to maintain satisfactory physico-mechanical properties. SEM micrographs provide an insight in the ceramic microstructural evolution with temperature.
... The experiments by Matos et al. [13] showed that the incorporation of 10% (58 kg/m 3 ) of calcined foundry sand reduced 76 kg of cement in the mortar with equivalent performance. Mymrin et al. [14] used until 75% of foundry sand to produce ceramics with a flexural resistance of up to 14 MPa and leaching and solubility values hundreds of times lower than the permitted by Brazilian legislation. Bhardwaj and Kumar [15] reported the influence of the inclusion of foundry sand waste on the resistance, permeability, and microstructure of low-calcium fly ash geopolymer concrete and blast furnace slag-based alkali-activated slag concrete, both cured under atmospheric conditions. ...
The aim of this study was the experimental tests of the mechanical properties and structure formation processes of sustainable ceramics from hazardous lead ore flotation waste, spent foundry sand, and natural red clay to produce sustainable ceramics. The lead was mined on a large scale from lead ores in the city of Adrianópolis, Brazil, for 58 years. The wastes from this activity bequeathed profound environmental and social impacts. The mechanical characteristics of twenty compositions of the ceramics were analyzed through the flexural resistance, water absorption, apparent density, and linear shrinkage; the study of the physicochemical processes of the ceramics’ mineral composite transitions and structure formation during sintering at 900–1250 °C was accomplished using XRD, SEM, EDS, AAS, and LAMMA methods. All ceramics presented flexural resistance (until 10.08 MPa) in comparison with the values established in the Brazilian national standards (> 1.5 MPa), with low water absorption and shrinkage. Ceramics with 7% of the flotation waste and 10% spent foundry sand, whose resistance reached from 3.7 to 10.1 MPa, showed the best mechanical properties. Leaching and solubility analyses by AAS method showed that there is no environmental jeopardy in using these compositions to produce sustainable ceramics.
... These by-products are categorized as dangerous and hazardous industrial waste (Mymrin et al., 2014;Boreiko, 1991). The main problem of these waste products lies in its disposal due to the high concentration of heavy metals as cadmium, lead, chromium, mercury and zinc. ...
The steelmaking industry that uses electric arc furnaces to recycle steel scrap generates dust (EAFD) as its main residue. This waste must be treated to recycle some heavy metals for economic reasons and to prevent negative environmental impacts. It is formed basically by different metallic oxides with heterogeneous composition and size. The Waelz Kiln Technology is the most commonly used technology for this purpose, generating concentrates of Zn and Pb oxides (called Waelz oxides). The main component of Waelz oxides is zinc and nowadays the production of metallic zinc and high purity zinc oxide covers approximately 97 % of the zinc market. The impurities content in the Waelz oxides (different heavy metals, halogens, …) makes impossible to use it as raw material to produce industrial high purity zinc oxide or in the electrolytic production of metallic zinc. At present, the Waelz oxides are blended with other purer raw materials. That supposes the unfeasibility of obtaining these products only through direct recycling EAFD. Therefore, the goal of this work is an in-depth study of the newest hydrometallurgical processes in order to achieve the production of these zinc products from Waelz oxides, showing their possibilities and limitations.
... Both are regulated by EPA standards for land disposal of EAFD; the first is regulated by delisting for converting the EAFD into a non-hazardous material for placement, while the other is regulated by land disposal regulations (LDR) for placement. Before the conventional municipal landfills method is used, a pre-treatment process is needed such as the solidification/stabilization process [78,79,100,104] or verification/neutralization process [3,[105][106][107][108][109][110][111][112]. ...
This paper reviews the latest research findings on the combined treatment of both electric arc furnace dust (EAFD) and halogenated plastic wastes, mainly polyvinyl chloride (PVC) and brominated flame-retardants (BFRs). EAFD contains heavy metals (Zn, Pb, Fe, Cd, etc.); its disposal using the traditional landfilling method threatens the environment. On the other hand, halogenated plastic wastes accumulate annually at an alarming rate due to their excessive production, consumption, and disposal. PVC, for example, does not decompose naturally; it remains one of the most dangerous plastics, as it contains high proportions of chlorine that is responsible for hazardous emissions of chlorinated organic compounds (dioxins) and hydrochloric acid vapour. Recent research have focused on the combined treatment of PVC/BFRs and EAFD. HCl/HBr acids produced from the pyrolysis of PVC/BFRs can react with the metal oxides in the EAFD to convert them into readily separable metal halides. Alternatively, several researches illustrated the advantages of using additives such as metal oxides during the incineration treatment of waste PVC/BFRs to fix gaseous HCl/HBr, and consequently, EAFD would be considered an excellent and cheap candidate for PVC dechlorination, as well as dehalogenation of other halogenated plastics during thermal recycling processes. In this review we critically discuss literature findings on thermal treatment of PVC/BFR materials under oxidative and pyrolytic environments, typically at temperatures of 200 –900 °C in presence of metal oxides or EAFD. We also discuss the treatment/disposal routes for both waste materials (EAFD and halogenated plastic wastes) and the environmental impact of these disposal options. The review, finally, proposes the research necessary to minimize the hazards of these waste materials; Several future research areas were identified including the need to study the behaviour of real EAFD-plastic waste mixtures under oxidative thermal conditions with focus on both the selective recovery of metals and identification, quantification, and minimization of halogenated organic compounds released during the combined thermal treatment.
... Material resources in the production of most building materials account constitute the major portion for more than 55 %. Thus, it can be argued that the industrial waste use in the construction industry is one of the ways to preserve the natural environment [5][6][7][8][9][10][11][12]. ...
... Several examples of inertization by this approach can be found in the literature: polluted soils (Careghini et al., 2010;Navarro et al., 2013), radioactive wastes (Cieci nska et al., 2015;Davydov et al., 1996;Hrma et al., 2014;Pioro et al., 2001), incineration ashes (Cheng, 2004;Cheng et al., 2002;Haugsten and Gustavson, 2000;Jung et al., 2005;Kavouras et al., 2003;Romero et al., 2001). The production of glass-ceramics from these glasses enables further inertization due to the emplacement of toxic elements in the structure of minerals (Binhussain et al., 2014;Garcia-Valles et al., 2007;Mymrin et al., 2014;Varitis et al., 2015). The glass-ceramic process also provides recycled materials with superior mechanical properties (Marinoni et al., 2013;Teixeira et al., 2014). ...
The composition of sewage sludge from urban wastewater treatment plants is simulated using P-doped basalts. Electron microscopy analyses show that the solubility of P in the basaltic melt is limited by the formation of a liquid-liquid immiscibility in the form of an aluminosilicate phase and a Ca-Mg-Fe-rich phosphate phase. The rheological behavior of these compositions is influenced by both phase separation and nanocrystallization. Upon a thermal treatment, the glasses will crystallize into a mixture of inosilicates and spinel-like phases at low P contents and into Ca-Mg-Fe phosphate at high P contents. Hardness measurements yield values between 5.41 and 7.66 GPa, inside the range of commercial glasses and glass-ceramics. Leaching affects mainly unstable Mg 2þ-PO 4 3-complexes.
... Nowadays, limited amounts of FA are being reused, while more than 80% of the overall FA output is directly deposited into ponds and landfills. However, the contamination from FA deposits can easily occur, because the FA particles usually contain potentially hazardous trace elements (heavy metals) due to their high surface area [8,9]. Subsequently, there are serious concerns that this situation will possibly cause severe and irreversible long-term environmental effects. ...
Te development of value-added ceramic materials deriving only from industrial by-products is particularly interesting from technological, economic, and environmental point of views. In this work, the synergistic sintering of ternary and binary mixtures of fly ash, steelmaking electric arc furnace dust, and ladle furnace slag for the synthesis of compacted ceramics is reported. Te sintered specimens’ microstructure and mineralogical composition were characterized by SEM-EDS and XRD, respectively.
Moreover, the shrinkage, apparent density, water absorption, and Vickers microhardness (HV) were investigated at different sintering temperatures and raw material compositions. Te characterization of the sintered compacts revealed the successful consolidation of the ceramic microstructures. According to the experimental findings, the ceramics obtained from fly ash/steel dust mixtures exhibited enhanced properties compared to the other mixtures tested. Moreover, the processing temperature affected the final properties of the produced ceramics. Specifically, a 407% HV increase for EAFD and a 2221% increase for the FA-EAFD mixture were recorded, by increasing the sintering temperature from 1050 to 1150∘C. Likewise, a 972% shrinkage increase for EAFD and a 577% shrinkage increase for the FA-EAFD mixture were recorded, by increasing the sintering temperature from 1050 to 1150∘C.Te research results aim at shedding more light on the development of sustainable sintered ceramics from secondary industrial resources towards circular economy
... In the last years, synergy of various mixtures of industrial and/or agricultural wastes containing useful oxides has been under investigation for the fabrication of construction products including ceramics, glass- ceramics and cement-based materials [14][15][16][17][18]. Limited data are reported, however, regarding synergistic utilization of fly ash with steel-industry solid residues in the formation of fired clay ceramics, although appropriate mixture combinations of industrial residues of these categories can be attractive starting materials for ceramics development, taking advantage from differences in their chemical and mineralogical composition [19]. ...
In the present work, the development of ceramics is examined by using two industrial solid by-products as 100% the raw material mixture, a challenge with technological, environmental (sustainable waste management and earth mineral resources conservation) and economic benefits (utilization of largely available industrial secondary resources). Specifically, fly ash derived from lignite-fed power station and electric arc furnace-carbon slag (EAFC) from steelmaking plant, were used as secondary resources. These powdery materials were mixed in various proportions (0-70%wt. EAFC content), cold compacted at 20 tn load using an automated hydraulic press to form a series of 5 cm diam. disc-shaped specimens, and then sintered at three different peak temperatures (1000, 1100 and 1140 oC) for 3 h. The microstructures produced were studied via SEM-EDS, and specimen physico-mechanical properties were evaluated. For a 50-50%wt. fly ash-EAFC mixture, the experimental data
show that as the firing temperature is increased from 1000oC up to 1140oC, the produced specimens hopefully are not deformed during the sintering process. For that mixture, the diametral tensile strength (DTS) increases from approx. 1.5MPa at 1000oC and 1100oC up to 7.4MPa at 1140oC. The coefficient of thermal conductivity also remains practically constant up to 1100oC, attaining its max. value at 1140oC. At this peak temperature, max. DTS was recorded for the 100% fly ash specimens (11.6MPa). Nevertheless, mixtures containing up to 60%wt. EAFC (at 1140 oC) seem to maintain satisfactory physico-mechanical properties. SEM micrographs provide an insight in the ceramic microstructural evolution with temperature.
... To reduce the environmental impact associated with the production of ceramics, the introduction of wastes as alternative raw materials for the ceramic industry is especially viable with the aim of energy and materials savings (Raut et al., 2011;Zhang, 2013). This is possible due to the peculiar features of the ceramic manufacturing process, that includes a firing step at high temperatures (>850 C) that allows the waste to release its calorific value during the sintering process, if an organic nature residue is added (Demir, 2008;Barbieri et al., 2013), or to be incorporated into the internal structure of ceramics if an inorganic one is used (Alonso-Santurde et al., 2011;Binhusaain et al., 2014;Gencel et al., 2013;Mymrin et al., 2014). ...
The paper studies the addition of electric arc furnace stainless steel (EAF-SS) slag to clay raw materials for ceramic brick manufacturing in order to get more sustainable materials without compromising their final properties. Different amounts (10 wt%, 20 wt% and 30 wt%) of EAF-SS slag were added to a reference clay material. The samples were processed by extrusion and the main technological properties were determined to characterize the behavior of the materials during the shaping and drying processes (working moisture, drying linear shrinkage and modulus of rupture) and the final properties of sintered materials (bulk density, linear shrinkage, water absorption and modulus of rupture) at five maximum temperatures (850, 900, 950, 1000 and 1050 °C). The environmental impact was evaluated by qualitatively analyzing gaseous emissions during firing and by leaching tests on laboratory specimens. Furthermore, energy demand and fuel (natural gas) required to produce the formulated compositions, according to a standard industrial scale, was calculated in both the dryer and the kiln. Calculation of CO2 emissions during such theoretical industrial processing was also performed. Results show that the incorporation of EAF-SS leads in general to adequate technological properties and causes a potential saving of up to 17% of natural gas consumption and a reduction in CO2 emissions of up to 24% during manufacturing materials with 30 wt% of EAF-SS slag at 950 °C. However, in these materials the higher metals leaching potential would restrain the EAF-SS slag incorporation to a content of about 10 wt% or less and to sintering temperatures >950 °C. Therefore, clay ceramics incorporating EAF-SS slag in their composition can be technologically feasible and environment-friendly depending on both sintering temperature and amount of waste addition.
... Furthermore, by recycling metallurgical waste mixtures, including foundry sands, exhaust metallurgical dust, spent galvanic glass microspheres and acid inertization salt, into ceramic materials containing 75-85 % of the industrial wastes and fired at 950-1010°C, heavy metals leaching and solubility levels remained hundreds of times less than those permitted by national standards. This is due to the formation of a glassy structure with inclusion of newly formed minerals [46]. Galvanic sludges are derived from physico-chemical treatments of electroplating plant wastewaters. ...
Safe management of hazardous metals deriving from solid wastes constitutes an important environmental challenge. In the present study, recent progress in the stabilization/solidification of heavy metals from various solid wastes into ceramics and glass?ceramic materials is reviewed. Coal/lignite-fired power plant fly and bottom ashes, steel industry by-products, metallurgical and urban/municipal wastewater sludge, and pharmaceutical wastes are included. The environmental behavior of the ceramics produced is studied via several leaching tests and ecotoxicological analyses. The goal is to assess the potential of these materials for retention of pollutants into their microstructure, for safe use as building materials. These objectives are in line with green chemistry and sustainable development principles. Moreover, the aim of turning waste into useful feedstock for another industrial sector towards symbiosis, ample coordination, and circular economy, is strongly encouraged by current environmental policies. Such secondary resources can be considered as substitute materials in ceramics production, as they contain useful oxides. However, the presence of heavy metals remains a significant environmental issue. Possible leaching of pollutants caused by rain from construction materials incorporating solid wastes would lead to contamination of surface and subsurface water, thus raising critical environmental concerns. Inertization of potentially hazardous metals into environmentally-friendly ceramics and glass?ceramics is shown to be feasible, as concentrations of these elements in the leachates remain within acceptable limits. Certainly, this also depends on the leaching method employed and system parameters. In conclusion, stabilization of these elements into ceramic matrices can be an effective and beneficial alternative for protecting human health and the environment.
... In Greece, MS is being considered for recycling in the cement industry, steelworks and the chemical industry [13]. Recently, synergy of various mixtures of several industrial solid wastes containing silica, alumina and lime as the predominant oxides has been under consideration for the development of construction materials, including ceramics, glass-ceramics and cement-based materials [14,15]. In the presence of FA-clay mixtures in particular, waste generated from galvanizing and metal finishing processes, considered to be hazardous due to their toxic metals content, have already been added and thermally treated for the immobilization of toxic metals and the production of building construction materials. ...
In the present work, mixtures of mill scale (MS), an industrial by-product derived from the flaky surface of hot rolled steel, and lignite power station fly ash (FA), both originating from Greek industries, are examined as 100% the starting materials for the sustainable development of ceramics employing powder metallurgy (P/M) fabrication procedures. It should be emphasized that the safe management of such low price and largely available industrial secondary resources by their utilization as 100% the feedstock for another industrial sector (ceramic industry) is strongly prioritized by current EU policies. FA and MS were mixed in various proportions (30–80% wt. in MS), cold compacted at 20 tn using an automated hydraulic press to form a series of 5 cm diam. disc-shaped specimens, and then sintered at three different peak temperatures (1000°C, 1100°C and 1140°C) for 3 h. The experimental results are encouraging, showing that the mechanical performance (diametral tensile strength) of the integral ceramic materials so-produced sharply increases, from 0.77 MPa up to as much as 13.42 MPa, with the temperature increase from 1000°C up to 1140°C, for a 50–50 %wt. FA–MS mixture. Scanning electron microscopy mapping enables a better understanding of the microstructural changes occurring at higher sintering temperatures. On the other hand, the coefficient of thermal conductivity increases with temperature and the MS content in the mixture.
... The associated long-term financial burden led to the investigation of the re-use potential of many of those abundant waste materials, particularly in the ceramic industry. Studies on the recycling possibilities of construction waste, 1,2 waste incineration and power plant ashes, 3,4 ornamental stone cutting sludges and other mineral tailings, [5][6][7][8] various agricultural wastes like sugar cane bagasse, [9][10][11] grain-crops, coffee and rice husks, [12][13][14][15][16] and potentially hazardous industrial wastes 11,[17][18][19][20] can be found in the literature. ...
Brazil produces massive amounts of granite sawing waste and coffee husk ash and their inadequate and, often, illegal disposal causes enormous environmental problems. In the past decade, these and other industrial wastes have been intensively studied aiming at determining their potential as alternative raw materials, particularly for the ceramic industry. This work describes research carried out on the joint incorporation of those wastes in ceramic roof tile formulations. The results indicated that the simultaneous use of both materials translates into a very forgivable industrial working range, both composition-and temperature-wise, which, given the technological properties values observed after firing at 1100°C, enables industrial upgrade to wall tile production. As collateral benefits, the use of granite waste and coffee husk ash as alternative raw materials in the manufacture of clay-based products will relieve the stress on feldspars consumption and attenuate waste disposal concerns.
... clay, alumina-silicon carbide and silica sand to produce more economically glass-ceramics with adequate physical and mechanical properties (e.g. compressive strength as high as 80 MPa) and low content of hazardous elements [39,40]. ...
In the present experimental study, the valorization potential of various industrial wastes, namely fly ash, red mud and ferronickel slag was investigated for the production of CaO–Al2O3–Fe2O3–SiO2 glass–ceramics. Glass was first produced in alumina crucibles at 1300 and 1500 °C and then cast in stainless steel moulds. After cooling, glass was pulverized, uniaxially pressed at 60 MPa and used for the production of glass–ceramics in the form of disks. The chemical composition of glass and the sintering temperature affected the properties, namely microstructure, porosity, compressive strength, Vickers microhardness and linear thermal expansion coefficient of the produced glass–ceramics. The leaching potential of hazardous elements present in glass–ceramics was investigated with the Toxicity Characteristics Leaching Procedure test, their chemical stability was evaluated through immersion of specimens in distilled water, simulated acid rain solution and seawater for a maximum period of 1 month, while their structural integrity was assessed according to ASTM standard C1262-10. Several analytical techniques, namely X-ray Diffraction, Scanning Electron Microscopy, Differential Thermal Analysis and Fourier Transform Infrared Spectroscopy (FTIR) were used to provide insights on the microstructure of the produced glass–ceramics.
... Moreover, the utilization of steel mill scale waste as an admixture in clay bricks manufacturing has been evaluated [10]. Recently, synergy of various mixtures of several industrial solid wastes has been under consideration for the development of construction materials, including ceramics, glass-ceramics and cement-based materials [11,12]. However, limited data are reported regarding synergistic use of fly ashes with steel-industry residues in the formation of fired clay bricks. ...
In the present research, the combined utilization of fly ash (FA), derived from a lignite-fed power station, along with scrap-soil (SS), a steel industry by-product, is investigated, for the development of eco-friendly ceramics, thus enhancing innovation and sustainability. The valorization of these low price and largely available industrial secondary resources as 100% the raw materials mixture in ceramic industry arises interesting technological, environmental and economical benefits. FA and SS were mixed in various proportions (0-70%wt. in SS), cold compacted at 20 tn load using an automated hydraulic press to form a series of 5 cm diameter disc-shaped specimens, and finally sintered at three different peak temperatures (1000oC, 1100oC and 1140oC) for 3h. Then, the specimen microstructure and physico-mechanical properties were characterized. According to the experimental results, a sintering temperature increase from 1000°C up to 1140oC significantly improves specimen densification, thus sharply enhancing the diametral tensile strength (DTS), from 0.5 MPa up to 12.8 MPa respectively for a 50-50%wt. FA-SS mixture. Mechanical strength also varies with the SS percentage in the raw materials. Physico-mechanical properties seem to be constant for specimens containing SS up to 60% at 1140oC.
... In a similar cradle-to-cradle approach, waste rubber from tyre had been utilized to make new tyres or to generate fuel [15]. Industrial waste items like metallurgical dust, foundry sands, galvanic glass microspheres have been recycled to produce eco-friendly construction materials, thus, reducing waste disposal at dumps and protecting the environment better [16]. Fine recycled glass blends, recycled concrete aggregate and waste rock were put together to make an unbound pavement base/sub-base material [17]. ...
A variety of waste materials is generated at a construction site which is referred as inert. Dumping such waste materials in a landfill do not generate any further useful by-product like gas or fertilizer. Here, the aim is to reuse and recycle waste materials like glass cuttings, wooden shredding, plaster of paris, floor polish, waste putty, etc. generated at construction site to make a designer brick. The machinery involved in the process is mostly available at the site itself. It has been tested to be hard and durable to serve the purpose of being used as a part of a wall. An electric circuit has been installed inside the brick which lights up the LED strip in the brick. This mode of production of designer brick follows the cradle-to-cradle approach and helps in better sustenance of the environment.
... Recently, synergy of various mixtures of several industrial solid wastes containing silica, alumina and lime as the predominant oxides has been under consideration for the development of construction materials, including ceramics, glass-ceramics and cement-based materials (Mymrin et al. 2014;Sun et al. 2011;Porreca et al. 2007;Vilches et al. 2003). In the presence of fly ash-clay mixtures in particular, waste generated from galvanizing and metal finishing processes, considered to be hazardous due to their toxic metals content, have already been added and thermally treated for the immobilization of toxic metals and the production of building construction materials. ...
Limited amounts of industrial residues are recycled while the remaining huge quantities are stockpiled or disposed of, thus frequently leading to soil contamination. The utilization of industrial residues as valuable secondary resources into ceramics can contribute to efficient waste management and substitution for massive amounts of natural resources (clayey minerals) demanded for ceramic production. The low cost of these residues and even possible energy savings during mixture firing may also be beneficial. In the present study, the innovative combination of lignite fly ash with steel-making dust into clay-based red ceramics is undertaken, to contribute both to sustainable use of resources and prevention of soil contamination. Brick specimens were shaped by extrusion and fired, their microstructure was examined and the effect of the mixture composition and firing temperature on physico-mechanical properties was determined. Ceramic microstructures were successfully obtained by a suitable combination of fly ash with steel dust (5 + 5 wt%) into clays. Properties can be predicted and tailored to meet the needs for specific applications by appropriately adjusting the mixture composition and sintering temperature.
This paper demonstrates the possibility of producing new red ceramics composites from red mud of hazardous bauxite waste (50–100 wt%), and foundry sand (10–50%) replacing the traditional clay-sand mix and preventing the environment pollution by such industrial wastes. The newly developed environment-friendly ceramics exhibit high physical properties (flexural strength, linear shrinkage, water absorption, and density). The ceramics’ analysis by X-rays fluorescence, X-rays diffractometry, atom absorption spectroscopy, scanning electron microscopy, energy-dispersion spectroscopy, and laser micro-mass analysis revealed the synthesis of mainly glass-like structures with a small inclusion of crystalline structures. The values of flexural strength reached 10.54 MPa; after sintering at 1150 °C, linear shrinkage varied between 6.62 and 7.92%, water absorption – 2.77 and 14.41% and bulk density – 1.65 and 2.07 g/cm³. The most valuable property of the developed materials is the ecological purity due to the heavy metal’s complete neutralization from both industrial wastes.
This paper reports an optimisation study for producing fired bricks using organic solid wastes used as partial substitutes to the soil. A series of experiments were carried out following Design of Experiments approach proposed by Taguchi (L25 orthogonal array with four factors and five levels). Different type of wastes (additives) were added to two different types of soils (laterite and alluvial) in various mix ratio and fired at two different temperatures (850 and 900 °C) in line with the commercial kiln practice. The effects of additives, soils, firing temperature and mix ratio on the performance characteristic were analysed using ANOVA, Signal to Noise (S/N) ratio and Random Forest regression analysis. It was inferred that (i) firing temperature of a brick is the least important parameter affecting a brick's compressive strength, water absorption or linear shrinkage, and (ii) substituting up to 15% of fertile soil by an appropriate additive (waste type) can still achieve compressive strength comparable to the normal clay brick.
The paper describes the production, in single fast firing, of tiles containing 30 wt% of a natural red clay and a mixture of 42 wt% of paper mill sludge and 28 wt% of glass cullet which were coated with a commercial ‘matt white’ glaze. Fired materials have been characterized as a function of the top temperature (1090 or 1140 °C) reached at the top of the fast sintering process made by an industrial roller kiln. It has been observed that tiles fired at 1090 °C display the best overall performances because the matt glaze well covers the substrate, thus ensuring that the mechanical and physical properties of the tiles conform to the official standard.
The properties of ceramic are studied in the case where clay is modified by adding small amounts of glass fiber in the process of ultrasonic extrusion of laboratory samples. Ultrasound increases the strengthening action of the modifier. It consolidates the batch and orients its elongated particles along the direction of extrusion. After firing the modifier particles become hollow concretions-geodes which have a polycrystalline shell comprised of anorthite and are filled with needle-shaped crystals. The proposed method of extrusion increases the accuracy and informativeness of tests performed on modified clays.
Municipal solid waste incineration (MSWI) fly ash is a by-product from municipal waste incineration. According to incomplete statistics, each year more than one million tons MSWI fly ash was produced in China. Owing to high heavy elements content, widely used disposal methods of landfill are not suitable for MSWI fly ash treatment. In this study, by using MSWI fly ash as raw materials, glass–ceramics was synthesized for the solidification of heavy metals and waste recycle. Process parameters, including composition, heat treatment temperature and time, were studied and optimized. Under optimizing conditions, the product has good properties of density of 3.42 g·cm⁻³ and Vickers hardness of 6.91 GPa. Moreover, the leaching concentration of heavy metal elements meets allowable values of toxicity characteristic leaching procedure (TCLP). This study offers an alternative for MSWI fly ash recycle. © 2017 The Nonferrous Metals Society of China and Springer-Verlag GmbH Germany
This article presents a case study conducted as an experiment with the incorporation of different types of industrial waste in brick manufacturing process in laboratory scale. The main objective of this work is to incorporate large amounts of different types of waste as raw material in brick's formulation. Three types of wastes were mixed with clay: automotive industry waste sludge containing heavy metal concentrations; glass waste, from a galvanic plant, mainly consisting of glass microspheres; and wood ash, from the ceramic burning furnace. The formulation's materials were analyzed by X-ray diffraction, X-ray fluorescence and electronic microscopy. The dried samples were milled separately and then dry mixed. Water was added to the mixture in order to contribute to the compaction process. The samples were dried and then burned at temperatures similar to those used for brick firing furnace. The obtained ceramics were analyzed for their retraction and then submitted to flexural strength testing. Samples obtained value above 4 MPa were approved. Among the samples tested, the formulation that showed higher flexural strength was chosen. It was prepared sufficient sample to perform the solubilization and leaching tests. For tests, the samples were reduced to dust. The results of such analyzes did not identify the presence of elements described in the initial samples' formulation. Morphological analysis was performed using scanning electron microscopy. Tested sample showed glassy characteristic of material that has been sintered during the firing process. This effect is also a proof that the waste identified in initial sample's formulation were inerted. Obtained results characterizes that the tested formulation can be considered as an alternative for bricks manufacturing with incorporation of industrial waste and an activity non-hazardous to the environment.
The applications of waste material particularly palm oil sludge in the production of stoneware as a contributory agent will reduce the cost of production and enhance waste management as well. Moreover, it will be a solution for the environmental problems caused by such waste. In this project, the addition of palm oil waste in different content (5–20 wt%) to the stoneware in purpose of eco-friendly artwork production has been assessed. In order to investigate the ultimate body characteristics, various factors such as linear shrinkage, water absorption, and bending strength have been tested. In accordance with the output characteristics, there was a least proportion between content of the residue and linear shrinkage finding. On the other hand, the level of water absorption has risen by addition of sludge, while there was a drop in bending strength after application of sludge. The modified stoneware changes have not affected the ceramic artwork production. Although the modified body shows some changes due to addition of waste, it has met the standards and expectations for the stoneware body used by artist, and it has followed the same procedure as ceramic artwork production.
This paper analyzes the significant scientific publications worldwide for the last 15 years concerning construction ceramics (predominantly brick) made with various inorganic industrial wastes added to the ceramic raw material for the improvement of properties and for eco-friendly disposal. The information gap resulting from the lack of mentions of the Russian publications on this subject in English-language reviews is filled. The paper includes brief summaries of 34 dissertations and 29 patents issued in Russia since 2000. The waste additives described in these summaries are grouped by origin type (mining industry waste, ore enrichment waste, metallurgical waste, sludge, ashes, cullet, large-capacity building wastes and waste from various chemical production processes) with the ceramic mixture compositions, molding and firing conditions, final strength, water absorption and other parameters of the final ceramic samples reported. Russian scientists have expanded the nomenclature of each group of wastes significantly upon addition to the list described in English-language reviews for 2000–2015. References to the recent Russian developments in the field of ecological management in ceramic industry are provided.
This article presents a case study conducted as an experiment with the incorporation of different types of industrial waste in brick manufacturing process in laboratory scale. The main objective of this work is to incorporate large amounts of different types of waste as raw material in brick's formulation. Three types of wastes were mixed with clay: automotive industry waste sludge containing heavy metal concentrations; glass waste, from a galvanic plant, mainly consisting of glass microspheres; and wood ash, from the ceramic burning furnace. The formulation's materials were analyzed by X-ray diffraction, X-ray fluorescence and electronic microscopy. The dried samples were milled separately and then dry mixed. Water was added to the mixture in order to contribute to the compaction process. The samples were dried and then burned at temperatures similar to those used for brick firing furnace. The obtained ceramics were analyzed for their retraction and then submitted to flexural strength testing. Samples obtained value above 4 MPa were approved. Among the samples tested, the formulation that showed higher flexural strength was chosen. It was prepared sufficient sample to perform the solubilization and leaching tests. For tests, the samples were reduced to dust. The results of such analyzes did not identify the presence of elements described in the initial samples' formulation. Morphological analysis was performed using scanning electron microscopy. Tested sample showed glassy characteristic of material that has been sintered during the firing process. This effect is also a proof that the waste identified in initial sample's formulation were inerted. Obtained results characterizes that the tested formulation can be considered as an alternative for bricks manufacturing with incorporation of industrial waste and an activity non-hazardous to the environment.
Herein, we report the synthesis, characterizations, photocatalytic and sensing applications of ultra-wide cadmium sulfide (CdS) nanosheets. The CdS nanosheets were prepared by simple solution process at low-temperature using cetyltrimethyl ammonium bromide (CTAB) as a stabilizing agent. The synthesized CdS nanosheets were characterized by several techniques which confirmed large-scale growth, well-crystallinity and hexagonal crystal phase of the prepared nanosheets. The synthesized nanosheets were used as effective photocatalyst for the photocatalytic degradation of harmful toxic dye, i.e. methyl orange. The photocatalytic activities were evaluated by measuring the photodegradation rate of MO in presence of CdS nanosheets under UV light irradiation. Interestingly, over 90% degradation of MO dye was achieved in 75 min using 0.15 g of photocatalyst, i.e. CdS nanosheets. Further, the synthesized nanosheets were used as efficient scaffold to fabricate highly sensitive, selective and reproducible fluorescent sensor for the detection of Picric Acid (PA). The observed detection of limit for the fabricated sensor was ~2.46 μM. Moreover, the interfering studies confirmed that the developed sensor possesses very good selectivity towards PA as it detect selectively even in presence of several other coexisting aromatic compounds such as phenol, benzaldehyde, benzoic acid and aniline.
This paper reports on recycling of industrial wastes (three pharmaceutical industrial sludges) into environmental friendly value-added materials. Stabilization/Solidification (S/S or bricks) process was applied to make a safer way for the utilization of pharmaceutical waste. The additives in this study include binders (cement, lime and bentonite) and strengthening material (pulverized fuel ash (PFA), silica fume and quarry dust) was used at different compositions. Bricks were cured for 28 days, and the following analysis-like compressive strength, leachability of heavy metals, mineralogical phase identity by X-ray diffraction (XRD) spectroscopy, Fourier transform infrared spectroscopy (FTIR) and thermal behaviour by thermogravimetric-differential thermal analysis (TG-DTA) had done. All the bricks were observed to achieve the standard compressive strength as required for construction according to BIS standards. Metal concentration in the leachate has reached the dischargeable limits according to Brazilian standards. Results of this study demonstrate that production of bricks is a promising and achievable productive use of pharmaceutical sludge.
A reforming method of a metallurgical furnace generated exhaust gas includes reforming a high temperature exhaust gas discharged from a metallurgical furnace by adding a reducing agent to the gas, wherein addition of the reducing agent is initiated when an oxygen concentration in the exhaust gas is 1 vol % or less, and a reforming reaction is completed when a temperature of the exhaust gas is 800° C. or higher, and an apparatus thereof. The reducing agent is blown from a reducing agent blowing nozzle having a double pipe structure.
The investigations of the atmospheric dusts in the Głogów-Żukowice area detected the presence of unaltered grains and fragments of ore minerals characteristic of the ore from the Legnica Głogów Copper District. Industry in the Żukowice area emits not only sulphides and arsenides of such metals as Cu, Pb, Zn, and Ni but also alloys of Pb and Pb-Cu as well as precious metals. Size of the dust particles varies considerably from submicroscopic grains to several hundreds of micrometers. The particles are usually xenomorphic grains or crystals and ore fragments (mainly shale ore). Intergrowths of ore minerals are rare. The biggest grains consist of semigraphite blades and unaltered fragments of bituminous shale. Bornite, chalcopyrite, goethite, chalcocite, hematite, covellite, marcasite, arsenides of Ni-Co (rammelsbergite-safflorite), fragments of Bessemer and shaft furnace slag, metallic silver and copper, metallic iron, ilmenite, magnetite, malachite, cuprite, pyrrhotite, metallic lead and lead alloys were detected in the polished samples.
Manganese furnace dust is made up of volatiles and raw materials fines collected from the off-gas during smelting of manganese alloys. Currently, manganese furnace dust is accumulated in large settling ponds. Major factors preventing recycling of the manganese furnace dust to the ferroalloy furnaces are handling, due to its tar content, and accumulation of zinc in the furnaces, which can cause irregularities in their operation. This paper presents characteristics of manganese furnace dust generated in ferromanganese and silicomanganese production at Tasmanian Electrometallurgical Company and analyses zinc balances in light of furnace dust recycling. If manganese furnace dust is recycled to the ferroalloy furnaces via the sinter plant, the overall zinc input will increase by 51-143% depending on charging materials.
The Egyptian Iron and Steel Company generates a great amount of blast furnace flue dust. The recovery of metals and carbon from this flue dust becomes a very important demand due to the increase of the price of coke breeze and the decrease of the primary source of metals. At the same time, it make the environment more safe by decreasing pollution. Introducing these dust fines in the sintering process proves to be very harmful for different operating parameters. Thus, this study aims at investigating the production of pellets resulting from these fines, using molasses as organic binder and its application in sintering of iron ore. The sintering experiments were performed using flue dust as pellets as a substitute of coke breeze. The results revealed that, sintering properties such as inter strength increases with using the flue dust pellets, while productivity of both the sinter machine and sinter machine at blast furnace yard decreases. Also the vertical velocity of the sinter machine and the weight loss during the reduction of produced the sinter by hydrogen decrease.
In order to make a complete characterization of electric-arc furnace (EAF) dust, as hazardous industrial waste, and to solve its permanent disposal and/or recovery, bearing in mind both the volumes formed in the Croatian steel industry and experiences of developed industrial countries, a study of its properties was undertaken. For this purpose, samples of EAF dust, taken from the regular production process in the Zeljezara Sisak Steel Mill between December 2000 and December 2001, were subjected to a series of tests. The chemical composition of EAF dust samples was investigated by means of a several different analytical methods. The results from the chemical analysis show that the approximate order of abundance of major elements in EAF dusts is as follows: Fe, Zn, Mn, Ca, Mg, Si, Pb, S, Cr, Cu, Al, C, Ni, Cd, As and Hg. Granular-metric composition of single samples was determined by applying sieve separation. Scanning electron micro-structural examination of EAF dust microstructure was performed and results indicated that all twelve EAF dusts were composed of solid spherical agglomerates with Fe, Zn, Pb, O, Si and Ca as the principal element. The investigation of grain morphology and the mineralogical composition of EAF dust were taken by combination of high resolution Auger electron spectroscopy (HR AES), X-ray photoelectron spectroscopy (XPS) and X-ray powder diffraction analysis. The analysis of XPS-spectra determined the presence of zinc in the form of ZnO phase and the presence of lead in the form of PbO phase, i.e. PbSO3/PbSO4 forms. The results of the X-ray diffraction phase analysis show that the basis of the examined EAF dust samples is made of a mixture of metal oxides, silicates and sulphates. The metal concentration, anions, pH value and conductivity in water eluates was determined in order to define the influence of EAF dust on the environment.
Electric arc furnace dust (EAFD) is a hazardous industrial waste generated in the collection of particulate material during steelmaking process via electric arc furnace. Important elements to the industry such as, Fe and Zn are the main ones in EAFD. Due to their presence, it becomes very important to know how these elements are combined before studying new technologies for its processing. The aim of this work was to carry out a chemical, physical, structural and morphological characterization of the EAFD. The investigation was carried out by using granulometry analysis, chemical analysis, scanning electron microscopy (SEM), energy dispersive spectroscopy via SEM (EDS), X-ray mapping analysis via SEM, X-ray diffraction (XRD) and Mössbauer spectroscopy. By XRD the following phases were detected: ZnFe(2)O(4), Fe(3)O(4), MgFe(2)O(4), FeCr(2)O (4), Ca(0.15)Fe(2.85)O(4), MgO, Mn(3)O(4), SiO(2) and ZnO. On the other hand, the phases detected by Mössbauer spectroscopy were: ZnFe(2)O(4), Fe(3)O(4), Ca(0.15)Fe(2.85)O(4) and FeCr(2)O(4). Magnesium ferrite (MgFe(2)O(4)), observed in the XRD pattern as overlapped peaks, was not identified in the Mössbauer spectroscopy analysis.
During the BOF process for the production of crude steel, the specific amount of dust emitted is of the order of 2% of the steel weight at turn down. The process gas conveys the dust through the boiler system into the primary and secondary dust catchers. The transportation of dust particles is influenced by blowing parameters; physical properties of process gas and of dust phases; and, type and layout of the converter and the filter system. In this work, a numerical simulation model is developed that simulates the pneumatic conveyance and sedimentation of primarily coarse dust particles in the BOF gas cleaning system. Comparison is then made of predicted coarse dust characteristics with values for dust sampled from an existing plant in order to verify the plausibility of the developed model.
This study examines potential waste diatomite and catalyst reuse to prepare water absorption and retain porous ceramics. The operating conditions are constant pressure (5 MPa), sintering temperature (1000–1270°C), sintering time (2 h), waste diatomite containing waste catalyst at different proportions (0–20%), respectively. The porous ceramic samples containing waste catalyst show low thermal conductivity properties (0.278–0.349 W/mK), probably owing to the more pores than those in the concrete (1.458 W/mK). Water release (t1/2 value) by the porous ceramic samples is decelerated by porous ceramic samples containing waste catalyst, due to the synergy effect of high water absorption by the waste catalyst and better than in the foamed glass material (4 h). Porous ceramic samples containing waste catalyst is highly promising for use in water absorption and retention applications. © 2012 American Institute of Chemical Engineers Environ Prog, 32: 640–648, 2013
This work focused on the applicability and viability analysis of oil-contaminated diatomite waste and other two industrial residues (galvanic sludge and glass waste materials) in red ceramic fabrication. Red ceramic samples were produced varying the amount of waste materials. Diatomite content, galvanic sludge, and glass wastes in new materials ranged from 25% to 35%, 20% to 25%, and 5% to 20%, respectively. Natural clay was present by 30%. Mixtures of initial components were hydrated, compacted, dried and baked with different temperatures (950 °C, 1000 °C, 1050 °C, and 1100 °C) during 6 h. The materials were analyzed by Scanning Electronic Microscopy (SEM), Electron Dispersive Spectroscopy (EDS), X-Ray Fluorescence Spectroscopy (XRF) and X-Ray Diffraction (XRD) techniques. Red ceramic samples were subjected to flexion resistance tests. High resistance, low dilatation values, water absorption, solubility and leaching of heavy metals could be observed in the obtained ceramic samples. Those outcomes can be explained by melting of some crystal structures of raw components (completely of Illite and partly of Quartz) and partial transition to amorphous glassy formations, well visible by SEM micrographs. The developed materials can be highly economically attractive because of the utilization of industrial wastes to produce construction materials. The wide-scale use of the method can be environmentally effective.
A viscosity model for predicting the complete viscosity curve of glass was developed using a global statistical approach and more than 2200 composition-viscosity data for silicate glasses collected from over 50 years of scientific literature, including soda-lime-silica container and float glasses, TV panel glasses, borosilicate fibre wool and E type glasses, low expansion borosilicate glasses, glasses for nuclear waste vitrification, lead crystal glasses, binary alkali silicates, and various other compositions. It is shown that, within a measurement series from a specific laboratory, the reported viscosity values are commonly overestimated at higher temperatures due to evaporation losses during the measurement and glass preparation; this includes data presented by Lakatos et al (1972) and the recent 'High temperature glass melt property database for process modelling' by published by Seward et al (2005). Similarly, in the glass transition range many experimental data reported for borosilicate glasses are too high due to phase separation effects. The global model developed here corrects those errors. The model standard error was 9-17°C, with R2=0·985-0·989. The prediction confidence interval in mass production largely depends on the glass composition of interest, the composition uncertainty, and the viscosity level. The mixed alkali effect for the viscosity is derived from nonlinear alkali-silica interactions in binary systems.
Zinc and lead-bearing metallurgical dust (ZLMD) exhibit strong desulfuration ability due to their higher content of metal oxides, such as Fe2O3, ZnO, PbO and CaO. In present work, their performances as a sulfur absorbent used in the combustion process of briquette, which is made up of coal and ZLMD, are investigated. Experimental results show that a large part of H2S and a small part of COS, CS2 are volatilized from briquette and react with ZnO and PbO to form ZnS and PbS at the earlier stage of combustion, and that O2 oxidizes FeS2 to form SO2 at the later stage. The adsorption reaction of sulfur depends on the content of CaO. ZnO, ZnS and CaSO4 are stable during the combustion process at temperatures lower than 1100 °C. When the weight percent of ZLMD in the briquette is kept at around 2.5%, and sulfur in coal at around 2.1%, the absorption efficiency of sulfur can reach 90%. These results suggest that utilizing ZLMD as a sulfur absorbent in the combustion process of briquette is a cheap and highly efficient method to treat both ZLMD and toxic emission such as H2S/SO2 released during briquette combustion processes.
This paper presents the results of an investigation for the possible uses of electric-arc furnace dust (EAFD) by-product in concrete manufacturing. The effects of EAFD on the properties of fresh and hardened concrete are investigated. The results of standard tests on fresh concrete indicate that EAFD can be used as an effective set retarder. In addition, other standard tests appear to indicate that EAFD will enhance engineering properties of hardened concrete without any side-effects.
The present paper is the first of a series of two articles dealing with the development of an integrated process for the recovery of zinc from electric arc furnace dust (EAFD), a hazardous industrial waste generated in the collection of particulate material during steelmaking process via electric arc furnace. Part I presents the EAFD characterization and its leaching process by diluted sulphuric acid, whereas Part II deals with the purification of the leach liquor and the recovery of zinc by solvent extraction/electrowinning. The characterization of the examined electric arc furnace dust was carried out by using granulometry analysis, chemical analysis, X-ray diffraction (XRD), thermogravimetric/differential thermal analysis (TG/DTA) and scanning electron microscopy (SEM). The leaching process was based on the Zn extraction with diluted sulphuric acid from EAFD under atmospheric conditions and without using any preliminary treatment. Statistical design and analysis of experiments were used, in order to determine the main effects and interactions of the leaching process factors, which were: acid normality, temperature and solid to liquid ratio. The zinc recovery efficiency on the basis of EAFD weight reached 80%. X-ray diffraction and scanning electron microscopy were used for the characterization of the leached residues.
This work evaluates the feasibility of incorporating electric arc furnace dust (EAFD), as filler in a polymer matrix, to obtain a moldable heavyweight sheet, useful for acoustic insulation in automotive industry. For this purpose EAFD from a steel factory that manufactures high quality steels, was characterized and different formulations of composites were prepared. Physical and mechanical properties, as well as fire behaviour were tested and compared with a polymer composite compounded with common mineral fillers. Optimum formulation with 25% EAFD fulfils the RoHs Directive used by automotive industry to regulate heavy metals content. Leaching test was also performed on prepared composites to classify the material after use.
A study on laboratory scale to evaluate the environmental compatibility of electric arc furnace dust (EAFD) is reported in this article. EAFD, a waste by-product of the steel-making process, was generated on a steel plant located in Brazil. Different leaching tests, NBR10005 (Brazilian), AFNORX31-210 (French), JST-13 (Japanese), DIN38414-S4 (German), TCLP (American), and NEN 7343 (Netherland) were conducted. These leaching procedures are batch tests and are columns conducted in a way that an equilibrium condition should be achieved. The pH of the medium showed a crucial parameter governing the release of metals from the solid phase into solution. As the pH of the medium varies with the leachant used, this determines the dissolution of the elements. Zn, Pb, Mn, Cd, and Cu presented high leachability at NBR10005 procedures (acid pH). Except Pb and Cr, the leachability of all others metals in leaching tests with alkaline pH decreases with the increase of the pH. NBR10005 classifies the EAFD as a hazardous waste due to high concentration of Pb and Cd in leachate. The column tests are presented in the following order of leaching: Pb>Cr>Zn>Mn>Cu>Cd.
The application of class F fly ash, cement and lime to the Stabilization/Solidification (S/S) of electric arc furnace dust containing hazardous metals such as Zn, Pb, Cd, and Cr is described. The aim of the study was to determine the influence of the setting conditions during the S/S treatment and to know the behaviour of an aged solidified and stabilized waste. In order to determine the efficiency attained by the S/S process, USEPA TCLP, and other leaching tests have been accomplished. In addition, the compressive strength of the solidified waste at different times has been determined. In order to study the influence of the environmental conditions in which setting occurs, experiments were carried out with samples of the same composition, under different setting conditions: laboratory environment, stove at a temperature of 40-60 degrees C and setting in a hermetically sealed plastic bag at room temperature. All the samples were subjected to the TCLP test at 28 days, and the metal content of the resulting leachates was analysed. The results show that in some cases the setting conditions of the mixtures have a noticeable influence on the characteristics of the leachate. The evolution with time of some S/S solids, one month after their manufacture and more than 9 years after that has also been evaluated, by means of their leaching behaviour. The results obtained in this work have shown, in all the laboratory cured samples that the leachate pH decrease in the course of time, and consequently the leaching behaviour is in general worse. This could be due to the carbonation of the S/S solid and the subsequent loss of alkalinity.
Metallurgical Furnace Flue Gas Negative Energy Dust Removing Exhaust Heat Recovering Method and Special Purpose Equipment, US Patent CN 101264404 A
- Wuxi Hans-Jorg
- B Gunter
- K Hans
- V J Wenze
G. Wuxi, Metallurgical Furnace Flue Gas Negative Energy Dust
Removing Exhaust Heat Recovering Method and Special Purpose
Equipment, US Patent CN 101264404 A, 2008.
[14] B. Hans-Jorg, B. Gunter, K. Hans, V.J. Wenze, Method of Removing
Sulfur Dioxide from a Dust Containing Exhaust Gas Stream. US Patent
3914387 A, 1974.
Recycling of blast furnace sludge into clayey ceramics
- S N Monteiro
- C A C M Dias
- A V Mothe
- C M F Vieira
S.N.Monteiro, C.A.C.M. Dias, A.V. Mothe, C.M.F. Vieira, Recycling of
blast furnace sludge into clayey ceramics, In: TMS 2007 136th Annual
Meeting & Exhibition (2007), Orlando. In: Extraction, Processing,
Structure and Properties Proceedings. TMS (The Minerals, Metals &
Materials Society) (2007) 21-27.
Solid Wastes: Classification
NBR 10.004, Solid Wastes: Classification. Rio de Janeiro. (2004) 71
(In Portuguese).
Industrial and Municipal Wastes Utilization as Economical and Environment Efficient Raw Materials
- V Mymrin
V. Mymrin, Industrial and Municipal Wastes Utilization as Economical
and Environment Efficient Raw Materials, 2012, 〈http://paginapessoal.
utfpr.edu.br/mymrinev〉.
Ceramic Solid Brick for Masonry—Specification
NBR 7170, Ceramic Solid Brick for Masonry—Specification, Rio de
Janeiro (1983) 4 (In Portuguese).
Flexural Rupture Strength Measurement and Water Adsorption Measurements of Ceramic Bricks
NBR 15270-3, Flexural Rupture Strength Measurement and Water
Adsorption Measurements of Ceramic Bricks, Rio de Janeiro. (2005)
(In Portuguese).
EAFD recycling-a new source of pig iron
- A Woollett
- P Minet
A. Woollett, P. Minet, EAFD recycling-a new source of pig iron,
Intern.Pig. Iron Ass., 2007, 〈http://www.metallics.org.uk/PDF_library/
EAFD%20 Recycling. pdf〉.
Appearance of the samples of various compositions of developed ceramic materials with dimensions 6 Â 2 cm
- Fig
Fig. 10. Appearance of the samples of various compositions of developed ceramic materials with dimensions 6 Â 2 cm.
Metallurgical Furnace Flue Gas Negative Energy Dust Removing Exhaust Heat Recovering Method and Special Purpose Equipment, US Patent CN 101264404 A
- G Wuxi
G. Wuxi, Metallurgical Furnace Flue Gas Negative Energy Dust
Removing Exhaust Heat Recovering Method and Special Purpose
Equipment, US Patent CN 101264404 A, 2008.
Method of Removing Sulfur Dioxide from a Dust Containing Exhaust Gas Stream. US Patent 3914387 A
- B Hans-Jorg
- B Gunter
- K Hans
- V J Wenze
B. Hans-Jorg, B. Gunter, K. Hans, V.J. Wenze, Method of Removing
Sulfur Dioxide from a Dust Containing Exhaust Gas Stream. US Patent
3914387 A, 1974.