Eco-Efficient Artificial Stones Produced Using Quartzite Quarry Waste and Vegetable Resin

Abstract

The ornamental stone industry plays a crucial role in the world economy, and thus the production process of ornamental stones generates a large volume of waste that is normally destined for landfills. Given the growing market import of artificial stones, there is a need for more sustainable practices to reduce waste and improve the use of natural resources. Thus, the present study aims to develop artificial stones with waste from the ornamental stone extraction process from the quarry, and vegetable polyurethane resin derived from castor oil, in order to analyze its viability in the production of artificial stone slabs. The wastes used in this work were three quartzites, fragmented and mixed with three grain sizes, called coarse, medium, and fine. These wastes were characterized using X-ray fluorescence (XRF), X-ray diffraction (XRD), Fourier transform infrared (FTIR), and thermal analysis (TGA/DTG/DSC). Artificial stone slabs were produced using 15 wt.% vegetable polyurethane resin derived from castor oil and 85 wt.% ornamental stone wastes (quartzite). These slabs underwent apparent density, water absorption, porosity, 3-point flexural strength, scanning electron microscopy (SEM), petrography, and X-ray diffraction (XRD) tests. According to the results obtained, it was possible to prove the technical viability of manufacturing artificial stones with ornamental stone wastes and with the use of vegetable polyurethane resin derived from castor oil. The use of these raw materials not only resulted in the manufacture of a new material but also in an environmentally conscious and sustainable approach, following precepts such as the circular economy. The creation of these eco-efficient products is a significant contribution to the search for solutions that value environmental preservation and the optimization of natural resources.