Industrial Waste Research Articles

FA-GGBFS based geopolymer concrete incorporating CMRW and SS as fine and coarse aggregates

Abstract Geopolymer concrete, which utilizes aluminosilicate precursor materials such as metakaolin, volcanic ash, industrial solid waste including fly ash and ground granulated blast furnace slag as a binder, is an eco-friendly alternative to Portland cement concrete. Although geopolymer concrete does not use cement, it still has shortcomings in terms of environmental friendliness because the aggregates (fine and coarse) used to prepare geopolymer concrete are natural resources and their excessive use in concrete manufacturing leads to natural resource depletion. In view of this, several researchers have tried to replace natural aggregates with various waste materials, which not only conserves natural resources but also helps in waste management. In the present study, the potential of steel slag and coal mine rock waste as a substitute for coarse and fine aggregates in geopolymer concrete to make it truly green is experimentally evaluated. The use of steel slag and coal mine rock waste as coarse and fine aggregates in geopolymer concrete was observed to significantly improve its strength and durability properties compared to fly ash based geopolymer concrete.

Environmental Management in Coal Mining Companies Utilizing Wooden Pallet Waste with Wood Chipper Machines for Hydrocarbon Spill Absorbent in Maintenance Activities

Wooden pallets often accumulate as waste, potentially causing environmental problems such as pest infestation, soil and water pollution, and large-scale waste accumulation. Efficient waste management methods such as recycling are needed to reduce these impacts, especially in industrial environments. This study aims to explore the potential utilization of wood pallet waste as a hydrocarbon spill sorbent through processing with wood cutting machines at PT AMM Jobsite Mifa Bersaudara. This research involves the collection and processing of wood pallet waste using a wood chipper machine. The process includes sorting, cleaning, crushing, and packaging wood waste into powder. The tools and materials used are wood pallet shredder, hammer, crowbar, and personal protective equipment. This research follows a systematic flow from problem identification to evaluation and analysis of results. Results of the study showed that the application of wood pallet shredder machine significantly reduced the volume of wood pallet waste. From January to May 2024, the unutilized waste accumulated to 4.67 tons. After introducing the shredding process in June and July 2024, waste utilization increased, achieving an 80% reduction in solid waste. The processed wood powder was effectively used to absorb hydrocarbon spills, optimize resource use, and reduce disposal costs. This research has implications for the feasibility of converting industrial wood waste into useful products, contributing to environmental conservation and cost efficiency. It emphasizes the importance of sustainable waste management practices in reducing the environmental footprint of industrial activities while fostering employee awareness on environmental protection.

Properties of alkali activated cellular lightweight binder blocks with industrial and agro waste

The construction industry is continuously seeking sustainable alternatives to conventional building materials. Alkali-Activated Cellular Lightweight Binder Blocks (AACLBs) present a promising solution by utilizing alkali activation technology to augment the properties of lightweight concrete. This research focuses on optimizing the composition of AACLBs by replacing conventional binders with alkali-activated materials derived from industrial by-products and agro waste with the help of a protein based foaming agent (FA). The industrial waste materials investigated include Fly Ash (F) and Blast Furnace Slag (BFS) while agro waste such as Rice Husk Ash (RHA) are considered as sustainable alternatives. With Sodium Hydroxide (NaOH) and Sodium Silicate (Na2SiO3) as activators, 8 different combinations are adopted in this study. Properties such as density and compressive strength (CS) are analyzed to assess the structural capabilities of the AACLBs and are compared with that of cement-based blends. The alkaline solution to binder ratio is kept constant as 2.5 for two dilution ratios (1:30 & 1:60) and ambient curing is adopted. The target densities for conventional cement-based mixes are set as 1200–1600 kg/m3 and 1500–1800 kg/m3 for alkali-based mixes. The findings show that, the highest CS of 42.76 MPa and a density of 1870 kg/m3 is observed for FB1 combination at a dilution ratio of 1:30. Conversely, the FBR2 combination at a dilution ratio of 1:60 yielded a CS of 21.23 MPa, accompanied by a minimum density of 988 kg/m3.

Effects of waste glass dust incorporation on the tribological performance of flax-epoxy hybrid composites

Waste glass dust, an industrial waste, generated in the glass-cutting industries, is considered carcinogenic and poses health risks as it is high in silica content. This research essentially explores the alternative use of these waste glass dust as functional fillers in fabricating wear-resistant hybrid polymer composites. It includes fabrication of the hybrid epoxy composites in hand lay-up route with varying weight fractions (0–0.2) of the waste glass dust along with the flax fiber (30 wt. %) and their dry sliding wear behavior is observed. Test sample preparation follows ASTM-G99–05 standard and experiments are conducted considering Taguchi's L25 design. Significant improvement in the wear resistance of the hybrid composites is obtained after incorporating the waste glass dust and flax fibers. Filler content is found to be the most effective factor in affecting the wear rate followed by the sliding velocity during the Taguchi analysis with respective contributions of 54.51% and 38.59% as obtained from the ANOVA analysis of the wear results. Normal load and sliding distance are found to affect marginally the wear rates of the composites. A predictive model is proposed to find the specific wear rate (SWR) using the test results through the regression analysis. The minimum wear rate is obtained for 20 wt. % of filler, 1000 m of sliding distance, 50 cm/sec of sliding velocity, and 10 N of load. The mechanisms predominantly responsible for the wear loss have also been studied using a scanning electron microscope.

Optimizing floor tile design in residential spaces using nesting algorithm and multi-objective optimization with BIM data

This study presents an innovative strategy for optimizing floor tile arrangements, addressing the high demand for tiles and the environmental challenges posed by the tile manufacturing process. By utilizing the nesting algorithm and multi-objective optimization with data from Building Information Modeling (BIM), this approach bridges the gap between efficient design and practical application. The proposed method allows for the optimization of floor tiling based on multiple objectives and construction drawings, offering a practical framework that reduces waste and environmental impact in tile manufacturing and installation. This solution has the potential to significantly decrease material waste, leading to both cost savings and environmental benefits.

Unveiling the Potential of Civil Briquette Furnace Slag as a Silico–Aluminon Additive in Alkali-Activated Materials

Civil briquette furnace slag (FS), as a type of industrial solid waste, is not currently being recycled as a resource by the building materials industry. This study focuses on the potential of FS in the formulation of alkali-activated materials (AAMs) compared with calcium carbide slag (CS). This study encompasses three distinct AAM systems: alkali-activated fly ash alone (AAFA), fly ash–slag powder blends (AAFB), and slag powder alone (AABS). Electrical conductivity, fluidity, drying shrinkage, and flexural and compressive strengths were also assessed. Advanced characterization techniques, including SEM-EDS, XRD, FTIR, and TG-DSC, were utilized to examine the morphology, mineralogy, and reaction products. Despite the chemical similarity between FS and CS, FS exhibits limited active chemical components (SiO2, Al2O3, CaO, and MgO) and primarily functions as a physical filler, and thus lacks the chemical binding properties of CS. FS has a positive effect on the long-term compressive strength of the AABS system but not on the AAFA and AAFB systems. The NaOH-activated SP mortar sample with 20% FS reaches a compressive strength of 29.8 MPa at 360 days. The binding strength in AAMs incorporating FS is predominantly attributed to the gel formation within the alkali-activated matrix. This research offers valuable insights into the strategic use and substitution of CS, FS, and other silico–aluminon additives within the context of AAMs development.

Strength and Durability of Paving Block with Seawater and POFA (Palm Oil Fuel Ash)

Seawater has the potential to replace fresh water in the production of concrete. Given the restricted availability of freshwater sources and the high cost of transportation, it is crucial to optimize this scenario. On the other hand, agricultural residue is a potential material that can replace cement-based materials, thereby reducing CO2 emissions. Sustainability in the concrete sector is important, hence, research on using alternative renewable resources such as palm oil fuel ash (POFA) for concrete production is necessary. POFA is an agricultural byproduct and industrial waste that is potentially used as a partial substitution for cement due to the presence of pozzolan. The objective of this study is to examine the impact of icluding POFA (Palm Oil Fuel Ash) as a substitute in the paving block, while also considering the influence of seawater mixing and curing water. Further, POFA is used as a supplementary binder for paving blocks at 0%, 10%, 20%, 30%, 40%, and 50% for Portland Composite Cement replacement. The paving blocks properties, such as workability, density, compressive strength, water absorption, and resistance to sulfate attack, were evaluated. The results of the tests confirmed that 10% POFA mixed with seawater and cured with freshwater met the minimum necessity for Class B, as specified by the Indonesian National Standard for parking park applications. As a result of incorporating POFA as a cement replacement, a more environmentally friendly paving block could be established.

Parametric analysis and prediction of dry adhesive wear characteristics of waste glass dust filled hemp-epoxy composites

Waste glass dust, an industrial waste, generated in the glass cutting industries, is carcinogenic and possesses health risk due to high silica content. As an attempt to gainfully utilize this, the possibility of using this waste glass dust as a functional filler in wear-resistant polymer composites is explored. It includes fabrication of epoxy composites in hand lay-up route with varying weight fractions (0–0.2) of the waste glass dust along with multiple layers of hemp fiber. The dry sliding wear behavior of these composites under different test conditions are studied. ASTM G99-05 standard is followed for preparing the test samples and experiments are conducted as per Taguchi’s L25 design. Wear resistance is significantly improved with addition of the filler. Among the control parameters, the filler content is the most effective factor influencing the wear rate and next comes the sliding velocity as obtained from the ANOVA and Taguchi analysis. A predictive model is proposed to find the specific wear rate (SWR). The minimum wear rate is obtained for 20 wt. % of filler, 250 m sliding distance, 50 cm/sec sliding velocity and 10 N load. The mechanisms predominantly responsible for the wear loss have also been studied using a scanning electron microscope.

The Use of Diatomite-Based Composites for the Immobilization of Toxic Heavy Metals in Industrial Wastes Using Post-Flotation Sediment as an Example

Composite materials based on diatomite (DT) with the addition of biochar (BC), dolomite (DL), and bentonite (BN) were developed. The effect of chemical modification on the chemical structure of the resulting composites was investigated, and their influence on heavy metal immobilization and the ecotoxicity of post-flotation sediments was evaluated. It was demonstrated that the chemical modifications resulted in notable alterations to the chemical properties of the composites compared to pure DT and mixtures of DT with BC, DL, and BN. An increase in negative charge was observed in all variants. The addition of BC introduced valuable chemically and thermally resistant organic components into the composite. Among the chemical modifications, composites with the addition of perlite exhibited the lowest values of negative surface charge, which was attributed to the dissolution and transformation of silicon compounds and traces of kaolinite during their initial etching with sodium hydroxide. The materials exhibited varying efficiencies in metal immobilization, which is determined by both the type of DT additive and the type of chemical modification applied. The greatest efficacy in reducing the mobility of heavy metals was observed in the PFS with the addition of DT and BC without modification and with the addition of DT and BC after the modification of H2SO4 and H2O2: Cd 8% and 6%; Cr 71% and 69%; Cu 12% and 14%; Ni 10% and Zn 15%; and 4% and 5%. In addition, for Zn and Pb, good efficacy in reducing the content of mobile forms of these elements was observed for DT and DL without appropriate modification: 4% and 20%. The highest reduction in ecotoxicity was observed in the PFS with the addition of DT and BC, followed by BN and DL, which demonstrated comparable efficacy to materials with DT and BN.

Evaluating the sustainability of biohydrogen, biogas, and biohythane generation from agricultural, industrial, and municipal waste sources

AbstractBiofuel production from waste materials offers an effective solution for generating renewable energy in biohydrogen, biogas, and biohythane while reducing waste and recycling valuable nutrients. This review examines recent advances in biohydrogen and biogas production from renewable resources, focusing on the environmental impacts of different production techniques. It emphasizes life cycle analysis (LCA) as an important tool for assessing these impacts and discusses key production pathways and processes. The variability in LCA methodologies – including differences in software, impact categories, system boundaries, functional units, and analytical approaches – poses challenges for direct comparisons of studies. Despite these challenges, fermentation‐based production methods show substantial environmental advantages, such as reduced CO2 emissions, diminished ozone depletion potential, improved human health outcomes, lower ecotoxicity, and reduced fossil fuel use. Combining biohydrogen production with anaerobic digestion for biohythane generation demonstrates even greater energy efficiency and greenhouse gas reduction. Adopting waste‐to‐energy strategies grounded in life cycle principles could advance renewable energy system implementation and sustainability significantly.

Utilization of graphite tailings and coal gangue in the preparation of foamed ceramics

AbstractTo enhance the effective utilization of graphite tailings and coal gangue (CG), both considered typical industrial solid waste materials, we synthesized foamed ceramics incorporating these materials. The optimization process led to improvements in compressive strength, water absorption, and thermal conductivity by regulating critical parameters, including the proportions of SiC and Na2O, as well as the duration of ball milling. Employing techniques such as X‐ray diffraction, thermogravimetric analysis, and differential scanning calorimetry, we investigated the phase composition, high‐temperature reactions, and microstructural characteristics of the foamed ceramics. The incorporation of graphite tailings (GT) facilitated the formation of a rich network of pore structures and amorphous glass phases, which enhanced the lightweight nature, mechanical strength, and thermal insulation properties of the foamed ceramics. By analyzing the GT content as a variable, we determined that the G50C40 (GT:CG:potassium feldspar = 40:50:10) sample exhibited optimal performance overall. Under these experimental conditions, the foamed ceramic demonstrated a bulk density of 0.749 g/cm3, a compressive strength of 12.37 MPa, a thermal conductivity of 0.21 W/(m·K), and a water absorption rate of 0.79%. Therefore, it is posited that GT possesses considerable potential to broaden the application spectrum of foamed ceramics within the domain of building insulation materials.

Heavy metal detection in industrial waste water using Ficus Benjamina leaf extract–mediated Ag nanoparticles

Heavy metal detection in industrial waste water using Ficus Benjamina leaf extract–mediated Ag nanoparticles

Numerical simulation of heat transfer processes in shell and tube phase change heat exchangers for recovering industrial waste heat

Abstract This article combines phase change energy storage technology with shell and tube heat storage and exchange devices to establish a three-dimensional numerical model of the shell and tube phase change heat storage and exchange device. The hexahedral structured grid division is used to make the simulation results more accurate. Combined with the computational fluid dynamics software Fluent and the related principles of phase change heat transfer, the effects of different heat transfer fluid temperatures and flow rates on the phase change process of phase change materials and the fluid outlet temperature in the phase change heat exchanger were numerically simulated. The results show that under the set parameters, when the inlet water temperature increases from 70℃ to 90℃, the time required for the outlet temperature to increase from 20℃ to 60℃ is shortened by 23%, while when the temperature is constant, the inlet temperature of heat transfer fluid is shortened by 69%. Analysis shows that the influence of the inlet temperature of the heat transfer fluid on the heat storage and release of phase change materials is significantly greater than the inlet flow rate.

Effect of Starch-Based Adhesives in the Production of Plaster Casts from Industrial Waste

In this work, the waste gypsum from industry is repurposed to add value in the medical field by transforming it into Plaster cast. The waste gypsum or calcium sulfate dihydrate is heated to a temperature of 120 °C for three hours to obtain calcium sulfate hemihydrate or Plaster of Paris. Subsequently, it is mixed with water in a 1:1 ratio before embedded on gauze. To enhance the strength of the plaster cast, different types of starch-based adhesives are mixed with plaster solution to investigate their impact on shaping and the strength of the plaster. Three types of starch, including potato starch, tapioca starch, and cornstarch, are utilized. After testing the strength of plaster cast mixed with adhesive starch, it is found that with 5% potato starch, the plaster cast exhibits the highest strength among all variants. In addition, its result from SEM indicated that the potato starch was distributed and packed tightly onto gauze.

Microstructure Analysis of Different NaOH Molarity Towards Fly Ash Geopolymer for Underwater Concreting Material

Geopolymer concrete is a new sustainable and environmentally friendly composite with great potential to replace conventional concrete that is mostly produced by ordinary Portland cement (OPC). Binders used for geopolymer concrete such as fly ash and blast furnaces are mostly industrial wastes or by -products containing high silica and aluminium content that act as stimulants for geopolymerization. Furthermore, geopolymers also exhibit better durability and corrosion resistance than OPCs. However, material subjected to underwater placement method typically exhibit a decrease in properties. While geopolymer has not been widely used as underwater concreting material, this research is purposed to identify the effect of underwater placement method towards geopolymer in terms of microstructure analysis. Using different molarities of sodium hydroxide (NaOH), the optimum compressive strength will be discussed for underwater concrete while correlating with the microstructure result. For alkaline activators, the ratio used is 2.5 and the ratio for solid to liquid is 2.5. The molarities used for alkaline activators were 8 M, 10 M and 12 M. Using the tremie method for underwater concrete, it is possible to measure the leaching loss with respect to the objective of this research. The best compressive strength result is 12 M. The SEM result support with 12 M molarity had less cavities and lowest density.

A Comparative Review on Low-Cost Adsorbent based Alkali-Activated Materials by Adsorption Study

The degradation of the condition of wastewater is becoming more and more serious due to the endless development. One of the main reasons is heavy metal contamination, which causes significant harm to the climate and humanity, such as bad health consequences, environmental degradation, and air pollution. Adsorption, which uses proven adsorbents such as activated carbon, is one of the most common methods for heavy metal removal in wastewater. However, since activated carbon is very expensive to build and repair due to complex production, most people choose another material to overcome this problem. Researchers have recently focused on finding low-cost adsorbents, which are typically industrial, agricultural and food wastes that can generate in large quantities. However, Alkali-Activated Materials (AAMs) have been recognized as a novel possible adsorbent because they are cheap, made from solid aluminosilicate and extremely alkaline activator solution, making them appropriate for usage in the civil engineering specialty. Moreover, they have become an option for various applications due to their unique geopolymer structure, which is highly mechanically, chemically and thermally stable. Hydroxyapatite (HAP) can be extremely useful in this application, as it is a promising biomaterial that has great potential for a low-cost AAMs adsorbent. The purpose of this study is to analyze the present development of a potential economic alternative adsorbent, particularly based on alkali-activated materials (known as geopolymers), for the elimination of heavy metal pollutants in wastewater using adsorption techniques.

Properties of Artificial Lightweight Aggregates from Various Pozzolan Materials – A Review

The use of lightweight aggregate can bring advantages to the construction field. Lightweight aggregate has been used due to its lower density and can reduce the dead load applied to the structural elements. Due to the number of natural resources, such as natural aggregate having decreased, producing lightweight aggregate from industrial waste materials can overcome the problem. Different methods produce lightweight aggregates, such as sintering, cold bonding, and autoclaving. From earlier studies, spherical sintered lightweight aggregate can manufacture structural concrete. Using artificial lightweight aggregate in concrete can achieve the minimum strength requirement of structural concrete and has been applied in the construction field. The properties of lightweight aggregate, such as specific gravity, water absorption, crushing strength, and impact value, are reviewed. Besides that, the mechanical and thermal properties review is also important for using lightweight aggregate in concrete. The review also indicates that aggregate produced using the cold bonding method and autoclaving method potential can be used in the concrete.

Effects of Fine Particle Size on the Characteristics of Coal Bottom Ash as an Environmentally Friendly Material in Concrete Production

In the current era, concern about the responsible disposal of industrial waste and its reuse has increased in all societies from the industry. Therefore, the researchers’ institution is focusing its efforts on developing more environmentally friendly products from recycled waste, particularly in the area of sustainable construction. For instance, one of recycled waste is Coal Bottom Ash (CBA), a by-product of coal combustion that is produced in large quantities from thermal power plants. The aims of this study to investigate the physical, chemical and element characteristics of CBA obtained from thermal power plant in Malaysia. Also, CBA compared with cement characteristics to be used as cement replacement in the concrete mixture. Therefore, numerous tests have been performed to investigate CBA’s physical and chemical characteristics. For physical properties such as specific gravity, particle size analysis, fineness modulus, bulk density and loss on ignition. For chemical properties such as X-ray fluorescence (XRF), X-ray diffraction (XRD), Fourier transform infrared spectroscopy (FTIR) and thermogravimetric analysis (TGA) in an effort to obtain sustainable materials from thermal power plant waste. Based on the findings in this study, it can be concluded that CBA can be utilized as cement substitute in the production of concrete mixtures.

The Effects of CaO and MgO on Thermal, Mechanical and Optical Properties of Porcelain Tiles by Utilizing Blast Furnace Slag

In this study, the Blast Furnace Slag (BFS) of Zonguldak Eregli Iron and Steel Factories was used as a recycling raw material for the porcelain tile samples. A kind of clay with high MgO content was also used in the porcelain tile recipes. Maximum 10% of BFS was used instead of Na-feldspar. Sintering temperature for all samples was 1205°C for 50 minutes in the industrial roller kiln. Technological properties such as shrinkage, water absorption, colour measurement, and flexural strength were investigated as well as sintering properties and microstructures of the green and the sintered samples. As a result of the study, the addition of BFS did not adversely affect the technical properties of porcelain tile bodies. Particularly, the addition of BFS up to 3% contributed to an increase in flexural strength, and whiteness values of all samples increased because of the formation of anorthite and diopside compared to the reference body. The phase transformations and crystal formations such as anorthite and diopside resulted in a decrease in the firing shrinkage. Although the anorthite formation and diopside formation in the investigated samples had an adverse effect on condensation, it was found that they showed similar sintering behaviours compared to the reference body. This study showed that an industrial waste material can be converted into an environmentally friendly raw material that can create added value and provide energy efficiency.

Use Of Aerogel In Brick Production: A Review

Brick is one of the building materials that has survived from the past to the present. It has not been able to meet the needs over time and has been improved. These improvements can be made with organic waste, industrial waste or new materials derived from them. One of the popular materials used for improvement in recent years is aerogel. Aerogel, which is used in many areas, has also started to be used in the construction industry. In this study, it was aimed to investigate the effects of aerogel on bricks by examining the studies on brick improvement with aerogel. In the study, articles and theses about aerogel were examined. As a result of the study, it was seen that aerogel improved some properties of the brick while negatively affecting some of its properties. It was also concluded that aerogel can be used in the re-functionalization of heritage structures. It has been determined that sustainable bricks with excellent thermal properties can be produced by using aerogel.