Recycling PC and TV waste glass in clay bricks and roof tiles

Hazardous element inertisation in vitrified silicate ceramics: Effect of different matrices

The ceramic industry is a production sector that can efficiently recycle its own processing residues, achieving a reuse index of almost 100%. Recently, the range of waste from other industrial sectors that can be used as secondary raw materials in ceramic bodies has expanded. However, such an expansion potentially introduces hazardous components. This study aimed to quantitatively assess the efficiency of inertising hazardous elements (HEs) through ceramisation. The ceramics were characterised through XRPD, SEM-EDS and leaching tests to determine their leaching behaviour and the mechanisms of element immobilisation in neoformation phases during the ceramisation process. The results indicate high immobilisation efficiency for Ba, Co, Cr, Cu, Pb, Sb, Sn and Zn. However, Mo is the main element of concern owing to its poor retention in ceramic bodies. This is likely due to the formation of oxyanionic complexes that are difficult to immobilise in silicate matrices. In addition, the ceramic bodies exhibit substantial differences that appear to be associated with variations in pseudo-structural components and the degree of polymerisation of their vitreous phase.

Applications of Recycled and Crushed Glass (RCG) as a Substitute for Natural Materials in Various Fields-A Review

Glass is a substance that is present in most houses since glass-based items are made and consumed in relatively high quantities. This has led to the buildup of glass in concerning quantities all over the world, which is a problem for the environment. It is well known that glass has several advantageous physiochemical features that qualify it as an appropriate material for use in the construction industry as an aggregate. The features include being non-biodegradable, resistant to chemical assault, having low water absorption, having high hydraulic conductivity, having temperature-dependent ductility, having alterable particle gradation, and having a wide availability in a variety of forms and chemical compositions. Because of these qualities, glass has been used in various investigations and field tests conducted in civil engineering to evaluate its effectiveness as an engineering aggregate and to develop environmentally friendly management strategies for waste glass. These studies and research have utilized glass in various forms, such as fine recycled glass, medium recycled glass, coarse recycled glass, powdered glass, and glass-based geopolymers. This study focuses on research studies that present results on physicochemical, mechanical, and durability characteristics. These studies and research contain samples of pure glass or glass as replacement percentages in materials (0-100%), including but not limited to unbound granular materials (such as recycled concrete aggregates and crushed rock). In light of the information assembled in this review article, it is legitimate to claim that glass has strong promise as a material in various civil applications.

Recycling of Iron Slag Waste in the Production of Ceramic Roof Tiles

The merit of this study is manufacturing cheaper roof tiles using fluxed waste material such as granulated iron slag, in addition to the environmental benefit of decreasing the cost and negative impact of their disposal and landfilling. Waste water-cooled granulated iron slag was ground and added in proportions ranging from 0 to 30 wt.% to kaolin clay to prepare roof tiles for the economic purpose of decreasing the production cost by incorporating cheap waste and to serve sustainability. The raw materials were characterized by XRD, XRF, and particle size analysis. The specimens were shaped using a rectangular mould with dimensions of 150 × 30 × 30 mm3 under an axial pressure of 10 MPa and then dried in a dryer at 110°C. The firing of the dried specimens was carried out at 900, 1000, and 1100°C. The characteristics of fired specimens were determined by their linear firing shrinkage, water absorption, compressive strength, and freezing-thawing resistance. Results showed that samples containing 20% slag waste and fired at 1000°C displayed a cold water absorption of 12% and a saturation coefficient of 0.82, both values being lower than the maximum value recommended by standards. Also, the recorded breaking strength of 5040 N was much higher than the minimum standard value. These samples were also subjected to 50 freeze-thawing cycles, which they passed without the appearance of any cracks. It was concluded that samples containing 20% slag waste and fired to 1000°C or 1100°C fulfilled the requisites of ASTM C1167 for grade 3 normal duty roof tiles.

Preparation of hydrothermally solidified materials from waste cathode ray tube panel glass for construction applications

Solidification of cathode ray tube (CRT) panel glass was carried out using a hydrothermal processing method. In this way, the glass powder was first compacted in a mold at 20 MPa, and then hydrothermally cured in an autoclave under saturated steam pressure at 200 ℃ for 6 h. The CRT panel glass was then hydrothermally solidified by the formation of tobermorite (Ca₅Si₆O₁₆(OH)₂·4H₂O), which was encouraged by the addition of slaked lime (Ca(OH)₂). The strength of solidified specimen heavily depended on the amount of tobermorite formed, with higher concentrations of tobermorite producing commensurately greater mechanical strength. With the addition of Ca(OH)₂ at 20-30% by mass, the specimen achieved a bending strength of approximately 16 MPa, which was sufficiently great for using as a construction material. As such, there is cause to believe that the hydrothermal processing method used here may have great potential for resource utilization of CRT panel glass, and the performance of the product is suitable for use as building materials.

Potential for Use of Recycled Cathode Ray Tube Glass in Making Concrete Blocks and Paving Flags

The potential to use waste glass, including cathode ray tube (CRT) glass, for making new products or as an admixture to existing ones is being intensively investigated. This kind of research intensified particularly in the period after CRT TV sets and computer monitors were replaced in the market by the advanced technology of thin film transistor (TFT) and liquid crystal display (LCD) screens. Cathode ray tube glass represents a considerable part of electronic waste (e-waste). E-waste globally increases at a far higher rate than other solid waste materials. There is a possibility to recycle cathode ray tube glass and use it in the construction industry. This paper shows the test results of physical and mechanical properties of blocks and paving flags. The reference specimen was made with quartz sand, while the other product employed a combination of quartz sand and ground panel cathode ray tube glass. The glass was ground to the fraction 0.25/1.00 mm, which corresponds to quartz sand fineness. The following tests were performed: shape and dimensions, resistance to freeze/thaw and de-icing salts, water absorption, splitting tensile strength and tensile strength by bending. Special attention was paid to the tests of Böhme wear resistance, slip resistance of the top surface of CRT products using a pendulum, radioactivity and leaching. The texture of the experimental concrete products was observed by SEM (scanning electron microscopy) and analyzed. The results obtained by experimental testing unequivocally show that CRT glass can successfully be used for making concrete blocks and paving flags.

Ceramisation of hazardous elements: Benefits and pitfalls of the inertisation through silicate ceramics

The addition of wastes to silicate ceramics can considerably expand the compositional spectrum of raw materials with a possible inclusion of hazardous components. The present work quantitatively examines relevant literature to determine whether the benefits of incorporating hazardous elements (HEs) into silicate ceramics outweigh the pitfalls. The mobility of various HEs (Ba, Zn, Cu, Cr, Mo, As, Pb, Ni, and Cd) has been parameterised by three descriptors (immobilisation efficiency, mobilised fraction, and hazard quotient) using leaching data. HEs can be incorporated into both crystalline and glassy phases, depending on the ceramic body type. Moreover, silicate ceramics exhibit a remarkably high immobilisation efficiency (often exceeding 99.9%), as accomplished for Ba, Cd, Ni, and Zn elements. The pitfalls of the inertization process include an insufficient stabilisation of incorporated HEs, as indicated by the high hazard quotients (beyond the permissible limits established for inert materials) obtained in some cases for Mo, As, Cr, Pb, and Cu elements. Such behaviour is related to oxy-anionic complexes (Mo, As, Cr) that can form their own phases or are not linked to the tetrahedral framework of aluminosilicate glass. Pb and Cu elements are preferentially partitioned to glass with a low coordination number, while As and especially Mo are not always stabilised in silicate ceramics. These drawbacks necessitate conducting additional studies to develop appropriate inertisation strategies for these elements.

Recycling Crushed Waste Beer Bottle Glass in Fired Clay Bricks

Waste glass is a readily available domestic material. Each year, around 257,000 tonnes of glass waste are produced in Victoria, and the majority is glass packings. Typically, mixed waste glass cullet is deposited in landfills due to the limited recycling techniques. As a result, landfills are facing a growing issue. Therefore, this study investigates the addition of waste beer bottle glass (BG) in fired clay bricks and examines the effects of varying firing temperatures on the physical and mechanical properties of the manufactured samples. Clay bricks containing 10% BG at a firing temperature of 950 °C depicted similar compressive strength results (41 MPa) to the control samples (42 MPa). The results of all tested bricks were found to be below the water absorption limit of 17%. The thermal conductivity of the bricks incorporating BG was investigated, and it was found that the thermal performance improved with the decreasing firing temperature. Moreover, an initial rate of absorption (IRA), XRD, and XRF analysis was conducted. The experimental results have been discussed and compared with the recommended acceptable properties for standard bricks.

Utilization of Polymer Concrete Composites for a Circular Economy: A Comparative Review for Assessment of Recycling and Waste Utilization

Polymer composites have been identified as the most innovative and selective materials known in the 21st century. Presently, polymer concrete composites (PCC) made from industrial or agricultural waste are becoming more popular as the demand for high-strength concrete for various applications is increasing. Polymer concrete composites not only provide high strength properties but also provide specific characteristics, such as high durability, decreased drying shrinkage, reduced permeability, and chemical or heat resistance. This paper provides a detailed review of the utilization of polymer composites in the construction industry based on the circular economy model. This paper provides an updated and detailed report on the effects of polymer composites in concrete as supplementary cementitious materials and a comprehensive analysis of the existing literature on their utilization and the production of polymer composites. A detailed review of a variety of polymers, their qualities, performance, and classification, and various polymer composite production methods is given to select the best polymer composite materials for specific applications. PCCs have become a promising alternative for the reuse of waste materials due to their exceptional performance. Based on the findings of the studies evaluated, it can be concluded that more research is needed to provide a foundation for a regulatory structure for the acceptance of polymer composites.

Glass Cullet as Additive to New Sustainable Composites Based on Alumina Binder

The article investigated the possibility of reusing heat resistant glass cullet to improve the mechanical properties of high-temperature composites. This is an excellent recycled aggregate that may be used as a substitute for alumina cement, and for fine natural aggregate in the production of concrete based on hydraulic binder. The experimental programme comprised of strength testing conducted on 40 × 40 × 160 mm cuboidal samples. The model mixture was modified by filler that comprised glass recyclate, amounting to 5%, 10%, and 15% of the mass of gravel and cement. Given the degree of glass grounding, use was made of two fractions, 0/4 and 0/0.125 mm. Six modified mixtures were produced. Tests were then carried out on their selected physical and mechanical properties as well as the impact of temperature, topography, and chemical composition exerted on the composite. Next, the progress and development of compressive strength and flexural strength after 14 and 28 days of curing were studied. Results showed that concrete with a 5% content of glass dust had a maximum compressive strength at the level of 85.1 MPa. Results also showed that concrete (Zk.I.5) heated at a temperature of 500 °C had a 46% higher compressive strength when compared to basic concrete (Z.I.0). The results show that it is possible to use the described components to obtain a composite that meets requirements imposed on structural materials used in construction engineering.

Development of Geopolymers as Substitutes for Traditional Ceramics for Bricks with Chamotte and Biomass Bottom Ash

The greater environmental awareness, new environmental regulations and the optimization of resources make possible the development of sustainable materials as substitutes for the traditional materials used in construction. In this work, geopolymers were developed as substitutes to traditional ceramics for brick manufacture, using as raw materials: chamotte, as a source of aluminosilicate, and biomass bottom ashes from the combustion of almond shell and alpeorujo (by-product produced in the extraction of olive oil composed of solid parts of the olive and vegetable fats), as the alkaline activator. For the feasibility study, samples were made of all possible combinations of both residues from 100% chamotte to 100% biomass bottom ash. The tests carried out on these sample families were the usual physical tests for ceramic materials, notably the compression strength test, as well as colorimetric tests. The freezing test was also carried out to study the in-service behavior of the different sample groups. The families with acceptable results were subjected to Fourier transform infrared (FTIR) analysis. The results of the previous tests showed that the geopolymer was indeed created for the final families and that acceptable mechanical and aging properties were obtained according to European standards. Therefore, the possibility of creating geopolymers with chamotte and biomass bottom ashes as substitutes for conventional ceramics was confirmed, developing an economical, sustainable material, without major changes in equipment and of similar quality to those traditionally used for bricks.

Reuse of Heat Resistant Glass Cullet in Cement Composites Subjected to Thermal Load

The article describes the possibility of using waste glass cullet as an alternative aggregate for the production of cement composites. Three concrete mixes based on Portland cement CEM I 42.5 R with different contents of recyclate were designed. Borosilicate glass cullet was introduced into the batch by reducing the content of natural aggregate by 0%, 2.5% and 7.5%. Apparent density, water absorption and compressive strength at elevated temperature were measured. The temperature distribution, in cubic samples, was followed by thermocouples. The elements were heated in a special furnace at the temperatures of 200 °C, 400 °C, 600 °C and 800 °C. The composite topography and phase composition were observed using X-ray energy scattering electron microscopy. The results show that the appropriate modification of the cement composite with 2.5% heat-resistant glass cullet improves both the thermal and mechanical properties. Compressive strength reaches an average value of 48.6 MPa after 28 days. The increase in temperature weakens the structure of the composite. It was found that the obtained cement composite has good physico–chemical properties. The research results are presented in the article.

Utilization of Recycled Liquid Crystal Display (LCD) Panel Waste in Concrete

The paper presents the possibility of using the liquid crystal display (LCD) waste as a partial substitute of fine aggregate. Concretes with two types of cement, CEM I 42.5 R and CEM II/B-S 42.5 N, with and without LCD addition, were investigated. The properties that influence the structures exposed to severe environments were examined. The results and analyses pertaining to their micro-structure, including interfacial transition zone (ITZ), were presented as well. All concretes exhibited good freeze–thaw (F–T) resistance after 150 F–T cycles. The water-tightness was established as 0.8 MPa. All concretes both with and without LCD achieved the same class C50/60.

Clay-Based Brick Porosity Estimation Using Image Processing Techniques

This work intends to apprehend and emphasize the contribution of image-processing techniques and computer vision in the treatment of clay-based material known in Meknes region. One of the various characteristics used to describe clay in a qualitative manner is porosity, as it is considered one of the properties that with “kill or cure” effectiveness. For this purpose, we use scanning electron microscopy images, as they are considered the most powerful tool for characterising the quality of the microscopic pore structure of porous materials. We present various existing methods of segmentation, as we are interested only in pore regions. The results show good matching between physical estimation and Voronoi diagram-based porosity estimation.

Cathode ray tubes glass recycling: A review

With the rapid development in kinescope technologies, Cathode Ray Tubes (CRTs) now are almost completely replaced by thinner and lighter flat panel displays, such as liquid crystal displays (LCD), plasma display panels (PDP) and light emitting diode (LED) displays. Waste CRT glass contains many poisonous and harmful substances, especially lead. If it is not properly disposed of, it would pose a serious threat to the environment and human health. This paper reviews the existing waste CRT glass recycling technologies, analyses the obstacles that hinder their industrial application, pinpoints its future directions. This paper also points out the academic conflict in the risk of lead contained CRT glass and proposes a basic rule for waste treatment and disposal: the lower risk principle. The results of this study could help to understand waste CRT glass recycling and guide its future research and development.

The reuse of waste glass for enhancement of heavy metals immobilization during the introduction of galvanized sludge in brick manufacturing

The mixing of galvanized sludge in fired clay brick manufacturing has been regarded as an alternative approach for the consumption of galvanized sludge. Decreasing the surface area and porosity of fired brick definitely lowers the risk of heavy metal release. In this study, a novel method is proposed to reduce the surface area and porosity of bricks and promote heavy metal immobilization by adding waste glass. The introduction of waste glass enhanced the physical and mechanical performances of fired clay bricks and resulted in an increase in bulk density and compressive strength and a decrease in water absorption. Microstructure analysis showed that the texture of the bricks turned from porous to smooth and homogeneous due to the introduction of waste glass. Porosity analysis showed that surface area and pore volume of fired brick were substantially reduced. When the added waste glass amount exceeded 15 wt%, the heavy metal concentrations that leached from bricks containing 10 wt% galvanized sludge fired at 950 °C met the regulatory requirement. These results demonstrate that waste glass can be reused to enhance the stabilization/solidification of heavy metals, during the mixing of hazardous waste in bricks and ceramics manufacturing process.

A Proposal for Recycling the World’s Unused Stockpiles of Treated Wastewater Sludge (Biosolids) in Fired-Clay Bricks

Millions of tonnes of leftover biosolids are increasingly stockpiled every year around the globe. Biosolids are a product of the wastewater sludge treatment process. Stockpiles necessitate the use of large areas of increasingly valuable land. Biosolids have many beneficial uses and are currently utilised in agricultural and land rehabilitation applications. However, it is estimated that 30% of biosolids are unused and stockpiled. A second and seemingly unrelated environmental issue is the massive excavation of virgin soil for brick production. The annual production of 1500 billion bricks globally requires over 3.13 billion cubic metres of clay soil—equivalent to over 1000 soccer fields dug 440 m deep or to a depth greater than three times the height of the Sydney Harbour Bridge. This paper investigates and proposes a practical solution for the utilisation of the world’s excess biosolids in fired–clay bricks. The physical, chemical and mechanical properties of fired–clay bricks incorporating 25%, 20%, 15% and 10% biosolids have been tested. Bricks were produced from three different biosolids samples collected at Melbourne’s Eastern Treatment Plant (ETP 22) and the Western Treatment Plant (WTP 10 & WTP 17–29). Compressive strength testing indicated results ranging between 35.5 MPa and 12.04 MPa for the biosolids-amended bricks. Leachate analysis was conducted on the bricks before and after firing, and the results demonstrate that between 43 and 99% of the heavy metals tested were immobilised inside the fired bricks compared to the heavy metals tested in the raw mixture. All leachate concentrations were found to be insignificant for the biosolids-incorporated bricks tested in this study. Biosolids can have significantly different chemical characteristics depending on the origin of the wastewater and the treatment procedure. Suitable leachate analysis should be undertaken on biosolids and test bricks before large-scale production is approved. Scanning Electron Microscopy (SEM) images illustrate that biosolids-amended bricks have a higher porosity than the control bricks, which corresponds to the lower thermal conductivity values recorded for biosolids-amended bricks. In addition, brick firing energy demands are estimated to decrease by up to 48.6% for bricks incorporating 25% WTP 17–29 biosolids due to the higher organic content of the mixture containing biosolids. The emissions study and comparative Life Cycle Assessment results show that the incorporation of biosolids into bricks is a positive and sustainable alternative approach with respect to all environmental impacts arising from the stockpiling of biosolids and brick manufacturing. Based on the results found in this comprehensive study, this paper proposes the inclusion of a minimum of 15% biosolids content into 15% of brick production in order to completely recycle all the approximately 5 million tonnes of annual leftover biosolids production in Australia, New Zealand, the EU, the USA and Canada. This is a practical and sustainable proposal for recycling all the leftover biosolids worldwide. Utilisation of only 15% of biosolids in brick production would reduce the carbon footprint of brick manufacturing whilst satisfying all the environmental and engineering requirements for bricks.

Properties of Fired Bricks Incorporating TFT-LCD Waste Glass Powder with Reservoir Sediments

In view of increasing concerns over nonrenewable resource depletion and waste management, this study aimed to apply the Taguchi optimization technique to determine the process conditions for producing bricks by incorporating thin-film transition liquid crystal display (TFT-LCD) waste glass powder with reservoir sediments. An orthogonal array L16(45) was adopted, which consisted of five controllable four-level factors (i.e., cullet content, drying method, preheat time, sintering temperature, and error). Moreover, the analysis of variance method was used to explore the effects of the experimental factors on the density, water absorption, shrinkage ratio, loss on ignition, porosity, and compressive strength of the fired bricks. The microstructures of the fired specimens were investigated by scanning electron microscopy. Then, large-scale production techniques for fired bricks containing recycled TFT-LCD glass cullet and reservoir sediments were developed in a commercially available tunnel kiln. The test results showed that the structure of the fired specimen was loose at a sintering temperature ranging from 900 to 950 °C. However, the fired specimen showed a significant densification at the sintering temperature of 1050 °C. In addition, the Taguchi method was found to be a feasible approach for optimizing the process condition of bricks using recycled TFT-LCD glass cullet and reservoir sediments and it significantly reduced the number of tests. Further, the characteristics of fired bricks developed in the tunnel kiln were in compliance with Chinese National Standards class Ι building bricks criteria.

Lead extraction from Cathode Ray Tube (CRT) funnel glass: Reaction mechanisms in thermal reduction with addition of carbon (C)

This study quantitatively determined the extraction of lead from CRT funnel glass and examined the mechanisms of thermally reducing lead in the products of sintering Pb-glass with carbon in the pre-heated furnace. The experimentally derived results indicate that a 90.3 wt% lead extraction efficiency can be achieved with 20 wt% of C addition at 950 °C for 3 min under air. The formation of viscous semi-liquid glass blocked the oxygen supply between the interaction of C and Pb-glass, and was highly effective for the extraction of metallic Pb. A maximum of 87.3% lead recover was obtained with a C to Na₂CO₃ ratio of 1/3 at 1200 °C. The decrease of C/Na₂CO₃ ratio enhanced the metallic lead recovery by increasing the glass viscosity for effective sedimentation of metallic lead in the bottom. However, with the further increase of temperature and treatment time, re-vitrification of lead back to silicate-glass matrix was detected in both Pb-glass/C and Pb-glass/C/Na₂CO₃ systems. The findings indicated that with proper controls, using C as an inexpensive reagent can effectively reduce treatment time and energy, which is crucial to a waste-to-resource technology for economically recovering lead from the waste CRT glass.

Management of spent shea waste: An instrumental characterization and valorization in clay bricks construction

This work studies the reuse of spent shea waste as an economic construction material in improving fired clay bricks manufacture aside providing a novel approach to ecofriendly managing its excessive generated from the shea agroindustry. For this purpose, the influence of spent shea waste addition on the chemical, mineralogical, molecular bonding and technological properties (i.e. compressive strength and water absorption) of the fired clay bricks were extensively investigated. The results indicated that the chemical, mineralogical, phase transformations, molecular bonding and thermal behavior of the produced bricks were practically unaffected by the addition of spent shea waste. However, spent shea waste addition increased the compressive strengths and water absorptions of the brick products. Potential performance benefits of reusing spent shea waste was improved fluxing agents, energy-contribution reaction, excellent porosifying effect, reduced thermal conductivity and enhanced compressive strengths of the brick products. This research has therefore provided compelling evidence that could create newfound route for the synergistic ecofriendly reuse of spent shea waste to enhance clay brick construction aside being a potential mainstream disposal option.

Utilization of inorganic industrial wastes in producing construction ceramics. Review of Russian experience for the years 2000-2015

This paper analyzes the significant scientific publications worldwide for the last 15years 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.

Global responses for recycling waste CRTs in e-waste

The management of used cathode ray tube (CRT) devices is a major problem worldwide due to rapid uptake of the technology and early obsolescence of CRT devices, which is considered an environment hazard if disposed improperly. Previously, their production has grown in step with computer and television demand but later on with rapid technological innovation; TVs and computer screens has been replaced by new products such as Liquid Crystal Displays (LCDs) and Plasma Display Panel (PDPs). This change creates a large volume of waste stream of obsolete CRTs waste in developed countries and developing countries will be becoming major CRTs waste producers in the upcoming years. We studied that there is also high level of trans-boundary movement of these devices as second-hand electronic equipment into developing countries in an attempt to bridge the 'digital divide'. Moreover, the current global production of e-waste is estimated to be '41million tonnes per year' where a major part of the e-waste stream consists of CRT devices. This review article provides a concise overview of world's current CRTs waste scenario, namely magnitude of the demand and processing, current disposal and recycling operations.

Recent development of recycling lead from scrap CRTs: A technological review

Cathode ray tubes (CRTs) contain numerous harmful substances with different functions. Lead is found in the funnel glass of CRTs. Improperly treated toxic lead may pose significant risks to human health and the environment. This paper reviews and summarizes existing technological processes on the recycling of lead from waste CRTs, including pyrometallurgy, hydrometallurgy, and product-regeneration. The present situation, advantages, and disadvantages of these techniques are described in detail. Generally, pyrometallurgy shows better practicability in recovery lead from waste CRT than hydrometallurgy and hydrometallurgy, in view of environmental impact, energy-consumption, product formats and safety and maturity of technology. Moreover, the gaps in the existing technologies were identified and recommendations for future research were provided.

Water-soluble lead in cathode ray tube funnel glass melted in a reductive atmosphere

In the reduction-melting process, lead can be recovered from cathode ray tube funnel glass (PbO=25wt%); however, resulting glass residues still contain approximately 1-2wt% of unrecovered lead. For environmental protection in the residue disposal or recycling, it is important to evaluate the quantities of water-soluble species among the unrecovered lead. This study examined water-soluble lead species generated in the reduction-melting process of the funnel glass and factors determining their generation. In the reduction-melting, metallic lead was generated by reducing lead oxides in the glass, and a part of the metallic lead remained in the glass residue. Such unrecovered metallic lead can dissolve in water depending on its pH level and was regarded as water-soluble lead. When 10g Na2CO3 was added to 20g funnel glass during reduction-melting, the resulting glass contained high concentrations of sodium. In a water leaching of the glass, the obtained leachate was alkalized by the sodium-rich glass (pH=12.7-13.0). The unrecovered metallic lead in the glass was extracted in the alkalized leachate. The quantity of the unrecovered metallic lead (water-soluble lead) in the glass decreased when the melting time, melting temperature, and carbon dosage were controlled during reduction-melting.

Management practices for end-of-life cathode ray tube glass: Review of advances in recycling and best available technologies

Cathode ray tubes are image display units found in computer monitors and televisions. In recent years, cathode ray tubes have been generated as waste owing to the introduction of newer and advanced technologies in image displays, such as liquid crystal displays and high definition televisions, among others. Generation and subsequent disposal of end-of-life cathode ray tubes presents a challenge owing to increasing volumes and high lead content embedded in the funnel and neck sections of the glass. Disposal in landfills and open dumping are anti-environmental practices considering the large-scale contamination of environmental media by the potential of toxic metals leaching from glass. Mitigating such environmental contamination will require sound management strategies that are environmentally friendly and economically feasible. This review covers existing and emerging management practices for end-of-life cathode ray tubes. An in-depth analysis of available technologies (glass smelting, detoxification of cathode ray tube glass, lead extraction from cathode ray tube glass) revealed that most of the techniques are environmentally friendly, but are largely confined to either laboratory scale, or are often limited owing to high cost to mount, or generate secondary pollutants, while a closed-looped method is antiquated. However, recycling in cementitious systems (cement mortar and concrete) gives an added advantage in terms of quantity of recyclable cathode ray tube glass at a given time, with minimal environmental and economic implications. With significant quantity of waste cathode ray tube glass being generated globally, cementitious systems could be economically and environmentally acceptable as a sound management practice for cathode ray tube glass, where other technologies may not be applicable.

Removal of lead from cathode ray tube funnel glass by combined thermal treatment and leaching processes

The reduction melting process is useful to recover toxic lead from cathode ray tube funnel glass; however, this process generates SiO2-containing residues that are disposed in landfill sites. To reduce the volume of landfill waste, it is desirable to recycle the SiO2-containing residues. In this study, SiO2 powder was recovered from the residue generated by reduction melting. The funnel glass was treated by a process combining reduction melting at 1000°C and annealing at 700°C to recover a large quantity of lead from the glass. The oxide phase generated by the thermal treatment was subjected to water leaching and acid leaching with 1M hydrochloric acid to wash out unwanted non-SiO2 elements for SiO2 purification. In the water washing, the oxide phase was microparticulated, and porous structures formed on the oxide surfaces. This increased the surface area of the oxide phase, and the unwanted elements were effectively washed out during the subsequent acid leaching. By controlling the acid leaching time and the amount of added acid, porous and amorphous SiO2 (purity >95 wt%) was recovered. In the obtained SiO2-concentrated product, unrecovered lead remained at concentrations of 0.25-0.79 wt%. When the Na2CO3 dosage in the thermal treatment was increased, the lead removal by acid leaching was enhanced, and the lead concentration in the obtained product decreased to 0.016 wt%.

Lead extraction from cathode ray tube funnel glass melted under different oxidizing conditions

Lead was extracted into hydrochloric acid from cathode ray tube funnel glass melted under reducing atmosphere, oxidizing atmosphere, or a sequential combination of both to mechanistically investigate effects of the melting atmosphere on lead extraction. Melting funnel glass in a reductive atmosphere led to the generation of metallic lead particles that were readily soluble in the acid, increasing the quantity of lead extracted into the acid. Meanwhile, the glass product obtained after melting funnel glass in an oxidative atmosphere exhibited higher corrosion resistance in the acid, and the quantity of lead extracted from the treated glass decreased. However, Na2CO3 addition to the glass during melting hindered the enhancement of corrosion resistance and the immobilization of lead in the acid. X-ray photoelectron spectroscopic analysis of the treated glass samples showed that the positions of the peak or the profiles of the spectra attributed to Pb 4f, Si 2p, and O 1s signals were modified by oxidative melting, an indication that oxidative melting results in structural changes in the SiO2 framework of the glass.

Effects of waste glass additions on quality of textile sludge-based bricks

This research investigated the utilization of textile sludge as a substitute for clay in brick production. The addition of textile sludge to a brick specimen enhanced its pores, thus reducing the quality of the product. However, the addition of waste glass to brick production materials improved the quality of the brick in terms of both compressive strength and water absorption. Maximum compressive strength was observed with the following composition of waste materials: 30% textile sludge, 60% clay and 10% waste glass. The melting of waste glass clogged up pores on the brick, which improved water absorption performance and compressive strength. Moreover, a leaching test on a sludge-based brick to which 10% waste glass did not detect significant heavy metal compounds in leachates, with the product being in conformance with standard regulations. The recycling of textile sludge for brick production, when combined with waste glass additions, may thus be promising in terms of both product quality and environmental aspects.

Development of eco-friendly porous fired clay bricks using pore-forming agents: a review

Today, clay bricks are facing technological challenges and are uncompetitive compared to materials such as concrete. Their performance must be improved if they are to stand up to the competition. Increasing environmental concerns over the accumulation of unmanaged wastes from agricultural or industrial productions have made these good candidates for incorporation into building materials to improve their performance. This process leads to the formation of pores in the bricks, producing lightweight and sustainable building materials. This paper reviews the different pore-forming agents from renewable or mineral resources as described in the literature. It also presents the impact of pore-forming agents on the physical, mechanical and thermal properties of clay bricks.

Reduction-melting combined with a Na₂CO₃ flux recycling process for lead recovery from cathode ray tube funnel glass

With large quantity of flux (Na2CO3), lead can be recovered from the funnel glass of waste cathode-ray tubes via reduction-melting at 1000°C. To reduce flux cost, a technique to recover added flux from the generated oxide phase is also important in order to recycle the flux recovered from the reduction-melting process. In this study, the phase separation of sodium and the crystallization of water-soluble sodium silicates were induced after the reduction-melting process to enhance the leachability of sodium in the oxide phase and to extract the sodium from the phase for the recovery of Na2CO3 as flux. A reductive atmosphere promoted the phase separation and crystallization, and the leachability of sodium from the oxide phase was enhanced. The optimum temperature and treatment time for increasing the leachability were 700°C and 2h, respectively. After treatment, more than 90% of the sodium in the oxide phase was extracted in water. NaHCO3 can be recovered by carbonization of the solution containing sodium ions using carbon dioxide gas, decomposed to Na2CO3 at 50°C and recycled for use in the reduction-melting process.

Pollution due to hazardous glass waste

Pollution resulting from hazardous glass (HG) is widespread across the globe, both in terms of quantity and associated health risks. In waste cathode ray tube (CRT) and fluorescent lamp glass, mercury and lead are present as the major pollutants. The current review discusses the issues related to quantity and associated risk from the pollutant present in HG and proposes the chemical, biological, thermal, hybrid, and nanotechniques for its management. The hybrid is one of the upcoming research models involving the compatible combination of two or more techniques for better and efficient remediation. Thermal mercury desorption starts at 100 °C but for efficient removal, the temperature should be >460 °C. Involvement of solar energy for this purpose makes the research more viable and ecofriendly. Nanoparticles such as Fe, Se, Cu, Ni, Zn, Ag, and WS2 alone or with its formulation can immobilize heavy metals present in HG by involving a redox mechanism. Straight-line equation from year-wise sale can provide future sale data in comparison with lifespan which gives future pollutant approximation. Waste compact fluorescent lamps units projected for the year 2015 is 9,300,000,000 units and can emit nearly 9,300 kg of mercury. On the other hand, CRT monitors have been continuously replaced by more improved versions like liquid crystal display and plasma display panel resulting in the production of more waste. Worldwide CRT production was 83,300,000 units in 2002 and can approximately release 83,000 metric tons of lead.

An integrated experimental-modeling approach to study the acid leaching behavior of lead from sub-micrometer lead silicate glass particles

This work focuses on the development of a procedure to study the mechanism of leaching of lead from sub-micrometer lead glass particles using 0.3 mo ll(-1) HNO3 as a leachant. Glass particles with an effective size distribution range from 0.05 to 1.4 μm were generated by laser ablation (213 nm Nd:YAG laser) and collected on an inline 0.2 μm syringe filter. Subsequently, the glass particles on the filter were subjected to online leaching and continuous monitoring of lead (Pb-208) in the leachate by quadrupole ICP-MS. The lead leaching profile, aided by the particle size distribution information from cascade impaction, was numerically fitted to a mathematical model based on the glass intraparticle diffusion, liquid film distribution and thermodynamic glass-leachant distribution equilibrium. The findings of the modeling show that the rate-limiting step of leaching is the migration of lead from the core to the surface of the glass particle by an ion-exchange mechanism, governed by the apparent intraparticle lead diffusivity in glass which was calculated to be 3.1 × 10(-18) m(2)s(-1). Lead leaching is illustrated in the form of graphs and animations of intraparticle lead release (in time and intraparticle position) from particles with sizes of 0.1 and 0.3 μm.

Recycling of residual IGCC slags and their benefits as degreasers in ceramics

This work studies the evolution of IGCC slag grains within a ceramic matrix fired at different temperatures to investigate the effect of using IGCC slag as a degreaser. Pressed ceramic specimens from two clay mixtures are used in this study. The M1 mixture is composed of standard clays, whereas the M2 mixture is composed of the same clay mixture as M1 mixture but contains 15% by weight IGCC slag. The amount of IGCC slag added coincides with the amount of slag typically used as a degreaser in the ceramic industry. Specimens are fired at 950 °C, 1000 °C, 1050 °C, 1100 °C and 1150 °C. The mineralogical composition and the IGCC slag grain shape within the ceramic matrix are determined by X-ray diffraction, polarized light microscopy and scanning electron microscopy. The results reveal that the surface of the slag grains is welded to the ceramic matrix while the quartz grains are separated, which causes increased water absorption and reduces the mechanical strength. IGCC slag, however, reduces water absorption. This behaviour is due to the softening temperature of the slag. This property is quite important from an industrial viewpoint because IGCC slag can serve as an alternative to traditional degreasing agents in the ceramic building industry. Additionally, using IGCC slag allows for the transformation of waste into a secondary raw material, thereby avoiding disposal at landfills; moreover, these industrial wastes are made inert and improve the properties of ceramics.

Extraction of metallic lead from cathode ray tube (CRT) funnel glass by thermal reduction with metallic iron

A novel and effective process of thermal reduction treatment with the addition of metallic iron (Fe(0)) to recover lead from cathode ray tube (CRT) funnel glass is introduced. The key technological breakthrough of this process is the use of a relatively lower temperature and an inexpensive reducing agent to extract the metallic lead. The influences of temperature, the reducing agent content, and the holding time for lead reduction were examined to determine the optimal extraction efficiency. The lead extraction efficiency first increased and then decreased with increasing temperature. The maximum lead extraction efficiency occurred at 700 °C. The growth of crystalline lead first increased significantly with an increase in the Fe content, reaching maximum growth at an Fe addition of 50 wt %. The most effective treatment time was determined to be 30 min, as the vitrification of lead back to the glass matrix occurred under longer treatment times. The experimentally derived results indicate that a 58 wt % lead extraction can be achieved with the optimized operational parameters (50 wt % Fe addition, heating at 700 °C for 30 min) in a single extraction operation.

Energy-efficient modification of reduction-melting for lead recovery from cathode ray tube funnel glass

Lead can be recovered from funnel glass of waste cathode ray tubes via reduction melting. While low-temperature melting is necessary for reduced energy consumption, previously proposed methods required high melting temperatures (1400 °C) for the reduction melting. In this study, the reduction melting of the funnel glass was performed at 900-1000 °C using a lab-scale reactor with varying concentrations of Na(2)CO(3) at different melting temperatures and melting times. The optimum Na(2)CO(3) dosage and melting temperature for efficient lead recovery was 0.5 g per 1g of the funnel glass and 1000 °C respectively. By the reduction melting with the mentioned conditions, 92% of the lead in the funnel glass was recovered in 60 min. However, further lead recovery was difficult because the rate of the lead recovery decreased as with the recovery of increasing quantity of the lead from the glass. Thus, the lead remaining in the glass after the reduction melting was extracted with 1M HCl, and the lead recovery improved to 98%.

A novel process utilizing mechanochemical sulfidization to remove lead from cathode ray tube funnel glass

A novelprocess ofmechanochemical sulfidization for the treatment of cathode ray tube (CRT)funnel glass has been investigated by co-grinding with the element sulfur The ground samples were characterized by means of a set of analytical methods, including scanning electron microscopy (SEM), x-ray diffraction (XRD), x-ray photoelectron spectroscopy (XPS), Raman spectroscopy, and thermogravimetric analysis (TG). The analytical results showed that during the co-grinding of the CRTfunnel glass with sulfur, the Si-O-Pb bond in glass and S-S bond broke and recombined into lead sulfide (PbS). The sulfidizing reaction proceeded with an increase in grinding time and the amount of the added sulfur. The sulfidizing rate increased rapidly from 16.6%for the JO-min ground sample to 96.7% for the 120-min ground sample. Using this process, current mineralprocessing technology, such as flotation separation, might be used to recover PbS. The proposed technology could also be used to treat other leaded glass and even other lead-containing wastes.

IMPLICATIONS

In this research, a mechanochemical sulfidization method was proposed to recover lead from waste cathode ray tube (CRT) funnel glass. CRT funnel glass was co-ground with sulfur in N2 atmosphere by mechanical milling. After milling, lead in CRT funnel glass was transferred into lead sulfide (PbS). Using this process, current nfiineral processing technology, such as flotation separation, might be used to recover PbS from the ground sample. The process can be applied to treat other leaded glass or lead-containing wastes.

Utilization of cathode ray tube waste: encapsulation of PbO-containing funnel glass in Portland cement clinker

The disposal of cathode ray tube (CRT) generates large quantities of leaded glass waste. The encapsulation of glass from the funnel portion of CRT in cement clinker was investigated. Samples of cement raw material containing 0 (control), 0.1, 0.2, 0.3, 0.4, or 0.5 wt% of CRT funnel glass ground to less than 75 μm were heated to 1480 °C in an electric furnace for 1.5 h at a heating rate of 5 °C/min to produce cement clinker. The Pb encapsulation and chemical composition of the clinkers were analysed using X-ray techniques and atomic absorption spectroscopy (AAS). The maximum PbO encapsulation occurred in mixtures containing 0.1 wt% funnel glass.

Elucidating the effects of solar panel waste glass substitution on the physical and mechanical characteristics of clay bricks

This study deals with the effect of solar panel waste glass on fired clay bricks. Brick samples were heated to temperatures which varied from 700-1000 degrees C for 6 h, with a heating rate of 10 degrees C min(-1). The material properties of the resultant material were then determined, including speciation variation, loss on ignition, shrinkage, bulk density, 24-h absorption rate, compressive strength and salt crystallization. The results indicate that increasing the amount of solar panel waste glass resulted in a decrease in the water absorption rate and an increase in the compressive strength of the solar panel waste glass bricks. The 24-h absorption rate and compressive strength of the solar panel waste glass brick made from samples containing 30% solar panel waste glass sintered at 1000 degrees C all met the Chinese National Standard (CNS) building requirements for first-class brick (compressive strengths and water absorption of the bricks were 300 kg cm(-2) and 10% of the brick, respectively). The addition of solar panel waste glass to the mixture reduced the degree of firing shrinkage. The salt crystallization test and wet-dry tests showed that the addition of solar panel waste glass had highly beneficial effects in that it increased the durability of the bricks. This indicates that solar panel waste glass is indeed suitable for the partial replacement of clay in bricks.

Cathode ray tube (CRT) recycling: current capabilities in China and research progress

It is estimated that approximately 6,000,000 scrap TVs and 10,000,000 personal computers are generated each year in China. Cathode ray tubes (CRTs) from these machines consist of 85% glass (65% panel, 30% funnel and 5% neck glass). The leaded glass (funnel-24%, neck-30%) may seriously pollute the environment if it is not properly disposed of. In this paper, the past, current and future status of CRT dismantling technologies as well as the CRT glass recycling situation in China are presented and discussed. Recycling technology for waste CRTs in China is still immature. While the conventional CRT dismantling technologies have disadvantages from both economic and environmental viewpoints, some of the new and emerging treatments such as automatic optical sorting facilities that have been applied in developed countries offer advantages, and therefore should be transferred to China in the next few years to solve the CRT pre-processing problem. Meanwhile, because the demand for CRT glass closed-loop recycling is extremely limited, the authorities should take effective measures to improve CRT glass recycling rates and to facilitate a match to local conditions. Moreover, we also provide a broad review of the research developments in recycling techniques for CRT cullet. The challenge for the future is to transfer these environmentally friendly and energy-saving technologies into practice.

Eco-efficient waste glass recycling: Integrated waste management and green product development through LCA

As part of the EU Life + NOVEDI project, a new eco-efficient recycling route has been implemented to maximise resources and energy recovery from post-consumer waste glass, through integrated waste management and industrial production. Life cycle assessment (LCA) has been used to identify engineering solutions to sustainability during the development of green building products. The new process and the related LCA are framed within a meaningful case of industrial symbiosis, where multiple waste streams are utilised in a multi-output industrial process. The input is a mix of rejected waste glass from conventional container glass recycling and waste special glass such as monitor glass, bulbs and glass fibres. The green building product is a recycled foam glass (RFG) to be used in high efficiency thermally insulating and lightweight concrete. The environmental gains have been contrasted against induced impacts and improvements have been proposed. Recovered co-products, such as glass fragments/powders, plastics and metals, correspond to environmental gains that are higher than those related to landfill avoidance, whereas the latter is cancelled due to increased transportation distances. In accordance to an eco-efficiency principle, it has been highlighted that recourse to highly energy intensive recycling should be limited to waste that cannot be closed-loop recycled.

Innovated application of mechanical activation to separate lead from scrap cathode ray tube funnel glass

The disposal of scrap cathode ray tube (CRT) funnel glass has become a global environmental problem due to the rapid shrinkage of new CRT monitor demand, which greatly reduces the reuse for remanufacturing. To detoxificate CRT funnel glass by lead recovery with traditional metallurgical methods, mechanical activation by ball milling was introduced to pretreat the funnel glass. As a result, substantial physicochemical changes have been observed after mechanical activation including chemical breakage and defects formation in glass inner structure. These changes contribute to the easy dissolution of the activated sample in solution. High yield of 92.5% of lead from activated CRT funnel glass by diluted nitric acid leaching and successful formation of lead sulfide by sulfur sulfidization in water have also been achieved. All the results indicate that the application of mechanical activation on recovering lead from CRT funnel glass is efficient and promising, which is also probably appropriate to detoxificate any other kind of leaded glass.

Environmental issues and management strategies for waste electronic and electrical equipment

Issues surrounding the impact and management of discarded or waste electronic and electrical equipment (WEEE) have received increasing attention in recent years. This attention stems from the growing quantity and diversity of electronic and electrical equipment (EEE) used by modern society, the increasingly rapid turnover of EEE with the accompanying burden on the waste stream, and the occurrence of toxic chemicals in many EEE components that can pose a risk to human and environmental health if improperly managed. In addition, public awareness of the WEEE or "e-waste" dilemma has grown in light of popular press features on events such as the transition to digital television and the exportation of WEEE from the United States and other developed countries to Africa, China, and India, where WEEE has often not been managed in a safe manner (e.g., processed with proper safety precautions, disposed of in a sanitary landfill, combusted with proper air quality procedures). This paper critically reviews current published information on the subject of WEEE. The definition, magnitude, and characteristics of this waste stream are summarized, including a detailed review of the chemicals of concern associated with different components and how this has changed and continues to evolve over time. Current and evolving management practices are described (e.g., reuse, recycling, incineration, landfilling). This review discusses the role of regulation and policies developed by governments, institutions, and product manufacturers and how these initiatives are shaping current and future management practices.

Reuse of ornamental rock-cutting waste in aluminous porcelain

Large amounts of solid wastes are discarded in the ornamental rocks industry. This work investigates the incorporation of ornamental rock-cutting waste as a raw material into an aluminous porcelain body, replacing natural feldspar material by up to 35 wt.%. Formulations containing rock-cutting waste were pressed and sintered at 1350 °C. The porcelain pieces were tested to determine their properties (linear shrinkage, water absorption, apparent density, mechanical strength, and electrical resistivity). Development of the microstructure was followed by scanning electron microscopy (SEM) and X-ray diffraction (XRD) analyses. The results showed that ornamental rock-cutting waste could be used in aluminous porcelains, in the range up to 10 wt.%, as a partial replacement for traditional flux material, resulting in a valid route for management of this abundant waste.

Technological behaviour and recycling potential of spent foundry sands in clay bricks

The feasibility of recycling spent foundry sand in clay bricks was assessed in laboratory, pilot line and industrial trials, using naturally occurring sand as a reference. Raw materials were analyzed by X-ray fluorescence, X-ray diffraction, particle size distribution, and leaching and combined to produce bodies containing up to 35% wt. sand. The extrusion, drying and firing behaviour (plasticity, drying sensitivity, mechanical strength, bulk density, water absorption, and shrinkage) were determined. The microstructure, phase composition, durability and leaching (EN 12457, granular materials, end-life step, European Waste Landfill Directive; NEN 7345, monolithic materials, use-life step, Dutch Building Material Decree) were evaluated for bricks manufactured at optimal firing temperature. These results demonstrate that spent foundry sand can be recycled in clay bricks. There are no relevant technological drawbacks, but the feasibility strongly depends on the properties of the raw materials. Spent foundry sand may be introduced into bricks up to 30% wt. Most of the hazardous elements from the spent foundry sand are inertized during firing and the concentrations of hazardous components in the leachates are below the standard threshold for inert waste category landfill excepting for chromium and lead; however, their environmental risk during their use-life step can be considered negligible.

Characterization of lead, barium and strontium leachability from foam glasses elaborated using waste cathode ray-tube glasses

Foam glass manufacture is a promising mode for re-using cathode ray tube (CRT) glasses. Nevertheless, because CRTs employ glasses containing heavy metals such as lead, barium and strontium, the leaching behaviour of foam glasses fabricated from CRTs must be understood. Using the AFNOR X 31-210 leaching assessment procedure, the degree of element inertization in foam glasses synthesized from waste CRT glasses (funnel and panel glasses, containing lead and barium/strontium respectively) were determined. The amount of leached lead from foam glasses prepared from funnel glass depends on the nature and concentration of the reducing agent. The effects of the reducing agents on the generation of cellular structure in the fabrication of foam glass were studied. The fraction of lead released from foam glass was less than those extracted from funnel glass and was lower than the statutory limit. Leached concentrations of barium and strontium were found to be approximately constant in various tests and were also below regulatory limits.