One More Step towards a Circular Economy for Thermal Insulation Materials-Development of Composites Highly Filled with Waste Polyurethane (PU) Foam for Potential Use in the Building Industry

The rapid development of the building sector has created increased demand for novel materials and technologies, while on the other hand resulting in the generation of a severe amount of waste materials. Among these are polyurethane (PU) foams, which are commonly applied as thermal insulation materials. Their management is a serious industrial problem, due to, for example, their complex chemical composition. Although some chemical and thermochemical methods of PU foam recycling are known, their broader use is limited due to requirements related to the complexity and safety of their installation, thus implicating high costs. Therefore, material recycling poses a promising alternative. The incorporation of waste PU foams as fillers for polymer composites could make it possible to take advantage of their structure and performance. Herein, polypropylene-based composites that were highly filled with waste PU foam and modified using foaming agents were prepared and analyzed. Depending on the foam loading and the foaming agent applied, the apparent density of material was reduced by as much as 68%. The efficient development of a porous structure, confirmed by scanning electron microscopy and high-resolution computed micro-tomography, enabled a 64% decrease in the thermal conductivity coefficient. The foaming of the structure affected the mechanical performance of composites, resulting in a deterioration of their tensile and compressive performance. Therefore, developing samples of the analyzed composites with the desired performance would require identifying the proper balance between mechanical strength and economic, as well as ecological (share of waste material in composite, apparent density of material), considerations.

Production and Evaluation of Synthetic Lightweight Aggregates Based on Mixture of Fluidized Bed Fly Ash and Post-Mining Residues

This paper presents an attempt to obtain technically valuable lightweight aggregate produced from a mixture of fluidized bed fly ash and post-mining residues. The motivation to take up this study is a problem with the reasonable utilization of huge amounts of ashes produced by power plants in Poland. The ashes still produced and those stored in heaps amount to a tonnage of millions, and new ways to utilize them are desired. A real lack of mineral aggregates (non-renewable resources) demands the search for alternative materials. Using the industrial ashes as aggregates is a possible solution to the two above-mentioned problems. The aim of the study was to produce the lightweight aggregate components and to assess them in terms of their physical and mechanical properties. The components were prepared by mixing, granulation, and sintering at the temperature of over 1170 °C. Evaluation of physical parameters was based on parameters such as bulk density and water absorption. The study of mechanical properties was carried out on the basis of aggregates' resistance to crushing. The obtained results revealed that using a mixture of the combustion and post-mining residues in the production of a lightweight aggregate is beneficial and results in the formation of a porous and durable structure. The measured resistance to the crushing of the produced aggregates varied from 5.9 MPa to 7.5 MPa. They also showed a high freeze-thaw resistance and good resistance to aggressive environments (bases, acids, salt). The registered properties indicate that the aggregates meet the basic requirements for materials used in construction and road-building. This study has a scientific and didactic value in that it describes the step-by-step process of planning and implementing the production of synthetic mineral aggregates.

Manufacturing of Lightweight Aggregates as an Auspicious Method of Sewage Sludge Utilization

Sewage sludge is a high-volume and low-cost waste commonly generated worldwide, so its utilization is a vital issue. The application of this waste in the manufacturing of lightweight aggregates was investigated. The process was performed using intensive mixers with volumes of 5 and 30 L, as well as the industrial 500 L mixer. Then, granulates were sintered in a tube furnace. The influence of composition and mixer size on the particle size, microstructure, mechanical performance, and stability of lightweight aggregates in different environments was analyzed. The best results were obtained for a 500 L mixer, enhancing the industrial potential of the presented process. Increasing the share of sewage sludge in the composition of aggregates enhanced their porosity and reduced the specific weight, which caused a drop in compressive strength. Nevertheless, for all analyzed materials, the mechanical performance was superior compared to many commercial products. Therefore, sewage sludge can be efficiently applied as a raw material for the manufacturing of lightweight aggregates. The presented results confirm that a proper adjustment of composition allows easy the tailoring of aggregates' performance and cost.

Comparative Analysis of Carbon, Ecological, and Water Footprints of Polypropylene-Based Composites Filled with Cotton, Jute and Kenaf Fibers

Composites containing natural fibers are considered environmentally friendly materials which is related to the reduced use of fossil fuels and the emission of carbon dioxide compared to petroleum-based polymers. Nevertheless, a complete evaluation of their environmental impact requires a broader view. This paper presents a carbon, ecological, and water footprints assessment of polypropylene-based composites filled with cotton, jute, and kenaf fibers based on a standardized European pallet (EUR-pallet) case study. Obtained results were compared with unmodified polypropylene and composite with glass fibers. Incorporation of 30 wt% of cotton, jute, and kenaf fibers into a polypropylene matrix reduced its carbon footprint by 3%, 18%, and 18%, respectively. Regarding the ecological footprint, an 8.2% and 9.4% reduction for jute and kenaf fibers were noted, while for cotton fibers, its value increased by 52%. For these footprints, the use of jute and kenaf fibers was more beneficial than glass fibers. Nevertheless, the application of natural fibers caused a 286%, 758%, and 891% drastic increase of water footprint of the final product, which was mainly affected by cultivation and irrigation of crops. Therefore, in a holistic view, the incorporation of natural fibers into the polypropylene matrix definitely cannot be impartially considered as an environmentally friendly solution.

Waste tire rubber as low-cost and environmentally-friendly modifier in thermoset polymers - A review

Nowadays, waste tire rubber (WTR) management is a growing and serious problem. Therefore, research works focused on the development of cost-effective and environmentally-friendly methods of WTR recycling are fully justified. Incorporation of WTR into polymer matrices and composite materials attracts much attention, because this approach allows sustainable development of industrially applicable waste tires recycling technologies. Generally, utilization of WTR as a filler for polymer composites noticeably reduces materials costs, while suitable modification/functionalization of WTR may significantly enhance the performance of plastics and rubbers. This work aims to summarize the literature reports related to the thermoset/WTR composites based on various matrices such as: polyurethanes, epoxy and other resins. It particularly focuses on compatibilization strategies in thermosets/WTR systems and their impact on the chemistry and physical interfacial interactions between thermoset matrix and WTR filler phase, what significantly affecting performance properties of prepared materials. Moreover, future trends and limitation related to thermoset/WTR composites development are discussed.

Water Footprint Assessment of Selected Polymers, Polymer Blends, Composites, and Biocomposites for Industrial Application

This paper presents a water footprint assessment of polymers, polymer blends, composites, and biocomposites based on a standardized EUR-pallet case study. The water footprint analysis is based on life cycle assessment (LCA). The study investigates six variants of EUR-pallet production depending on the materials used. The system boundary included the production of each material and the injection molding to obtain a standardized EUR-pallet of complex properties. This paper shows the results of a water footprint of six composition variants of analyzed EUR-pallet, produced from biocomposites and composites based on polypropylene, poly(lactic acid), cotton fibers, jute fibers, kenaf fibers, and glass fibers. Additionally, a water footprint of applied raw materials was evaluated. The highest water footprint was observed for cotton fibers as a reinforcement of the analyzed biocomposites and composites. The water footprint of cotton fibers is caused by the irrigation of cotton crops. The results demonstrate that the standard EUR-pallet produced from polypropylene with glass fibers as reinforcement can contribute to the lowest water footprint.

Effect of Compounding Conditions on Static and Dynamic Mechanical Properties of High Density Polyethylene/Ground Tire Rubber Blends

Searching for new and cost-effective methods of waste rubber recycling is a subject of research in many scientific centers in the world. In this paper there are presented results of the research of the extrusion process of cheap and environmentally friendly thermoplastic compositions containing 50% wt. of masses of ground tire rubber (GTR). The aim of this study was to determine the relationship between the mixing conditions and properties of obtained products, which is important from a technological point of view. The mixing conditions were determined by using two variables: the screw configuration (co-rotating and counter-rotating) and the type of polyethylene. In the case of both variables, thermoplastic compositions were treated with various shear forces induced by screw speed changes. The influence of mixing conditions on the extrusion process was determined (screw torque, melt flow rate) as well as static and dynamic mechanical properties of obtained materials.