The aluminum Bayer production process is widespread all over the world. One of the waste products of the Bayer process is a basic aluminosilicate bauxite residue called red mud. The aluminosilicate nature of red mud makes it suitable as a precursor for alkali-activated materials. In this work, red mud was mixed with different percentages of blast furnace slag and then activated by sodium silicate solution at different SiO2/Na2O ratios. Obtained samples were characterized by chemical–physical analyses and compressive strength determination. Very high values of compressive strength, up to 50 MPa, even for high percentage of red mud in the raw mixture (70 wt.% of RM in powder mixture), were obtained. In particular, the higher compressive strength was measured for cubic samples containing 50 wt.% of RM, which showed a value above 70 MPa. The obtained mixtures were characterized by no or scarce environmental impact and could be used in the construction industry as an alternative to cementitious and ceramic materials.
Power plants based on solar energy are spreading to accomplish the incoming green energy transition. Besides, affordable high-temperature sensible heat thermal energy storage (SHTES) is required. In this work, the temperature distribution and thermal performance of novel solid media for SHTES are investigated by finite element method (FEM) modelling. A geopolymer, with/without fibre reinforcement, is simulated during a transient charging/discharging cycle. A life cycle assessment (LCA) analysis is also carried out to investigate the environmental impact and sustainability of the proposed materials, analysing the embodied energy, the transport, and the production process. A Multi-Criteria Decision Making (MCDM) with the Analytical Hierarchy Process (AHP) approach, taking into account thermal/environmental performance, is used to select the most suitable material. The results show that the localized reinforcement with fibres increases thermal storage performance, depending on the type of fibre, creating curvatures in the temperature profile and accelerating the charge/discharge. High-strength, high-conductivity carbon fibres performed well, and the simulation approach can be applied to any fibre arrangement/material. On the contrary, the benefit of the fibres is not straightforward according to the three different scenarios developed for the LCA and MCDM analyses, due to the high impact of the fibre production processes. More investigations are needed to balance and optimize the coupling of the fibre material and the solid medium to obtain high thermal performance and low impacts.
This contribution presents the preparation and characterization of new geopolymer-based mortars obtained from recycling waste deriving from the production process and the “end-of-life” of porcelain stoneware products. Structural, morphological, and mechanical studies carried out on different kinds of mortars prepared by using several types of by-products (i.e., pressed burnt and extruded ceramic waste, raw pressed and gypsum resulting from exhausted moulds) point out that these systems can be easily cast, also in complex shapes, and show a more consistent microstructure with respect to the geopolymer paste, with a reduced amount of microcracks. Moreover, the excellent adhesion of these materials to common substrates such as pottery and earthenware, even for an elevated concentration of filler, suggests their use in the field of technical-artistic value-added applications, such as restoration, conservation, and/or rehabilitation of historic monuments, or simply as materials for building revetments. For all these reasons, the proposed materials could represent valuable candidates to try to overcome some problems experienced in the cultural heritage sector concerning the selection of environmentally friendly materials that simultaneously meet art and design technical requirements.
The aluminum Bayer production process is the most diffused process in the world, but it creates a high amount of basic waste material known as red mud (RM). The use of RM as a precursor of alkali-activated materials is one of the best opportunities for both the ecosystem and the economy. In the present work, mortar samples were obtained by alkali activation of RM with various percentages of blast-furnace slag (BFS) and inert construction and demolition sands. This process creates samples that have a low environmental impact and that can be used as an alternative in the construction industry to cement materials or ceramic ones. The development of these new materials could also represent a way to reduce the CO2 emissions linked to cement and ceramic brick production. In the present study, cubic 40 mm samples reported very interesting values in compressive strength, with a maximum of about 70 MPa for low environmental impact mortars. With such a material, it is possible to create solid bricks for structural use and concrete tiles for road paving or use it for other purposes. Mortar specimens were prepared and characterized, and an LCA analysis with a “cradle-to-gate” approach was carried out for a comparison of the environmental impact of the studied mortars with other materials currently marketed.
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