Energy efficient production of glass-ceramics using photovoltaic (P/V) glass and lignite fly ash

Experimental Study of Amphibolite-Basalt (SiO2-AlO3-CaO-Fe2O3) Glasses for Glass-Ceramic Materials Production

The paper presents research on multicomponent glasses obtained from natural and secondary raw materials, i.e., basalt, amphibolite, and cullet. The raw materials were used as potential sets to produce mineral fibres or glass-ceramic materials. FTIR spectroscopy and XRD studies were carried out to identify the composition of the phase type in the glass sets. The results were supported by SEM-EDS microstructural studies of the obtained materials. The ability of the melts to crystallize and their basic properties required in producing mineral fibres, i.e., the hardness and the acidity modulus, were also determined. In the glass samples after the crystallization process, the spectroscopic studies revealed an increase in the half-width of the band at 1200-800 cm-1 and splitting at the values of about 870 cm-1 and 970 cm-1. These changes probably indicate the formation of pyroxene-type crystalline phases. Moreover, based on the XRD results, it was confirmed that the obtained materials were fully amorphous. After annealing at 800 °C for 2 h, the materials show a small proportion of crystalline phases. For the materials annealed at higher temperatures, clear peaks from the crystalline phases were represented mainly by pyroxenes. The proportion of crystalline phases in the samples was also found to rise with increasing temperature, and the hardness values for the basalt glasses and glasses after crystallization rose from 753 to 946 HV0.05. Such an effect positively affects the properties of the obtained glass-ceramic materials based on the proposed sets. However, in the case of mineral fibres, crystallization at early 2 h at 800 °C can be a disadvantageous feature from the point of view of their application because crystalline phases can lead to fibre damage after a short period of operation; this will be confirmed in this study.

Photovoltaic Glass Waste Recycling in the Development of Glass Substrates for Photovoltaic Applications

Because of the increasing demand for photovoltaic energy and the generation of end-of-life photovoltaic waste forecast, the feasibility to produce glass substrates for photovoltaic application by recycling photovoltaic glass waste (PVWG) material was analyzed. PVWG was recovered from photovoltaic house roof panels for developing windows glass substrates; PVWG was used as the main material mixed with other industrial waste materials (wSG). The glass was casted by air quenching, annealed, and polished to obtain transparent substrates samples. Fluorine-doped tin oxide (FTO) was deposited as back contact on the glass substrates by spray pyrolysis. The chemical composition of the glass materials was evaluated by X-ray fluorescence (XRF), the thermal stability was measured by differential thermal analysis (DTA) and the transmittance was determined by UV-VIS spectroscopy. The surface of the glass substrates and the deposited FTO were observed by scanning electron microscopy (SEM), the amorphous or crystalline state of the specimens were determined by X-ray diffraction (XRD) and the sheet resistance was evaluated by the four-point probe method. The sheet resistance of the deposited FTO on the wSG substrate was 7.84 ± 3.11 Ω/□, lower than that deposited on commercial soda-lime glass (8.48 ± 3.67 Ω/□), meaning that this material could present improved conduction of the produced electrons by the photovoltaic effect. This process may represent an alternative to produce glass substrates from waste materials that could be destined for photovoltaic applications, especially the production of ecological photovoltaic windows.

Sustainable and Clean Utilization of Yellow Phosphorus Slag (YPS): Activation and Preparation of Granular Rice Fertilizer

Yellow phosphorus slag (YPS) is a typical industrial solid waste, while it contains abundant silicon micronutrient required for the growth of rice. The key scientific problem to use the YPS as rice fertilizer is how to activate the slag efficiently during the phosphorite reduction smelting process. In this work, an alkaline rice fertilizer from the activated YPS was successfully prepared to use the micronutrients. Thermodynamic analyses of SiO₂-CaO, SiO₂-CaO-Al₂O_3, and SiO₂-CaO-Al₂O₃-MgO systems were discussed to optimize the acidity for reduction smelting. Results showed that the reduction smelting followed by the water quenching process can realize the reduction of phosphorite and activation of YPS synchronously. Ternary acidity m(SiO₂)/(m(CaO) + m(MgO)) of 0.92 is suitable for the reduction smelting and activation of the slag. After smelting, the molten YPS can be effectively activated by water quenching, and 78.28% P, 90.03% Ca, and 77.12% Si in the YPS are activated, which can be readily absorbed by the rice roots. Finally, high-strength granular rice fertilizers with a particle size of Φ2–4 mm were successfully prepared from the powdery nitrogen-phosphorus-potassium (NPK) and activated YPS mixture.

Application of General Full Factorial Statistical Experimental Design’s Approach for the Development of Sustainable Clay-Based Ceramics Incorporated with Malaysia’s Electric Arc Furnace Steel Slag Waste

This study aims to optimize the composition (body formulation) and firing temperature of sustainable ceramic clay-based ceramics incorporated with electric arc furnace (EAF) steel slag waste using general full factorial design (GFFD). The optimization is necessary to minimize drawbacks of high iron oxide’s fluxing agent (originated from electric arc furnace, EAF steel slag waste), which led to severe surface defects and high closed porosity issue of the ceramics. Statistical analysis of GFFD including model adequacy checking, analysis of variance (ANOVA), interaction plots, regression model, contour plot and response optimizer were conducted in the study. The responses (final properties of ceramics) investigated were firing shrinkage, water absorption, apparent porosity, bulk density and modulus of rupture (MOR). Meanwhile, the factors employed in experimental parameters were weight percentage (wt.%) of EAF slag added and firing temperature. Upon statistical analysis, GFFD has deduced that wt.% amount of EAF slag added and firing temperatures are proven to significantly influence the final properties of the clay-based ceramic incorporated with EAF slag. The results of conducted statistical analysis were also highly significant and proven valid for the ceramics. Optimized properties (maximum MOR, minimum water absorption and apparent porosity) of the ceramic were attained at 50 wt.% of EAF slag added and firing temperature of 1180 °C.

Synthesis of Zeolites from Greek Fly Ash and Assessment of Their Copper Removal Capacity

The objective of this study was to synthesize zeolites through fusion of lignite fly ash and NaOH or KOH pellets at 600 °C and assess their removal efficiency in terms of decontamination of solutions containing Cu(II) ions. The removal efficiency of the produced zeolites was tested in batch kinetic experiments using different zeolites and Cu(II) ion concentrations. Experimental data revealed that zeolites synthesized with the use of NaOH exhibited higher removal efficiency compared with those synthesized with the use of KOH. Kinetic data showed that the pseudo-second-order equations described well the removal process. Copper removal was mainly accomplished through the concerted action of chemisorption and intraparticle diffusion. Analytical techniques involving XRF, XRD, FTIR, SEM/EDS and XPS were used for the characterization and morphology analysis of the produced zeolites. SEM/EDS confirmed the presence of copper on the zeolite surface. XPS spectra of Cu2p at 934.3 eV proved the presence of Cu(II) oxidation state, confirming the possible formation of CuO and/or Cu-Cl.

Preparation of porous glass-ceramics from coal fly ash and asbestos tailings by high-temperature pore-forming

This paper presented a new method of preparing porous glass-ceramics by high-temperature pore-forming using coal fly ash and asbestos tailings as raw materials. The effects of the content of asbestos tailings and sintering temperature on the phase composition, microstructure and properties of the porous glass-ceramics had been systematically discussed, furthermore, the pore formation mechanism was also expounded. Compared with T0, porous glass-ceramics from T1, T2 and T3 experienced more violent self-expansion during the sintering process due to the addition of asbestos tailings. The porosity of porous glass-ceramics from T3 was 51%, the bulk density was 1.42 g/cm³, the flexure strength was 19 MPa, the main crystal phase was indialite, along with several secondary phases such as anorthite, enstatite, and forsterite. Due to the high strength, the material was expected to be used as a porous construction material with load-bearing function. This work provided a convenient and promising method for the utilization of coal fly ash and asbestos tailings to prepare porous glass-ceramics without adding foaming agents.