Skip to main content

Advertisement

SpringerLink
Log in

Sustainable materials from hazardous lead ore flotation waste in composites with spent foundry sand and clay

  • ORIGINAL ARTICLE
  • Published:
The International Journal of Advanced Manufacturing Technology Aims and scope Submit manuscript

Abstract

The aim of this study was the experimental tests of the mechanical properties and structure formation processes of sustainable ceramics from hazardous lead ore flotation waste, spent foundry sand, and natural red clay to produce sustainable ceramics. The lead was mined on a large scale from lead ores in the city of Adrianópolis, Brazil, for 58 years. The wastes from this activity bequeathed profound environmental and social impacts. The mechanical characteristics of twenty compositions of the ceramics were analyzed through the flexural resistance, water absorption, apparent density, and linear shrinkage; the study of the physicochemical processes of the ceramics’ mineral composite transitions and structure formation during sintering at 900–1250 °C was accomplished using XRD, SEM, EDS, AAS, and LAMMA methods. All ceramics presented flexural resistance (until 10.08 MPa) in comparison with the values established in the Brazilian national standards (> 1.5 MPa), with low water absorption and shrinkage. Ceramics with 7% of the flotation waste and 10% spent foundry sand, whose resistance reached from 3.7 to 10.1 MPa, showed the best mechanical properties. Leaching and solubility analyses by AAS method showed that there is no environmental jeopardy in using these compositions to produce sustainable ceramics.

This is a preview of subscription content, log in via an institution to check access.

Access this article

Log in via an institution

Price excludes VAT (USA)
Tax calculation will be finalised during checkout.

Instant access to the full article PDF.

Institutional subscriptions

Fig. 1
Fig. 2
Fig. 3
Fig. 4
Fig. 5

Similar content being viewed by others

References

  1. Zhang L, Xu Z (2018) A critical review of material flow, recycling technologies, challenges and future strategy for scattered metals from minerals to wastes. Review J Clean Prod 202:1001–1025. https://doi.org/10.1016/j.jclepro.2018.08.073

    Article  Google Scholar 

  2. Metal Bulleting in Research, American Metal Market, 2018. http://www.metal bulletinresearch.com/Stub/10279/Consultancy.html

  3. Hossiney N, Das P, Mohan MK, George J (2018) In plant production of bricks containing waste foundry sand— a study with Belgaum foundry industry. Case Studies in Construction Materials 9:e00170

    Article  Google Scholar 

  4. Mackay I, Videla AR, Brito-Parada PR (2020) The link between particle size and froth stability - implications for reprocessing of flotation tailings. J Clean Prod 242:118436. https://doi.org/10.1016/j.jclepro.2019.118436

    Article  Google Scholar 

  5. Romero-García A, Iglesias-González N, Romero R, Lorenzo-Tallafigo J, Mazuelos A, Carranza F (2019) Valorization of a flotation tailing by bioleaching and brine leaching, fostering environmental protection and sustainable development. J Clean Prod 233:573–581. https://doi.org/10.1016/j.jclepro.2019.06.118

    Article  Google Scholar 

  6. Salokhe EP, Desai DB (2013) Application of foundry wastes and in manufacture of concrete. J Mec Civil Eng:43–48

  7. Bhimani RD, et al. (2012) A study on foundry sand: opportunities for sustainable and economical concrete GRA - global research analysis X 60.https://doi.org/10.15373/22778160/January2013/64

  8. Alekseev K, Mymrin V, Avanci MA, Klitzke W, Magalhães WLE, Silva PR, Catai RE, Silva DA, Ferraz FA (2019) Environmentally clean construction materials from hazardous bauxite waste red mud and spent foundry sand. J Constr Build Mat 229:116860. https://doi.org/10.1016/j.conbuildmat.2019.116860

    Article  Google Scholar 

  9. Ercikdi B, Külekci G, Yılmaz T (2015) Utilization of granulated marble wastes and waste bricks as mineral admixture in cemented paste backfill of sulphide-rich tailings. J Constr Build Mat 93:573–583. https://doi.org/10.1016/j.conbuildmat.2015.06.042

    Article  Google Scholar 

  10. Sua-iam G, Makul N, Cheng S, Sokrai P (2019) Workability and compressive resistance development of self-consolidating concrete incorporating rice husk ash and foundry sand waste – a preliminary experimental study. J Con Build Mat 228:116813. https://doi.org/10.1016/j.conbuildmat.2019.116813

    Article  Google Scholar 

  11. Coppio GJL, de Lima MG, Lencioni JW, Cividanes LS, Dyer PPOL, Silva SA (2019) Surface electrical resistivity and compressive resistance of concrete with the use of waste foundry sand as aggregate. J Constr Build Mat 212:514–521. https://doi.org/10.1016/j.conbuildmat.2019.03.297

    Article  Google Scholar 

  12. Souza CS et al (2019) Use of waste foundry sand (WFS) to produce protective coatings on aluminum alloy by plasma electrolytic oxidation. J Clean Prod. https://doi.org/10.1016/j.jclepro.2019.03.013

  13. Matos PR et al. (2020) Self-compacting mortars produced with fine fraction of calcined waste foundry sand (WFS) as alternative filler: fresh-state, hydration and hardened-state properties. J Clean Prod https://doi.org/10.1016/j.jclepro.2019.119871

  14. Mymrin V, Ribeiro RAC, Alekseev K, Zelinskaya E, Tolmacheva N, Catai R (2014) Environment friendly ceramics from hazardous industrial wastes. J Ceram Intern 40:9427–9437

    Article  Google Scholar 

  15. Bhardwaj B, Kumar P (2019) Comparative study of geopolymer and alkali activated slag concrete comprising waste foundry sand. J Constr Build Mat. https://doi.org/10.1016/j.conbuildmat.2019.03.107

  16. NBR 7170 (1993) Ceramic solid brick for masonry – specification, Rio de Janeiro

  17. NBR 15270 (2005) Ceramic components, part 2: ceramic blocks for structural masonry and sealing - terminology and requirements, Rio de Janeiro

  18. NBR 7178 (1997) Solo, Análise granulométrica. Rio de Janeiro

  19. Emel A, Egemen O (2017) The effects of additives on particle size and morphology on BaSO4 crystals. In: 3rd International Conference on New Trends in Chemistry p. 91

  20. NBR 10,004 (2004) Solid waste classification, Rio de Janeiro

  21. Ojovan M (2008) Configurations: thermodynamic parameter sand symmetry change satglass transition. J Entropy 10:334–364

    Article  Google Scholar 

  22. Callister WD et al (2005) Materials science and engineering: an introduction. Wiley, New York

    Google Scholar 

  23. Machado AT et al (2014) Structural ceramics made with clay and steel dust pollutants. J Appl Clay Sci. https://doi.org/10.1016/j.clay.2011.01.004

  24. NBR 1818 (1997) Ceramic tiles - specification and methods of test. Rio de Janeiro

  25. Dos Santos AV et al (2014) Reuse of sand disposed of foundry in lieu of sand natural in the manufacture of structural blocks. Int Conf Mat Eng Appl ICMEA

  26. Xu R (2015) Light scattering: a review of particle characterization applications. J Particuology 8:11–21

    Article  Google Scholar 

  27. Civera A, Pavese M, Saracco G, Specchia V (2003) Combustion synthesis of perovskite-type catalysts for natural gas combustion. J Catalysis Today 83:199–211

    Article  Google Scholar 

  28. Anastas PT, Warner JC (1998) Green chemistry: theory and practice. Oxford University Press, Oxford

    Google Scholar 

Download references

Acknowledgments

Thanks to the metallurgical company Voigt for the raw material supplied (foundry sand) and to those in charge of the administration of the (closed) mining area of the city of Adrianópolis, Brazil.

Author information

Authors and Affiliations

  1. Federal Technological University of Paraná, 4900, Deputado Heitor Alencar Furtado, str., Campus Curitiba, Ecoville, Paraná, CEP: 81280-340, Brazil

    Vsévolod Mymrin, Renata A. M. Correia, Kirill Alekseev, Monica A. Avanci & Paulo H. B. Rolim

  2. Federal University of Paraná, Curitiba, Brazil

    Walderson Klitzke & Marco A. Argenta

  3. VALE, rua Aarão Reis, 423, Praça da Estação, Centro, Belo Horizonte, MG, Brazil

    João B. Carmo

Authors
  1. Vsévolod Mymrin
    View author publications

    You can also search for this author in PubMed Google Scholar

  2. Renata A. M. Correia
    View author publications

    You can also search for this author in PubMed Google Scholar

  3. Kirill Alekseev
    View author publications

    You can also search for this author in PubMed Google Scholar

  4. Walderson Klitzke
    View author publications

    You can also search for this author in PubMed Google Scholar

  5. Monica A. Avanci
    View author publications

    You can also search for this author in PubMed Google Scholar

  6. Paulo H. B. Rolim
    View author publications

    You can also search for this author in PubMed Google Scholar

  7. Marco A. Argenta
    View author publications

    You can also search for this author in PubMed Google Scholar

  8. João B. Carmo
    View author publications

    You can also search for this author in PubMed Google Scholar

Corresponding author

Correspondence to Vsévolod Mymrin.

Additional information

Publisher’s note

Springer Nature remains neutral with regard to jurisdictional claims in published maps and institutional affiliations.

Rights and permissions

Reprints and permissions

About this article

Check for updates. Verify currency and authenticity via CrossMark

Cite this article

Mymrin, V., Correia, R.A.M., Alekseev, K. et al. Sustainable materials from hazardous lead ore flotation waste in composites with spent foundry sand and clay. Int J Adv Manuf Technol 109, 1333–1344 (2020). https://doi.org/10.1007/s00170-020-05722-y

Download citation

  • Received:

  • Accepted:

  • Published:

  • Issue Date:

  • DOI: https://doi.org/10.1007/s00170-020-05722-y

Keywords

Search

Navigation