Università degli studi di Modena e Reggio Emilia

: To achieve carbon neutrality by 2050, many companies have started implementing sustainability policies. The aim of this work, as result of collaboration between Universities and companies, is to assess the environmental impacts associated with the production of alternative formulations of porcelain stoneware. The proposed formulations contain extraction scraps and chamotte and have promising technological properties. A comparative analysis of the life cycle in three different scenarios was carried out to assess the environmental footprint of the final products. The analyzed scenarios were a glazed porcelain stoneware (which was taken as a reference and is commercially available), a porcelain stoneware containing pumice scraps, and one containing volcanic lapillus scraps. It was observed that the transportation of raw materials has the largest environmental impact, followed by the production and extraction of the raw materials themselves. From the performed analysis, it was possible to observe that by replacing the currently used materials by the ones hereby studied, environmental benefits can be obtained. In particular, depending on the considered pollutant, the environmental impact can be reduced between a minimum of about 8 % (Freshwater Aquatic Ecotoxicity category) to a maximum of 48 % (Acidification category). In a time when raw materials supply is difficult, the use of scraps, which would otherwise be disposed of, is particularly interesting and can lead to the production of an environmentally friendly product.

The chemical, microstructural and mechanical characterization of novel lightweight composites produced by adding waste cork dust to a metakaolin-based geopolymeric matrix prepared by alkaline activation is presented. The alkaline activator solutions used for the reticulation of the 3D aluminosilicate network at room temperature are composed of NaOH and sodium silicate to maintain a low cost of the final composite. In this line, the research of the highest addition of waste, e.g. cork dust, is pursued starting from 1 and reaching a maximum content of 10 wt% over metakaolin. The chemical stability is evaluated in water as well as in HNO3 or in H2SO4 0.5 and 2.5 N solutions. The addition of cork does not affect the reticulation of the geopolymeric binder used as matrix, as is demonstrated by FT-IR and XRD analyses. The modification of the dense geopolymeric microstructure with the introduction of cork dust weakens the hardened composites that become more permeable to water and acid solutions increasing the weight loss after immersion and decreasing the mechanical resistance to compression. The mechanical performance of the hardened composite with 10 wt% of cork dust still seems to be sufficient for application as self-supporting thermal insulation panels.

This work started as a joint academia and company research project with the aim of finding new applications for domestically sourced volcanic products and related waste (pumice, lapillus, zeolitic tuff and volcanic debris from Tessennano and Arlena quarry) by creating a database of secondary volcanic raw materials and their intrinsic characteristics to help industry replace virgin materials and enhance circularity. In this context, accurate chemical, mineralogical, morphological, granulometric and thermal characterizations were performed. Based on the results presented, it can be concluded that due to their lightness, these materials can be used in the design and preparation of lightweight aggregates for agronomic purposes or in the construction field. Furthermore, due to their aluminosilicate nature and amorphous fraction, pumice and lapillus can play the role of precursor or activator for geopolymer preparation. With its porous nature, zeolitic tuff can be exploited for flue gas treatment. Due to the presence of feldspathic phase (sanidine), these materials can be used in tile production as a fluxing component, and with their pozzolanic activity and calcium content, they have application in the binder field as supplementary cementitious material or as aggregates.

Italian volcanic quarry scraps, with fine particle size and of little market interest, have been considered for the manufacturing of lightweight geopolymers and highly porous foams. Both powders have been alkali activated with NaOH solution at 8 M and 3 M, respectively. Geopolymers were characterized in terms of density, porosity, humidity absorption/desorption, mechanical strength and microstructure. All samples (with a bulk density of 1.5–1.6 g/cm3) exhibited a porosity of approximatively 35 vol% but featured a quite variable compressive strength (3–7 MPa), depending on the use of pumice or lapillus. The same quarry scraps were easily converted into highly porous foams (porosity of 75 vol%), by intensive mechanical stirring of alkali-activated suspensions, with the help of a surfactant.

Italian pumice and volcanic lapillus scraps have been used in different percentages as alternative raw materials to foreign feldspars in porcelain stoneware mixtures. The aim of this work was to create naturally colored support to limit the use of artificial dyes while maintaining the technical properties of the reference product. For this purpose, the significant presence of chromophores (Fe and Ti in particular) in by-products from extraction of Italian volcanic pumice and lapillus was exploited. The work was carried out in collaboration with a company: the products were made on a laboratory scale and then they were glazed and fired within the industrial production cycle (48 min, 1210 ◦C). The resulting slip and the fired samples were characterized by measuring the efflux time, density, linear shrinkage, water absorption and tensile strength to evaluate the technological performance. In addition, thermogravimetric analysis (TG), differential thermal analysis (DTA), and optical and mechanical dilatometry were performed to study the thermal behavior of the formulations. The obtained products could be classified as porcelain stoneware and belong to the BIa group (WA 0.5%, B. S.>35 MPa) in accordance with UNI EN 14411 ISO 13006.