Nuova ricerca

CATERINA SGARLATA

Assegnista di ricerca
INTERMECH Centro Interd. per la Ricerca Applicata e i Servizi nel settore della Meccanica Avanzata e della Motoristica

Home |


Pubblicazioni

2023 - Use of Foundry Sands in the Production of Ceramic and Geopolymers for Sustainable Construction Materials [Articolo su rivista]
Sgarlata, C.; Ariza-Tarazona, M. C.; Paradisi, E.; Siligardi, C.; Lancellotti, I.
abstract

The aim of this research was to evaluate the possibility of reusing waste foundry sands derived from the production of cast iron as a secondary raw material for the production of building materials obtained both by high-temperature (ceramic tiles and bricks) and room-temperature (binders such as geopolymers) consolidation. This approach can reduce the current demand for quarry sand and/or aluminosilicate precursors from the construction materials industries. Samples for porcelain stoneware and bricks were produced, replacing the standard sand contained in the mixtures with waste foundry sand in percentages of 10%, 50%, and 100% by weight. For geopolymers, the sand was used as a substitution for metakaolin (30, 50, 70 wt%) as an aluminosilicate precursor rather than as an aggregate to obtain geopolymer pastes. Ceramic samples obtained using waste foundry sand were characterized by tests for linear shrinkage, water absorption, and colorimetry. Geopolymers formulations, produced with a Si/Al ratio of 1.8 and Na/Al = 1, were characterized to evaluate their chemical stability through measurements of pH and ionic conductivity, integrity in water, compressive strength, and microstructural analysis. The results show that the addition of foundry sand up to 50% did not significantly affect the chemical-physical properties of the ceramic materials. However, for geopolymers, acceptable levels of chemical stability and mechanical strength were only achieved when using samples made with 30% foundry sand as a replacement for metakaolin.

2022 - Mine clay washing residues as a source for alkali-activated binders [Articolo su rivista]
Sgarlata, C.; Formia, A.; Siligardi, C.; Ferrari, F.; Leonelli, C.
abstract

The aim of this paper is to promote the use of mine clay washing residues for the preparation of alkali activated materials (AAMs). In particular, the influence of the calcination temperature of the clayey by-product on the geopolymerization process was investigated in terms of chemical stability and durability in water. The halloysitic clay, a mining by-product, has been used after calcination and mixed with an alkaline solution to form alkali activated binders. Attention was focused on the influence of the clay’s calcination treatment (450–500–600◦C) on the geopolymers’ microstructure of samples, remaining in the lower limit indicated by the literature for kaolinite or illite calcination. The mixtures of clay and alkali activators (NaOH 8M and Na-silicate) were cured at room temperature for 28 days. The influence of solid to liquid ratio in the mix formulation was also tested in terms of chemical stability measuring the pH and the ionic conductivity of the eluate after 24-h immersion time in water. The results reported values of ionic conductivity higher for samples made with untreated clay or with low temperature of calcination (≥756 mS/m) compared with values of samples made with calcined clay (292 mS/m). This result suggests that without a proper calcination of the as-received clay it was not possible to obtain 25◦C-consolidated AAMs with good chemical stability and dense microstructure. The measures of integrity test, pH, and ionic conductivity in water confirmed that the best sample is made with calcined clay at 600◦C, being similar (53% higher ionic conductivity of the eluate) or equal (integrity test and pH) to values recorded for the metakaolin-based geopolymer considered the reference material. These results were reflected in term of reticulation and morphology of samples through the analysis with scanning electron microscope (SEM) and X-ray diffraction (XRD), which show a dense and homogeneous microstructure predominantly amorphous with minor amounts of quartz, halloysite, and illite crystalline phases. Special attention was dedicated to this by-product to promote its use, given that kaolinite (and metakaolin), as primary mineral product, has a strong impact on the environment. The results obtained led us to consider this halloysite clay very interesting as an aluminosilicate precursor, and extensively deepening its properties and reactivity for the alkaline activation. In fact, the heart of this work is to study the possibility of reusing this by-product of an industrial process to obtain more sustainable high-performance binders.

2022 - Sustainable Chromium Encapsulation: Alkali Activation Route [Articolo su rivista]
Sgarlata, C.; Leonelli, C.; Lancellotti, I.; Mortalo, C.; Berrettoni, M.; Fattobene, M.; Zamponi, S.; Giorgetti, M.
abstract

This article highlights recent experimental advances in the use of inorganic substances in the encapsulation of pollutants and, in particular, discusses the potential applicability and constraints of the geopolymerization process for the treatment of wastewater containing chromium. A great percentage of waste containing chromium salts is produced by the leather industry during the tannery process. Such industrial waste is in the form of liquor containing almost 40% of the initial chromium combined with many other pollutants. The stabilization/solidification (S/S) treatment of this type of waste must be combined with chromium encapsulation in an economic, environmentally friendly and efficient process to be industrially feasible. Here we present a novel process in which the wastewater is used as a component of the formulation together with a clay by-product and with the addition of NaOH pellets with the goal of a no-water plus no-waste technology approach. The final solidified “ceramic-like” material successfully immobilized the heavy metal cations as well as anions and macromolecules of surfactants, avoiding environmental damages to soil and groundwater. The article is completed by mentioning other S/S processes where wastewater has been treated and the resulting sludge encapsulated. The future of the S/S technologies in the tannery industry should progress in the direction of significantly reducing the amount of wastewater directed to the treatment plants, with associated reductions in transport and their CO2 emissions. This article intends to be a contribution in the direction of preventing waste, aligning circular economy and waste management objectives.

2021 - Antibacterial Properties and Cytotoxicity of 100% Waste Derived Alkali Activated Materials: Slags and Stone Wool-Based Binders [Articolo su rivista]
Sgarlata, C.; Dal Poggetto, G.; Piccolo, F.; Catauro, M.; Traven, K.; Cesnovar, M.; Nguyen, H.; Yliniemi, J.; Barbieri, L.; Ducman, V.; Lancellotti, I.; Leonelli, C.
abstract

In this study we compare the leaching behavior and the antibacterial and cytotoxic properties of 100% slag or stone wool derived alkali activated materials. The antibacterial activity was measured as the inhibiting capacity against two Gram-negative bacterial strains, Escherichia coli and Pseudomonas aeruginosa and one Gram-positive bacterial strain: Enterococcus faecalis. The cytotoxicity properties were tested on mouse embryonic fibroblast NIH-3T3 cell-line. It was proved that the high quality of the 3D aluminosilicate network of the consolidated materials obtained from powders of CaO or MgO-rich slags or stone wool, opportunely activated with NaO and/or Na-silicate, was capable of stabilizing heavy metal cations. The concentrations of leachate heavy cations were lower than the European law limit when tested in water. The effect of additives in the composites, basal fibers or nanocellulose, did not reduce the chemical stability and slightly influenced the compressive strength. Weight loss in water increased by 20% with basalt fibers addition, while it remained almost constant when nanocellulose was added. All the consolidated materials, cement-like in appearance, exhibited limited antibacterial properties (viability from 50 to 80% depending on the bacterial colony and the amount of sample) and absence of cytotoxicity, envisaging good acceptance from part of the final consumer and zero ecological impact. CaO-rich formulations can replace ordinary Portland cement (showing bacterial viability at 100%) with a certain capability for preventing the reproduction of the E. coli and S. aureus bacteria with health and environmental protection results.

2021 - Effect of the introduction of reactive fillers and metakaolin in waste clay-based materials for geopolymerization processes [Articolo su rivista]
Sgarlata, C.; Formia, A.; Ferrari, F.; Leonelli, C.
abstract

In this study, the role of two reactive fillers, specifically a sand from a clay washing process as an alternative to waste glass powder and a commercial metakaolin (MK), into the geopolymerization process of waste clay-based materials was assessed. Three kinds of clayey wastes from mining operations-halloysitic, kaolinitic and smectitic clays-were tested as potential precursor of geopolymeric materials in view of a potential valorisation of these by-products. A mix-design based on the addition of low percentages (20%) of these fillers or MK to improve the mechanical and chemico-physical properties of geopolymeric formulations was evaluated. All the clays were thermally treated at a temperature of 650 °C, while the geopolymeric pastes were cured at room temperature. In particular, the chemical stability in water (pH and ionic conductivity of leachate water, weight loss), the variations in the microstructure (XRD, SEM), and in the mechanical performance (compressive strength) were analysed. The most reactive additive was MK, followed by sand and waste glass at very similar levels-1:1 or 2:1-depending upon the type of the clay but not strictly related to the clay type. The increase of geopolymeric gel densification due to the presence of MK and sand was replaced by a crack deflection mechanism in the case of the WG grains. The worst performance (chemical stability and mechanical properties) was found for the halloysitic clay, while kaolinitic and smectitic clays developed strengths slightly below 30 MPa.

2021 - Efficient chemical stabilization of tannery wastewater pollutants in a single step process: Geopolymerization [Articolo su rivista]
Boldrini, G.; Sgarlata, C.; Lancellotti, I.; Barbieri, L.; Giorgetti, M.; Ciabocco, M.; Zamponi, S.; Berrettoni, M.; Leonelli, C.
abstract

The treatment of tannery wastewaters is a complex task due to the complexity of the waste: a mixture of several pollutants, both anionic and cationic as well as organic macromolecules which are very hard to treat for disposal all together. Geopolymers are a class of inorganic binders obtained by alkali activation of aluminosilicate powders at room temperature. Such activation process leads to a cement like matrix that drastically decreases mobility of several components via entrapment. This process taking place in the matrix can be hypothesized to be the in-situ formation of zeolite structures. In this work we use a metakaolin based geopolymer to tackle the problem directly in an actual industrial environment. To obtain a geopolymer, the metakaolin was mixed with 10 wt% of wastewater added with sodium hydroxide and sodium silicate as activating solutions. This process allowed a rapid consolidation at room temperature, the average compressive strength was between 14 and 43 MPa. Leaching tests performed at different aging times confirm a high immobilization efficiency close to 100%. In particular, only the 0.008 and 2.31% of Chromium and Chlorides respectively are released in the leaching test after 7 months of aging.

2021 - Metakaolin addition to improve geopolymerization process and properties of waste clay-based materials [Articolo su rivista]
Sgarlata, C.; Formia, A.; Ferrari, F.; Piccolo, F.; Leonelli, C.
abstract

The exploitation of different kind of clayey waste (halloysitic, smectitic/illitic, kaolinitic) for the production of geopolymers in the view of a circular economy of mines is the main goal of this study. In particular, the addition of low percentages of metakaolin (5-15%) was evaluated to improve the chemical-physical properties and the consolidation degree of geopolymeric formulations produced with clays classified as mine’s by-products. In fact, these secondary raw materials are often not sufficient alone to obtain chemically stable formulations with acceptable mechanical properties but require the addition of reactive fillers. All samples contained thermally treated clays (600°C-700°C) and metakaolin as aluminosilicate precursors, alkaline solution of NaOH and Na2SiO3, and were cured at room temperature. The influence on the final products with MK addition was monitored with the evaluation of the chemical stability in water (pH and ionic conductivity measures), the comparison of setting times (Vicat needle) and mechanical performance.

2021 - Potentiality of the Use of Pyroclastic Volcanic Residues in the Production of Alkali Activated Material [Articolo su rivista]
Barone, Germana; Finocchiaro, Claudio; Lancellotti, Isabella; Leonelli, Cristina; Mazzoleni, Paolo; Sgarlata, Caterina; Stroscio, Antonio
abstract

Volcanic rocks have been used for building activity by the inhabitants of important cities located on the slopes of Mt. Etna, Italy. In this paper, the potential use of volcanic residues (code 20 03 03—“Municipal waste” residues from road cleaning in the European Waste Catalogue (EWC)) for the production of alkali activated material, especially devoted to the restoration of buildings belonging to the Baroque Sicilian architecture, was investigated. In particular, large volcanic pyroclastic deposits of recent eruptions considered waste materials were studied and a volcanic paleo-soil, locally named ghiara, widely used for mortars and plaster production in XVII–XVIII century with good pozzolanic features, was also considered. Both volcanic materials were activated using different mixtures of NaOH and Na2SiO3. Furthermore, formulations with different amount of metakaolin addition (10–25 wt%) were prepared due to low reactivity of volcanic materials and to allow the activation at room temperature. X ray diffraction revealed the formation of small quantities of zeolites as a result of the alkali activation process. The mechanical-physical results evidenced that the mechanical strength is strongly dependent on the metakaolin amount (10–38 MPa); accessible porosity average 25% and an average pore diameter of 0.06 µm; water absorption range 9–15%, eluates conductivity in the range 20–350 µS/m. These results confirm the occurring of alkali activation and the good potential for these pyroclastic wastes for valorization in the restoration field.

2020 - Artificial neural networks test for the prediction of chemical stability of pyroclastic deposits-based AAMs and comparison with conventional mathematical approach (MLR) [Articolo su rivista]
Finocchiaro, Claudio; Barone, Germana; Mazzoleni, Paolo; Sgarlata, Caterina; Lancellotti, Isabella; Leonelli, Cristina; Romagnoli, Marcello
abstract

Abstract: The investigation on the reticulation degree of volcanic alkali-activated materials, AAMs, were experimentally determined in terms of chemico-physical properties: weight loss after leaching test in water, ionic conductivity and pH of the leachate and compressive strength. Artificial neural network (ANN) was successfully applied to predict the chemical stability of volcanic alkali-activated materials. Nine input data per each chemico-physical parameter were used to train each ANN. The training series of specific volcanic precursors were tested also for the other one. Excellent correlations between experimental and calculated data of the same precursor type were found reaching values around one. The evidence of strong effect on chemical stability of the alkaline activator SiO2/Na2O molar ratio as well as the Si/Al ratio of precursor mixtures on the reticulation degree of ghiara-based formulation with respect to volcanic ash-based materials is presented. It must be noted that such effect was much less pronounced on the compressive strength values, appearing more insensitive the molar ratio of the alkaline activator. The comparison of the ANN results with more conventional multiple linear regression (MLR) testifies the higher prediction performance of the first method. MLRs results, less significant, are useful to confirm the powerful capacity of ANNs to identify the more suitable formulation using a set of experimental AAMs. This study, as few others, on the correlation between chemical stability and compressive strength of AAMs provide a great contribution in the direction of durability and in-life mechanical performance of these class of materials. Graphic abstract: [Figure not available: see fulltext.].

2020 - Thermal and microbiological performance of metakaolin-based geopolymers cement with waste glass [Articolo su rivista]
Catauro, M.; Dal Poggetto, G.; Sgarlata, C.; Vecchio Ciprioti, S.; Pacifico, S.; Leonelli, C.
abstract

In this paper, we investigated the behavior of the metakaolin-based geopolymeric matrix incorporated with waste glass. Pure metakaolin and mixtures obtained by adding different percentages (30, 40, and 50 wt%) of waste glass were consolidated via alkali activation at 50 °C. Infrared spectroscopy was able to reveal the formation of bonds in the mixtures between the clay and the glass in the geopolymeric matrix. Leaching tests were carried out to evaluate the eventual release of toxic metals, while cytotoxicity and antibacterial tests completed the environmental evaluation of the final consolidated products that showed how the mechanical performance were improved by adding different amount of waste glass under compression in the range of 18–39 MPa. Simultaneous thermogravimetry/differential thermal analysis (TG/DTA) experiments showed that about 20 wt% of water was retained in all the samples and released up to 500 K, while lower amount of water was removed by dehydroxylation in the two glass-rich mixtures because of the lower degree of reticulation i.e. lower number of hydroxyl groups underwent to condensation.