Valorização de resíduos industriais na formulação de produtos e pigmentos cerâmicos: processamento e desenvolvimento de cor

A valorização de diferentes resíduos industriais provenientes dosector de tratamento/revestimento de superfícies metálicas pode ser obtida utilizando-os como matérias-primas na formulação de pigmentos cerâmicos, sintetizados pelo método cerâmico convencional. Neste trabalho avaliou-se a viabilidade de incorporar lamas geradas pelos processos de (i) anodização, ricas em alumínio, (ii) de niquelagem e cromagem de torneiras, usadas como fonte de níquel e crómio, e (iii) da decapagem química de aços de uma trefilaria, ricas em ferro, utilizadas por si só, ou em conjunto com matérias-primas comerciais, para a obtenção depigmentos cerâmicos que coram, de forma estável, diversas matrizes cerâmicas e vítreas. Esta solução assegura ainda a inertização de potenciaisespécies perigosas presentes nos resíduos, resultando produtos inócuospara a saúde pública. Procedeu-se à caracterização de cada resíduo, em termos de composição química e mineralógica, comportamento térmico, grau de toxicidade, distribuição granulométrica, teor de humidade, etc. Verificou-se a constância das características das lamas, recorrendo à análise de lotes recolhidos em momentos distintos. Os resíduos são essencialmente constituídos por hidróxidos metálicos e foram utilizados após secagem e desagregação. No entanto, a lama de anodização de alumínio sofreu um tratamento térmico suplementar a 1400ºC. O método de síntese dos pigmentos englobou as seguintes etapas: (i) doseamento; (ii) homogeneização; (iii) calcinação; (iv) lavagem e moagem.Procedeu-se à caracterização dos pigmentos, avaliando a cor por espectroscopia de reflectância difusae pelo método CIELAB e determinando as características físico-químicas relevantes. Posteriormente, testou-se o seu desempenho em produtos cerâmicos distintos (corpos e vidrados), aferindo o desempenho cromático e a estabilidade. Numa primeira fase, desenvolveram-se e caracterizaram-se tipos distintos de pigmentos: (i) com base na estrutura do corundo (ii) verde Victória deuvarovite (iii) violeta de cassiterite com crómio (iv) pigmento carmim de malaiaíte; (v)pretos e castanhos com base na estrutura da espinela. Aprofundaram-se depois os estudos do pigmento carmim de malaiaítee do pigmento preto com base na estrutura da espinela. O pigmento carmim de malaiaíte, CaSnSiO5:Cr2O3, é formulado coma lama gerada no processo de niquelagem e cromagem. Avaliou-se a influência do teor de lama na temperatura de síntese e na qualidade cromática, em comparação com um pigmento formulado com reagentes puros. O pigmento preto com estrutura de espinela de níquel, crómio e ferro, foii formulado exclusivamente a partir das lamas geradas nos processos de cromagem/niquelagem e de decapagem química do aço. Avaliaram-se as características cromáticas e o grau de inertização dos elementos tóxicospresentes, em função da estequiometria e do tratamento térmico. Estudou-se ainda um novo sistema com base na estrutura da hibonite(CaAl12O19), que permite a obtenção de pigmentos azuis e que utiliza a lama de cromagem e niquelagem. As espécies cromóforas (Ni2+ ou Co2+) assumem coordenação tetraédrica quando substituem os iões Al3+ que ocupam as posições M5 da rede da hibonite. A formação simultânea de anortite permite reduzir a temperatura de síntese.Para além do carácter inovador deste pigmento de dissolução sólida, a qualidade cromática e a sua estabilidade são interessantes. Além disso, os teores de cobalto ou níquel são reduzidosrelativamente aos utilizados em formulações comerciais de pigmentos azuis, o que se traduz em importantes vantagens económicas e ambientais.

Materials and concepts for CO2 lean ironmaking by pyroelectrolysis

The main purpose of this PhD thesis was to provide convincing demonstration for a breakthrough concept of pyroelectrolysis at laboratory scale. One attempted to identify fundamental objections and/or the most critical constraints, to propose workable concepts for the overall process and for feasible electrodes, and to establish the main requirements on a clearer basis. The main effort was dedicated to studying suitable anode materials to be developed for large scale industrial units with molten silicate electrolyte. This concept relies on consumable anodes based on iron oxides, and a liquid Fe cathode, separated from the refractory materials by a freeze lining (solid) layer. In addition, one assessed an alternative concept of pyroelectrolysis with electron blocking membranes, and developed a prototype at small laboratory scale. The main composition of the molten electrolyte was based on a magnesium aluminosilicate composition, with minimum liquidus temperature, and with different additions of iron oxide. One studied the dynamics of devitrification of these melts, crystallization of iron oxides or other phases, and Fe2+/Fe3+ redox changes under laser zone melting, at different pulling rates. These studies were intended to provide guidelines for dissolution of raw materials (iron oxides) in the molten electrolyte, to assess compatibility with magnetite based consumable anodes, and to account for thermal gradients or insufficient thermal management in large scale cells. Several laboratory scale prototype cells were used to demonstrate the concept of pyroelectrolysis with electron blocking, and to identify the most critical issues and challenges. Operation with and without electron blocking provided useful information on transport properties of the molten electrolyte (i.e., ionic and electronic conductivities), their expected dependence on anodic and cathodic overpotentials, limitations in faradaic efficiency, and onset of side electrochemical reactions. The concept of consumable anodes was based on magnetite and derived spinel compositions, for their expected redox stability at high temperatures, even under oxidising conditions. Spinel compositions were designed for prospective gains in refractoriness and redox stability in wider ranges of conditions (T, pO2 and anodic overpotentials), without excessive penalty for electrical conductivity, thermomechanical stability or other requirements. Composition changes were also mainly based on components of the molten aluminosilicate melt, to avoid undue contamination and to minimize the dissolution rate of consumable anodes. Additional changes in composition were intended for prospective pyroelectrolysis of Fe alloys, with additions of different elements (Cr, Mn, Ni, Ti).

Assessing the effectiveness of chemical treatment with nanomaterials in improving the quality of different industrial effluents

Industrial activities are the major sources of pollution in all environments. Depending on the type of industry, various levels of organic and inorganic pollutants are being continuously discharged into the environment. Although, several kinds of physical, chemical, biological or the combination of methods have been proposed and applied to minimize the impact of industrial effluents, few have proved to be totally effective in terms of removal rates of several contaminants, toxicity reduction or amelioration of physical and chemical properties. Hence, it is imperative to develop new and innovative methodologies for industrial wastewater treatment. In this context nanotechnology arises announcing the offer of new possibilities for the treatment of wastewaters mainly based on the enhanced physical and chemical proprieties of nanomaterials (NMs), which can remarkably increase their adsorption and oxidation potential. Although applications of NMs may bring benefits, their widespread use will also contribute for their introduction into the environment and concerns have been raised about the intentional use of these materials. Further, the same properties that make NMs so appealing can also be responsible for producing ecotoxicological effects. In a first stage, with the objective of selecting NMs for the treatment of organic and inorganic effluents we first assessed the potential toxicity of nanoparticles of nickel oxide (NiO) with two different sizes (100 and 10-20 nm), titanium dioxide (TiO2, < 25 nm) and iron oxide (Fe2O3, ≈ 85x425 nm). The ecotoxicological assessment was performed with a battery of assays using aquatic organisms from different trophic levels. Since TiO2 and Fe2O3 were the NMs that presented lower risks to the aquatic systems, they were selected for the second stage of this work. Thus, the two NMs pre-selected were tested for the treatment of olive mill wastewater (OMW). They were used as catalyst in photodegradation systems (TiO2/UV, Fe2O3/UV, TiO2/H2O2/UV and Fe2O3/H2O2/UV). The treatments with TiO2 or Fe2O3 combined with H2O2 were the most efficient in ameliorating some chemical properties of the effluent. Regarding the toxicity to V. fischeri the highest reduction was recorded for the H2O2/UV system, without NMs. Afterwards a sequential treatment using photocatalytic oxidation with NMs and degradation with white-rot fungi was applied to OMW. This new approach increased the reduction of chemical oxygen demand, phenolic content and ecotoxicity to V. fischeri. However, no reduction in color and aromatic compounds was achieved after 21 days of biological treatment. The photodegradation systems were also applied to treat the kraft pulp mill and mining effluents. For the organic effluent the combination NMs and H2O2 had the best performances in reduction the chemical parameters as well in terms of toxicity reduction. However, for the mine effluent the best (TiO2/UV and Fe2O3/UV) were only able to significantly remove three metals (Zn, Al and Cd). Nonetheless the treatments were able of reducing the toxicity of the effluent. As a final stage, the toxicity of solid wastes formed during wastewater treatment with NMs was assessed with Chironomus riparius larvae, a representative species of the sediment compartment. Certain solid wastes showed the potential to negatively affect C. riparius survival and growth, depending on the type of effluent treated. This work also brings new insights to the use of NMs for the treatment of industrial wastewaters. Although some potential applications have been announced, many evaluations have to be performed before the upscaling of the chemical treatments with NMs.