Recycled, Bio-Based, and Blended Composite Materials for 3D Printing Filament: Pros and Cons—A Review

In recent years, additive manufacturing (AM), known as “3D printing”, has experienced exceptional growth thanks to the development of mechatronics and materials science. Fused filament deposition (FDM) manufacturing is the most widely used technique in the field of AM, due to low operating and material costs. However, the materials commonly used for this technology are virgin thermoplastics. It is worth noting a considerable amount of waste exists due to failed print and disposable prototypes. In this regard, using green and sustainable materials is essential to limit the impact on the environment. The recycled, bio-based, and blended recycled materials are therefore a potential approach for 3D printing. In contrast, the lack of understanding of the mechanism of interlayer adhesion and the degradation of materials for FDM printing has posed a major challenge for these green materials. This paper provides an overview of the FDM technique and material requirements for 3D printing filaments. The main objective is to highlight the advantages and disadvantages of using recycled, bio-based, and blended materials based on thermoplastics for 3D printing filaments. In this work, solutions to improve the mechanical properties of 3D printing parts before, during, and after the printing process are pointed out. This paper provides an overview on choosing which materials and solutions depend on the specific application purposes. Moreover, research gaps and opportunities are mentioned in the discussion and conclusions sections of this study.

Bird’s-eye view of recycled solid wastes in road engineering

Recent trends in road engineering have explored the potential of incorporating recycled solid wastes into infrastructures that including pavements,bridges,tunnels,and accessory structures.The utilization of solid wastes is expected to offer sustainable solutions to waste recycling while enhancing the performance of roads.This review provides an extensive analysis of the recycling of three main types of solid wastes for road engineering purposes:industrial solid waste,infrastructure solid waste,and municipal life solid waste.Industrial solid wastes suitable for road engineering generally include coal gangue,fly ash,blast furnace slag,silica fume,and steel slag,etc.Infrastructure solid wastes recycled in road engineering primarily consist of construction&demolition waste,reclaimed asphalt pavements,and recycled cement concrete.Furthermore,recent exploration has extended to the utilization of municipal life solid wastes,such as incinerated bottom ash,glass waste,electronics waste,plastic waste,and rubber waste in road engineering applications.These recycled solid wastes are categorized into solid waste aggregates,solid waste cements,and solid waste fillers,each playing distinct roles in road infrastructure.Roles of solid waste acting aggregates,cements,and fillers in road infrastructures were fully investigated,including their pozzolanic properties,integration effects to virgin materials,modification or enhancement solutions,engineering performances.Utilization of these materials not only addresses the challenge of waste management but also offers environmental benefits aiming carbon neutral and contributes to sustainable infrastructure development.However,challenges such as variability in material properties,environmental impact mitigation,secondary pollution to environment by leaching,and concerns regarding long-term performance need to be further addressed.Despite these challenges,the recycled solid wastes hold immense potential in revolutionizing road construction practices and fostering environmental stewardship.This review delves into a bird’seye view of the utilization of recycled solid wastes in road engineering,highlighting advances,benefits,challenges,and future prospects.

Developing Sustainable High Strength Concrete Mixtures Using Local Materials and Recycled Concrete

This study presents the development of high strength concrete (HSC) that has been made more sustainable by using both local materials from central Texas and recycled concrete aggregate (RCA), which has also been obtained locally. The developed mixtures were proportioned with local constituents to increase the sustainable impact of the material by reducing emissions due to shipping as well as to make HSC more affordable to a wider variety of applications. The specific constituents were: limestone, dolomite, manufactured sand (limestone), locally available Type I/II cement, silica fume, and recycled concrete aggregate, which was obtained from a local recycler which obtains their product from local demolition. Multiple variables were investigated, such as the aggregate type and size, concrete age (7, 14, and 28-days), the curing regimen, and the water-to-cement ratio (w/c) to optimize a HSC mixture that used local materials. This systematic development revealed that heat curing the specimens in a water bath at 50℃ (122oF) after demolding and then dry curing at 200℃ (392oF) two days before testing with a w/c of 0.28 at 28-days produced the highest compressive strengths. Once an optimum HSC mixture was identified a partial replacement of the coarse aggregate with RCA was completed at 10%, 20%, and 30%. The results showed a loss in compressive strength with an increase in RCA replacement percentages, with the highest strength being approximately 93.0 MPa (13,484 psi) at 28-days for the 10% RCA replacement. The lowest strength obtained from an RCA-HSC mixture was approximately 72.9 (MPa) (10,576 psi) at 7-days. The compressive strengths obtained from the HSC mixtures containing RCA developed in this study are comparable to HSC strengths presented in the literature. Developing this innovative material with local materials and RCA ultimately produces a novel sustainable construction material, reduces the costs, and produces mechanical performance similar to prepackaged, commercially, available construction building materials.

Experimental study on countermeasure against liquefaction-induced flotation of manhole using recycled materials packed in sandbags

The 2004 Niigata-ken Chuetsu earthquake in Japan caused serious damage to sewage facilities such as uplift of manholes and settlement of pavement above backfill soil for pipes.This paper deals with shake table tests in a 1 g gravity field on application of recycled materials for ground improvement to mitigation of liquefaction-induced flotation of manhole during earthquakes.The recycled materials used in tests were tire chips made of waste tires and crushed gravels made of waste reinforced concrete,and they were packed in sandbags.From the test results,it was confirmed that the recycled materials packed in sandbags could be treated as one of the countermeasures to restrain the flotation of manholes and settlement of ground surrounded by sandbags.

A closed-loop process for recycling LiNi_xCo_yMn_((1-x-y))O_2 from mixed cathode materials of lithium-ion batteries

With the rapid development of consumer electronics and electric vehicles(EV), a large number of spent lithium-ion batteries(LIBs) have been generated worldwide. Thus, effective recycling technologies to recapture a significant amount of valuable metals contained in spent LIBs are highly desirable to prevent the environmental pollution and resource depletion. In this work, a novel recycling technology to regenerate a LiNi_(1/3)Co_(1/3)Mn_(1/3)O_2 cathode material from spent LIBs with different cathode chemistries has been developed. By dismantling, crushing,leaching and impurity removing, the LiNi_(1/3)Co_(1/3)Mn_(1/3)O_2(selected as an example of LiNi_xCo_yMn_(1-x-y)O_2) powder can be directly prepared from the purified leaching solution via co-precipitation followed by solid-state synthesis. For comparison purposes, a fresh-synthesized sample with the same composition has also been prepared using the commercial raw materials via the same method. X-ray diffraction(XRD), scanning electron microscopy(SEM) and electrochemical measurements have been carried out to characterize these samples. The electrochemical test result suggests that the re-synthesized sample delivers cycle performance and low rate capability which are comparable to those of the freshsynthesized sample. This novel recycling technique can be of great value to the regeneration of a pure and marketable LiNi_xCo_yMn_(1-x-y)O_2 cathode material with low secondary pollution.

Progress,challenges,and prospects of spent lithium-ion batteries recycling:A review

The recycling and reutilization of spent lithium-ion batteries(LIBs)have become an important measure to alleviate problems like resource scarcity and environmental pollution.Although some progress has been made,battery recycling technology still faces challenges in terms of efficiency,effectiveness and environmental sustainability.This review aims to systematically review and analyze the current status of spent LIB recycling,and conduct a detailed comparison and evaluation of different recycling processes.In addition,this review introduces emerging recycling techniques,including deep eutectic solvents,molten salt roasting,and direct regeneration,with the intent of enhancing recycling efficiency and diminishing environmental repercussions.Furthermore,to increase the added value of recycled materials,this review proposes the concept of upgrading recycled materials into high value-added functional materials,such as catalysts,adsorbents,and graphene.Through life cycle assessment,the paper also explores the economic and environmental impacts of current battery recycling and highlights the importance that future recycling technologies should achieve a balance between recycling efficiency,economics and environmental benefits.Finally,this review outlines the opportunities and challenges of recycling key materials for next-generation batteries,and proposes relevant policy recommendations to promote the green and sustainable development of batteries,circular economy,and ecological civilization.

Exploration on the Recycling of Waste Building Materials in Comprehensive Land Consolidation from the Perspective of Ecological Civilization

The necessity and difficulties of waste building material utilization in comprehensive land consolidation are put forward by analyzing the source,quantity and harm of waste building materials.Combined with the practice of Shanghai,the mechanism and pattern of waste building materials recycling are explored,in order to provide the reference for recycling of waste building materials and efficient promotion of land consolidation.

Recycling of minute metal scraps by semisolid processing:Manufacturing of design materials

As a new attempt to recycle minute metal scraps, the possibility of manufacturing design materials by semisolid extrusion processing was shown.A design material with an intended shape, such as a character or petal shape, was manufactured using minute metal scraps.Similarly, a design material with an intended color pattern for each metal, such as red copper in a white aluminum matrix, resembling grainlike wood, was manufactured by mixing two or more types of minute metal scrap.In addition, secondary design materials, which have engraved patterns on the surface of the target metal made by an electric discharge machine using the above primary design material as an electrode, were manufactured.

Critical Materials Institute develops new acid-free magnet recycling process

A new rare-earth magnet recycling process developed by researchers at the Critical Materials Institute (CMI) dissolves magnets in an acid-free solution and recovers high purity rare earth elements. For shredded magnet-containing electronic wastes, the process does not require pre-processing such as pre-sorting or demagnetization of the electronic waste.

Development and Application of a High-Volume Recycled Powder Solidifying Material for Waterworks Sludge

Recycled powder(RP)is produced as a by-product during the process of recycling construction and demolition(C&D)wastes,presenting a low additional value.Using RP-based solidifying material can not only improve its utilization efficiency,but also reduce the cost of commercial solidifying materials.To date,this is the best solidifying material utilized to dispose the original waterworks sludge(OWS)with high moisture contents(60%),and the product could be used to fabricate non-fired bricks.This has become a new environment-friendly technology of“using waste to treat waste”.In this paper,the influence of different particle sizes and dosages of RP on the prepared solidifying material was studied.Besides,unconfined compression strength(UCS),volume stability,chemical composition,and heat of hydration,pore structure of the solidifying material were characterized.Then,non-fired bricks were prepared by using the solidifying material,recycled aggregate,and original waterworks sludge.The UCS and softing coefficient(SC)of the non-fired bricks were evaluated.As a result,the 28-day UCS of the solidifying material with optimal(M30)was 35.40 MPa,which could reach 84.37%of Portland cement(PC).The addition of RP increased the volume stability of the solidifying material.The addition of a large amount of RP reduced the heat flux and cumulative heat release of the solidifying material,while its porosity increased.The UCS of non-fired brick(NF20)in 28 days was 15.19 MPa and the SC after 28 days was 78.35%.In conclusion,the preparation of solidifying material using RP could be a promising approach and has a great potential in disposal of original waterworks sludge.

Properties of Rapid Hardening Controlled Low Strength Material Made of Recycled Fine Aggregate from Urban Red Brick Construction Waste

In some cases of emergency backfill engineering projects, traditional backfill materials cannot meet the requirements of fast construction due to their long curing time. This study presents a new kind of rapid hardening controlled low strength material, which utilizes both rapid hardening sulphoaluminate cement and recycled fine aggregate from urban red brick construction waste. Totally, sixteen mixtures were prepared for the experiment with different cement-to-sand ratios and water-to-solid ratios. The flowability and bleeding rate of fresh mixture were measured to evaluate its workability, and the compressive strength of hardened mixture was tested to evaluate its rapid hardening and mechanical properties. Test results indicate that rapid hardening controlled low strength material containing recycled fine aggregate from urban red brick construction waste can achieve the desirable flowability, but the bleeding rate increases with the increase of flowability. In addition, 2-hour compressive strength can reach 0.08 - 0.12 MPa, and 4-hour compressive strength is 0.32 - 1.54 MPa, which can meet the requirements of emergency backfill construction. At last, based on the derived compressive strength, a fitting model for predicting compressive strength evolution of this new rapid hardening backfill material is developed, which fits accurately with these experimental data.

Ophiolites as Archives of Recycled Crustal Material Residing in the Deep Mantle

Deeply subducted lithospheric slabs may reach to the mantle transition zone(MTZ,410-660 km depth)or even to the core–mantle boundary(CMB)at depths of^2900km.Our knowledge of the fate of subducted surface material at the MTZ or near the CMB is poor and based mainly on the tomography data and laboratory experiments through indirect methods.Limited data come from the samples of deep mantle diamonds and their mineral inclusions obtained from kimberlites and associated rock assemblages in old cratons.We report in this presentation new data and observations from diamonds and other UHP minerals recovered from ophiolites that we consider as a new window into the life cycle of deeply subducted oceanic and continental crust.Ophiolites are fragments of ancient oceanic lithosphere tectonically accreted into continental margins,and many contain significant podiform chromitites.Our research team has investigated over the last 10 years ultrahigh-pressure and super-reducing mineral groups discovered in peridotites and/or chromitites of ophiolites around the world,including the Luobusa(Tibet),Ray-Iz(Polar Urals-Russia),and 12 other ophiolites from 8orogenic belts in 5 different countries(Albania,China,Myanmar,Russia,and Turkey).High-pressure minerals include diamond,coesite,pseudomorphic stishovite,qingsongite(BN)and Ca-Si perovskite,and the most important native and highly reduced minerals recovered to date include moissanite(Si C),Ni-Mn-Co alloys,Fe-Si and Fe-C phases.These mineral groups collectively confirm extremely high?pressures(300 km to≥660 km)and super-reducing conditions in their environment of formation in the mantle.All of the analyzed diamonds have unusually light carbon isotope compositions(δ13C=-28.7 to-18.3‰)and variable trace element contents that*d i stinguish them from most kimberlitic and UHPmetamorphic varieties.The presence of exsolution lamellae of diopside and coesite in some chromite grains suggests chromite crystallization depths around>380 km,near the mantle transition zone.The carbon isotopes and other features of the high-pressure and super-reduced mineral groups point to previously subducted surface material as their source of origin.Recycling of subducted crust in the deep mantle may proceed in three stages:Stage 1–Carbon-bearing fluids and melts may have been formed in the MTZ,in the lower mantle or even near the CMB.Stage 2–Fluids or melts may rise along with deep plumes through the lower mantle and reach the MTZ.Some minerals,such as diamond,stishovite,qingsongite and Ca-silicate perovskite can precipitate from these fluids or melts in the lower mantle during their ascent.Material transported to the MTZ would be mixed with highly reduced and UHP phases,presumably derived from zones with extremely low f O2,as required for the formation of moissanite and other native elements.Stage 3–Continued ascent above the transition of peridotites containing chromite and ultrahigh-pressure minerals transports them to shallow mantle depths,where they participate in decompressional partial melting and oceanic lithosphere formation.The widespread occurrence of ophiolite-hosted diamonds and associated UHP mineral groups suggests that they may be a common feature of in-situ oceanic mantle.Because mid-ocean ridge spreading environments are plate boundaries widely distributed around the globe,and because the magmatic accretion of oceanic plates occurs mainly along these ridges,the on-land remnants of ancient oceanic lithosphere produced at former mid-ocean ridges provide an important window into the Earth’s recycling system and a great opportunity to probe the nature of deeply recycled crustal material residing in the deep mantle

Recent advancements in hydrometallurgical recycling technologies of spent lithium-ion battery cathode materials

The rapidly increasing production of lithium-ion batteries(LIBs)and their limited service time increases the number of spent LIBs,eventually causing serious environmental issues and resource wastage.From the perspectives of clean production and the development of the LIB industry,the effective recovery and recycling of spent LIBs require urgent solutions.This study provides an overview of the current hydrometallurgical processes employed in the recycling of spent cathode materials,focusing on the leaching of valuable metals and their postprocessing.In particular,this research reviews the various leaching systems(inorganic acid,organic acid,and ammonia)and the separation of valuable metals,and then,recommendations for subsequent study are offered in an attempt to contribute to the development of highly efficient methods for recycling spent cathode materials.In addition,a range of existing technologies,such as solvent extraction,chemical precipitation,electrochemical deposition,and regeneration,for the postprocessing of leaching solutions are summarized.Finally,the promising technologies,existing challenges and suggestions with respect to the development of effective and environmentally friendly recycling methods for handling spent cathode materials are identified.

Synthesis of steel slag ceramics: chemical composition and crystalline phases of raw materials

Two types of porcelain tiles with steel slag as the main raw material （steel slag ceramics） were synthesized based on the CaO-A1203-SiO2 and CaO--MgO-SiO2 systems, and their bending strengths up to 53.47 MPa and 99.84 MPa, respectively, were obtained. The presence of anorthite, a-quartz, magnetite, and pyroxene crystals （augite and diopside） in the steel slag ceramics were very different from the composition of traditional ceramics. X-ray diffraction （XRD） and electron probe X-ray microanalysis （EPMA） results illustrated that the addition of steel slag reduced the temperature of extensive liquid generation and further decreased the firing temperature. The considerable contents of glass-modifying oxide liquids with rather low viscosities at high temperature in the steel slag ceramic adobes promoted element diffusion and crystallization. The results of this study demonstrated a new approach for extensive and effective recycling of steel slag.

Feasibility Study of Applying Recycled Aggregate from Building Debris in Concrete

Coarse and fine aggregate constitutes an average of approximately 55% to 80% of the total volume of concrete materials.Concrete remains the most commonly-used building material worldwide.As a result,the massive use of aggregate will have a direct impact on the earth′s natural resources if an appropriate replacement material is not found,violating the spirit of sustainable development.This study makes a preliminary examination of using coarse and fine aggregate produced from discarded construction materials in concrete.Results indicate that the compressive strength of densified mixture concrete at 28 days can reach 56.88 MPa(recycled materials used as coarse aggregate,and natural sand used as fine aggregate)and 53.33 MPa(recycled materials used as both coarse and fine aggregate).While this type of material is not yet fully understood,further research into this area should enable feasible applications in concrete.However,unsuitable mixtures have serious impact on the durability and overall economy of concrete.Pending further research on suitable mixture designs,a complete application of recycled aggregate in concrete can be expected.

Preparation of LiNi_(1/3)Co_(1/3)Mn_(1/3)O_2 cathode materials from spent Li-ion batteries

A recycling process including separation of electrode materials by ultrasonic treatment,acid leaching,Fe-removing,precipitation of cobalt,nickel,manganese and lithium has been applied successfully to recycle spent lithium-ion batteries and to synthesize LiNi1/3Co1/3Mn1/3O2. When ultrasonic treatment with 2-nitroso-4-methylphenol(NMP) at 40 ℃ for 15 min,the electrode materials are separated completely. Above 99% of Co,Ni,Mn and Li,95% of Fe in the separated electrodes are acid-leached in the optimized conditions of 2 mol/L H2SO4,1∶2 H2O2-H2SO4(molar ratio),70 ℃,1∶10 initial S∶L ratio,and 1 h. 99.5% of Fe and less than 1% of Co,Ni,Mn in the leaching solution can be removed in the conditions of initial pH value 2.0-2.5 adjusted by adding 18% Na2CO3,90 ℃ and stirring time 3 h. After adjusted to be equal by adding NiSO4,CoSO4 and MnSO4 solution,97.1% of Ni,Co,Mn in the Fe-removing surplus leaching solution can be recovered as Ni1/3Co1/3Mn1/3(OH)2. 94.5% of Li in the surplus filtrate after the deposition of Co,Ni and Mn can be recovered as Li2CO3. The LiNi1/3Co1/3Mn1/3O2,prepared from the recovered compounds,is found to have good characteristics of the layered structure and elecrtochemical performance.