Recycling of mineral wool waste as supplementary cementitious material through thermochemical treatment.

Mineral wool is commonly used in construction as thermal insulation material. After the product's lifetime, it is classified as hazardous waste if no trademark of the European Certification Board for Mineral Wool Products (EUCEB) or the German Institute for Quality Assurance and Labelling (RAL) exists. Mineral Wool Waste (MWW) is typically landfilled in Europe, which is challenging due to its low bulk density and dimensional stability. This circumstance highlights the need for alternative recycling methods that increase the recycling rate of construction and demolition (C&D) waste. This article outlines the recycling opportunities of MWW and focuses on the use of thermochemical treatment of different mixtures of input materials to produce a supplementary cementitious material (SCM). The material characterisation results and investigations on the binder suitability demonstrate that the slag fractions after the thermochemical treatment are well-qualified to be used as reactive binder components. Additionally, a material flow analysis was conducted to estimate the substitution potential of MWW as SCM in the Austrian cement industry.

Predicting the in vitro dissolution rate constant of mineral wool fibers from fiber composition.

OBJECTIVE: We developed predictive formulae for the in vitro dissolution rate constant kdis of acid-soluble synthetic vitreous fibers (SVF), paralleling our earlier work with glass wools, which are typically more soluble at neutral pH. Developing simple models for predicting the kdis of a fiber can allow prediction of in vivo behavior, aid fiber developers, and potentially reduce in vivo testing. METHODS: The kdis of several acid-soluble SVF were determined using high simulant fluid flow/fiber surface area (F/A) conditions via a single-fiber measurement system. Four fluids were employed, varying in base composition and citrate levels. Equations predicting the kdis were derived from fiber chemistry and dissolution measurements for two of the fluids. RESULTS: Testing of several fibers showed a ∼10× increase in the kdis when citrate was included in the simulant solution. Data from tests with Stefaniak's citrate-free Phagoloysosmal Simulant Fluid (PSF) yielded kdis values aligned with expectations from in vivo results, unlike results from citrate-containing modified Gamble's solution. Predictive equations relating fiber chemistry to kdis showed reasonable agreement between the measured and predicted values. CONCLUSIONS: Citrate inclusion in the solution under high F/A conditions significantly increased the measured kdis. This resulted in more biorelevant data being obtained using the PSF fluid with the high F/A method used. The developed predictive equations, sufficient for fiber development work, require refinement before a recommending their use in place of in vivo biopersistence testing. Significant fit improvements are possible through additional measurements under these experimental conditions.

Exposure to MMVF in residential and commercial buildings: A literature review and quantitative synthesis.

Man-made vitreous fibers (MMVF) are a class of inorganic fibrous materials that include glass and mineral wools, continuous glass filaments, and refractory ceramic fibers valued for their insulative properties in high temperature applications. Potential health effects from occupational exposure to MMVF have been investigated since the 1970s, with focus on incidence of respiratory tract cancer among MMVF-exposed production workers. The general population may experience exposure to MMVF in residential and/or commercial buildings due to deterioration, construction, or other disruption of materials containing these fibers. Numerous studies have characterized potential exposures that may occur during material disruption or installation; however, fewer have aimed to measure background MMVF concentrations in residential and commercial spaces (i.e., non-production settings) to which the general population may be exposed. In this study, we reviewed and synthesized peer-reviewed studies that evaluated respirable MMVF exposure levels in non-production, indoor environments. Among studies that analyzed airborne respirable MMVF concentrations, 110-fold and 1.5-fold differences in estimated concentrations were observed for those studies utilizing phase contrast optical microscopy (PCOM) versus transmission electron microscopy (TEM) and scanning electron microscopy (SEM), respectively. A positive correlation was observed between respirable air concentrations of MMVF and total surface concentrations of MMVF in seldom-cleaned areas. Ultimately, available evidence suggests that both ambient air and surface concentrations of MMVF in indoor environments are consistently lower than exposure limits developed to prevent negative health outcomes among sensitive populations.

Effects of cement addition and briquetting of rock wool on its geomechanical stability in landfills.

Landfilling of mineral wool waste in big bags at separate landfill compartments is required in Austria. This results in enormous differences in the Young's moduli between common construction and demolition (C&D) waste compartments and mineral wool compartments, which causes severe accidents in terms of overturned vehicles due to sudden subsidence of the subsurface. Conditioning of mineral wool waste might be applied to adjust its geomechanical behaviour to that of common C&D waste but has never been investigated scientifically before. In this study we compare three scenarios for the conditioning of rock wool for landfilling: (A) loosely packing, (B) cutting comminution + cement addition and (C) cutting comminution + cement-supported briquetting. The performance of the different sample bodies under landfill conditions was simulated at the lab scale by cyclic loading (1223-3112 N, up to 160 cycles) using a 'Wille Geotechnik UL 300' press. The deformation was monitored during the experiment and Young's modulus was derived graphically, whereas the test execution was piston controlled. The Young's modulus increased during the experiments from 0.2 MPa to 4.6 MPa for scenario (A), from 0.6 MPa to 20.5 MPa for scenario (B) and from 7.5 MPa to 111.0 MPa for scenario (C). These results show that a combination of comminution and cement-supported briquetting significantly increases the geotechnical performance of mineral wool waste with respect to landfilling, which is still three orders of magnitude below that of common C&D waste, which is in the range of 30,000 MPa.

Reuse of ultrafine mineral wool production waste in the manufacture of refractory concrete.

The paper deals with the mineral wool production waste (cupola dust - CD), presents CD characterization and aims to reuse CD in production of refractory concrete with calcium aluminate cement. The study of CD covers its chemical, phase and thermal analyses along with the morphological study and determination of particles size distribution. Zeta-potential, electrical conductivity and pH values of CD suspension are presented in the paper as well. Commercial microsilica additive in refractory concrete has been replaced with cupola dust. Compositions of refractory concrete have been prepared by incorporating 1%, 2% and 3% of CD. The bulk density, ultrasonic wave velocity, cold crushing strength and thermal shock resistance of the created refractory concrete have been determined. Based on experimental results, it has been found that cupola dust may be used for the production of refractory concrete. The environmental impact related to the CD reuse in refractory concrete production has been evaluated as well.

Do insulation products of man-made vitreous fibres still cause skin discomfort?

BACKGROUND: Man-made vitreous fibres (MMVFs) are used in products for insulation and as reinforcement in materials. Contamination of the skin may arise through direct or indirect contact, and from the deposition of airborne fibres. The scientific basis regarding the effects on skin of MMVFs dates from 1970-1980. OBJECTIVES: To investigate whether currently used insulation MMVF products still cause skin discomfort. METHODS: Focus group interviews and structured interviews were performed among workers engaged in insulation tasks and among do-it-yourself consumers with a recent experience of MMVF products. RESULTS: A majority of interviewees experienced skin discomfort when handling MMVF products. Complaints caused by traditional (yellow) glass fibre products were more severe than those caused by products of rock or slag wool fibres. The wrists, forearms, neck and face were the locations where the skin was most affected. The situations causing problems varied between occupational tasks, but working with the hands over the head or in narrow spaces were described as the worst situations. Building construction apprentices performed insulation tasks more often than senior workers. CONCLUSIONS: MMVF insulation products do still cause skin discomfort. Updated knowledge about people's experiences of work with such products should influence legislation.

The Effect of Mineral Wool Fiber Additive on Several Mechanical Properties and Thermal Conductivity in Geopolymer Binder.

The article discusses the effect of additives of waste mineral wool fibers on geopolymer binder. This is an important study in terms of the possibility of recycling mineral wool waste. The paper describes an effective method for pulverizing the wool and the methodology for forming geopolymer samples, labeled G1 for glass-wool-based geopolymer and G2 for stone-wool-based geopolymer. The compressive and flexural strengths and thermal conductivity coefficient of the geopolymer with the addition of mineral fibers were determined. The key element of the article is to verify whether the addition of mineral wool fibers positively affects the properties of the geopolymer. The results obtained prove that the addition of fibers significantly improves the flexural strength. For the G1 formulation, the ratio of compressive strength to flexural strength is 18.7%. However, for G2 samples, an even better ratio of compressive strength to flexural strength values of 26.3% was obtained. The average thermal conductivity coefficient obtained was 1.053 W/(m·K) for the G1 series samples and 0.953 W/(m·K) for the G2 series samples. The conclusions obtained show a correlation between the porosity and compressive strength and thermal conductivity coefficient. The higher the porosity, the better the thermal insulation of the material and the weaker the compressive strength.

Dissolution behavior of stone wool fibers in synthetic lung fluids: Impact of iron oxidation state changes induced by heat treatment for binder removal.

Stone wool fiber materials are commonly used for thermal and acoustic insulation, horticulture and filler purposes. Biosolubility of the stone wool fiber (SWF) materials accessed through acellular in vitro dissolution tests can potentially be used in future as an indicator of fiber biopersistence in vivo. To correlate acellular in vitro studies with in vivo and epidemiological investigations, not only a robust dissolution procedure is needed, but fundamental understanding of fiber behavior during sample preparation and dissolution is required. We investigated the influence of heat treatment procedure for binder removal on the SWF iron oxidation state as well as on the SWF dissolution behavior in simulant lung fluids (with and without complexing agents). We used heat treatments at 450 °C for 5 min and 590 °C for 1 h. Both procedures resulted in complete binder removal from the SWF. Changes of iron oxidation state were moderate if binder was removed at 450 °C for 5 min, and there were no substantial changes of SWF's dissolution behavior in all investigated fluids after this heat treatment. In contrast, if binder was removed at 590 °C for 1 h, complete Fe(II) oxidation to Fe(III) was observed and significant increase of dissolution was shown in fluids without complexing agent (citrate). PHREEQC solution speciation modeling showed that in this case, released Fe(III) may form ferrihydrite precipitate in the solution. Precipitation of ferrihydrite solid phase leads to removal of iron cations from the solution, thus shifting reaction towards the dissolution products and increasing total mass loss of fiber samples. This effect is not observed for heat treated fibers if citrate is present in the fluid, because Fe(III) binds with citrate and remains mobile in the solution. Therefore, for developing the most accurate SWF in vitro acellular biosolubility test, SWF heat treatment for binder removal is not recommended in combination with dissolution testing in fluids without citrate as a complexing agent.

Comparative Study on Selected Insulating Materials for Industrial Piping.

This paper describes the results of an experimental assessment of the thermal conductivity of pipe insulation. The need for reducing energy loss in industrial piping systems makes the availability of relevant and reliable insulation materials of special importance. Several specimens of pipe laggings, made of different materials, including mineral wool, polyethylene foam (PEF), expanded polystyrene (EPS), flexible elastomeric foam (FEF) and polyurethane foam (PUR), were tested in accordance with the European standard ISO 8497. The thermal conductivity of the materials was measured for a wide range of temperatures. The results were compared with the values reported in the technical specifications as well as with the literature data. The assessment of measurement uncertainty was also described. The results showed that, in a few cases, thermal conductivity turned out to be greater than that declared by the manufacturer by as much as over 10%.

Effect of Mechanically Activated Nepheline-Syenite Additive on the Physical-Mechanical Properties and Frost Resistance of Ceramic Materials Composed of Illite Clay and Mineral Wool Waste.

This study investigates the coupling effect of mechanically activated nepheline-syenite (NS) and mineral wool melt waste (MWMW) on the physical-mechanical properties of a ceramic body. The results indicate that an optimal amount (10-20%) of NS additive promotes the formation of the smallest pore size from 0.001 to 0.01 µm, as well as improves physical, mechanical, and durability properties of the ceramic samples with MWMW, when fired at temperatures between 1000 and 1080 °C. As the NS content increases, the composition becomes more alkaline, leading to enhanced vitrification and the formation of a glass phase during firing. This reduces open porosity, modifies pore size distribution, and enhances compressive strength and frost resistance. An NS content of 15% produces the best results, increasing the smallest pore fraction and yielding favourable properties, such as reduced open porosity, water absorption and density, increased compressive strength, and does not affect the linear shrinkage. The frost resistance test demonstrates that the coupling effect of NS additive and MWMW improves the samples' resistance to freeze-thaw cycles, with the best performance observed at 15% NS content. The study also highlights the usefulness of structural parameters and ultrasound testing for assessing and predicting the frost resistance of ceramic samples.

Determination of Thermal Properties of Mineral Wool Required for the Safety Analysis of Sandwich Panels Subjected to Fire Loads.

The paper presents theoretical, experimental and numerical studies on the thermal behavior of mineral wool used in sandwich panels. The aim of this study is to investigate the thermal properties of mineral wool at elevated temperatures and provide a simple model that would allow us to determine the heat propagation in sandwich panels during a fire. The paper proposes a new method to experimentally evaluate thermal diffusivity, derived from theoretical premises. Experiments are conducted in a laboratory furnace where specimens are placed and temperatures inside specimens are measured. Different methods are used to process the test results and calculate the thermal diffusivity of mineral wool. Finally, a numerical analysis of heat transfer using the finite element method (FEM) is performed to validate the obtained thermal properties.

Pleural Plaques and the Role of Exposure to Mineral Particles in the Asbestos Post-exposure Survey.

BACKGROUND: Previous studies have inconsistently reported associations between refractory ceramic fibers (RCFs) or mineral wool fibers (MWFs) and the presence of pleural plaques. All these studies were based on chest radiographs, known to be associated with a poor sensitivity for the diagnosis of pleural plaques. RESEARCH QUESTION: Does the risk of pleural plaques increase with cumulative exposure to RCFs, MWFs, and silica? If the risk does increase, do these dose-response relationships depend on the co-exposure to asbestos or, conversely, are the dose-response relationships for asbestos modified by co-exposure to RCFs, MWFs, and silica? STUDY DESIGN AND METHODS: Volunteer workers were invited to participate in a CT scan screening program for asbestos-related diseases in France. Asbestos exposure was assessed by industrial hygienists, and exposure to RCFs, MWFs, and silica was determined by using job-exposure matrices. A cumulative exposure index (CEI) was then calculated for each subject and separately for each of the four mineral particle exposures. All available CT scans were submitted to randomized double reading by a panel of radiologists. RESULTS: In this cohort of 5,457 subjects, significant dose-response relationships were determined after adjustment for asbestos exposure between CEI to RCF or MWF and the risk of PPs (ORs of 1.29 [95% CI, 1.00-1.67] and 1.84 [95% CI, 1.49-2.27] for the highest CEI quartile, respectively). Significant interactions were found between asbestos on one hand and MWF or RCF on the other. INTERPRETATION: This study suggests the existence of a significant association between exposure to RCFs and MWFs and the presence of pleural plaques in a large population previously exposed to asbestos and screened by using CT scans.

Low Formaldehyde Binders for Mineral Wool Insulation: A Review.

Insulating materials are ubiquitous in a built environment and play a critical role in reducing the energy consumed to maintain habitable indoor environments. Mineral wool insulation (MWI) products, including glass, stone, and slag variants, are the most widely used class of insulating materials in Europe and account for more than 50% of the total market by volume. MWI typically consists of two key components: a mesh of inorganic fibers that are several micrometers in diameter, and an organic thermosetting adhesive commonly referred to as the "binder." Traditional phenol-formaldehyde-urea (PFU) binders used in the manufacture of MWI are increasingly being scrutinized for the formaldehyde released during their manufacture and service lifetime. The recent classification of formaldehyde as a carcinogen by various safety organizations has accelerated a paradigm shift within the industry toward alternative binder technologies that minimize or indeed eliminate formaldehyde emissions. This review examines more recent strategies for achieving low- or zero-added formaldehyde binders for MWI, with a particular focus on the patent literature. The chemistry underpinning traditional PFU binders is presented and compared to new strategies involving scavenging molecules that decrease formaldehyde emissions, as well as zero-added formaldehyde binder technologies such as polyester, Maillard, and epoxide thermosets.

Development of Fibre-Reinforced Cementitious Mortar with Mineral Wool and Coconut Fibre.

Globally, as human population and industries grow, so does the creation of agricultural, industrial, and demolition waste. When these wastes are not properly recycled, reused, or disposed of, they pose a threat to the environment. The importance of this study lies in the beneficial use of coconut fibre and mineral wool in the form of fibres in cement mortar production. This study examines the use of coconut and mineral wool fibres in the production of fibre-reinforced mortar. Five different mortar mixtures were prepared, having one control mortar along with four fibre-reinforced mortars. The control mortar is denoted as CM while 1% and 1.5% of mineral wool are incorporated into this mortar mix and denoted as RMM-1.0 and RMM-1.5, respectively. Additionally, the mortar sample configurations contain 1% and 1.5% coconut fibers, designated as RCM-1.0 and RCM-1.5. These samples were subjected to different strength and durability tests to determine their suitability for use in mortar production. The testing findings show that mortar containing 1.5% mineral wool has better compared flexural strength and durability properties. The investigation results will form part of the database for the efficient utilization of natural and waste fibres in the construction and building sectors.

The dissolution of stone wool fibers with sugar-based binder and oil in different synthetic lung fluids.

The biopersistence of fiber materials is one of the cornerstones in estimating potential risk to human health upon inhalation. To connect epidemiological and in vivo investigations with in vitro studies, reliable and robust methods of fiber biopersistence determination and understanding of fiber dissolution mechanism are required. We investigated dissolution properties of oil treated stone wool fibers with and without sugar-based binder (SBB) at 37 °C in the liquids representing macrophages intracellular conditions (pH 4.5). Conditions varied from batch to flow of different rates. Fiber morphology and surface chemistry changes caused by dissolution were monitored with scanning electron microscopy and time-of-flight secondary ion mass spectrometry mapping. Stone wool fiber dissolution rate depends on liquid composition (presence of ligands, such as citrate), pH, reaction products transport and fibers wetting properties. The dissolution rate decreases when: 1) citrate is consumed by the reaction with the released Al cations; 2) the pH increases during a reaction in poorly buffered solutions; 3) the dissolution products are accumulated; 4) fibers are not fully wetted with the fluid. Presence of SBB has no influence on dissolution rate if fiber material was wetted prior to dissolution experiment to avoid poorly wetted fiber agglomerates formation in the synthetic lung fluids.

Physical Properties of Mineral Fibers Depending on the Mineralogical Composition.

A developed methodology for determining the physical properties of mineral fibers prepared from different input mixtures under the same spinning wheel conditions is described and discussed. Energy dispersive X-ray fluorescence spectroscopy was combined with simultaneous thermal analysis and thermogravimetry to study the mineralogical composition and typical melting and crystallization temperatures. The mechanical properties measured with nanoindentation were related to the mineralogical properties and the results obtained are in agreement with the literature. The developed methodology shows reliable performance and demonstrates the ability to study the mechanical properties of mineral fibers, their mineralogical composition, and thermal properties. The presented experimental methodology opens up the possibility of researching the mechanical properties of mineral fibers for the purpose of defining production recipes in the field of mineral thermal insulation materials.

Characterization of mineral wool waste chemical composition, organic resin content and fiber dimensions: Aspects for valorization.

Despite mineral wool waste is only a small fraction of total construction and demolition waste (CDW) by mass, it requires large transportation and landfilling capacities due to its low bulk density, and its utilization remains low compared to other CDW types. It is essential to understand the physical and chemical properties of this waste fraction in order to utilize it, e.g. as fiber reinforcement in composites or as supplementary cementitious material. Here, we provide a chemical and physical characterization of 15 glass wool and 12 stone wool samples of different ages collected from various locations across Europe. In addition, the chemical compositions of 61 glass and stone wool samples obtained from the literature are presented. Glass wool samples show little variation in their chemical composition, which resembles the composition of typical soda-lime silicate glass. Stone wool presents a composition similar to basaltic glass but with variability between samples in terms of calcium, magnesium, and iron content. Potentially toxic elements, such as Cr, Ba, and Ni, are present in mineral wools, but in low concentrations (<0.2%). Both wool types contain organic resin, which may decompose into smaller molecular fragments and ammonia upon heating or contact with alkaline solution. Mineral wool wastes have relatively similar length and width distributions, despite the age and type of the mineral wool. Overall, both mineral wool waste types have homogenous chemical and physical properties as compared to many other mineral wastes which makes their utilization as a secondary raw material promising.

Occupational risk resulting from exposure to mineral wool when installing insulation in buildings.

Mineral wool is widely used for thermal and sound insulation. The subject of the study is to identify hazards for employees resulting from exposure to mineral wool, when it is used to insulate buildings, and to assess the risk arising from this exposure. When installing mineral wool insulation, respirable mineral fibers, dust, and volatile organic compounds may pose a hazard at workplaces. Based on the results of concentration measurements, it was assessed that the probability of adverse health effects related to the work of insulation installers, resulting from exposure to mineral wool fibers, is low, but for dust associated with exposure, an average health risk was estimated. An additional threat may be the sensitizing effect of substances used as binders and additives improving the utility properties of mineral wool, for example, phenol formaldehyde resins. The paper also contains some information on the labeling of mineral wool; this is very important because the label allows downstream users to recognize mineral wools, the composition and properties of which cause that they are not classified as carcinogens. Int J Occup Med Environ Health. 2020;33(6):757-69.

Adjusting the melting and crystallization behaviors of ferronickel slag via partially replacing of SiO2 by B2O3 for mineral wool production.

Utilization of ferronickel slag as a raw material for mineral wool production not only conserves natural resources, but also achieves the sustainable development for the ferronickel industry. In order to utilize the ferronickel slag more efficiently, the melting and crystallization behaviors of the slag with the partial replacement of SiO2 by B2O3 were investigated in this paper. The results show that the initial and complete melting temperatures decreased with B2O3 substitution for SiO2, which indicates that the addition of B2O3 can reduce the energy consumption during the melting process. The incubation time of the slag in the Time Temperature Transformation (TTT) diagram increased, whereas the initial crystallization temperature in the Continuous Cooling Transformation (CCT) diagram decreased when SiO2 was substituted by B2O3. In addition, the main crystalline phases precipitated in the slags were columnar MgSiO3 and Mg2SiO4. The weakening of crystallization ability caused by the substitution of B2O3 for SiO2 will be beneficial for the improvement of fiber quality when the ferronickel slag is used as a raw material for mineral wool production.

The Influences of Moisture on the Mechanical, Morphological and Thermogravimetric Properties of Mineral Wool Made from Basalt Glass Fibers.

Mineral wool made from basalt fibers is frequently used as an insulating material in construction systems. In this study, both unused mineral wool and wool obtained from the softened roofing area were comprehensively analyzed in a laboratory using different characterization techniques. Firstly, the initial water content and compressive strength at 10% deformation were determined. Secondly, microstructure and surface chemical composition were analyzed by scanning electron microscopy (SEM) equipped with energy dispersive X-ray spectroscopy (EDX). To study heterogeneities near the fiber surface and to examine cross-sectional composition, a scanning transmission electron microscope (STEM) was used. Finally, to verify possible reasons for resin degradation, thermogravimetric analysis and differential scanning colometry (TGA-DSC) were simultaneously carried out. The results show that natural aging under high humidity and thermal fluctuations greatly affected the surface morphology and chemical composition of the fibrous composite. Phenol-formaldehyde and other hydrophobic compounds that protect fibers against moisture and give compressive resistance were found to be degraded.