This study was focused on the historical evolution of the waste management policy carried out by the Spanish industry devoted to titanium dioxide pigments manufacturing for minimising its environmental impact. This challenge was achieved by modifying the original chemical process and converting the originally dissolved sulphate and sulphuric acid present in the final streams of the factory into sulphate minerals (melanterite FeSO4·7H2O, szomolnokite FeSO4·H2O, and gypsum CaSO4·2H2O). These by-products were physicochemically, mineralogically and radiologically characterised in order to gain basic information for its subsequent commercial use. Some of the uses summarised in this study for both ferrous sulphates are as a supplier of iron to prevent chlorosis, animal food, manufacture of cement (to reduce Cr VI), primary flocculants for ferrous sulphates, magnetite nanoparticle and nano-Fe2O3 formation, production of magnetite concentrate, remediation of polluted soils with metals, and treatment of wastewaters. Red gypsum was analysed as a substitute for natural gypsum in the manufacture of cement, construction materials, inhibitor in soil erosion, and the immobilisation of heavy metals in agricultural soils and carbonation processes.
The immobilization of hazardous wastes in ordinary Portland cement (OPC)-based materials has been widely studied and implemented. OPC-based materials have a high carbon footprint associated with their production and geopolymer materials are a sustainable and eco-friendly alternative. Therefore, this work aimed to immobilize two hazardous industrial wastes: copper wastewater sludge and phosphogypsum in one-part geopolymer materials. For that purpose, the precursor was partially substituted by these wastes (5, 10 and 20 wt.%) in the formulations. The geopolymer fresh and hardened state properties were evaluated, and the immobilisation of pollutants was determined through leaching tests. In phosphogypsum pastes (PG5, PG10 and PG20) it was observed that the compressive strength decreased with the increase in its amount, varying between 67 MPa and 19 MPa. In copper sludge pastes, the compressive strength of the specimens (CWS5 and CWS10) reached ~50 MPa. The mortars, MPG10 and MCWSs10, had compressive strengths of 13 MPa and 21 MPa, respectively. Leaching tests showed that pastes and mortars immobilise the hazardous species of the wastes, except for As from copper sludge, whose the best result was found in the compact paste (CWSs10) that leached 2 mg/kg of As. Results suggest that optimized compositions are suitable for the construction sector.
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