Cenospheres

The study presents the investigation results concerning the thermal properties of non-cross-linked and cross-linked silicone rubber with organic peroxide. The rubber was filled with mineral fillers such as cenospheres, including cenospheres covered with iron, attapulgite, wollastonite, aluminum hydroxide and silica. The thermal stability of the silicone rubber was considered from the point of view of the mineral fillers used, particularly taking into account the modern cenospheric filler. Thermal analysis was carried out under both air and a neutral gas at temperatures ranging from 120 to 700 °C. The activation energy value of the silicone rubber destruction was determined with the use of the non-isothermal method of Flynn–Wall–Ozawa.

The utilisation of industrial residual products to develop new value-added materials and reduce their environmental footprint is one of the critical challenges of science and industry. Development of new multifunctional and bio-based composite materials is an excellent opportunity for the effective utilisation of residual industrial products and a right step in the Green Deal’s direction as approved by the European Commission. Keeping the various issues in mind, we describe the manufacturing and characterisation of the three-component bio-based composites in this work. The key components are a bio-based binder made of peat, devulcanised crumb rubber (DCR) from used tyres, and part of the fly ash, i.e., the cenosphere (CS). The three-phase composites were prepared in the form of a block to investigate their mechanical properties and density, and in the form of granules for the determination of the sorption of water and oil products. We also investigated the properties’ dependence on the DCR and CS fraction. It was found that the maximum compression strength (in block form) observed for the composition without CS and DCR addition was 79.3 MPa, while the second-highest value of compression strength was 11.2 MPa for the composition with 27.3 wt.% of CS. For compositions with a bio-binder content from 17.4 to 55.8 wt.%, and with DCR contents ranging from 11.0 to 62.0 wt.%, the compressive strength was in the range from 1.1 to 2.0 MPa. Liquid-sorption analysis (water and diesel) showed that the maximum saturation of liquids, in both cases, was set after 35 min and ranged from 1.05 to 1.4 g·g −1 for water, and 0.77 to 1.25 g·g−1 for diesel. It was observed that 90% of the maximum saturation with diesel fuel came after 10 min and for water after 35 min.

Aluminosilicate microspheres are a valuable fraction of coal fly ash with diverse applications due to their low density. Currently, there is no efficient and ecologically rational method of cenosphere recovery from fly ash. A combination of dry methods for the recovery of both fine ash particles and aluminosilicate microspheres from coal fly ash is presented. It is comprised of fluidised bed separation followed by screening and pneumatic separation in a free-fall air chamber. Fluidised bed separation was assisted by a mechanical activator to prevent agglomeration. This step reduced the portion of material that required further treatment by 52-55 wt.%, with the recovery of microspheres exceeding 97%. Then, the concentrates were individually subjected to pneumatic separation. The final separation product for the fly ash containing 0.64 wt.% cenospheres was a cenosphere concentrate that constituted about 17 wt.% of the initial fly ash. The recovery of cenospheres was around 81%. Usage of a combination of dry methods allowed for maintaining almost 83 wt.% of the raw material in its dry form. Furthermore, the produced fly ash grain fractions could be used for different industrial purposes.

The paper presents results of a study of oxidative decomposition of methanol in a fl uidized bed of silver catalyst. The process of methanol oxidation was carried out on Ag-coated cenospheres core-shell catalyst. The catalyst was obtained by precipitation of silver from methanolic solution of silver nitrate on cenospheres. Cenospheres are lightweight, inert, hollow spheres, which can be easily introduced into a fl uidized bed. Application of the catalyst in a form of fl uidized bed should ensure good temperature equalization which is very important at low temperatures due to the possibility of generation of formaldehyde. It turned out that local hot points occur in that kind of a catalyst (in the form of a fl uidized bed but with very low density), thus use of additional acoustic wave is necessary to ensure good control over the temperature of the process. The products of the process of methanol oxidation were monitored on-line by Fourier transform infrared spectroscopy (FTIR). The catalyst has proven to be highly active in the oxidative decomposition of methanol. Full of methanol conversion in reaction of complete oxidation was achieved at 350 o C.