Porous glass-ceramics from alkali activation and sinter-crystallization of mixtures of waste glass and residues from plasma processing of municipal solid waste

Alkali-activated aqueous slurries of fine glass powders, mostly deriving from the plasma processing of municipal solid waste (‘Plasmastone’), were found to undergo progressive hardening at low temperature (75 °C) owing to the formation of C–S–H (calcium silicate hydrate) gels. Before complete setting, slurries could be easily foamed by vigorous mechanical stirring, with the help of a surfactant; finally, the resulting open-celled structure could be ‘frozen’ by a subsequent sintering treatment, with crystallization of Ca–Fe silicates. The densification of the struts upon firing was enhanced by mixing Plasmastone with up to 30 wt% recycled glasses and increasing the firing temperature from 800 to 1000 °C. A total porosity exceeding 75 vol%, comprising both well-interconnected macro- and micro-sized pores on cell walls, was accompanied by good compressive strength, well above 1 MPa. The stabilization of pollutants generally increased with increasing firing temperature and glass content, with some exceptions; no practical leaching was observed from samples deriving from Plasmastone combined with 30 wt% boro-alumino-silicate glass from the recycling of pharmaceutical vials.