Grantee Research Project Results
Final Report: Recycling of Industrial Phosphate Waste as Raw Material for Innovative Iron Phosphate Glass Fibers
EPA Contract Number: 68D03030Title: Recycling of Industrial Phosphate Waste as Raw Material for Innovative Iron Phosphate Glass Fibers
Investigators: Neidt, Tod M.
Small Business: MO-SCI Corporation
EPA Contact: Richards, April
Phase: I
Project Period: April 1, 2003 through September 1, 2003
Project Amount: $70,000
RFA: Small Business Innovation Research (SBIR) - Phase I (2003) RFA Text | Recipients Lists
Research Category: Hazardous Waste/Remediation , SBIR - Waste , Small Business Innovation Research (SBIR)
Description:
The overall goal of this research project was to demonstrate the feasibility of utilizing industrial phosphate waste as raw material for the manufacture of innovative, iron phosphate-based glass fibers. More than 50 iron phosphate glass compositions were melted and evaluated by the MO-SCI Corporation to identify a target composition. The percentage of industrial iron and zinc-phosphating waste that could be incorporated in the target glass batch without adversely affecting chemical durability, strength, and fiberizability was determined. The safety of using industrial phosphate waste as a glass raw material was confirmed by Toxicity Characteristic Leaching Procedure (TCLP) testing of the most highly loaded waste-derived glasses.
Summary/Accomplishments (Outputs/Outcomes):
A family of iron phosphate glass compositions was developed with dramatically increased chemical durability in acidic and alkaline solutions over previously known compositions. Ten percent iron and 30 percent zinc-phosphating waste can easily be used as raw material in these glasses without significantly degrading the chemical durability, strength, and fiberizability. Results suggest that higher percentage waste loadings are possible with improved waste characterization and further glass development. It is estimated that a $12 (per ton glass) cost savings is possible for each 10 weight percent phosphate waste used as a raw material in the glass batch. Iron phosphate glass produced using 67 weight percent phosphate waste as a raw material adequately passed the TCLP test. All Resource Conservation and Recovery Act (RCRA)-listed elements tested at less than 0.01 of the published regulatory levels, demonstrating the safety of using phosphating waste as a raw material.
Conclusions:
Industrial iron and zinc phosphate waste are useful raw materials for producing chemically durable, high-strength iron phosphate glass that is easily processed into textile fibers using conventional glass fiber-manufacturing techniques. These iron phosphate glass fibers are technically and economically competitive with commercial silica-based glass fibers, especially for glass fiber reinforced concrete applications.
Supplemental Keywords:
glass fiber, reinforced concrete, zinc phosphate waste, iron, Toxicity Characteristic Leaching Procedure, TCLP, Resource Conservation and Recovery Act, RCRA, RCRA-listed elements, silica, small business, SBIR., Sustainable Industry/Business, Scientific Discipline, Chemical Engineering, Chemistry, Environmental Chemistry, Analytical Chemistry, Economics and Business, cleaner production/pollution prevention, pollution prevention, industrial waste, iron phosphate glass fibers, green technology, insulation, automobile manufacturing, automotive supply chain, phosphate industry, environmentally friendly technology, industrial innovationsThe perspectives, information and conclusions conveyed in research project abstracts, progress reports, final reports, journal abstracts and journal publications convey the viewpoints of the principal investigator and may not represent the views and policies of ORD and EPA. Conclusions drawn by the principal investigators have not been reviewed by the Agency.