Agnieszka Przybek

The growing demand for CO₂ emission reduction and efficient waste management has created a need for the development of sustainable construction materials. This study presents a comparative investigation of geopolymer and cement-based composites modified with bio-based additives originating from two abundant and underutilized waste streams: apple-processing waste and biomass collected during lake restoration activities. Geopolymer and cement composites containing 5 and 10 wt.% apple-processing waste or 5 and 10 vol.% lake fibers were prepared, and their compressive strength, flexural strength, density, and thermal conductivity were experimentally evaluated. The results revealed substantial differences between the investigated binder systems. Apple-processing waste significantly deteriorated the mechanical performance of both materials, particularly in cement-based composites, where disturbances in cement hydration and loss of structural integrity were observed. Although geopolymer composites also exhibited reduced compressive strength after the incorporation of apple residues, their structural cohesion was maintained. In contrast, biomass fibers obtained from lake restoration demonstrated considerably better compatibility with the geopolymer matrix, limiting compressive strength reductions to approximately 13–16% while contributing to improved crack resistance and post-failure integrity. The incorporation of bio-based additives reduced composite density and decreased thermal conductivity, resulting in enhanced thermal insulation performance. The lowest thermal conductivity was obtained for the geopolymer containing 10 wt.% wet apple waste, reaching 0.4216 W/(m·K), compared with 0.7067 W/(m·K) for the reference geopolymer. The findings indicate that lake-restoration biomass represents a promising reinforcement for geopolymer-based construction materials, whereas fruit-processing residues require further pretreatment before practical application. Overall, the study highlights the superior compatibility of geopolymers with organic waste streams and demonstrates their potential as sustainable, non-structural construction materials supporting circular economy strategies, waste valorization, and environmental remediation efforts.

This study presents a comparative evaluation of geopolymer foams incorporating either commercially available shape-stabilized phase change materials (PCMs) or laboratory-developed diatomite–paraffin PCM granules with controlled particle size fractions ranging from 2.5 mm. All PCM variants were incorporated at a constant dosage of 7.5 wt.% to isolate the influence of PCM type on the properties of the resulting composites. The commercial materials comprised PX-4, PX15, and PX20 (Rubitherm Technologies GmbH), whereas the laboratory-developed PCM consisted of paraffin immobilized within a porous diatomite matrix to produce granular shape-stabilized composites. The experimental program included the determination of bulk density, total porosity, pore size distribution, thermal conductivity (λ), thermal resistance (R), specific heat capacity (Cp), and compressive strength. The pore structure was characterized by mercury intrusion porosimetry (MIP), while the morphology and dispersion of PCM particles within the geopolymer matrix were investigated using scanning electron microscopy (SEM). All mixtures were produced using the same alkali-activated matrix and identical curing conditions, with the PCM content maintained at 7.5 wt.%. The results demonstrated that the type of PCM significantly affected the microstructure and thermophysical performance of the geopolymer foams. The laboratory-developed diatomite–paraffin PCM provided the most favorable thermal insulation performance, exhibiting the lowest thermal conductivity (0.095 W/m·K) together with the highest thermal resistance (0.278 m²·K/W). In contrast, the commercial PX15 and PX20 materials exhibited the highest specific heat capacities (1.740 and 1.778 kJ/kg·K, respectively), indicating superior thermal energy storage capability. In addition, the estimated production cost of the laboratory-developed PCM (2.5–4.0 EUR/kg) was substantially lower than that of the commercial PX materials (approximately 20 EUR/kg), highlighting its potential as a cost-effective alternative for sustainable, energy-efficient building materials. These findings demonstrate that both commercial and laboratory-developed PCM systems can effectively enhance the functionality of geopolymer foams, although they provide different balances between thermal insulation, heat storage capacity, and production cost.

Battery housings are critical structural and safety components in electric vehicles, fulfilling multiple functions related to mechanical protection, crashworthiness, thermal management, fire resistance, electromagnetic shielding, and integration of battery modules into the vehicle body. While metallic housings, particularly aluminum and steel, remain dominant in industrial applications, increasing attention is being given to composite materials as lightweight alternatives capable of improving energy efficiency and extending driving range. However, the growing use of composites in battery enclosures raises important questions regarding recyclability, end-of-life management, and compatibility with circular economy principles. This review critically examines the current state of the art in composite materials used for electric vehicle battery housings, with particular emphasis on glass- and carbon-fiber-reinforced thermoplastics, thermoset composites, sandwich structures, and hybrid multi-material systems. The paper discusses the functional requirements imposed on battery housings and analyzes how these requirements influence material selection and design strategies. Particular attention is devoted to recycling pathways applicable to composite battery enclosures, including mechanical recycling, thermal treatment, chemical recycling, and reuse-oriented approaches, as well as to the limitations associated with mixed-material assemblies, adhesives, coatings, and integrated functions. The review also addresses circular design strategies for battery housings, including design for disassembly, material traceability, modularity, and the incorporation of recycled polymers and secondary reinforcements into new housing systems. Current research gaps are identified in the integration of structural performance, fire safety, manufacturability, and recyclability within a single design framework. The analysis shows that thermoplastic composites currently offer the most promising route toward circular battery enclosures, while thermoset-based systems still face significant challenges in high-value recycling. The paper concludes by outlining future research directions required for the development of lightweight, safe and recyclable composite battery housings aligned with sustainable mobility and circular economy goals.

Geopolymer concretes are increasingly regarded as advanced construction materials for applications requiring high thermal and chemical resistance. This article is a continuation of previously published research and focuses on the mechanical behaviour of geopolymer concretes containing aggregates made of foamed geopolymers and lightweight mineral aggregates, such as expanded clay and perlite, intended for use in chimney flue components. The aim of the study was to determine the influence of lightweight aggregates on the relationship between thermal insulation and the strength parameters of geopolymer concretes intended for use at elevated temperatures. Foamed geopolymer aggregates were produced by a controlled chemical foaming process, followed by grinding to specific grain sizes, yielding highly porous aggregates with low thermal conductivity, reaching approximately 0.075–0.099 W/(m·K). These aggregates were used as lightweight fillers in geopolymer concretes based on class F fly ash activated with alkaline solutions. The resulting composites were designed to combine low density and high thermal insulation with adequate mechanical strength. The mechanical properties of the developed concretes were assessed on the basis of compressive strength tests on cubic specimens and tensile strength in beam bending tests, carried out in accordance with standards. The results presented confirm that the use of foamed geopolymer aggregates enables a simultaneous increase in thermal insulation and the design of ultra-lightweight structural elements with sufficient load-bearing capacity for chimney systems (including suspended ones). This combination of low thermal conductivity, reduced mass, and appropriate mechanical properties makes geopolymer concretes with lightweight mineral and geopolymer aggregates a promising alternative to traditional ceramic materials.

In recent years, circular economy principles have become a key paradigm in the design and evaluation of industrial processes, including recycling technologies. Direct recycling of used lithium-ion batteries is attracting particular attention, as it can significantly reduce energy consumption, reagent costs, and the carbon footprint of the entire process compared to traditional hydro- and pyrometallurgical methods. This paper provides an overview of the current state of knowledge, synthesizes contemporary methods of Li-ion battery cell recycling, and presents the most important achievements in the field of direct recycling, with particular emphasis on the regeneration and re-leaping of cathode materials, and discusses the implementation and economic premises. Key challenges and research gaps are also identified, including the need to use computational modeling (CFD/DEM, kinetic and data-driven models) to optimize the deactivation, separation, and regeneration stages. This review concludes that direct recycling has the potential to become the leading circular economy pathway for Li-ion batteries, provided that quality standardization and process modeling tools are developed in parallel.

Paraffin-based phase change materials (PCMs) have emerged as promising candidates for thermal energy storage (TES) applications due to their high latent heat, chemical stability, and low cost. However, their inherently low thermal conductivity and the risk of leakage during melting–solidification cycles significantly limit their practical performance. To address these limitations, numerous studies have investigated composite PCMs in which paraffin is incorporated into porous supporting matrices. Among these, diatomite has garnered particular attention due to its high porosity, large specific surface area, and chemical compatibility with organic materials. Serving as both a carrier and stabilizing shell, diatomite effectively suppresses leakage and enhances thermal conductivity, thereby improving the overall efficiency and reliability of the PCM. This review synthesizes recent research on paraffin–diatomite composites, with a focus on impregnation methods, surface modification techniques, and the influence of synthesis parameters on thermal performance and cyclic stability. The mechanisms of heat and mass transport within the composite structure are examined, alongside comparative analyses of paraffin–diatomite systems and other inorganic or polymeric supports. Particular emphasis is placed on applications in energy-efficient buildings, passive heating and cooling, and hybrid thermal storage systems. The review concludes that paraffin–diatomite composites present a promising avenue for stable, efficient, and sustainable phase change materials (PCMs). However, challenges such as the optimization of pore structure, long-term durability, and large-scale manufacturing must be addressed to facilitate their broader implementation in next-generation energy storage technologies.

This paper presents the development and characteristics of geopolymer foams modified with paraffin-based phase change materials (PCMs) encapsulated in diatomite. The aim was to increase both the thermal insulation and heat storage capacity of the foams while maintaining sufficient mechanical strength for construction applications. Eleven variants of composites with different PCM fractions (5–10% by mass) and grain sizes (2.5 mm) were synthesized and tested. The inclusion of PCM encapsulated in diatomite modified the porous structure: the total porosity increased from 6.6% in the reference sample to 19.6% for the 1.6–1.8 mm_10% wt. variant, with pore diameters ranging from ~4 to 280 µm. Thermal conductivity (λ) ranged between 0.090–0.129 W/m·K, with the lowest values observed for composites 2.0–2.5 mm_5–10% wt. (≈0.090–0.091 W/m·K), which also showed high thermal resistance (R ≈ 0.287–0.289 m²·K/W). The specific heat (Cp) increased from 1.28 kJ/kg·K (reference value) to a maximum value of 1.87 kJ/kg·K for the 2.0–2.5 mm_10% mass variant, confirming the effective energy storage capacity of PCM-modified foams. Mechanical tests showed compressive strength values in the range of 0.7–3.1 MPa. The best structural performance was obtained for the 1.6–1.8 mm_10% wt. variant (3.1 MPa), albeit with a higher λ (≈0.129 W/m·K), illustrating the classic trade-off between porosity-based insulation and mechanical strength. SEM microstructural analysis and mercury porosimetry confirmed the presence of mesopores, which determine both thermal and mechanical properties. The results show that medium-sized PCM fractions (1.6–2.0 mm) with moderate content (≈10% by weight) offer the most favorable compromise between insulation and strength, while thicker fractions (2.0–2.5 mm) maximize thermal energy storage capacity. These findings confirm the possibility of incorporating natural PCMs into geopolymer foams to create multifunctional materials for sustainable and energy-efficient building applications. A unique contribution to this work is the use of diatomite as a natural PCM carrier, ensuring stability, compatibility, and environmental friendliness compared to conventional encapsulation methods.

Contemporary construction faces the need to reduce its negative impact on the environment, prompting designers, investors, and contractors to seek more sustainable materials and technologies. One area of dynamic development is the use of natural fibers as an alternative to conventional, often synthetic, building components. Plant- and animal-based fibers, such as hemp, flax, jute, straw, bamboo, and sheep’s wool, are characterized by low energy consumption in production, renewability, and biodegradability. Their use is in line with the concept of a circular economy and reduces the carbon footprint of buildings. Natural fibers offer a number of beneficial physical and functional properties, including good thermal and acoustic insulation parameters, as well as hygroscopicity, which allows for the regulation of indoor humidity, improving air quality and comfort of use. In recent years, there has also been a renaissance of traditional building techniques, such as straw construction, often combined with modern engineering standards. Their potential is particularly recognized in green and energy-efficient construction. The article provides an overview of the types of natural fibers available for use in construction and analyzes their technical, environmental, and economic properties. It also draws attention to current regulations, standards, and certifications (e.g., LEED, BREEAM) that promote the popularization of these solutions. In light of the analyzed data, the role of natural fibers as a viable alternative supporting the transformation of the construction sector towards sustainable development is considered.

In the context of the growing need to reduce greenhouse gas emissions and to develop sustainable solutions for the construction industry, foamed geopolymers represent a promising alternative to traditional binders and insulation materials. This study investigates the thermal properties of novel low-emission, insulating geopolymer binders made from fly ash with diatomite, chalcedonite, and wood wool aiming to assess their potential for use in thermal insulation systems in energy-efficient buildings. The stability of the foamed geopolymer structure is also assessed. Measurements of thermal conductivity, specific heat, microstructure, density, and compressive strength are presented. The findings indicate that the selected geopolymer formulations exhibit low thermal conductivity, high heat capacity and low density, making them competitive with conventional insulation materials—mainly load-bearing ones such as aerated concrete and wood wool insulation boards. Additionally, incorporating waste-derived materials reduces the production carbon footprint. The best results are represented by the composite incorporating all three additives (diatomite, chalcedonite, and wood wool), which achieved the lowest thermal conductivity (0.10154 W/m·K), relatively low density (415 kg/m³), and high specific heat (1.529 kJ/kg·K).

Despite the availability of various materials for chimney applications, ongoing research seeks alternatives with improved thermal and chemical resistance. Geopolymers are a promising solution, exhibiting exceptional resistance to high temperatures, fire, and aggressive chemicals. This study investigates fly ash-based lightweight geopolymer concretes that incorporate expanded clay aggregate (E.C.A.), perlite (P), and foamed geopolymer aggregate (F.G.A.). The composites were designed to ensure a density below 1200 kg/m³, reducing overall weight while maintaining necessary performance. Aggregate content ranged from 60 to 75 wt.%. Physical (density, thickness, water absorption), mechanical (flexural and compressive strength), and thermal (conductivity, resistance) properties were evaluated. F.G.A. 60 achieved a 76.8% reduction in thermal conductivity (0.1708 vs. 0.7366 W/(m·K)) and a 140.4% increase in thermal resistance (0.1642 vs. 0.0683). The F.G.A./E.C.A./P 60 mixture showed the highest compressive strength (18.069 MPa), reaching 52.7% of the reference concrete’s strength, with a 32.3% lower density (1173.3 vs. 1735.0 kg/m³). Water absorption ranged from 4.9% (REF.) to 7.3% (F.G.A. 60). All samples, except F.G.A. 70 and F.G.A. 75, endured heating up to 800 °C. The F.G.A./E.C.A./P 60 composite demonstrated well-balanced performance: low thermal conductivity (0.2052 W/(m·K)), thermal resistance up to 1000 °C, flexural strength of 4.386 MPa, and compressive strength of 18.069 MPa. The results confirm that well-designed geopolymer lightweight concretes are suitable for chimney and flue pipe linings operating between 500 and 1000 °C and exposed to acidic condensates and aggressive chemicals. This study marks the initial phase of a broader project on geopolymer-based prefabricated chimney systems.