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Four organic solid wastes (coffee grounds, ground nut shell, paper money sewage sludge and cork powder) have been investigated as bloating inducing agents in lightweight aggregate (LWA) manufacturing when mixed in small proportions (2.5 wt.%) with three types of clays. The pellets obtained were fired in a rotary kiln at the maximum feasible temperature for 4 min. A similar impact was observed both in the working conditions and in the properties of the LWAs, showing that the differences between said residues are not as decisive as those of the clays to which they are added. The organic wastes have played a crucial role in achieving reducing conditions inside the aggregate. Thus, their addition has led to substantial improvements both from an operational point of view, lowering the working temperature, and from a technological perspective, favoring bloating and the development of a highly porous and lightweight structure. Leachate studies have shown that the LWAs meet the regulatory limits. The outcomes of this investigation show that, in line with the precepts of the Circular Economy, the recovery of organic wastes of different nature can have a place in the production of environmentally friendly LWAs. Resumen: Se han investigado cuatro residuos sólidos orgánicos (posos de café, cáscara molida de frutos secos, lodos de depuradora de papel moneda y polvo de corcho) como agentes expansivos en la fabricación de áridos ligeros (LWAs) al mezclarse en pequeñas proporciones (2,5 wt.%) con tres tipos de arcillas. Los pellets conformados se han cocido en un horno rotatorio a la máxima temperatura viable durante 4 min. Se observó un impacto similar tanto en las condiciones de trabajo como en las propiedades de los LWAs, mostrando que las diferencias entre dichos residuos no son tan influyentes como las de las arcillas a las que se añaden. El componente orgánico ha jugado un papel crucial en la consecución de las condiciones reductoras dentro del árido. Así, su adición ha supuesto mejoras sustanciales tanto desde el punto de vista operativo, reduciendo la temperatura de trabajo, como desde una perspectiva tecnológica, favoreciendo la expansión y el desarrollo de una estructura altamente porosa y ligera. Por otro lado, los LWAs obtenidos cumplirían con los límites reglamentarios de lixiviación de metales pesados. Se demuestra que la valorización de residuos orgánicos de distinta naturaleza puede tener cabida en la producción de LWAs respetuosos con el medio ambiente.

The effect of the addition of Fe0 and Fe3+ on the formation of expanded clay aggregates was studied using iron-free kaolin as an aluminosilicates source. Likewise, the incorporation of cork powder as a source of organic carbon and Na2CO3 as a flux in the mixtures was investigated in order to assess its effect in combination with the iron phases. An experimental protocol, statistically supported by a mixture experiments/design of experiments approach, was applied to model and optimize the bloating index, density, absorption capacity, and mechanical strength. The process of expansion and pore generation and the associated decrease in density required the addition of iron, such that the optimum mixtures of these properties presented between 25 and 40 wt.% of Fe0 or Fe3+, as well as the incorporation of 3.5–5 wt.% of organic carbon. The addition of Fe3+ produced a greater volumetric expansion (max. 53%) than Fe0 (max. 8%), suggesting that the formation of the FeO leading to this phenomenon would require reducing and oxidizing conditions in the former and the latter, respectively. The experimental and model-estimated results are in good agreement, especially in the aggregates containing Fe0. This reinforces the application of statistical methods for future investigations.

The application of Life Cycle Assessment in the construction sector can be a very useful tool to reduce the environmental impact generated by the sector. In order to quantify the improvement in environmental terms with the use of artificial lightweight aggregates (LWA) manufactured with waste, in this work, we conducted a comparative evaluation of the life cycle of LWAs for a total of five different scenarios: LWAs obtained in a traditional way, i.e., using exclusively clay in their manufacture (Spanish blond clay, Portuguese red clay and Portuguese blond clay), and LWAs manufactured with four different wastes, with a partial substitution of 2.5% for each of the clays per waste (almond and hazelnut shells, sludge from the purification of paper money, cork dust and coffee grounds). The functional unit was set as the production of 1 kilo of lightweight aggregates and the CML 2000 methodology and the SimaPro software were used. The results obtained in this research allow us to conclude that the addition of organic wastes showed a slightly higher environmental performance than the conventional system, the ALAs manufactured with almond and hazelnut shells being the most environmentally friendly option, with reductions of more than 30% in some cases, followed by the LWAs manufactured with coffee grounds. On the other hand, the addition of paper sewage sludge and cork dust represents minimal environmental optimization.

Investigations on the application of Life Cycle Assessment (LCA) to the construction sector have shown that the environmental impact of construction products can be significantly reduced. To achieve this, the use of best available techniques and eco-innovation in production plants must be promoted. In this way, the use of finite natural resources can be replaced by waste generated in other production processes, preferably available locally, stimulating the creation of more sustainable products. Conducting a comparative LCA study between the traditional ceramic brick manufacturing process and the ceramic brick manufacturing process incorporating ‘alperujo’ (waste generated in the virgin oil extraction process), is an inevitable step to achieve the integration of circularity and eco-innovation in the production system of traditional ceramic materials, through the CML(Centrum voor Milieukunde Leiden) and IPCC(The Intergovernmental Panel on Climate Change) methodology. The obtained results suggest that the environmental benefits in this practice are very limited, even taking into account the contribution of different amounts of this waste to the production of bricks.

A Life Cycle Assessment (LCA) using SimaPro software has been carried out concerning the manufacture of artificial lightweight aggregates (LWAs). The study aims to evaluate the changes in the environmental impact when an additive of residual origin, specifically olive pomace (OP), is added following the principles of the Circular Economy. This residue (commonly known as alperujo) was used as a substitute for clay in 1.25, 2.5 and 5 wt%. The environmental impact related to the use of olive pomace in the mixture was estimated using the CML 2000 methodology, yielding improvements of 3.8%, 7.7% and 15.3% for 1.25, 2.5 and 5 wt% OP added, respectively. Optimum addition results are in the range of 1.25 and 2.5 wt% OP. In this way, the reduction of emissions associated with LWA manufacture would be favored without negatively affecting the technological properties of the resulting material.