This paper explores the new potential strategy of using fine recycled aggregates (fRA) derived from waste 3D printed concrete (3DPC) as a substitute for cement in additive manufacturing. This study hypothesizes that fRA can optimize mixture design, reduce cement content, and contribute to sustainable construction practices. Experimental programs were conducted to evaluate the fresh and hardened properties, printability window, and buildability of 3DPC mixes containing fRA. Mixes with replacement rates of cement with fRA by 10 vol%, 20 vol%, 30 vol%, 40 vol%, and 50 vol% were produced. A comprehensive experimental protocol consisting of rheological studies (static and dynamic yield stress), dynamic elastic modulus determination (first 24 h of hydration), flexural and compressive strengths (2 d and 28 d), and an open porosity test was performed. The obtained results were verified by printing tests. In addition, an economic and environmental life cycle assessment (LCA) of the mixes was performed. The results indicate that up to 50 vol% cement replacement with fRA is feasible, albeit with some technical drawbacks. While fRA incorporation enhances sustainability by reducing CO₂ emissions and material costs, it adversely affects the printability window, green strength, setting time, and mechanical properties, particularly in the initial curing stages. Therefore, with higher replacement rates (above 20 vol%), potential optimization efforts are needed to mitigate drawbacks such as reduced green strength and buildability. Notably, replacement rates of up to 20 vol% can be successfully used without compromising the overall material properties or altering the mixture design. The LCA analysis shows that reducing the cement content and increasing the fRA addition results in a significant reduction in mix cost (up to 24%) and a substantial decrease in equivalent CO₂ emissions (up to 48%). In conclusion, this study underscores the potential of fRA as a sustainable alternative to cement in 3D printed concrete.

This study determines the effect of spent garnet as a replacement for natural sand in 3D-printed mortar at early ages. Five mixes with different spent garnet amounts were prepared (0%, 25%, 50%, 75% and 100% by volume). The ratio of binder to aggregate remained unchanged. In all mixes the water/binder ratio was assumed as a constant value of 0.375. Tests were performed to confirm the printability of the mix (a path quality test using a gantry robot with an extruder). Determinations of key buildability properties of the mix (green strength and Young’s Modulus) during uniaxial compressive strength at 15 min, 30 min and 45 min after adding water were conducted. A hydraulic press and the GOM ARAMIS precision image analysis system were used to conduct the study. The results showed that an increase in spent garnet content caused a decrease in green strength and Young’s Modulus (up to 69.91% and 80.37%, respectively). It was found that to maintain proper buildability, the recommended maximum replacement rate of natural sand with garnet is 50%. This research contributes new knowledge in terms of using recycled waste in the 3D printing technology of cementitious materials.

Zinc chloride and potassium oxalate are often applied as activating agents for carbon materials. In this work, we present the preparation of ZnO/carbon spheres composites using resorcinol-formaldehyde resin as a carbon source in a solvothermal reactor heated with microwaves. Zinc chloride as a zinc oxide source and potassium oxalate as an activating agent were applied. The effect of their addition and preparation conditions on the adsorption properties towards carbon dioxide at 0 °C and 25 °C were investigated. Additionally, for all tested sorbents, the CO₂ sorption tests at 40 °C, carried out utilizing a thermobalance, confirmed the trend of sorption capacity measured at 0 and 25 °C. Furthermore, the sample activated using potassium oxalate and modified using zinc chloride (a carbon-to-zinc ratio equal to 10:1) displayed not only a high CO₂ adsorption capacity (2.69 mmol CO₂/g at 40 °C) but also exhibited a stable performance during the consecutive multicycle adsorption–desorption process.

In this work, low-pressure synthesis of carbon spheres from resorcinol and formaldehyde using an autoclave is presented. The influence of reaction time and process temperature as well as the effect of potassium oxalate, an activator, on the morphology and CO₂ adsorption properties was studied. The properties of materials produced at pressureless (atmospheric) conditions were compared with those synthesized under higher pressures. The results of this work show that enhanced pressure treatment is not necessary to produce high-quality carbon spheres, and the morphology and porosity of the spheres produced without an activation step at pressureless conditions are not significantly different from those obtained at higher pressures. In addition, CO₂ uptake was not affected by elevated pressure synthesis. It was also demonstrated that addition of the activator (potassium oxalate) had much more effect on key properties than the applied pressure treatment. The use of potassium oxalate as an activator caused non-uniform size distribution of spherical particles. Simultaneously higher values of surface area and total pore volumes were reached. A pressure treatment of the carbon materials in the autoclave significantly enhanced the CO₂ uptake at 25 °C, but had no effect on it at 0 °C.

This paper examines the synthesis of the ZnO/carbon spheres composites using resorcinol—formaldehyde resin as a carbon source and zinc nitrate as a zinc oxide source in a solvothermal reactor heated with microwaves. The influence of activation with potassium oxalate and modification with zinc nitrate on the physicochemical properties of the obtained materials and CO₂ adsorption capacity was investigated. It was found that in the case of nonactivated material as well as activated materials, the presence of zinc oxide in the carbon matrix had no effect or slightly increased the values of CO₂ adsorption capacity. Only for the material where the weight ratio of carbon:zinc was 2:1, the decrease of CO₂ adsorption capacity was reported. Additionally, CO₂ adsorption experiments on nonactivated carbon spheres and those activated with potassium oxalate with different amounts of zinc nitrate were carried out at 40 °C using thermobalance. The highest CO₂ adsorption capacity at temperature 40 °C (2.08 mmol/g adsorbent) was achieved for the material after activation with potassium oxalate with the highest zinc nitrate content as ZnO precursor. Moreover, repeated adsorption/desorption cycle experiments revealed that the as-prepared carbon spheres were very good CO₂ adsorbents, exhibiting excellent cyclic stability with a performance decay of less than 10% over up to 25 adsorption-desorption cycles.

A new photocatalyst for CO₂ reduction has been presented. The photocatalyst was prepared from a combination of a commercial P25 with a mesopore structure and carbon spheres with a microporous structure with high CO₂ adsorption capacity. Then, the obtained hybrid TiO₂-carbon sphere photocatalysts were deposited on a glass fiber fabric. The combined TiO₂-carbon spheres/silica cloth photocatalysts showed higher efficiency in the two-electron CO₂ reduction towards CO than in the eight-electron reaction to methane. The 0.5 g graphitic carbon spheres combined with 1 g of TiO₂ P25 resulted in almost 100% selectivity to CO. From a practical point of view, this is promising as it economically eliminates the need to separate CO from the gas mixture after the reaction, which also contains CH₄ and H₂.