Valorisation of Red Gypsum Waste in Polypropylene Composites for Agricultural Applications

This study investigates the industrial potential of red gypsum (RG), a major by-product of titanium dioxide (TiO2) production, for the development of thermoplastic polypropylene (PP)-based composites via melt extrusion, targeting agricultural applications. Prior to compounding, RG was thermally treated at approximately 200 °C to remove residual moisture and chemically bound water, resulting in its anhydrous form (CaSO4). PP/RG composites were then formulated with RG loadings up to 20 wt.%, employing stearic acid (SA) as a compatibilizer. The resulting materials were thoroughly characterized and successfully processed through industrial-scale injection molding up to 250 °C. Morphological and FTIR analyses confirmed the role of SA in enhancing both filler dispersion and interfacial adhesion between RG and the PP matrix. SEM images revealed finer and more uniformly distributed RG particles, resulting in a reduced loss of ductility and elongation at break typically associated with filler addition. Specifically, the Young's Modulus increased from 1.62 GPa (neat PP) up to 3.21 GPa with 20 wt.% RG and 0.6 wt.% SA. The addition of 0.6 wt.% SA also helped limit the reduction in stress at break from 46.68 MPa (neat PP) to 34.05 MPa and similarly mitigated the decrease in Charpy impact energy, which declined slightly from 2.66 kJ/m2 (neat PP) to 2.24 kJ/m2 for composites containing 20 wt.% RG. Preliminary phytotoxicity was assessed using germination tests on Lepidium sativum L. seeds. Eluates from both untreated and SA-treated RG powders resulted in germination indices below 80%, indicating phytotoxicity likely due to high sulfate ion concentrations. In contrast, eluates from composite pellets exhibited germination indices equal to or exceeding 100%, demonstrating the absence of phytotoxic effects. These results highlight the suitability of the developed composites for applications in floriculture and horticulture. The optimized composite pellets were successfully processed via injection molding to manufacture plant pots, which exhibited a dark brown coloration, confirming the effective pigmenting function of RG. These results demonstrate the potential of red gypsum to serve both as a functional filler and pigment in PP composites, providing a sustainable alternative to iron oxide pigments and promoting the valorization of industrial waste through resource recovery.