Influence of activator ratios and concentration on the physio-mechanical and microstructural characteristics of the geopolymers derived from sandstone processing waste

Natural stones have been utilized to meet various needs of human civilization since ancient times. The exploitation of any resource is associated with the production of redundant materials called wastes. Sandstone waste (SW) is one such waste obtained during the industrial processing of sandstones. Due to its siliceous composition, extensive yield, and disorganized dumping, noxious conditions related to land and human health are promoted. However, the lack of comprehensive engineering studies, mineralogical analysis, and design methodologies associated with the utilization of sandstone processing wastes restricted their applicability only to fillers or partial substitutes with pozzolans and traditional cement in meager volumes. In the past, limited efforts have been made to utilize SW as a construction entity, particularly for binding purposes. Thus, to enhance the scope of its utilization, a comprehensive investigation has been performed in this research to transform sandstone waste into a novel construction material by geopolymerization. Mix design tailoring and laboratory tests were implemented to understand the effects of sodium hydroxide concentration and sodium silicate to sodium hydroxide ratio on the dissolution and physio-mechanical characteristics of SW-based geopolymers. The activator-to-binder ratio was restricted to 0.4 to obtain pastes with sufficient workability without hindering the properties of the matrix. Besides, a high temperature-curing regime was selected based on SW's crystallographic and reactivity analysis. Subsequently, a total of 48 samples were prepared and tested at the curing age of 28 days. Detailed characterization of SW and SW-based geopolymer samples was performed using optical, X-ray, and infrared spectroscopies aided by electron imaging and thermogravimetric techniques. SW-based geopolymer samples showed compressive strengths in the range of 6-12 MPa, ~2 to 3 times higher than those obtained in previous experimentations. Phase analysis and microstructural examinations confirmed SW's participation in geopolymerization. Overall, it could be advocated that geopolymerization is an innovative approach for solving issues related to the disposal and re-utilization of SW, extending its possible application to the fields of cement mixes, wall tiles, mortars, and masonry as per the commendations of ASTM and ACI committee.

Valorizing hazardous lead glass sludge and alumina flakes filling waste for the synthesis of geopolymer building bricks

Geopolymer bricks from lead glass sludge (LGS) and alumina flakes filling (AFF) waste were synthesized in the present work. AFF waste was chemically treated to prepare sodium aluminate (NaAlO₂) powder. Silicate source (untreated LGS and thermally treated one at 600 °C (LGS600)) and sodium oxide (Na₂O) concentration (as NaAlO₂) were the compositional parameters, which affected the physical and mechanical properties (compressive strength, water absorption, and bulk density) of the prepared bricks. High organic matter content inside LGS caused a retardation effect on the geopolymerization process, resulting in the formation of hardened bricks with modest 90-day compressive strengths (2.13 to 4.4 MPa). Using LGS600 enhanced the mechanical properties of the fabricated bricks, achieving a maximum 90-day compressive strength of 22.35 MPa at 3 wt.% Na₂O. Sodium aluminosilicate hydrate was the main activation product inside all samples, as confirmed by X-ray diffraction and thermal analyses. Acetic acid leaching test also proved that all LGS600-NaAlO₂ mixtures represented Pb concentrations in leachates lower than the permissible level of characteristic leaching procedures, indicating the mitigation of environmental problems caused by these wastes.

Arsenic(V) immobilization in fly ash and mine tailing-based geopolymers: Performance and mechanism insight

Global mining activities produce thousands of millions of toxic-bearing mine tailing (MT) wastes each year. Storage of the mine tailings not only encroaches upon large areas of cropland but also arouses additional ecological and environmental risks. Herein we demonstrate that geopolymerization of a mixture of the toxic-bearing mine tailings and the coal fly ash (FA) can effectively immobilize exogenous arsenic (As) species in addition to inherent As from the raw materials. The geopolymers also possess high compressive strengths (e.g., >25 MPa for specimens with 54 wt% FA and activated with 10 M sodium hydroxide (NaOH)), allowing them to be further used as low-carbon, cement-free building materials. The geopolymer strength was found to depend clearly upon the NaOH concentration, the FA content, and the curing time, with the maximum being 37.07 MPa for a specimen with 54 wt% FA, 0.03 wt% As, activated with 10 M NaOH and cured for 28 days. Leaching tests showed that all specimens achieved an immobilization efficiency as high as 95.4% toward As, and that both the short-term and long-term leachabilities of all toxic elements are far below the standard maximum contaminant levels. Microstructural analyses indicate that calcite, calcium silicate, and calcium silicate hydroxide are likely to play a crucial role in immobilizing As species and heavy metals of concern in the geopolymer matrixes. Given the superior mechanical strengths and long-term stabilities, the FA/MT-based geopolymers demonstrate a promising low-carbon material for both the remediation of As-bearing lands and the construction industry.

Synthesis and characterization of coal fly ash and palm oil fuel ash modified artisanal and small-scale gold mine (ASGM) tailings based geopolymer using sugar mill lime sludge as Ca-based activator

The continuous accumulation of artisanal and small-scale gold mining (ASGM) tailings in the Philippines without adequate storage and disposal facility could lead to human health and environmental disasters in the long run. In this study, ASGM tailings was simultaneously stabilized and repurposed as construction material via geopolymerization using coal fly ash, palm oil fuel ash and a powder-based alkali activator. Scanning electron microscopy with energy dispersive X-ray spectroscopy (SEM-EDS) identified iron sulfides in the tailings containing arsenic (As), cadmium (Cd), copper (Cu), lead (Pb) and zinc (Zn), which could be released via weathering. The average unconfined compressive strengths (UCS) of tailings-based geopolymers at 14 days curing were 7.58 MPa and 7.7 MPa with fly ash and palm oil fuel ash, respectively. The tailings-based geopolymers with palm oil fuel ash had higher UCS most likely due to CASH reaction product formation that improved strength formation. The toxicity characteristic leaching procedure (TCLP) results showed very low leachabilities of As, Pb and Fe in the geopolymer materials suggesting ASGM tailings was effectively encapsulated within the geopolymer matrix. Overall, the geopolymerization of ASGM tailings is a viable and promising solution to simultaneously stabilize mining and industrial wastes and repurpose them into construction materials.

Morphologically designed micro porous zeolite-geopolymers as cool coating materials

Functionally modified fly ash zeolite-geopolymeric material was developed as cooling coatings for structural application. The tailored precursor of cool coating materials was obtained through modified grain behavior of zeolite with variable pour morphology and mechanical activation of fly ash followed by geopolymerization with alkaline activator. The modified zeolite was found to possess unique heat management properties through disorderly connected pores. The solar temperature profile showed a temperature variance of 4-6 °C for solar radiation. The samples showed a high solar reflective index (SRI) due to absorbance and less heat retention followed by cooling behavior in the sunshine.

Mechanism exploration on the aluminum supplementation coupling the electrokinetics-activating geopolymerization that reinforces the solidification of the municipal solid waste incineration fly ashes

Traditional cementation technique is insufficient in making municipal solid waste incineration (MSWI) fly ashes meet the permissible leaching threshold. Aluminum supplementation and electrokinetic (EK) activation were combinedly incorporated into the traditional solidification pathway to enhance the geopolymerization and the immobilization of Pb and Cd in MSWI fly ashes in this study. The aluminum addition remarkably affected the geopolymer formation. The minimum toxicity leaching as well as the maximum compressive strength were achieved at the combination of the voltage gradient of 1.0 V/cm, the proposing time of 48 or 72 h, the mass ratio of alkali activator to fly ash of 11.5%, and the modulus of 2.1. Chloride reduction in the mortar obtained during the EK process increased the negative charge relativity of oligomers. The leaching concentrations of Pb and Cd from the geopolymer were successfully predicted by a linear model based on the compressive strengths at 28 d. Higher reaction degree was found in the EK-activated mortar in the geopolymerization kinetics. Aluminum supplementation had induced the production of some amorphous aluminosilicate minerals including Al₆Si₂O₁₃, CaAl₂Si₂O₈·4H₂O, Ca₂Al₃(Si₃O₁₂)OH, Ca₂Al(OH)₇·3H₂O, and Ca₄Al₂O₆Cl₂·10H₂O during the EK process. Larger particles observed in the EK-treated specimen directly verified the EK-activated pozzolanic reactions.

Geopolymerization of solid waste of non-ferrous metallurgy - A review

The growing demand for non-ferrous metals (Aluminium, Copper, Nickle, Lead and Zinc) has grown the non-ferrous metallurgical industry, which generate huge amount of solid waste. Most common method for the disposal of these solid wastes is dumping at sites, which pollutes the soil and water and covers the useful land. Geopolymerization technique can be very helpful for the safe disposal of these solid wastes, which converts the solid wastes into valuable construction materials such as binders, mortar, bricks, paving blocks and concrete etc. However, to commercialize the use of these construction products, some key aspects require detailed examination. Alternative techniques and materials will have to be identified to increase their reactivity in geopolymerization and in-depth knowledge of reaction mechanism, mix design, strength and durability characteristics of resulting geopolymer will have to be studied. The present paper reviews the important studies on geopolymerization of different solid wastes produced from non-ferrous industry. The optimum synthesis parameters such as alkali activators, curing temperature, curing time and molar ratio etc. for the geopolymerization of these solid wastes are reported and exiting gaps and future trends are also discussed.

A review of recent strategies for acid mine drainage prevention and mine tailings recycling

Acid mine/rock drainage (AMD/ARD), effluents with low pH and high concentrations of hazardous and toxic elements generated when sulfide-rich wastes are exposed to the environment, is considered as a serious environmental problem encountered by the mining and mineral processing industries around the world. Remediation options like neutralization, adsorption, ion exchange, membrane technology, biological mediation, and electrochemical approach have been developed to reduce the negative environmental impacts of AMD on ecological systems and human health. However, these techniques require the continuous supply of chemicals and energy, expensive maintenance and labor cost, and long-term monitoring of affected ecosystems until AMD generation stops. Unfortunately, the formation of AMD could persist for hundreds or even thousands of years, so these approaches are both costly and unsustainable. Recently, two alternative strategies for the management of AMD and mine tailings are gaining much attention: (1) prevention techniques, and (2) mine waste recycling. In this review, recent advances in AMD prevention techniques like oxygen barriers, utilization of bactericides, co-disposal and blending, and passivation of sulfide minerals are discussed. In addition, recycling of mine tailings as construction and geopolymer materials to reduce the amounts of wastes for disposal are introduced.

Spectroscopic studies of fly ash-based geopolymers

In the present work fly-ash based geopolymers with different contents of alkali-activator and water were prepared. Alkali-activation was conducted with sodium hydroxide (NaOH) at the SiO₂/Na₂O molar ratio of 3, 4, and 5. Water content was at the ratio of 30, 40, and 50wt% in respect to the weight of the fly ash. Structural and microstructural characterization (FT-IR spectroscopy, ²⁹Si and ²⁷Al MAS NMR, X-ray diffraction, SEM) of the specimens as well as compressive strength and apparent density measurements were carried out. The obtained geopolymers are mainly amorphous due to the presence of disordered aluminosilicate phases. However, hydroxysodalite have been identified as a crystalline product of geopolymerization. The major band in the mid-infrared spectra (at about 1000cm^-1) is related to SiO(Si,Al) asymmetric stretching vibrations and is an indicator of the geopolymeric network formation. Several component bands in this region can be noticed after the decomposition process. Decomposition of band at 1450cm^-1 (vibrations of CO bonds in bicarbonate group) has been also conducted. Higher NaOH content favors carbonation, inasmuch as the intensity of the band then increases. Both water and alkaline activator contents have an influence on compressive strength and microstructure of the obtained fly-ash based geopolymers.

Volcanic ash-based geopolymer cements/concretes: the current state of the art and perspectives

The progress achieved with the use of volcanic ash for geopolymer synthesis has been critically reviewed in this paper. This consists of an overview of mineralogy and chemistry of volcanic ash. The role of chemical composition and mineral contents of volcanic ash on their reactivity during geopolymerization reaction and, consequently, mechanical properties have been accessed. An attempt has been made to establish a relationship between synthesis factors and final properties. A critical assessment of some synthesis conditions has been addressed and some practical recommendations given along with suggestions of future works that have to be done. All this has shown that there are still many works such as durability tests (carbonation, freeze-thaw, resistance, etc.), life cycle analysis, etc. that need to be done in order to satisfy both suitability and sustainability criteria for a large-scale or industrial application.

Risk assessment and technical feasibility of usage of paper mill sludge biochar-based exhausted adsorbent for geopolymeric brick formation

Risk assessment and technical feasibility of brick formation from exhausted paper mill sludge derived biochar obtained after its use as an adsorbent for the treatment of effluent containing pentachlorophenol was studied. The bricks were prepared by geopolymerization mechanism in presence of sodium hydroxide, and the extent of geopolymerization was determined on the basis of crystal structure, surface functionalities, and surface morphology of the bricks. The preparation parameters (sodium hydroxide dosage, initial water and calcium carbonate content and curing temperature) were optimized and the results were analyzed in terms of compressive strength, water absorption, and abrasion index. Risk assessment of heavy metals was performed to determine the contamination level and overall hazard index of the biochar-based geopolymer bricks. Hazard quotient and hazard index were calculated to assess the overall non-carcinogenic risk posed by selected heavy metals via ingestion and dermal contact. The leaching potential of heavy metal and pentachlorophenol from the biochar-based geopolymer bricks was also determined. The results showed that the biochar-based geopolymer bricks showed good mechanical properties and the concentration of heavy metals in the leachate falls within the permissible limits prescribed by Indian Standards for Industrial and Sewage Effluents Discharge (inland surface water).