Application-Oriented Chemical Optimization of a Metakaolin Based Geopolymer

Metallic aluminium in municipal solid waste incineration fly ash as a blowing agent for porous alkali-activated granules

Porous alkali-activated materials are synthetic aluminosilicates that should be often produced as granules for practical applications. In the present study, municipal solid waste incineration fly ash with ~1.2 wt% of metallic aluminium was used as a novel blowing agent for metakaolin (their ratio ranged from 0% to 100%) with an aqueous sodium silicate solution as the alkali-activator and granulation fluid in high-shear granulation. The compressive strength of all granules was sufficient (≥2 MPa). Water absorption indicated an increase in porosity as the fly ash content increased. However, X-ray microtomography imaging showed no clear correlation between the fly ash content and porosity. The granules exceeded the leaching limits for earth construction materials for antimony, vanadium, chloride and sulphate. Of those, antimony, chloride and sulphate could be controlled by decreasing the ash content, but the source of vanadium was identified as metakaolin. The increase in the fly ash content decreased the cation exchange capacity of the granules. In conclusion, the recommended fly ash content is equivalent to 0.3 wt% of Al0 and the developed granules could be best suited as light-weight artificial aggregates in concrete where the additional binder would provide stabilization to decrease the leaching.

Preparation of a Porous Geopolymer (SPG) to be Used as an Adsorbent for Cu2+ Removal

A porous geopolymer was synthesized using steel slag (accounting for 71.6 wt %) with the aim of effectively removing Cu2+ ions. The chemical composition and microstructure of this material were investigated using X-ray diffraction spectroscopy, Fourier transform infrared spectroscopy, scanning electron microscope analysis, and BET method. The effects of H2O2 doping, H2O doping, and the curing temperature on the properties of this porous geopolymer were systematically investigated. Subsequently, the adsorption behavior of the porous geopolymer toward Cu2+ was explored through static adsorption experiments. The findings reveal that there are a higher specific surface area and pore capacity for the porous geopolymer compared to the original steel slag, with a total porosity of 90.3%, compressive strength of 0.29 MPa, and volume water absorption rate of 69.4%. The adsorption capacity of this material toward Cu2+ is found to be 36.8 mg·g-1, which is slightly superior to that of commercial spherical 4A molecular sieves. The adsorption process follows the quasi-first-order kinetic model, while the isothermal adsorption conforms to the Freundlich model.

Preparation, characterization, electrical conductivity, and life cycle assessment of carbon nanofibers-reinforced Ecuadorian natural zeolite-based geopolymer composites

Geopolymers are inorganic crosslinked polymers with much less carbon footprint than ordinary Portland cement. Geopolymers and geopolymer-based materials have superior mechanical and durability properties with extreme thermal and chemical resistance. Carbon nano- or microfibers-reinforced geopolymers show potential properties such as electric conductivity, enhanced mechanical and thermal stability, and multi-functionality. This study evaluated the effect of incorporating carbon nanofibers in natural zeolite-based geopolymers and their impact on the mechanical, thermal, and electric conductivity of yielded geopolymer composites. Additionally, a life cycle assessment for 1 m3 geopolymer and its carbon fiber reinforced geopolymers' production has been conducted to evaluate the environmental impact of the processes.

Novel modeling and optimization framework for Navy Blue adsorption onto eco-friendly magnetic geopolymer composite

The disproportionate potency of dyes in textile wastewater is a global concern that needs to be contended. The present study comprehensively investigates the adsorption of Navy-Blue dye (NB) onto bentonite clay based geopolymer/Fe₃O₄ nanocomposite (GFC) using novel statistical and machine learning frameworks in the following steps; (1) synthesis and characterization of GFC, (2) experimental testing and modelling of NB adsorption onto GFC following Box-Behnken design and three response surface prediction models namely stepwise regression analysis (SRA), Support vector regression (SVR) and Kriging (KR), (3) parametric, sensitivity, thermodynamic and kinetic analysis of pH, GFC dose and contact time on adsorption performance, and (4) finding global parametric solution of the process using Latin Hypercube, Sobol and Taguchi orthogonal array sampling and combining SRA-SVR-KR predictions with novel hybrid simulated annealing (SA)-desirability function (DF) approach. Under the given testing range, parametric/sensitivity analysis revealed the critical role of pH over others accounting ∼37% relative effect and primarily derived the NB adsorption. The statistical evaluation of models revealed that all models could be utilized for elucidating and predicting the NB removal using GFC, however, SVR accuracy was better among others for this particular work, as the overall computed root mean squared error was only 0.55 while the error frequency counts remained <1 for 90% predictions. GFC showed 86.29% NB removal for the given experimental matrix which can be elevated to 96.25% under optimum conditions. The NB adsorption was found to be physical, spontaneous, favorable and obeyed pseudo-2nd order kinetics. The results demonstrate the suitability of GFC as the promising cost-effective and efficient alternative for the decolourization of urban and drinking water streams and elucidate the potential of machine learning models for accurate prediction & elevation of adsorption processes with less experimentation in water purification applications.

Fly ash geopolymer as a coating material for controlled-release fertilizer based on granulated urea

Nitrogen loss from urea fertiliser due to its high solubility characteristics has led to the invention of controlled release urea (CRU). Majority of existing CRU coatings are produced from a non-biodegradable, toxic and expensive synthetic polymers. This study determines the feasibility of fly ash-based geopolymer as a coating material for urea fertilizer. The effects of fly ash particle size (15.2 μm, 12.0 μm, and 8.6 μm) and solid to liquid (S : L) ratio (3 : 1, 2.8 : 1, 2.6 : 1, 2.4 : 1 and 2.2 : 1) on the geopolymer coating, the characterization such as FTIR analysis, XRD analysis, surface area and pore size analysis, setting time analysis, coating thickness, and crushing strength, and the release kinetics of geopolymer coated urea in water and soil were determined. Lower S : L ratio was beneficial in terms of workability, but it had an adverse impact on geopolymer properties where it increased porosity and decreased mechanical strength to an undesirable level for the CRU application. Geopolymer coated urea prepared from the finest fly ash fraction and lowest S : L ratio demonstrated high mechanical strength and slower urea release profile. Complete urea release was obtained in 132 minutes in water and 15 days in soil from geopolymer-coated urea whereas for uncoated urea it took only 20 minutes in water and 3 days in soil. Thus, geopolymer can potentially be used as a coating material for urea fertilizer to replace commonly used expensive and biodegradable polymer-based coatings.

A Scientometric-Analysis-Based Review of the Research Development on Geopolymers

A scientometric-based assessment of the literature on geopolymers was conducted in this study to determine its critical aspects. Typical review studies are restricted in their capability to link disparate segments of the literature in a systematic and exact way. Knowledge mapping, co-citation, and co-occurrence are very difficult components of creative research. This study adopted an advanced strategy of data mining, data processing and analysis, visualization and presentation, and interpretation of the bibliographic data on geopolymers. The Scopus database was used to search for and retrieve the data needed to complete the study’s objectives. The relevant sources of publications, keyword assessment, productive authors based on publications and citations, top papers based on citations received, and areas actively engaged in the research of geopolymers are recognized during the data assessment. The VOSviewer (VOS: visualization of similarities) software application was employed to analyze the literature data comprising citation, bibliographic, abstract, keywords, funding, and other information from 7468 relevant publications. In addition, the applications and restrictions associated with the use of geopolymers in the construction sector are discussed, as well as possible solutions to overcome these restrictions. The scientometric analysis revealed that the leading publication source (journal) in terms of articles and citations is “Construction and building materials”; the mostly employed keywords are geopolymer, fly ash, and compressive strength; and the top active and contributing countries based on publications are China, India, and Australia. Because of the quantitative and graphical representation of participating nations and researchers, this study can help academics to create collaborative efforts and exchange creative ideas and approaches. In addition, this study concluded that the large-scale usage of geopolymer concrete is constrained by factors such as curing regime, activator solution scarcity and expense, efflorescence, and alkali–silica reaction. However, embracing the potential solutions outlined in this study might assist in boosting the building industry’s adoption of geopolymer concrete.

Strengthening of Reinforced Concrete Beams Subjected to Concentrated Loads Using Externally Bonded Fiber Composite Materials

Renovation, restoration, remodeling, refurbishment, and the retrofitting of buildings often imply applying forces (i.e., concentrated loads) to beams that before were subjected to distributed loads only. In the case of reinforced concrete structures, the new condition causes a beam to bear a concentrated load with the crack pattern that resulted from the distributed loads which had acted before. If the concentrated load is applied at or near the beam’s midspan, the new shear demand reaches the maximum where cracks are vertical or quasi-vertical, and where inclined bars are not common according to any standards. So, the actual shear capacity can be substantially lower than new shear demand due to the concentrated load. This paper focuses on reinforced concrete beams whose load distribution has to be changed from distributed to concentrated and presents a design method to bring the beam’s shear capacity up to the new demand. The method consists of applying fiber composites (fiber-reinforced polymers or fiber-reinforced cementitious material) with fibers at an angle of 45° bonded to the beam’s web. This kind of external reinforcement arrangement has to comply with some practical measures, which are presented as well. The paper also provides the analytical model that predicts the concentrated load-carrying capacity of a beam in the strengthened state. The model accounts for the crack’s verticality, which nullifies the contributions of steel stirrups, aggregate interlock, and dowel action, and for the effective bond length of each fiber, which depends on the distance between the ends of the fiber and the crack it crosses.

Hybrid Cements with ZnO Additions: Hydration, Compressive Strength and Microstructure

The effect of ZnO has already been studied for Portland cement, but the study of its impact on hybrid pastes is scarce. Thus, in this investigation, the influence of ZnO addition on hydration, compressive strength, microstructure, and structure of hybrid pastes is presented. The analyses were made by setting time tests, compressive strength tests, X-ray diffraction, Fourier-transform infrared spectroscopy, thermogravimetric analysis with differential scanning calorimetry, and scanning electron microscopy coupled with energy-dispersive X-ray spectroscopy. The results indicate that the setting time of the cements was delayed up to 39 min with additions of 3 wt% ZnO. Alternatively, the higher values of compressive strength were observed when 0.5 wt% ZnO was added to the cements for all curing days. In addition, no important differences in the microstructure of samples with different additions of ZnO were observed after 28 days of curing. It is expected that the use of ZnO contributes to the delay of the setting time and the increase of the compressive strength without negatively modifying the microstructure of hybrid pastes.

Retention of Pollutants Elements from Mine Tailings of Lead in Geopolymers for Construction

The construction sector is one of the most demanding sectors of raw materials in existence today. As a consequence, the extraction of these materials has a significant impact on the environment. At the same time, mining activities produce a series of wastes, in some cases with polluting elements, which must be treated to avoid pollution. Therefore, the use of mining waste for the conformation of new construction materials is an important environmental advantage, even more so when such waste is prevented from producing polluting leachates. Therefore, in this research, geopolymers are developed with mine tailings from the Linares lead mines, chemically activated with potassium hydroxide. For this purpose, different percentages of the alkaline activator were tested and the physical and mechanical properties of the conformed materials were evaluated. The analysis of the different conformed geopolymers determined the optimum percentage of potassium hydroxide for conforming the geopolymer with the best mechanical and physical properties. In addition, the concentration in the leachate of potentially contaminating chemical elements in the mining waste was estimated to be lower than those regulated by the regulations. Consequently, this research shows the development of a sustainable material for construction with mining waste and reduction of the environmental impact of traditional products.

Novel Magnetic Inorganic Composites: Synthesis and Characterization

The addition of magnetic particles to inorganic matrices can produce new composites exhibiting intriguing properties for practical applications. It has been previously reported that the addition of magnetite to concrete improves its mechanical properties and durability in terms of water and chloride ions absorption. Here we describe the preparation of novel magnetic geopolymers based on two different matrices (G1 without inert aggregates and G2 with inert quartz aggregates) containing commercial SrFe12O19 particles with two weight concentrations, 6% and 11%. The composites' characterization, including chemical, structural, morphological, and mechanical determinations together with magnetic and electrical measurements, was carried out. The magnetic study revealed that, on average, the SrFe12O19 magnetic particles can be relatively well dispersed in the inorganic matrix. A substantial increase in the composite samples' remanent magnetization was obtained by embedding in the geopolymer SrFe12O19 anisotropic particles at a high concentration under the action of an external magnetic field during the solidification process. The new composites exhibit good mechanical properties (as compressive strength), higher than those reported for high weight concretes bearing a similar content of magnetite. The impedance measurements indicate that the electrical resistance is mainly controlled by the matrix's chemical composition and can be used to evaluate the geopolymerization degree.

Composite Performance Evaluation of Basalt Textile-Reinforced Geopolymer Mortar

Basalt fiber is a novel type of inorganic fiber which is produced from the extrusion of natural vocalnic basalt rocks through their melting process at high temperature. So the quality and strength characteristics of basalt fiber depend mainly on both the quality of raw material and manufacturing processing. Basalt fabric-reinforced cementitious composites (FRCM) are a novel composite and an extensive scientific investigation is still ongoing for geopolymer composite. Based on three types of basalt textile with respect to various net sizes, the aim of this paper is to evaluate the flexural performance of basalt textile-reinforced geopolymer composite through the four-point bending test. The specimens of rectangular form with the dimension of 400 × 100 × 15 mm3, reinforced with one to four layers of each type of basalt textile, were produced. They were then tested at the age of about 40 days after casting. On the other hand, the number of the specimens reinforced with four layers were considered to assess the mechanical strength of the specimens at longer periods of ageing time (60, 90, 150, 180 days). The experimental results showed that with the increasing number of reinforcing layers, the specimens significantly improved the mechanical strength, except for those reinforced with basalt textile of big net size. The specimens reinforced with basalt textile of big net size had no impact on post-crack mechanical strength, however, it helps to arrest the catastrophic brittle failure of the specimens; the failure of these specimens is due to localization of first crack. When the specimens were exposed to the further ageing times, the mechanical strength of the specimens were decreased over time. All the reinforced specimens have the same failure mode by flexural failure due to the rupture of fiber yarn in matrix, and no debonding of fiber yarn or a gradual peeling process of mortar matrix happened during testing.

Progressive utilisation prospects of coal fly ash: A review

The rapid surge in global energy needs has paved way for the development of various alternatives to natural resources every now and then. However, dependence on coal-based energy has not reduced greatly. Thus, massive quantities of coal fly ash (CFA) are generated worldwide, which is a serious threat to ecology owing to constraints associated with its storage and disposal. There exists a pressing and ongoing need to develop new, and green product streams from CFA to reduce the threat to the environment. The present review begins with an emphasis on the generation, physicochemical properties, and potential dangers of CFA. Then, it focuses on impending applications such as synthesis of geopolymers (alternative to cement), silica aerogels (insulating materials), carbon nanotubes (carbon allotropes) for electronic devices, and the separation of radioactive isotopes as well as rare earth elements from CFA. Furthermore, the review analyses factors restraining the motive for effective management strategies that drives utilisation of CFA (either in raw and processed state) for new product streams. Finally, the review elucidates the role of CFA as an emerging input in delivering eco-friendly amenities and future derivatives.

Additive Manufacturing of Geopolymers Modified with Microalgal Biomass Biofiller from Wastewater Treatment Plants

This paper deals with the additive manufacturing of metakaolin-based geopolymers and with the use of microalgal biomass from wastewater treatment plants as biofiller in this kind of cementitious material. The study was developed following the evolution stages of the material, which was prepared and printed as a soft paste and then hardened thanks to an inorganic polymerization reaction (geopolymerization). Thus, the characterization techniques adopted encompassed rheometry, mechanical tests performed on the hardened material, scanning electron microscopy (SEM), energy-dispersive X-ray spectroscopy (EDS) and mercury intrusion porosimetry (MIP). Microalgal biomass addition, evaluated in this study at 1, 3 and 5 php with respect to the powder weight, affected both the properties of the fresh and of the hardened material. Regarding the former aspect, biomass reduced the yield stress of the pastes, improving the ease of the extrusion process, but potentially worsening the ability to build structures in height. When hardened, geopolymers containing microalgae showed mechanical properties comparable to the unfilled material and a microstructure characterized by smaller pores. Finally, a printing test was successfully performed with a larger printer to assess the feasibility of producing large-scale structures. Taking into account these results, this study demonstrates the possibility of using microalgal biomass as biofiller in geopolymers for additive manufacturing.

Influence of Curing on the Strength Development of Calcium-Containing Geopolymer Mortar

This paper investigated the curing effects on the mechanical properties of calcium-containing geopolymer mortar. Three precursors are used: Class C fly ash, Class F fly ash plus calcium hydroxide and Class F fly ash plus slag. Curing conditions included: (1) standard curing at 20 ± 3 °C and RH 95% (C); (2) steam curing at 60 °C for 24 h (S); (3) steam curing at 60 °C for 6 h (S6); and (4) oven curing at 60 °C for 24 h (O), then the latter three followed by the standard curing. Under the standard conditions, the flexural strength and compressive strength of Class C fly ash geopolymer mortars developed quickly until the age of 7 days, followed by a gradual increase. Specimens with Class F fly ash plus Ca(OH)₂ showed slow increase till the age of 28 days. Under these non-standard conditions (2–4), all specimens showed higher 3-day strength, while later strengths were either higher or lower than those in standard conditions, depending on the type of the precursor.

Coal Combustion Wastes Reuse in Low Energy Artificial Aggregates Manufacturing

Sustainable building material design relies mostly on energy saving processes, decrease of raw materials consumption, and increase of waste and by-products recycling. Natural and lightweight artificial aggregates production implies relevant environmental impact. This paper addresses both the issues of residues recycling and energy optimization. Particularly, three coal combustion wastes (Weathered Fly Ash, WFA; Wastewater Treatment Sludge, WTS; Desulfurization Device Sludge, DDS) supplied by the Italian electric utility company (ENEL) have been employed in the manufacture of cold bonded artificial aggregates. Previously, the residues have been characterized in terms of chemical and mineralogical compositions, water content, particle size distribution, and heavy metal release behavior. These wastes have been used in the mix design of binding systems with the only addition of lime. Finally, the artificial aggregates have been submitted to physical, mechanical, and leaching testing, revealing that they are potentially suitable for many civil engineering applications.

Synthesis and Characterization of Novel Epoxy Geopolymer Hybrid Composites

The preparation and the characterization of novel geopolymer-based hybrid composites are reported. These materials have been prepared through an innovative synthetic approach, based on a co-reticulation in mild conditions of commercial epoxy based organic resins and a metakaolin-based geopolymer inorganic matrix. This synthetic strategy allows the obtainment of a homogeneous dispersion of the organic particles in the inorganic matrix, up to 25% in weight of the resin. The materials obtained present significantly enhanced compressive strengths and toughness with respect to the neat geopolymer, suggesting their wide utilization for structural applications. A preliminary characterization of the porous materials obtained by removing the organic phase from the hybrid composites by means of heat treatments is also reported. Possible applications of these materials in the field of water purification, filtration, or as lightweight insulating materials are envisaged.

Synthesis and characterizations of melamine-based epoxy resins

A new, easy and cost-effective synthetic procedure for the preparation of thermosetting melamine-based epoxy resins is reported. By this innovative synthetic method, different kinds of resins can be obtained just by mixing the reagents in the presence of a catalyst without solvent and with mild curing conditions. Two types of resins were synthesized using melamine and a glycidyl derivative (resins I) or by adding a silane derivative (resin II). The resins were characterized by means of chemical-physical and thermal techniques. Experimental results show that all the prepared resins have a good thermal stability, but differ for their mechanical properties: resin I exhibits remarkable stiffness with a storage modulus value up to 830 MPa at room temperature, while lower storage moduli were found for resin II, indicating that the presence of silane groups could enhance the flexibility of these materials. The resins show a pot life higher than 30 min, which makes these resins good candidates for practical applications. The functionalization with silane terminations can be exploited in the formulation of hybrid organic-inorganic composite materials.

Recycling of Pre-Washed Municipal Solid Waste Incinerator Fly Ash in the Manufacturing of Low Temperature Setting Geopolymer Materials

In this work, three samples of municipal solid waste incinerators fly ash (MSWI-FA) have been stabilized in systems containing coal fly ash to create geopolymers through a polycondensation reaction. Monolithic products have been obtained with both MSWI fly ash as received and after the partial removal of chloride and sulfate by water washing. The polycondensation products have been characterized qualitatively by means of Fourier transform infrared spectroscopy, X-ray diffraction and scanning electron microscopy and quantitatively, through the determination of the volume of reacted water and silicate. Furthermore, the heavy metals and chloride releases together with the physico-mechanical properties have been evaluated on the hardened products. In conclusion, considering the technological and environmental performances of the obtained geopolymers, they could be suitable for many non-structural applications, such as backfilling of abandoned quarries, decorative materials or brick fireplaces, hearths, patios, etc.

Use of Cement Kiln Dust, Blast Furnace Slag and Marble Sludge in the Manufacture of Sustainable Artificial Aggregates by Means of Cold Bonding Pelletization

In this work, three different samples of solid industrial wastes cement kiln dust (CKD), granulated blast furnace slag and marble sludge were employed in a cold bonding pelletization process for the sustainable production of artificial aggregates. The activating action of CKD components on the hydraulic behavior of the slag was explored by evaluating the neo-formed phases present in several hydrated pastes. Particularly, the influence of free CaO and sulfates amount in the two CKD samples on slag reactivity was evaluated. Cold bonded artificial aggregates were characterized by determining physical and mechanical properties of two selected size fractions of the granules for each studied mixture. Eighteen types of granules were employed in C28/35 concrete manufacture where coarser natural aggregate were substituted with the artificial ones. Finally, lightweight concretes were obtained, proving the suitability of the cold bonding pelletization process in artificial aggregate sustainable production.

Preparation and Characterization of New Geopolymer-Epoxy Resin Hybrid Mortars

The preparation and characterization of metakaolin-based geopolymer mortars containing an organic epoxy resin are presented here for the first time. The specimens have been prepared by means of an innovative in situ co-reticulation process, in mild conditions, of commercial epoxy based organic resins and geopolymeric slurry. In this way, geopolymer based hybrid mortars characterized by a different content of normalized sand (up to 66% in weight) and by a homogeneous dispersion of the organic resin have been obtained. Once hardened, these new materials show improved compressive strength and toughness in respect to both the neat geopolymer and the hybrid pastes since the organic polymer provides a more cohesive microstructure, with a reduced amount of microcracks. The microstructural characterization allows to point out the presence of an Interfacial Transition Zone similar to that observed in cement based mortars and concretes. A correlation between microstructural features and mechanical properties has been studied too.