Synthesis and Characterization of Fly Ash Geopolymer Sand

Geopolymers are an alternative binder to portland cement in the manufacture of mortars and concrete, as its three-dimensional aluminosilicate network imparts excellent mechanical properties. Use of geopolymers in place of ordinary portland cement is favored owing to the possible energy and carbon dioxide savings. River sand is another construction industry material that needs development of a sustainable alternate in India. Geopolymerization of fly ash amorphous silica mixtures is employed to produce fine aggregates as a possible replacement to river sand. Geopolymerization of fly ash amorphous silica mixtures in 10M NaOH solution at 100 degrees C for 7days produced fine aggregates termed fly ash geopolymer sand (FAPS)] that had comparable grain size distribution, specific gravity, and improved frictional resistance with river sand. The FAPS particles exhibited more alkaline pH (12.5) and higher total dissolved solids (TDS) concentration (TDS=747 mg/L) in comparison to the river sand specimen (pH=7.9 and TDS=32.5 mg/L). However, when used as fine aggregate in mortar, FAPS-mortar specimens develop similar pH, lower TDS, similar compressive strength, and modulus in relation to river sand-mortar specimens. The experimental results suggest that FAPS particles have the potential to replace river sand in the manufacture of mortar and concrete.

Selection and characterisation of geological materials for use as geopolymer precursors

Geopolymer binders are generally formed by reacting powdered aluminosilicate precursors with alkali silicate activators. Most research to date has concentrated on using either pulverised fuel ash or high purity dehydroxylated kaolin (metakaolin) in association with ground granulated blast furnace slag as the main precursor material. However, recently, attention has turned to alternative calcined clays that are abundant throughout the globe and have lower kaolinite contents than commercially available metakaolins. Due to the lack of clear and simple screening protocols enabling assessment of such geological resources for use as precursors in geopolymer systems, the present paper presents results from experimental work that was carried out to develop a functional binder using materials containing kaolinite taken from the Interbasaltic Formation of Northern Ireland. The influence of mineralogy has been examined, and a screening process, using three Interbasaltic materials as examples, that will assist in the rapid selection of suitable geopolymeric precursors from such materials is outlined.

Behavior of geopolymer concrete exposed to elevated temperatures

The research in the area of geopolymer is gaining momentum during the past 20 years. Studies confirm that geopolymer concrete has good compressive strength, tensile strength, flexural strength, modulus of elasticity and durability. These properties are comparable with OPC concrete.There are many occasions where concrete is exposed to elevated temperatures like fire exposure from thermal processor, exposure from furnaces, nuclear exposure, etc.. In such cases, understanding of the behaviour of concrete and structural members exposed to elevated temperatures is vital. Even though many research reports are available about the behaviour of OPC concrete at elevated temperatures, there is limited information available about the behaviour of geopolymer concrete after exposure to elevated temperatures. A preliminary study was carried out for the selection of a mix proportion. The important variable considered in the present study include alkali/fly ash ratio, percentage of total aggregate content, fine aggregate to total aggregate ratio, molarity of sodium hydroxide, sodium silicate to sodium hydroxide ratio, curing temperature and curing period. Influence of different variables on engineering properties of geopolymer concrete was investigated. The study on interface shear strength of reinforced and unreinforced geopolymer concrete as well as OPC concrete was also carried out. Engineering properties of fly ash based geopolymer concrete after exposure to elevated temperatures (ambient to 800 °C) were studied and the corresponding results were compared with those of conventional concrete. Scanning Electron Microscope analysis, Fourier Transform Infrared analysis, X-ray powder Diffractometer analysis and Thermogravimetric analysis of geopolymer mortar or paste at ambient temperature and after exposure to elevated temperature were also carried out in the present research work. Experimental study was conducted on geopolymer concrete beams after exposure to elevated temperatures (ambient to 800 °C). Load deflection characteristics, ductility and moment-curvature behaviour of the geopolymer concrete beams after exposure to elevated temperatures were investigated. Based on the present study, major conclusions derived could be summarized as follows. There is a definite proportion for various ingredients to achieve maximum strength properties. Geopolymer concrete with total aggregate content of 70% by volume, ratio of fine aggregate to total aggregate of 0.35, NaOH molarity 10, Na2SiO3/NaOH ratio of 2.5 and alkali to fly ash ratio of 0.55 gave maximum compressive strength in the present study. An early strength development in geopolymer concrete could be achieved by the proper selection of curing temperature and the period of curing. With 24 hours of curing at 100 °C, 96.4% of the 28th day cube compressive strength could be achieved in 7 days in the present study. The interface shear strength of geopolymer concrete is lower to that of OPC concrete. Compared to OPC concrete, a reduction in the interface shear strength by 33% and 29% was observed for unreinforced and reinforced geopolymer specimens respectively. The interface shear strength of geopolymer concrete is lower than ordinary Portland cement concrete. The interface shear strength of geopolymer concrete can be approximately estimated as 50% of the value obtained based on the available equations for the calculation of interface shear strength of ordinary portland cement concrete (method used in Mattock and ACI). Fly ash based geopolymer concrete undergoes a high rate of strength loss (compressive strength, tensile strength and modulus of elasticity) during its early heating period (up to 200 °C) compared to OPC concrete. At a temperature exposure beyond 600 °C, the unreacted crystalline materials in geopolymer concrete get transformed into amorphous state and undergo polymerization. As a result, there is no further strength loss (compressive strength, tensile strength and modulus of elasticity) in geopolymer concrete, whereas, OPC concrete continues to lose its strength properties at a faster rate beyond a temperature exposure of 600 °C. At present no equation is available to predict the strength properties of geopolymer concrete after exposure to elevated temperatures. Based on the study carried out, new equations have been proposed to predict the residual strengths (cube compressive strength, split tensile strength and modulus of elasticity) of geopolymer concrete after exposure to elevated temperatures (upto 800 °C). These equations could be used for material modelling until better refined equations are available. Compared to OPC concrete, geopolymer concrete shows better resistance against surface cracking when exposed to elevated temperatures. In the present study, while OPC concrete started developing cracks at 400 °C, geopolymer concrete did not show any visible cracks up to 600 °C and developed only minor cracks at an exposure temperatureof 800 °C. Geopolymer concrete beams develop crack at an early load stages if they are exposed to elevated temperatures. Even though the material strength of the geopolymer concrete does not decrease beyond 600 °C, the flexural strength of corresponding beam reduces rapidly after 600 °C temperature exposure, primarily due to the rapid loss of the strength of steel. With increase in temperature, the curvature at yield point of geopolymer concrete beam increases and thereby the ductility reduces. In the present study, compared to the ductility at ambient temperature, the ductility of geopolymer concrete beams reduces by 63.8% at 800 °C temperature exposure. Appropriate equations have been proposed to predict the service load crack width of geopolymer concrete beam exposed to elevated temperatures. These equations could be used to limit the service load on geopolymer concrete beams exposed to elevated temperatures (up to 800 °C) for a predefined crack width (between 0.1mm and 0.3 mm) or vice versa. The moment-curvature relationship of geopolymer concrete beams at ambient temperature is similar to that of RCC beams and this could be predicted using strain compatibility approach Once exposed to an elevated temperature, the strain compatibility approach underestimates the curvature of geopolymer concrete beams between the first cracking and yielding point.

Effects of adding Bauxite and Oyster shell on the properties of metakaolin-based geopolymer cements

This work has investigated the possibility of use bauxite and oyster shell as mineral admixtures,to enhance the properties of metakaolin-based geopolymer cements. Raw materials(metakaolin, bauxite and oyster shell) were characterized in the first time by determination of their chemical and mineralogical compositions, particles size distribution, specific surface area, thermal analysis and then in the second time use to synthesized geopolymers. Different methods of analysis such as Fourier Transform Infrared spectroscopy(FTIR), X-Ray Diffractometry (XRD), and Scanning Electron Microscopy (SEM) were used to assess the variation of setting time, linear shrinkage and 28 days compressive strength of geopolymer pastes. The results of these analysis has showed that bauxite and oyster shells are source of Al2O3 and CaO respectively, and also contain crystalline phases. The geopolymers obtained by mixing metakaolin and bauxite have their setting time between 235 and 420min and their compressive strength between 40 and 57MPa ; for those obtained by mixing metakaolin and oyster shell the setting time is between 330 and 485min and compressive strength between 40 and 58MPa . The addition of a moderate amount (20% by mass) of bauxite or oyster shell led to improve the compressive strength of a metakaolin-based geopolymer of 43% (metakaolin-bauxite-based geopolymers) and 45% (metakaolin-oyster shell-based geopolymers) and decrease the linear shrinkage. More than 20% mineral additive has a deleterious effect on compressive strength and increase the setting time. Keywords: Metakaolin ; Bauxite ; Oyster shell ; synthesis ; Optimization; Geopolymer cements.

DEVELOPMENT OF POROUS CONCRETE GEOPOLYMER USING HYDROGEN PEROXIDE AS BLOWING AGENT.

Metakaolin and volcanic ashes respectively called MK and ZG were used as aluminosilicate raw materials for the synthesis of porous geopolymers. The hydrogen peroxide was used as a blowing agent. The geopolymer prepared were characterized by Spectroscopy Fourier Transform Infrared (SFTI), X-ray Diffraction (XRD), Scanning Electron Microscopy (SEM) and the determination of some physical properties such as bulk density, total porosity, volume shrinkage, compressive strength and thermal conductivity was also carried out. The presence of pores in the geopolymer obtained is function of the percentage of hydrogen peroxide added, causing the concomitantly decrease in compressive strength, apparent density and thermal conductivity. The use of hydrogen peroxide as a blowing agent gave some thermal insulation properties to these geopolymers which could be close to the properties of some commercial insulation materials.

Factor 5 in eco-cement: Zeobond Pty Ltd

Cement production is estimated to be responsible for approximately 6 per cent of total global greenhouse gas emissions. One of the most promising alternatives to common Portland cement is geopolymer cement, and Australian company Zeobond is a bone fide leader in its manufacture.

广西合山固体废弃物制备地质聚合物胶凝材料

Geopolymer gelatinous material was prepared by ferroalloy slag (signed with NKT in laboratory) and circulating fluidization bed slag (CFB slag, signed with NM in laboratory) produced from Heshan city, Guangxi zhuang autonomous region, China. The mechanical properties of the geopolymer made of high content ferroalloy slag can reach the standard of 42.5# portland blastfurnace-slag cement, and it’s processing technology is more simple and not need of mill and burn and will not produce harmful gas. By means of chemical and XRD analyses, it is concluded that NKT is a kind of acidity water-granulated slag with better activation and fit to be activated by alkali activators. Low-cost industrial gypsum (signed with NG in laboratory), analytic reagent oxide(signed with NH in laboratory) and sulfate(signed with NS in laboratory) were selected as alkali activation in the experiment. The results showed NH is a good alkali activator for NKT. Both NH and NG can activate ferroally slag’s activities, but NS can’t alone. The activation effect of superimposing activation of NH and NG excel by separateness. Based on those experiments, optimization compounds were carried out: (1) NKT: NH: NG = 80: 10: 10 and (2) NM: NKT: NS: NG: NH = 10: 70: 2: 8: 10。. The soundness of the test blocks is good by boiling examination. Through XRD, SEM, IR, NMR analyses of geopolymer, the reaction mechanism of geopolymer prepared by alkalescent activating in solid wastes was discussed in the thesis first. It is point out, there is difference in reaction mechanism between traditional geopolymer preparation and the preparation of alkalescent activating solid wastes because NG is a industry product. There is the similar process of depolymerization and reunion of Si-O bond. The latter preparation process generate new subtance but the former doesn’t. In the experiment, we found a performance of NKT that the water requirement of normal consistency of geopolymer reduces with increasing content of NKT. The result shows NKT has some ability to reduce water requirement. The performance is worthy of further research and utilization. Making use of solid wastes to prepare geopolymer, not only can settle environment problem caused by a great deal of dump of NKT, but also settle the shortage of natural resources. Moreover it could take economic, environmental and social benefits and settle thoroughly contradiction in the environment protection and regional economy development and promote circulation economy development.

Alkali Activated Fuel Ash and Slag Mixes:Optimization Study from Mortars to Concrete Building Blocks

Alkali activated binders, based on ash and slag, also known as geopolymers, can play a key role in reducing the carbon footprint of the construction sector by replacing ordinary Portland cement in some concretes. Since 1970s, research effort has been ongoing in many research institutions. In this study, pulverized fuel ash (PFA) from a UK power plant, ground granulated blast furnace slag (GGBS) and combinations of the two have been investigated as geopolymer binders for concrete applications. Activators used were sodium hydroxide and sodium silicate solutions. Mortars with sand/binder ratio of 2.75 with several PFA and GGBS combinations have been mixed and tested. The optimization of alkali dosage (defined as the Na2O/binder mass ratio) and modulus (defined as the Na2O/SiO2 mass ratio) resulted in strengths in excess of 70 MPa for tested mortars. Setting time and workability have been considered for the identification of the best combination of PFA/GGBS and alkali activator dosage for different precast concrete products. Geopolymer concrete building blocks have been replicated in laboratory and a real scale factory trial has been successfully carried out. Ongoing microstructural characterization is aiming to identify reaction products arising from PFA/GGBS combinations.

Factors influencing the compressive strengths of fly ash based geopolymers

Several factors affecting the reactivity of pulverised fuel ash (pfa) as a precursor for geopolymer concrete have been investigated. These include physical and chemical properties of various pfa sources, inclusion of ground granulated blast furnace slag (ggbs), chemical activator dosages and curing temperature. Alkali-activated pfa was found to require elevated curing temperatures and high alkali concentrations. A mixture of sodium hydroxide and sodium silicate was used and this was shown to result in high strengths, as high as 70 MPa at 28-days. The presence of silicates in solution was found to be a key factor. Detailed physical and chemical characterisation was carried out on thirteen pfa sources from the UK. The most important factor affecting the reactivity was found to be the particle size of pfa. The loss on ignition (LOI) and the amorphous content are also important parameters that need to be considered for the selection of pfa for use in geopolymer concrete. The partial replacement of pfa by ground granulated blast furnace slag (ggbs) was found to be beneficial in not only avoiding the need for elevated curing temperatures but also in improving compressive strengths. Microstructural characterisation with scanning electron microscope (SEM) coupled with energy dispersive X-ray spectroscopy (EDS) was performed on pfa/ggbs pastes. The reaction product of pfa and ggbs in these binary systems was calcium aluminium silicate hydrate gel (C-A-S-H) with inclusion of Na in the structure.

Alkali activated fuel ash and slag mixes:optimization study from paste to concrete building blocks

Alkali activated binders, based on ash and slag, also known as geopolymers, can play a key role in reducing the carbon footprint of the construction sector by replacing ordinary Portland cement in some concretes. Since 1970s, research effort has been ongoing in many research institutions. In this study, pulverized fuel ash (pfa) from a UK power plant, ground granulated blast furnace slag (ggbs) and combinations of the two have been investigated as geopolymer binders for concrete applications. Activators used were sodium hydroxide and sodium silicate solutions. Mortars with sand/binder ratio of 2.75 with several pfa and ggbs combinations have been mixed and tested. The optimization of alkali dosage (defined as the Na2O/binder mass ratio) and modulus (defined as the Na2O/SiO2 mass ratio) resulted in strengths in excess of 70 MPa for tested mortars. Setting time and workability have been considered for the identification of the best combination of pfa/ggbs and alkali activator dosage for different precast concrete products. Geopolymer concrete building blocks have been replicated in laboratory and a real scale factory trial has been successfully carried out. Ongoing microstructural characterization is aiming to identify reaction products arising from pfa/ggbs combinations.

Argamassas e betões geopoliméricos: estado da arte e potencial de industrialização em Portugal

Dissertação para obtenção do grau de Mestre em Engenharia Civil

Otimização e análise mecânica de pastas geopoliméricas para uso em poços sujeitos à injeção cíclica de vapor

Oil wells subjected to cyclic steam injection present important challenges for the development of well cementing systems, mainly due to tensile stresses caused by thermal gradients during its useful life. Cement sheath failures in wells using conventional high compressive strength systems lead to the use of cement systems that are more flexible and/or ductile, with emphasis on Portland cement systems with latex addition. Recent research efforts have presented geopolymeric systems as alternatives. These cementing systems are based on alkaline activation of amorphous aluminosilicates such as metakaolin or fly ash and display advantageous properties such as high compressive strength, fast setting and thermal stability. Basic geopolymeric formulations can be found in the literature, which meet basic oil industry specifications such as rheology, compressive strength and thickening time. In this work, new geopolymeric formulations were developed, based on metakaolin, potassium silicate, potassium hydroxide, silica fume and mineral fiber, using the state of the art in chemical composition, mixture modeling and additivation to optimize the most relevant properties for oil well cementing. Starting from molar ratios considered ideal in the literature (SiO2/Al2O3 = 3.8 e K2O/Al2O3 = 1.0), a study of dry mixtures was performed,based on the compressive packing model, resulting in an optimal volume of 6% for the added solid material. This material (silica fume and mineral fiber) works both as an additional silica source (in the case of silica fume) and as mechanical reinforcement, especially in the case of mineral fiber, which incremented the tensile strength. The first triaxial mechanical study of this class of materials was performed. For comparison, a mechanical study of conventional latex-based cementing systems was also carried out. Regardless of differences in the failure mode (brittle for geopolymers, ductile for latex-based systems), the superior uniaxial compressive strength (37 MPa for the geopolymeric slurry P5 versus 18 MPa for the conventional slurry P2), similar triaxial behavior (friction angle 21° for P5 and P2) and lower stifness (in the elastic region 5.1 GPa for P5 versus 6.8 GPa for P2) of the geopolymeric systems allowed them to withstand a similar amount of mechanical energy (155 kJ/m3 for P5 versus 208 kJ/m3 for P2), noting that geopolymers work in the elastic regime, without the microcracking present in the case of latex-based systems. Therefore, the geopolymers studied on this work must be designed for application in the elastic region to avoid brittle failure. Finally, the tensile strength of geopolymers is originally poor (1.3 MPa for the geopolymeric slurry P3) due to its brittle structure. However, after additivation with mineral fiber, the tensile strength became equivalent to that of latex-based systems (2.3 MPa for P5 and 2.1 MPa for P2). The technical viability of conventional and proposed formulations was evaluated for the whole well life, including stresses due to cyclic steam injection. This analysis was performed using finite element-based simulation software. It was verified that conventional slurries are viable up to 204ºF (400ºC) and geopolymeric slurries are viable above 500ºF (260ºC)