Alkali-activated materials (AAMs) represent a promising alternative to conventional building materials and ceramics. Being produced in large amounts as aluminosilicate-rich secondary products, such as slags, they can be utilized for the formulation of AAMs. Slags are partially crystalline metallurgical residues produced during the high temperature separation of metallic and non-metallic materials in the steelmaking processes. In the present study, the electric arc furnace carbon or stainless steel slag (EAF) and secondary metallurgical slag such as ladle furnace basic slag (LS) were used as precursors in an alkali-activation process. EAF slag, with its amorphous fraction of about 56%, presented higher contents of soluble Si and Al species with respect to ladle slag R (35%). However, both are suitable to produce AAM. The leaching behavior shows that all the release values are below the regulation limit. All the bivalent ions (Ba, Cd, Cu, Ni, Pb, and Zn) are well immobilized in a geopolymeric matrix, while amphoteric elements, such as As and Cr, show a slight increase of release with respect to the corresponding slag in alkaline and aqueous environments. In particular, for Sb and As of AAM, release still remains below the regulation limits, while Mo presents an increase of leaching values that slightly exceeds the limit for landfill non-dangerous waste.
The aim of this research is to evaluate the possibility to realize alkali-activated materials exploiting biochar, a secondary raw material coming from pyrolysis/gasification processes, for environmental benefits, such as improvement of soil fertility and reduction of CO2 emissions into the atmosphere thanks to the carbon sink process where carbon dioxide is subtracted from the cycle of carbon. For the matrix of the geopolymers, a waste material derived from incinerator bottom ash was used and compared to pure metakaolin matrix. The materials obtained are lightweight and porous, with high water absorption capacity and moisture adsorption/desorption. BET analysis shows an increase in specific surface by increasing the biochar content and the biochar acts as a filler in the pores. From porosimetry analysis it is possible to follow the evolution of the curing process of the geopolymer prepared: specimens containing 70 wt% biochar after 28 and 90 days showed an increase in total Hg intrusion volume, pore area and total porosity but a decrease in the dimensions of pores. Due to the technical properties of materials containing biochar, they can be used in the future for a cleaner design of products in the field of sustainable construction for insulating panels or lightweight materials for houses and gardens in terraces and balconies.
In this study we compare the leaching behavior and the antibacterial and cytotoxic properties of 100% slag or stone wool derived alkali activated materials. The antibacterial activity was measured as the inhibiting capacity against two Gram-negative bacterial strains, Escherichia coli and Pseudomonas aeruginosa and one Gram-positive bacterial strain: Enterococcus faecalis. The cytotoxicity properties were tested on mouse embryonic fibroblast NIH-3T3 cell-line. It was proved that the high quality of the 3D aluminosilicate network of the consolidated materials obtained from powders of CaO or MgO-rich slags or stone wool, opportunely activated with NaO and/or Na-silicate, was capable of stabilizing heavy metal cations. The concentrations of leachate heavy cations were lower than the European law limit when tested in water. The effect of additives in the composites, basal fibers or nanocellulose, did not reduce the chemical stability and slightly influenced the compressive strength. Weight loss in water increased by 20% with basalt fibers addition, while it remained almost constant when nanocellulose was added. All the consolidated materials, cement-like in appearance, exhibited limited antibacterial properties (viability from 50 to 80% depending on the bacterial colony and the amount of sample) and absence of cytotoxicity, envisaging good acceptance from part of the final consumer and zero ecological impact. CaO-rich formulations can replace ordinary Portland cement (showing bacterial viability at 100%) with a certain capability for preventing the reproduction of the E. coli and S. aureus bacteria with health and environmental protection results.
Alternative cementitious binders, based on industrial side streams, characterized by a low carbon footprint, are profitably proposed to partially replace Portland cement. Among these alternatives, alkali-activated materials have attracted attention as a promising cementitious binder. In this paper, the chemical stability of the matrix, in fiber-reinforced slag-based alkali-activated composites, was studied, in order to assess any possible effect of the presence of the reinforcement on the chemistry of polycondensation. For this purpose, organic fiber, cellulose, and an inorganic fiber, basalt, were chosen, showing a different behavior in the alkaline media that was used to activate the slag fine powders. The novelty of the paper is the study of consolidation by means of chemical measurements, more than from the mechanical point of view. The evaluation of the chemical behavior of the starting slag in NaOH, indeed, was preparatory to the understanding of the consolidation degree in the alkali-activated composites. The reactivity of alkali-activated composites was studied in water (integrity test, normed leaching test, pH and ionic conductivity), and acids (leaching in acetic acid and HCl attack). The presence of fibers does not favor nor hinder the geopolymerization process, even if an increase in the ionic conductivity in samples containing fibers leads to the hypothesis that samples with fibers are less consolidated, or that fiber dissolution contributes to the conductivity values. The amorphous fraction was enriched in silicon after HCl attack, but the structure was not completely dissolved, and the presence of an amorphous phase is confirmed (C–S–H gel). Basalt fibers partly dissolved in the alkaline environment, leading to the formation of a C–N–A–S–H gel surrounding the fibers. In contrast, cellulose fiber remained stable in both acidic and alkaline conditions.
The exploitation of different kind of clayey waste (halloysitic, smectitic/illitic, kaolinitic) for the production of geopolymers in the view of a circular economy of mines is the main goal of this study. In particular, the addition of low percentages of metakaolin (5-15%) was evaluated to improve the chemical-physical properties and the consolidation degree of geopolymeric formulations produced with clays classified as mine’s by-products. In fact, these secondary raw materials are often not sufficient alone to obtain chemically stable formulations with acceptable mechanical properties but require the addition of reactive fillers. All samples contained thermally treated clays (600°C-700°C) and metakaolin as aluminosilicate precursors, alkaline solution of NaOH and Na2SiO3, and were cured at room temperature. The influence on the final products with MK addition was monitored with the evaluation of the chemical stability in water (pH and ionic conductivity measures), the comparison of setting times (Vicat needle) and mechanical performance.
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