Synthesis of Geopolymer from Ferronickel Aluminosilicate Waste

Tjokorde Walmiki Samadhi; Winny Wulandari; Aya Anisa Dwinidasari; Arum Rahmasari

doi:10.5614/j.eng.technol.sci.2025.57.4.1

Synthesis of Geopolymer from Ferronickel Aluminosilicate Waste

Published: 2025-01-01 | DOI: 10.5614/j.eng.technol.sci.2025.57.4.1 | Vol 57, Issue 4 (2025)

Authors

Tjokorde Walmiki Samadhi

Faculty of Industrial Technology, Institut Teknologi Bandung, Labtek X Building, Jalan Ganesa 10 Bandung 40132

Winny Wulandari

Faculty of Industrial Technology, Institut Teknologi Bandung, Labtek X Building, Jalan Ganesa 10 Bandung 40132

Aya Anisa Dwinidasari

Faculty of Industrial Technology, Institut Teknologi Bandung, Labtek X Building, Jalan Ganesa 10 Bandung 40132

Arum Rahmasari

Faculty of Industrial Technology, Institut Teknologi Bandung, Labtek X Building, Jalan Ganesa 10 Bandung 40132

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Abstract

The nickel industry in Indonesia generates massive volumes of ferronickel slag that may harm the environment. This research evaluates the feasibility of utilizing coal fly ash and slag from a ferronickel smelter in Obi Island in Indonesia to synthesize geopolymer, an environmentally friendly cementitious material. Compressive strength of geopolymer mortars was measured as a function of slag particle size (coarse and fine), fly ash mass fraction in the dry aluminosilicate binder precursor blends (0.4 and 0.8), and thermal curing period (24 and 48 hours). Mortar specimens were produced by mixing ash and slag with activator solution and sand. The activator solution contained Na2SiO3 and NaOH at a mass ratio of 2:1. Solid reactants to activator solution mass ratio was 3.33. After heat curing, specimens were held in ambient conditions to an age of 7 days. The compressive strength of the mortars was in the 2.1-24.8 MPa range. Geopolymer mortars were able to comply to Indonesian SNI 15-2049-2004 or US ASTM C1329-05 standards for Portland cement. FTIR and XRD characterizations confirmed the conversion of fly ash and slag into amorphous geopolymers at near ambient temperature. Finer slag particle size increased reactivity, ultimately producing higher compressive strength.

Keywords

aluminosilicate; ash; cement; ferronickel; geopolymer; slag; valorization; waste

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References

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[ref-1] Al-Safi, A. A. (2021). Blast furnace slag-based geopolymer mortars cured at different conditions: modeling and optimization of compressive strength. European Journal of Environmental and Civil Engineering, 25(11), 1949–1961. https://doi.org/10.1080/19648189.2019.1598502 DOI: 10.1080/19648189.2019.1598502

[ref-2] Bewa, C. N., Tchakouté, H. K., Banenzoué, C., Cakanou, L., Mbakop, T. T., Kamseu, E., & Rüscher, C. H. (2020). Acid-based geopolymers using waste fired brick and different metakaolins as raw materials. Applied Clay Science, 198, 105813. https://doi.org/10.1016/j.clay.2020.105813 DOI: 10.1016/j.clay.2020.105813

[ref-3] Bouaissi, A., Li, L., Al Bakri Abdullah, M. M., & Bui, Q.-B. (2019). Mechanical properties and microstructure analysis of FA-GGBS-HMNS based geopolymer concrete. Construction and Building Materials, 210, 198–209. https://doi.org/10.1016/j.conbuildmat.2019.03.202 DOI: 10.1016/j.conbuildmat.2019.03.202

[ref-4] Cao, R., Li, B., You, N., Zhang, Y., & Zhang, Z. (2018). Properties of alkali-activated ground granulated blast furnace slag blended with ferronickel slag. Construction and Building Materials, 192, 123–132. https://doi.org/10.1016/j.conbuildmat.2018.10.112 DOI: 10.1016/j.conbuildmat.2018.10.112

[ref-5] Carreño-Gallardo, C., Tejeda-Ochoa, A., Perez-Ordonez, O. I., Ledezma-Sillas, J. E., Lardizabal-Gutierrez, D., Prieto-Gomez, C., Valenzuela-Grado, J. A., Robles Hernandez, F. C., & Herrera-Ramirez, J. M. (2018). In the CO2 emission remediation by means of alternative geopolymers as substitutes for cements. Journal of Environmental Chemical Engineering, 6(4), 4878–4884. https://doi.org/10.1016/j.jece.2018.07.033 DOI: 10.1016/j.jece.2018.07.033

[ref-6] Chuewangkam, N., Kidkhunthod, P., & Pinitsoontorn, S. (2024). Direct evidence for the mechanism of early-stage geopolymerization process. Case Studies in Construction Materials, 21, e03539. https://doi.org/10.1016/j.cscm.2024.e03539 DOI: 10.1016/j.cscm.2024.e03539

[ref-7] Coelho, L. M., Guimarães, A. C. R., Alves Moreira, C. R. C. L., dos Santos, G. P. P., Monteiro, S. N., & da Silveira, P. H. P. M. (2024). Feasibility of Using Ferronickel Slag as a Sustainable Alternative Aggregate in Hot Mix Asphalt. Sustainability, 16(19), 8642. https://doi.org/10.3390/su16198642 DOI: 10.3390/su16198642

[ref-8] Detphan, S., & Chindaprasirt, P. (2009). Preparation of fly ash and rice husk ash geopolymer. International Journal of Minerals, Metallurgy and Materials, 16(6), 720–726. https://doi.org/10.1016/S1674-4799(10)60019-2 DOI: 10.1016/s1674-4799(10

[ref-9] Edwin, R. S., Ngii, E., Talanipa, R., Masud, F., & Sriyani, R. (2019). Effect of nickel slag as a sand replacement in strength and workability of concrete. IOP Conference Series: Materials Science and Engineering, 615(1), 012014. https://doi.org/10.1088/1757-899X/615/1/012014 DOI: 10.1088/1757-899x/615/1/012014

[ref-10] Falayi, T. (2019). Sustainable solidification of ferrochrome slag through geopolymerisation: a look at the effect of curing time, type of activator and liquid solid ratio. Sustainable Environment Research, 29(1), 21. https://doi.org/10.1186/s42834-019-0022-7 DOI: 10.1186/s42834-019-0022-7

[ref-11] Fansuri, H., Prasetyoko, D., Zhang, Z., & Zhang, D. (2012). The effect of sodium silicate and sodium hydroxide on the strength of aggregates made from coal fly ash using the geopolymerisation method. Asia-Pacific Journal of Chemical Engineering, 7(1), 73–79. https://doi.org/10.1002/apj.493 DOI: 10.1002/apj.493

[ref-12] Gomes, K. C., Carvalho, M., Diniz, D. de P., Abrantes, R. de C. C., Branco, M. A., & Carvalho Junior, P. R. O. de. (2019). Carbon emissions associated with two types of foundations: CP-II Portland cement-based composite vs. geopolymer concrete. Matéria (Rio de Janeiro), 24(4). https://doi.org/10.1590/s1517-707620190004.0850 DOI: 10.1590/s1517-707620190004.0850

[ref-13] Han, F., Zhang, H., Li, Y., & Zhang, Z. (2023). Recycling and comprehensive utilization of ferronickel slag in concrete. Journal of Cleaner Production, 414, 137633. https://doi.org/10.1016/j.jclepro.2023.137633 DOI: 10.1016/j.jclepro.2023.137633

[ref-14] Kaya, M., Uysal, M., Yilmaz, K., Karahan, O., & Atis, C. D. (2020). Mechanical properties of class C and F fly ash geopolymer mortars. Journal of the Croatian Association of Civil Engineers, 72(04), 297–309. https://doi.org/10.14256/JCE.2421.2018 DOI: 10.14256/jce.2421.2018

[ref-15] Kaze, C. R., Naghizadeh, A., Tchadjie, L., Adesina, A., Noel Yankwa Djobo, J., Deutou Nemaleu, J. G., Kamseu, E., Chinje Melo, U., & Tayeh, B. A. (2022). Lateritic soils based geopolymer materials: A review. Construction and Building Materials, 344, 128157. https://doi.org/10.1016/j.conbuildmat.2022.128157 DOI: 10.1016/j.conbuildmat.2022.128157

[ref-16] Kaze, R. C., Naghizadeh, A., Tchadjie, L., Cengiz, Ö., Kamseu, E., & Chinje, F. U. (2024). Formulation of geopolymer binder based on volcanic-scoria and clay brick wastes using rice husk ash-NaOH activator: Fresh and hardened properties. Sustainable Chemistry and Pharmacy, 40, 101627. https://doi.org/10.1016/j.scp.2024.101627 DOI: 10.1016/j.scp.2024.101627

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