Synergistic utilization of diverse industrial wastes for reutilization in steel production and their geopolymerization potential.

Recycling wastes back into a manufacturing process, or into a separate product, is an important challenge. The primary aim of this work was to combine wastes from the steel industry, the galvanizing industry and the pulp and paper industry to form two new useful products. The steel industry generates the wastes red dust, mill scale, blast oxygen furnace slag and iron ore fines. Galvanizing industrial facilities dispose of sulfuric acid contaminated with iron. The pulp and paper industry produces the byproduct black liquor, which is high in lignin. Inserting these wastes as resources into the steel industry, or as stand-alone products, could reduce the need for virgin materials. The main methodology of the work was three-fold. First, spent sulfuric acid was used to precipitate the lignin from black liquor. Second, this lignin was combined with steel industry wastes and geopolymeric materials to make briquettes, a sustainable reducing material for steelmaking furnaces. Briquettes contained red dust, mill scale, blast oxygen furnace slag, iron ore fines and lignin precipitated from black liquor with spent sulfuric acid. Key research findings of compressive strength and weight loss testing showed the briquettes to be feasible for steel-making furnace use. Third, these steel industry wastes were investigated as a partial fly ash replacement in geopolymers. Main research findings were that compared to the control geopolymer, these geopolymer samples improved compressive strength and gave similar workability. Thus, the investigated wastes have the potential to both increase recycling in the steel industry and to improve geopolymeric products.

Mechanical and Microstructural Evaluations of Lightweight Aggregate Geopolymer Concrete before and after Exposed to Elevated Temperatures.

This paper presents the mechanical and microstructural characteristics of a lightweight aggregate geopolymer concrete (LWAGC) synthesized by the alkali-activation of a fly ash source (FA) before and after being exposed to elevated temperatures, ranging from 100 to 800 °C. The results show that the LWAGC unexposed to the elevated temperatures possesses a good strength-to-weight ratio compared with other LWAGCs available in the published literature. The unexposed LWAGC also shows an excellent strength development versus aging times, up to 365 days. For the exposed LWAGC to the elevated temperatures of 100 to 800 °C, the results illustrate that the concretes gain compressive strength after being exposed to elevated temperatures of 100, 200 and 300 °C. Afterward, the strength of the LWAGC started to deteriorate and decrease after being exposed to elevated temperatures of 400 °C, and up to 800 °C. Based on the mechanical strength results of the exposed LWAGCs to elevated temperatures of 100 °C to 800 °C, the relationship between the exposure temperature and the obtained residual compressive strength is statistically analyzed and achieved. In addition, the microstructure investigation of the unexposed LWAGC shows a good bonding between aggregate and mortar at the interface transition zone (ITZ). However, this bonding is subjected to deterioration as the LWAGC is exposed to elevated temperatures of 400, 600 and 800 °C by increasing the microcrack content and swelling of the unreacted silicates.