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Fly Ash porous material using geopolymerization process for high temperature exposure

2012-04-10 , Mohd. Mustafa Al Bakri Abdullah , Liyana Jamaludin , Kamarudin Hussin , Mohamed Bnhussain , Che Mohd Ruzaidi Ghazali , Mohd Izzat Ahmad

This paper presents the results of a study on the effect of temperature on geopolymers manufactured using pozzolanic materials (fly ash). In this paper, we report on our investigation of the performance of porous geopolymers made with fly ash after exposure to temperatures from 600 °C up to 1000 °C. The research methodology consisted of pozzolanic materials (fly ash) synthesized with a mixture of sodium hydroxide and sodium silicate solution as an alkaline activator. Foaming agent solution was added to geopolymer paste. The geopolymer paste samples were cured at 60 °C for one day and the geopolymers samples were sintered from 600 °C to 1000 °C to evaluate strength loss due to thermal damage. We also studied their phase formation and microstructure. The heated geopolymers samples were tested by compressive strength after three days. The results showed that the porous geopolymers exhibited strength increases after temperature exposure.

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Effect of NaOH molar concentration on microstructure and compressive strength of Dolomite/Fly Ash-Based geopolymers

2021 , Emy Aizat Azimi , M.A.A. Mohd Salleh , Mohd. Mustafa Al Bakri Abdullah , Ikmal Hakem A. Aziz , Kamarudin Hussin , Jitrin Chaiprapa , Petrica Vizureanu , Sorachon Yoriya , Marcin Nabiałek , Jerzy J. Wyslocki

Dolomite can be used as a source of aluminosilicate to produce geopolymers; however, this approach is limited by its low reactivity. This study analyzes the viability of producing geopolymers using dolomite/fly-ash with sodium silicate and NaOH solutions (at multiple concentrations) by determining the resultant geopolymers’ compressive strengths. The dolomite/fly-ash-based geopolymers at a NaOH concentration of ~22 M resulted in an optimum compressive strength of 46.38 MPa after being cured for 28 days, and the SEM and FTIR analyses confirmed the denser surface of the geopolymer matrix. The synchrotron micro-XRF analyses confirmed that the Ca concentration exceeded that of Si and Mg, leading to the formation of calcium silicate hydrate, which strengthens the resulting geopolymers.

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Densification behavior and mechanical performance of Nepheline geopolymer ceramics: preliminary study

2023 , Nur Bahijah Mustapa , Romisuhani Ahmad , Mohd. Mustafa Al Bakri Abdullah , Wan Mastura Wan Ibrahim , Andrei Victor Sandu , Christina Wahyu Kartikowati , Puput Risdanareni , Wan Hasnida Wan Mohamed Saimi

Nepheline geopolymer ceramics have emerged as a promising sustainable alternative to traditional cementitious materials in various applications. As the sintering mechanism plays a crucial role in the densification and mechanical performance of ceramics, therefore, in this paper, a preliminary study was conducted to examine the effects of densification towards mechanical properties of geopolymer-based nepheline ceramics upon sintering. The said innovative geopolymer technology can convert raw materials of aluminosilicate activating with alkaline activator into ceramic-like materials requiring low temperatures. The experimental procedure includes the synthesis of nepheline geopolymer ceramics through the geopolymerization method, then sintered at different temperatures to explore the sintering behavior and its impact on the materials’ microstructure and mechanical performance. The densification behavior of nepheline geopolymer ceramics during sintering was analyzed by evaluating the changes in density, shrinkage, and porosity. The microstructural evolution and are determined by using SEM. The relationships between sintering conditions, microstructure, and mechanical performance were investigated to understand the underlying mechanisms affecting the material’s strength and durability. The geopolymer exhibited its highest flexural strength of 54.93 MPa when sintered at 1200 ℃, while the lowest strength of 6.07 MPa was observed at a sintering temperature of 200 ℃. The findings demonstrate a positive correlation between the sintering temperature and the flexural strength of the geopolymer ceramics, indicating that higher temperatures lead to increased strength. Ultimately, this knowledge can facilitate the broader utilization of nepheline geopolymer ceramics as sustainable materials in various engineering and construction applications.

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Role of sintering temperature in production of nepheline ceramics-based geopolymer with addition of ultra-high molecular weight polyethylene

2021 , Romisuhani Ahmad , Mohd. Mustafa Al Bakri Abdullah , Jitrin Chaiprapa , Kamarudin Hussin , Wan Mastura Wan Ibrahim , Fakhryna Hannanee Ahmad Zaidi , Jerzy J. Wysłocki , Katarzyna Błoch , Marcin Nabiałek

The primary motivation of developing ceramic materials using geopolymer method is to minimize the reliance on high sintering temperatures. The ultra-high molecular weight polyethylene (UHMWPE) was added as binder and reinforces the nepheline ceramics based geopolymer. The samples were sintered at 900 °C, 1000 °C, 1100 °C, and 1200 °C to elucidate the influence of sintering on the physical and microstructural properties. The results indicated that a maximum flexural strength of 92 MPa is attainable once the samples are used to be sintered at 1200 °C. It was also determined that the density, porosity, volumetric shrinkage, and water absorption of the samples also affected by the sintering due to the change of microstructure and crystallinity. The IR spectra reveal that the band at around 1400 cm−1 becomes weak, indicating that sodium carbonate decomposed and began to react with the silica and alumina released from gels to form nepheline phases. The sintering process influence in the development of the final microstructure thus improving the properties of the ceramic materials.

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Comparison of hook and straight steel fibers addition on malaysian fly ash-based geopolymer concrete on the slump, density, water absorption and mechanical properties

2021 , Meor Ahmad Faris bin Meor Ahmad Tajudin , Mohd. Mustafa Al Bakri Abdullah , Ratnasamy Muniandy , Mohammad Firdaus Abu Hashim , Katarzyna Błoch , Bartłomiej Jeż , Sebastian Garus , Paweł Palutkiewicz , Nurul Aida Mohd Mortar , Mohd Fathullah Ghazli@Ghazali

Geopolymer concrete has the potential to replace ordinary Portland cement which can reduce carbon dioxide emission to the environment. The addition of different amounts of steel fibers, as well as different types of end-shape fibers, could alter the performance of geopolymer concrete. The source of aluminosilicate (fly ash) used in the production of geopolymer concrete may lead to a different result. This study focuses on the comparison between Malaysian fly ash geopolymer concrete with the addition of hooked steel fibers and geopolymer concrete with the addition of straight-end steel fibers to the physical and mechanical properties. Malaysian fly ash was first characterized by X-ray fluorescence (XRF) to identify the chemical composition. The sample of steel fiber reinforced geopolymer concrete was produced by mixing fly ash, alkali activators, aggregates, and specific amounts of hook or straight steel fibers. The steel fibers addition for both types of fibers are 0%, 0.5%, 1.0%, 1.5%, and 2.0% by volume percentage. The samples were cured at room temperature. The physical properties (slump, density, and water absorption) of reinforced geopolymer concrete were studied. Meanwhile, a mechanical performance which is compressive, as well as the flexural strength was studied. The results show that the pattern in physical properties of geopolymer concrete for both types of fibers addition is almost similar where the slump is decreased with density and water absorption is increased with the increasing amount of fibers addition. However, the addition of hook steel fiber to the geopolymer concrete produced a lower slump than the addition of straight steel fibers. Meanwhile, the addition of hook steel fiber to the geopolymer concrete shows a higher density and water absorption compared to the sample with the addition of straight steel fibers. However, the difference is not significant. Besides, samples with the addition of hook steel fibers give better performance for compressive and flexural strength compared to the samples with the addition of straight steel fibers where the highest is at 1.0% of fibers addition.

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Assessment of the suitability of ceramic waste in geopolymer composites: an appraisal

2021 , Ismail Luhar , Salmabanu Luhar , Mohd. Mustafa Al Bakri Abdullah , Marcin Nabiałek , Andrei Victor Sandu , Janusz Szmidla , Anna Jurczyńska , Rafiza Abdul Razak , Ikmal Hakem A Aziz , Noorina Hidayu Jamil , Laila Mardiah Deraman

Currently, novel inorganic alumino-silicate materials, known as geopolymer composites, have emerged swiftly as an ecobenevolent alternative to contemporary ordinary Portland cement (OPC) building materials since they display superior physical and chemical attributes with a diverse range of possible potential applications. The said innovative geopolymer technology necessitates less energy and low carbon footprints as compared to OPC-based materials because of the incorporation of wastes and/or industrial byproducts as binders replacing OPC. The key constituents of ceramic are silica and alumina and, hence, have the potential to be employed as an aggregate to manufacture ceramic geopolymer concrete. The present manuscript presents a review of the performance of geopolymer composites incorporated with ceramic waste, concerning workability, strength, durability, and elevated resistance evaluation.

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Sustainable geopolymer adsorbents utilizing silica fume as a partial replacement for metakaolin in the removal of copper ion from synthesized copper solution

2025-07 , Pilomeena Arokiasamy , Mohd. Mustafa Al Bakri Abdullah , Eva Arifi , Noorina Hidayu Jamil , Md Azree Othuman Mydin , Andrei Victor Sandu , Shayfull Zamree Abd. Rahim , Shafiq Ishak

Biochar has great significance for controlling heavy metal pollution. Nevertheless, its application is impeded by certain shortcomings, such as a limited adsorption capacity, a slow adsorption rate, and poor reusability. Besides, the physical adsorption capacity of raw biochar to heavy metals is suboptimal. As a result, researchers prefer to use geopolymer-based adsorbents for the removal of heavy metals due to their excellent immobilization effect. However, no research has been done on the synthesis of geopolymer-based adsorbent using silica fume for heavy metal adsorption. Thus, the aim of this study is to partially replace metakaolin (MK) with silica fume (S1) (25, 50, 75 and 100 %) in geopolymer formulation at varied S:L ratio (0.4, 0.6, 0.8 and 1.0) to study the impact on the geopolymerization and its following properties in the removal efficiency of copper (Cu2 +). Characterization techniques such as Energy dispersive X-ray fluorescence (EDXRF), X-ray diffraction (XRD), Fourier-transform infrared spectroscopy (FTIR), Scanning electron microscope (SEM) and Energy dispersive X-ray spectroscopy (EDX) were used to study the physicochemical properties of the developed geopolymer. The concentration of Cu2+ before and after adsorption was determined by Atomic absorption spectroscopy (AAS) and the removal efficiency was calculated. Based on the experimental result, the geopolymer prepared with 25 % MK and 75 % S1 at S:L of 0.6 maintained the high removal efficiency of Cu2+ (99.62 %) with 100 % MK geopolymer (98.56 %). The generation of N-A-S-H gel with the 75 % replacement level of S1 producing more reactive Si and Al binding sites for Cu2+ adsorption. In addition, S1 contains exchangeable cations such as Ca2+, Mg2+ and Na+ which further promote the adsorption of Cu2+ by ion exchange. Moreover, the mechanisms such as chemical bonding and precipitation were involved in the adsorption of Cu2+. Hence, this research could serve as a basis for the development of solid waste based geopolymers that could remove heavy metal ions from aqueous solution.

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Geopolymer-based artificial aggregates: a review on methods of producing, properties, and improving techniques

2022 , Mohammad Almadani , Rafiza Abd Razak , Mohd. Mustafa Al Bakri Abdullah , Rosnita Mohamed

The depletion of aggregate-related natural resources is the primary concern of all researchers globally. Recent studies emphasize the significance of recycling and reusing various types of natural or by-product material waste from industry as a result of the building industry’s rising demand for aggregate as the primary component in concrete production. It has been demonstrated that the geopolymer system has exceptional features, such as high strength, superior durability, and greater resistance to fire exposure, making it a viable alternative to ordinary Portland Cement (OPC) concrete. This study will examine the present method utilized to generate artificial aggregate-based geopolymers, including their physical and mechanical properties, as well as their characterization. The production process of geopolymer derived from synthetic aggregates will be highlighted. In conjunction with the bonding of aggregates and the cement matrix, the interfacial transition zone (ITZ) is highlighted in this work as an additional important property to be researched in the future. It will be discussed how to improve the properties of geopolymers based on artificial aggregates. It has been demonstrated that cold bonding provides superior qualities for artificial aggregate while conserving energy during production. The creation of ITZ has a significant impact on the bonding strength between artificial aggregates and the cement matrix. Additionally, improvement strategies demonstrate viable methods for enhancing the quality of manufactured aggregates. In addition, other recommendations are discussed in this study for future work.

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Effect of the sintering mechanism on the crystallization kinetics of geopolymer-based ceramics

2023 , Nur Bahijah Mustapa , Romisuhani Ahmad , Andrei Victor Sandu , Mohd. Mustafa Al Bakri Abdullah , Ovidiu Nemes , Wan Mastura Wan Ibrahim , Petrica Vizureanu , Christina Wahyu Kartikowati , Puput Risdanareni

This research aims to study the effects of the sintering mechanism on the crystallization kinetics when the geopolymer is sintered at different temperatures: 200 °C, 400 °C, 600 °C, 800 °C, 1000 °C, and 1200 °C for a 3 h soaking time with a heating rate of 5 °C/min. The geopolymer is made up of kaolin and sodium silicate as the precursor and an alkali activator, respectively. Characterization of the nepheline produced was carried out using XRF to observe the chemical composition of the geopolymer ceramics. The microstructures and the phase characterization were determined by using SEM and XRD, respectively. The SEM micrograph showed the microstructural development of the geopolymer ceramics as well as identifying reacted/unreacted regions, porosity, and cracks. The maximum flexural strength of 78.92 MPa was achieved by geopolymer sintered at 1200 °C while the minimum was at 200 °C; 7.18 MPa. The result indicates that the flexural strength increased alongside the increment in the sintering temperature of the geopolymer ceramics. This result is supported by the data from the SEM micrograph, where at the temperature of 1000 °C, the matrix structure of geopolymer-based ceramics starts to become dense with the appearance of pores.

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Strength development and elemental distribution of Dolomite/Fly Ash geopolymer composite under elevated temperature

2020 , Emy Aizat Azimi , Mohd. Mustafa Al Bakri Abdullah , Petrica Vizureanu , Mohd Arif Anuar Mohd Salleh , Jitrin Chaiprapa , Sorachon Yoriya , Andrei Victor Sandu , Kamarudin Hussin , Ikmal Hakem Aziz

A geopolymer has been reckoned as a rising technology with huge potential for application across the globe. Dolomite refers to a material that can be used raw in producing geopolymers. Nevertheless, dolomite has slow strength development due to its low reactivity as a geopolymer. In this study, dolomite/fly ash (DFA) geopolymer composites were produced with dolomite, fly ash, sodium hydroxide, and liquid sodium silicate. A compression test was carried out on DFA geopolymers to determine the strength of the composite, while a synchrotron Micro-Xray Fluorescence (Micro-XRF) test was performed to assess the elemental distribution in the geopolymer composite. The temperature applied in this study generated promising properties of DFA geopolymers, especially in strength, which displayed increments up to 74.48 MPa as the optimum value. Heat seemed to enhance the strength development of DFA geopolymer composites. The elemental distribution analysis revealed exceptional outcomes for the composites, particularly exposure up to 400 °C, which signified the homogeneity of the DFA composites. Temperatures exceeding 400 °C accelerated the strength development, thus increasing the strength of the DFA composites. This appears to be unique because the strength of ordinary Portland Cement (OPC) and other geopolymers composed of other raw materials is typically either maintained or decreases due to increased heat.