PROJECT REPORT
ON
“Utilization of FERROCHROME ASH in synthesizing
activator for Geopolymer technology”
MINOR PROJECT – 20CV5PCPW2
IN
CIVIL ENGINEERING
VISVESVARAYA TECHNOLOGICAL UNIVERSITY, BELAGAVI
SUBMITTED BY:
Vidya Suresh Shivappanavar
1BM20CV183
Vikas R
1BM20CV184
Vinay M
1BM20CV185
Vishruth K Reddy
1BM20CV186
Vishwas Vinayak Hullur
1BM20CV187
Vismitha R
1BM20CV188
YashasChandra H M
1BM20CV189
Under the guidance of
Dr. Manjunath R
Assistant Professor
Department of Civil Engineering
BMS COLLEGE OF ENGINEERING
Bull Temple Road, Basavangudi, Bangalore -19
BMS COLLEGE OF ENGINEERING DEPARTMENT
OF CIVIL ENGINEERING
DECLARATION
We students 5th semester hereby declare that, this technical Mini-Project entitled
"GEOPOLYMER TECHNOLOGY" has been carried out under the guidance of Dr.Manjunath
R, Department of Civil Engineering, BMS College of Engineering, Bangalore, during the
academic year 2022-23. We also declare that to the best of our knowledge and belief, the
technical seminar report is not part of any other report made by any other students
Vidya Suresh Shivappanavar
Vikas R
Vinay M
Vishruth K Reddy
Vishwas Vinayak Hullur
Vismitha R
YashasChandra H M
BMS COLLEGE OF ENGINEERING DEPARTMENT
OF CIVIL ENGINEERING
This is to certify that the Technical Report titled "GEOPOLYMER TECHNOLOGY" has been
carried out by, V Semester Civil Engineering students, Section-'D' in academic year 2022-2023
Signature of the Guide
Signature of the HOD
BMS College of Engineering
BMS College of Engineering
ACKNOWLEDGMENT
We would like to express our gratitude and appreciation to all those who
gave us the opportunity to complete this report. A special thanks to our project coordinator Dr.
Manjunath R Sir, whose help, stimulating suggestions and encouragement has helped us finish
this project successfully.
Also, our thanks to all the faculty members who have helped
us throughout. Our deepest gratitude to our Civil department, our HOD, Principal for providing
us with this learning experience. We have learnt a lot about Geopolymer Technology and its
relevant topics. All the information gathered is precise and accurate to the best of our
knowledge. If any mistakes found, Kindly point it out. As students we are always open to
rectifying our mishaps and attain more knowledge about any topic.
Thank You.
CONTENTS
1.
2.
3.
4.
5.
6.
7.
8.
9.
INTRODUCTION
ALTERNATE MIX FOR CEMENT CONCRETE
MATERIALS USED
PREPARATION
TESTING OF CUBES
OBSERVATION AND GRAPH OBTAINED
OBSERVATIONS MADE WHILE MIXING ACTIVATOR AND GGBS
CONCLUSION
REFERENCE
OBJECTIVE
A novel method of developing activator from industrial waste FERROCHROME ASH.
INTRODUCTION
Geopolymers are inorganic aluminosilicate polymers that form solid ceramic-like
materials at near ambient temperatures. The term “Geopolymer” was coined by Davidovitis
in 1978. Geopolymer replaces C-S-H gel in concrete.It possess excellent mechanical
properties,does not dissolve in acidic solutions, and does not generate any deleterious alkali
aggregate reaction.
•
•
•
It significantly lower CO2 emissions than OPC concretes – up to~90%
It provides better thermal insulation properties.
It provides higher temperature/fire resistance
•
•
It provides a viable use for 'waste' materials which are often disposed in landfill.
Some applications of geopolymer include construction of marine structures and precast
concrete products such as railway sleepers, sewer pipes ,etc.
Categories of geopolymer cement include:
1. Slag-based geopolymer cement.
2. Rock-based geopolymer cement.
3. Fly ash-based geopolymer cement
▪
Type 1: alkali-activated fly ash geopolymer
▪
Type 2: slag/fly ash-based geopolymer
cement.
4. Ferro-silicate-based geopolymer cement.
ALTERNATE MIX FOR CEMENT CONCRETE:
• Sodium Hydroxide Flakes:
Sodium hydroxide flakes are a white solid chemical utilised for their basic or
alkaline qualities, which are the inverse of acidic. Sodium hydroxide has a pH of 13,
indicating that it is strongly basic or alkaline, and is mostly employed in the production
of soaps and cleaners.
• Ferrochrome ash:
Ferrochrome ash is generated from Ferro-alloy industry and fly-ash is produced in
thermal power plants are alternative materials which have the potential of being utilized in
concrete as a mineral admixture.
• GGBFS:
The ground granulated blast furnace slag (GGBFS) is a by-product of iron
manufacturing which when added to concrete improves its properties such as
workability, strength and durability. This material is obtained by the heating of iron
ore, limestone and coke at a temperature about 1500 degree Celsius.
• Water in required proportion:
The water in a geopolymer mixture, therefore, plays no role in the chemical
reaction that takes place; it merely provides workability to the mixture during handling.
There are two main constituents of geopolymers, namely the source materials and the
alkaline liquids.
MATERIALS USED:
Ferro Chrome Ash which passes through a 90μ sieve is used for this study, the residues left
in the sieve is further ground and sieved again to get the required quantity to synthesize sodium
silicate. This study has been utilized with sodium hydroxide as alkali activator with a
marketable grade of 97% pureness in flakes form. GGBFS which is resulting from the
manufacture of steel has been acquired from a native source for use as source material.
NaOH Flakes
Ground Granulated Blast Furnace Slag
Ferrochrome Ash
PREPARATION:
The NaOH flakes are made into fine powder for the better chemical reaction between the raw
materials. Finely powdered NaOH and FCA are mixed together for one minute to get a
homogeneous mixture of alkali activator. The grinding and mixing is done with help of an 810
W capacity mixer grinder at 22000 rpm. The mixing of raw materials is done in three steps of
20 second duration. Further the blend was retained in an electric oven at 100 0C for two-hour
duration, the process duration and temperature is selected based on the previous study, with
various proportion of FCA and NaOH powder (1:0.5, 1:1,1:1.5 and 1:2) for the thermal
treatment, these methods will enhance the solubility of extracting sodium silicate powder. The
extraordinary alkali content of NaOH will helps the easy dissolving of both crystalline and
amorphous silica present. To assess the efficiency of prepared alkali activator in the
manufacture of one-part geopolymer binder, a whole of six mixes were formulated with
different FCA:NaOH ratio. The geopolymer paste was prepared by mixing the prepared
GGBFS:Activator at a ratio of (1:0.5 and 1:1), at dry state for three minutes duration with the
intention of getting the homogeneous blend, subsequently the necessary quantum of water is
introduced to the dry blend and mixing was allowed to endure for three to four minutes till a
homogeneous workable geopolymer cement paste obtained. The obtained paste was cast in to
cubical mould of size 50mm and demoulded after 24 hours and permitted to cure at room
temperature for 3 and 7 days. The mechanical properties of the mixes were assessed with cube
specimens in the form of density and compressive strength.
TESTING OF CUBES:
COMPRESSIVE STRENGTH TESTING OF CUBES:
Compressive strength is the resistance offered by the cube to compressive force. It is tested for
an age of 3 and 7 days. The graph between compressive strength and age is plotted to determine
the nature of compressive strength for each of the proportioning ratio of Ferrochrome ash :
NaOH flakes by weight 1:0.5,1:1,1:1.5 and 1:2 with GGBFS.
OBSERVATION AND GRAPH OBTAINED:
A. RATIO OF ACTIVATOR: 1 : 0.5
RATIO OF GGBFS TO ACTIVATOR: 1 : 0.5
DAY 3
DAY 7
CUBE 1(MPa)
21.14
30.22
CUBE 2(MPa)
21.14
40.56
CUBE 3(MPa)
17.96
25.98
Graph obtained to the corresponding values:
Activator(1 : 0.5) and MIX (1:0.5)
COMPRESSIVE STREN(MPA)
45
40
40.56
35
30
30.22
25
20
15
25.98
21.14
21.14
17.96
10
5
0
day 3
day 7
cube 1
cube2
cube 3
B. RATIO OF ACTIVATOR: 1 : 1
RATIO OF GGBFS TO ACTIVATOR: 1 : 0.5
CUBE1 (MPA)
DAY 3
DAY 7
14.96
29.692
CUBE2 (MPA)
16.55
23.99
CUBE3 (MPA)
16.57
24.02
Graph obtained to the corresponding values:
COMPRESSIVE STRENGTH (MPA)
Activator(1 : 1) and MIX (1:0.5)
30
25
20
21.69
15
10
14.96
16.55
23.99
16.57
5
0
Day 3
Day 7
Cube 1
Cube 2
Cube 3
24.02
C. RATIO OF ACTIVATOR: 1 : 1
RATIO OF GGBFS TO ACTIVATOR: 1 : 1
DAY 3
CUBE 1(MPa)
6.41
CUBE 2(MPa)
7.59
CUBE 3(MPa)
5.44
Graph obtained to the corresponding values:
Activator(1 : 1) and MIX (1:1)
COMPRESSIVE STRENGTH(MPA)
8
7.59
7
6
6.41
5
5.4
4
3
2
1
0
0
cube 1
cube2
cube 3
DAY 3
D. RATIO OF ACTIVATOR: 1 : 1.5
RATIO OF GGBFS TO ACTIVATOR: 1 : 0.5
DAY 3
DAY 7
CUBE 1(MPa)
1.34
4.24
CUBE 2(MPa)
4.26
2.04
CUBE 3(MPa)
3.36
4.26
Graph obtained to the corresponding values:
Activator(1 : 1.5) and MIX (1:0.5)
COMPRESSIVE STRENGTH (MPA)
4.5
4
4.26
3.5
3.36
3
2.5
2
1.5
1
1.56
1.34
1.41
0.5
0
day 3
day 7
cube 1
cube2
cube 3
1.21
E. RATIO OF ACTIVATOR: 1 : 1.5
RATIO OF GGBFS TO ACTIVATOR: 1 : 1
DAY 3
DAY 7
CUBE 1(MPa)
0.71
9.96
CUBE 2(MPa)
1.84
5.42
CUBE 3(MPa)
0.43
7.54
Graph obtained to the corresponding values:
Activator(1 : 1.5) and MIX (1:1)
12
10
9.96
8
7.54
6
5.42
4
2
0.71
1.84
0.43
0
day 3
day 7
cube 1
cube2
cube 3
F. RATIO OF ACTIVATOR: 1 : 2
RATIO OF GGBFS TO ACTIVATOR: 1 : 0.5
DAY 3
DAY 7
CUBE 1(MPa)
16.77
27.2
CUBE 2(MPa)
20.68
27.01
CUBE 3(MPa)
17.4
26.86
Graph obtained to the corresponding values:
Activator(1 : 2) and MIX (1:0.5)
COMPRESSIVE STRENGTH (MPA)
30
27.2
25
20
15
27.01
20.68
17.4
16.77
10
5
0
day 3
day 7
cube 1
cube2
cube 3
26.86
OBSERVATIONS MADE WHILE MIXING THE ACTIVATOR
AND GGBS:
•
•
•
•
•
A lot of heat was produced.
The ratio of the activator being 1:1 was set at a rapid rate( a few minutes after adding
water).
For the ratios of 1:1 and 1:1.5 after 24 hours of casting were observed with the
presence of water on the surface.
For the ratio 1:1.5 activator (1[A]:1[G]), the water on the surface had almost frozen.
Upon increasing the proportion of NaOH in the activator the strength was less.
CONCLUSION:
•
•
•
•
•
The geopolymer obtained in both cases exhibits an amorphous homogeneous and
tightly-packed structure as well as a high compressive strength exceeding, that
obtained by conventional mortar.
Solid activator was most effectively produced in the laboratory using industrial
waste(Ferrochrom-ash).
The maximum value of the compression test was found in the activator ratio of 1:0.5
and mix ratio of (1[G]:0.5[A]).
Effective activation was observed with binder namely GGBFS and compressive
strength varying in the range of 20-25Mpa at the age of 3 and 7 days respectively.
Geopolymer made without using OPC is environmental friendly and energy efficient
construction material with an enormous potential in many infrastructural applications.
REFERENCES
1.
Construction and building materials 362(2023)-129681, A.Kalllamalayil Nassar
and
P. Karthirvel
2.
E. Bontempi, A new approach for evaluating the sustainability of raw materials
substitutionbased on embodied energy and the CO2 footprint, J. Clean. Prod. 162 (2017)
162–169 3. C. Tennakoon, R.S. Nicolas, J.G. Sanjayan, A. Shayan, Thermal effects of
activators on the setting time and rate of workability loss of geopolymers, Int. 42
(2016) 19257–19268
4. All photos attached are taken during the working of project
Graphs attached are plotted with the values obtained