Synthesis of water treatment sludge ash-based geopolymers in an Amazonian context

Water treatment plants (WTP) in the City of Manaus, Brazil, generate tons of sludge daily, which are then disposed of in landfills and main watercourses, particularly two important Amazonian Rivers: the blackwater Negro River and the pale sandy-colored water Solimões River. Because WTP-based sludges are rich in silicon and aluminum, they have been employed in the synthesis of geopolymers - alkaline activated inorganic polymers consisting of silicate and aluminosilicate chains. This paper reports the results of a geopolymeric synthesis process in which calcined sludge was explored as a source of silica and alumina. In this research, a laboratory testing program was developed to characterize the waste material generated from a water treatment plant in Manaus, whose intake water is influenced by the above referred rivers. Sample preparation involved kiln drying at 110 °C for 8 h, grinding in ball mill for 2 h, and calcination at 750 °C for 6 h. The calcined sludge was used as precursor, and potassium hydroxide added as activating alkali. Two geopolymers, one from each sludge source, were prepared following identical procedures. The chemical, compositional, morphological, thermal and mechanical properties of the fresh and hardened geopolymers were characterized. The geopolymers reached uniaxial compressive strengths of over 50 MPa at 28 days. Calcination conveyed more refined properties to the sludge-based geopolymers, akin to metakaolin-based geopolymers. The results presented herein support the technical feasibility of geopolymer synthesis in the lab scale.