Alkali-activated geopolymers based on calcined phosphate sludges and metakaolin

The extraction of phosphorite ore in Tunisia has resulted in the discharge of substantial amounts of phosphatic sludge into the region's water system. To mitigate this environmental issue and prevent heavy metal leaching, a geopolymerization process was employed using two types of Tunisian calcined phosphate sludges (Cal-PS1 and Cal-PS2) as substitutes for alkali-activated metakaolin. This study aimed to investigate and compare the physical and mechanical properties of the resulting geopolymers. The optimal substitution ratio of metakaolin with calcined phosphate sludge was determined to be 1.5, equivalent to 20 wt.% of calcined phosphate sludge. Compressive strength tests conducted after 28 days of curing revealed values of 37 MPa for Cal-PS1 specimens and 28 MPa for Cal-PS2 geopolymers while compressive strength of geopolymers soaked in water for 28 days showed a decrease with the addition of phosphate sludges. The specific surface areas of Cal-PS1 geopolymers ranged from 16.3 to 16.9 m²/g and from 17.62 to 18.73 m²/g for Cal-PS2 specimens exhibiting a mesoporous structure. The elasticity modulus of the geopolymers was found to increase with the increase of the apparent density of geopolymers and with the sludges content but it tended to be lower than the Portland cement elasticity modulus. Leaching test was conducted to evaluate the potential environmental applications of the geopolymers. This test demonstrated effective containment of heavy metals within the geopolymers' network, except for low levels of arsenic.