Processing and characterization of geopolymer and sintered geopolymer foams of waste glass powders

Geopolymer foams of fine and coarse waste glass (WG) powders were prepared using an activation solution of NaOH (8 M) and Na2SiO3. The effects of WG powder particle size, solid/liquid ratio (S/L = 1, 1.5, and 2) and Al foaming agent content (2-20 wt%) on the expansion and temperature behavior of the slurries were determined in-situ using a laser sensor and a thermocouple, respectively. The geopolymer foams processed using a coarse WG powder slurry, S/L = 2, and 2 wt% Al, were further sintered at 600, 700, 725, and 750 degrees C. The compression strengths and thermal conductivities of the geopolymer and sintered geopolymer foams were also determined. The slurry expansions continued until about a maximum, and the temperatures of the slurries increased to a maximum, 85-88 degrees C. At the maximum temperature, the slurry evaporation and the resultant increase in the S/L ratio limited the slurry expansion. Increasing the Al content decreased the final density of the foams (238-555 kg m-3), while the coarse powder slurries resulted in lower densities than the fine powder slurries. Three crystal phases, muscovite, sodium aluminum silicate hydrate, and thermonitrite, were determined in the geopolymer foams. The muscovite formation was noted to be favored at high S/L ratios. During sintering, the partial melting of glass particles started after about 700 degrees C, while sintering above this temperature decreased the final density of the foams. The reduced density above 700 degrees C was ascribed to the release of CO2 due to the decomposition of thermonitrite. Both the compressive strength and thermal conductivity of the geopolymer and sintered geopolymer foams increased with increasing foam density. The highest increase in the compressive strength and reduction in the density were seen in the geopolymer foams sintered at 750 degrees C.