Geopolymer Mortar Composition Utilizing Red Mud and Biomedical Waste for Enhanced Strength Properties

Abstract

This patent introduces a geopolymer mortar composition utilizing Incinerated Biomedical Waste Ash (IBWA) and industrial by-products as sustainable alternatives to traditional cement. Geopolymer mortars, formed by the activation of aluminosilicate materials with alkaline solutions, provide an environmentally friendly solution for construction. The invention leverages IBWA, derived from incinerated hospital waste such as cotton and degradable fibers (excluding plastics), which contain aluminum and silica suitable for geopolymerization. Other industrial waste Red mud which is -product generated during the Bayer process, which is used to extract alumina (aluminum oxide) from bauxite which further enhances the mortar’s performance. Key properties, including fresh performance (workability and setting time), mechanical strength (compressive, tensile, and flexural), and durability (acid resistance, high-temperature resistance, water absorption, and shrinkage), are significantly improved. The study highlights the potential of geopolymer mortars to replace conventional cement, promoting sustainability in construction practices. The work promotes environmental sustainability by repurposing biomedical and industrial waste, reducing the carbon footprint of traditional cement. It enhances the mechanical strength and durability of geopolymer mortars, offering better performance in harsh conditions. Additionally, it lowers construction costs by utilizing waste materials as affordable raw ingredients.

Specification

Description:FIELD OF INVENTION
[001] This invention relates to the field of construction materials, specifically to geopolymer binders used in sustainable building technologies. More particularly, it focuses on geopolymer mortars incorporating incinerated biomedical waste ash and industrial by-products as alternatives to traditional cement for enhanced strength and environmental benefits.
BACKGROUND AND PRIOR ART
[002] In recent years, the construction industry has been increasingly focused on developing sustainable alternatives to traditional cement-based materials due to the high carbon emissions and energy consumption associated with Ordinary Portland Cement (OPC) production. Geopolymer binders, which utilize aluminosilicate materials activated with alkaline solutions, have gained attention as eco-friendly substitutes. Various industrial by-products, such as fly ash, Ground Granulated Blast Furnace Slag (GGBS), and red mud, have been explored for use in geopolymer systems. These materials reduce waste disposal issues while offering improved durability and mechanical performance.
[003] Despite advancements in geopolymer technology, there remains a significant challenge in fully replacing OPC with sustainable materials while maintaining or improving performance properties. Prior efforts have focused primarily on industrial waste like fly ash and GGBS, but limited research has addressed the use of incinerated biomedical waste ash (IBWA). IBWA contains aluminum and silica, making it suitable for geopolymer applications. However, the full potential of combining IBWA with other industrial by-products, such as red mud, remains underexplored. Existing geopolymer mortars often face workability, setting times, and long-term strength challenges, which this invention seeks to overcome.
[004] The present invention addresses these gaps by introducing a novel geopolymer mortar composition that incorporates IBWA and red mud, enhancing mechanical strength, durability, and environmental sustainability, while reducing reliance on traditional cement.
SUMMARY OF THE INVENTION
[005] The study found that geopolymer mortar made from Red Mud (RM) and Incinerated Biomedical Waste Ash (IBWA) can achieve sufficient strength when cured at ambient temperatures. Incorporating Micro Silica in combination with RM and BIA improves the binding properties of the mortar. The strength of the ambient-cured geopolymer increases as the proportion of red mud rises, with the optimal composition being 60% BIA, 30% RM, and 10% Micro Silica. Additionally, a 10M sodium silicate and sodium hydroxide alkaline activator proved to be optimal for a 1:3 binder-to-sand ratio.
DETAILED DESCRIPTION OF THE INVENTION
[006] The present invention involves the development of geopolymer mortar utilizing Red Mud (RM) and Incinerated Biomedical Waste Ash (IBWA), with the aim of enhancing strength and sustainability in construction materials.
[007] A comprehensive literature review was conducted to explore the relevant technologies and materials for the project. This included a study of geopolymer technology, incinerator waste materials such as fly ash and red mud, mix design principles, and various standard testing methods.
[008] Material Procurement and Testing: Ordinary Portland Cement (OPC) 53-grade and sand were procured and used for the preparation of control mixes. Detailed testing was performed on the following materials: Cement, Fine aggregate, Incinerated Biomedical Waste Ash (IBWA), Red mud (RM). These tests ensured that the materials met the necessary specifications and standards.
[009] Mix Design Preparation: Cement mortar mixes were prepared based on the results obtained from the material tests, following the guidelines set out in IS 4031:1988 standards. This involved determining the optimal mix proportions for achieving the desired properties in the mortar.
[010] X-ray Diffraction (XRD) Analysis: Conducted on samples of red mud and incinerator waste to determine their Aluminum and silica content, which are crucial for their effectiveness as geopolymer materials.
[011] Energy Dispersive X-ray Spectroscopy (EDAX): Complemented XRD analysis to provide detailed compositional insights into the materials.
[012] Alkaline Solution Preparation: An alkaline solution was prepared by dissolving sodium hydroxide (NaOH) pellets in distilled water to achieve the required molarity (1M = 40 grams of NaOH pellets). This solution was then mixed with sodium silicate solution 24 hours prior to the preparation of the geopolymer mortar, ensuring optimal activation of the aluminosilicate materials.
[013] Geopolymer Mortar Preparation: Geopolymer mortar was prepared by varying the percentages of red mud and incinerator waste. Several mix proportion trials were conducted to determine the most effective combination for achieving the desired performance characteristics.
[014] Cube Casting: Mortar cubes were cast according to the optimized mix design.
[015] Strength Testing: The cubes were subjected to compressive strength tests at 7, 14, and 28 days of curing. The results were compared to those of control mix cubes to evaluate the performance of the geopolymer mortar.
[016] Microstructural Analysis: Scanning Electron Microscopy (SEM) was used to analyze the microstructure of the geopolymer mortar cubes after testing. This analysis provided insights into the structural integrity and bonding characteristics of the geopolymer mortar.
[017] Documentation and Reporting: A detailed project report will be compiled to document the methodology, findings, and implications of the study. This report will include the experimental procedures, test results, and an analysis of the performance of the geopolymer mortar compared to traditional cement-based materials.
[018] The invention offers a sustainable alternative to traditional cement mortars by effectively utilizing industrial and biomedical waste materials, resulting in enhanced mechanical properties and reduced environmental impact. , C , Claims:1. A geopolymer mortar composition comprising:
• Red Mud (RM) in a proportion of 30% by weight,
• Biomedical Incinerated Ash (BIA) in a proportion of 60% by weight,
• Micro Silica in a proportion of 10% by weight,
• An alkaline solution prepared by dissolving sodium hydroxide (NaOH) pellets to achieve a molarity of 10M and mixing with sodium silicate solution, wherein the binder-to-sand ratio is 1:3.
2. The geopolymer mortar of claim 1, wherein the red mud and biomedical incinerated ash are used in combination with the alkaline solution to enhance the binding properties and overall strength of the mortar.
3. The geopolymer mortar of claim 1, wherein the mixture of red mud, biomedical incinerated ash, and micro silica demonstrates improved compressive strength, split tensile strength, and flexural performance compared to traditional cement mortars.
4. The geopolymer mortar of claim 1, wherein the preparation process involves mixing the alkaline solution with the red mud, biomedical incinerated ash, and micro silica, followed by curing at ambient temperature to achieve optimal strength characteristics.
5. The geopolymer mortar of claim 1, wherein the strength of the geopolymer mortar increases with the increased percentage of red mud, and the mix composition of 60% BIA, 30% RM, and 10% Micro Silica is found to be optimal for achieving high performance.
6. the testing results and microstructural analysis provide insights into the performance and structural integrity of the geopolymer mortar, demonstrating its effectiveness as an environmentally friendly alternative to traditional cement-based materials.

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