碱激发三元固废流动固化高含水率废弃泥浆性能及机理研究

Performance and mechanistic study of alkali-activated ternary industrial solid wastes for the flowable solidification of high-water-content waste slurry

  • 摘要: 面向桩基废弃泥浆减量化与工业固废高值利用,本文构建水玻璃激发电石渣-矿渣-粉煤灰三元固废地聚物固化体系,制备适用于桩孔与管道沟槽回填的可控低强度流动固化材料. 基于单纯形质心设计,系统揭示固废配比与水玻璃掺量对流动度、无侧限抗压强度及结构致密化的协同影响规律. 结果表明:该体系可有效固化含水率140%泥浆,流动度随水玻璃增加而降低,强度呈显著非线性响应;最高流动度262 mm,28 d强度2970.5 kPa,最优水玻璃掺量约15%,矿渣为主要强度来源. 固化体微观结构由原始泥浆中以石英颗粒为主的松散骨架,演化为以水化(铝)硅酸钙凝胶为主的致密复合骨架. 试验结果表明,当电石渣、矿渣、粉煤灰的质量比为5∶90∶5,水玻璃掺量为15%时的碱激发流动固化泥浆具有最优的力学性能,为最优配比. 进一步分析发现,与水泥相比,该配比在单位强度下的碳排放和成本分别降低87.9%和74.1%,表明其具有较好的低碳回填应用前景.

     

    Abstract: To reduce the volume of pile-foundation waste slurry and promote the high-value utilization of industrial solid wastes, this study developed an alkali-activated geopolymer solidification system based on carbide slag (CS), ground granulated blast-furnace slag (GGBS), and fly ash (FA), activated with sodium silicate to produce a controllable low-strength flowable solidified material suitable for pile-hole and pipeline trench backfilling. Based on a constrained simplex-centroid mixture design, the synergistic effects of solid waste proportions and sodium silicate dosages on the flowability, unconfined compressive strength (UCS), and microstructure were systematically investigated. The solidification mechanism was revealed through X-ray diffraction, scanning electron microscopy, and energy-dispersive spectroscopy, and the carbon emissions and economic costs of the optimal mixture were evaluated. In the mixture design, the CS and FA contents were varied from 5% to 25%, whereas the GGBS content was automatically determined to be within 70%–90% under the condition that the sum of the three components was unity. Sodium silicate with a modulus of 2.4 was used as the activator, and its dosage was set at 15%, 20%, and 25% of the total binder mass. The results showed that the proposed system effectively solidifies the pile-foundation waste slurry with an initial water content of 140%. The prepared controlled low-strength material exhibited flowability values ranging from 91 to 262 mm, indicating that both the activator dosage and precursor composition strongly affect the fresh-state performance. In most cases, increasing the sodium silicate dosage reduced the flowability because the stronger alkaline environment accelerated the dissolution of reactive phases and the early formation of gel products, thereby increasing the slurry viscosity, although this effect was not monotonic for all the mixtures. The 28-d UCS demonstrated significant nonlinear responses to component variations with a peak value of 2970.5 kPa. An optimal sodium silicate dosage of 15% was identified, under which the formulation of CS∶GGBS∶FA = 5%∶90%∶5% achieved peak strength. When the dosage was increased to 20% and 25%, the system stability improved but the strength ceiling decreased, indicating that excessive alkalinity induced rapid early-age reactions and microstructural defects. Component synergy plays a decisive role in the development of performance. GGBS, which is rich in reactive calcium-rich glassy phases, rapidly dissolves under alkaline conditions to form abundant C–(A)–S–H gels, which serve as primary strength-contributing components. CS functions as both an alkaline activator and a calcium source. Appropriate dosages (5%–10%) increase the pH of the pore solution and supply Ca2+ ions, promoting precursor dissolution and accelerating gel nucleation, whereas excessive dosages dilute reactive precursors and lead to residual plate-like Ca(OH)2 crystals that form weak interfacial zones and hinder later strength development. FA primarily supplies aluminosilicate components but exhibits relatively low reactivity; therefore, increasing its content reduced the effective gel-forming fraction and led to a lower strength. Microstructural analysis revealed a progressive evolution from the original loose quartz-dominated skeleton of the raw slurry to a dense composite matrix dominated by C–(A)–S–H gels. High slag content combined with optimal sodium silicate dosage favored continuous gel formation and enhanced structural densification, whereas high FA or excessive CS content led to the accumulation of unreacted particles and crystalline phases with increased porosity, consistent with the observed “first increase then decrease” strength development pattern. Compared with conventional Portland cement solidification, the optimal formulation (CS∶FA∶GGBS = 5%∶5%∶90% with 15% sodium silicate) reduced carbon emissions per unit strength by 87.9% and material cost per unit strength by 74.1%, demonstrating substantial environmental and economic advantages. Therefore, the proposed CS–GGBS–FA alkali-activated ternary solid waste system provides a promising low-carbon approach for the flowable solidification of high-water-content waste slurry and offers an effective pathway for the coordinated resource utilization of waste slurry and industrial solid waste.

     

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