Strength development and microstructure of sustainable geopolymers made from alkali-activated ground granulated blast-furnace slag, calcium carbide residue, and red mud

• The recycled potential of RM and CCR wastes is evaluated. • Wet-basis CCR and its supernatant is used as activator to reduce the amount of strong alkali. • RM and GGBS are combined with the right proportion to ensure strength. • The toxic heavy metals in the leachate are below the detection limit, indicating the safety of geopolymers. Red mud (RM) and calcium carbide residue (CCR) are waste generated from alumina refining and acetylene gas producing, respectively. This study utilized alkali-activated ground granulated blast-furnace slag (GGBS) and wet-basis CCR stabilized RM to prepare geopolymers material. The alkali activator solution was composed of CCR supernatant, sodium hydroxide (NaOH) and sodium silicate (Na 2 SiO 3 ). CCR supernatant was used to reduce the amount of strong alkali. The effects of alkali activator on chemical composition and microstructure of geopolymers were studied by X-ray diffraction (XRD), thermogravimetric-derivative thermogravimetric (TG-DTG) analysis, and scanning electron microscopy-energy dispersive X-ray spectroscopy (SEM-EDS). The results show that the utilization of alkali activator improved the compressive strength and especially significantly improved the flexural strength of geopolymers. The strength was negatively correlated with the RM content: the geopolymers containing 30 % RM achieved a maximum 28-day compressive and flexural strength value of 20.3 MPa and 4.3 MPa, respectively. The microstructural analysis revealed that the strength increased due to the formation of calcium aluminate hydrates (C-A-H) and calcium silicate hydrates (C S H). The toxic heavy metals (Cr, Ni, Cu, Pb, Sb, and Zn) from RM formed some complex compounds and were combined in the geopolymers. The 28-day leaching experiment showed that the toxic heavy metals levels were below the test limits. In summary, this study confirmed the safety and feasibility of preparing RM-GGBS-CCR based geopolymers via alkali-activated method.