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BAYER - FLYASH GEOPOLYMERS: DEVELOPMENT AND APPLICATION

Jamieson, E.J. Penna, B. van Riessen, A. Nikraz, H.

Bayer liquor (from the alumina industry) and fly ash (coal combustion products) have been utilised to make a new class of ambient-cured construction geopolymers with compressive strength in excess of 30 MPa. Industrial synergy allows for the production of Bayer-derived flyash geopolymer products of very low embodied energy (Concrete binder of 0.27 Gj/t). To establish a Bayer derived geopolymer industry of large enough volume to allow economies of scale, several product markets and applications will be required to generate consistent demand. One such market is to manufacture artificial aggregate from Bayer-derived geopolymer mortars, where the embodied energy has been calculated to be 0.22 GJ/t; similar to other manufactured or recycled aggregates. Production rates could be between 0.1 and 10 million tonnes per annum per alumina refinery, depending upon economics and refinery operational conditions. Some potential construction products options are also discussed.