Table of Content Bago

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OPTIMIZATION OF FLY ASH FOR PRODUCTION
Optimization of Fly Ash for Production of Geopolymer Binder
Joyce Mari E. Adriano
Lenard A. Ayohan
Sweet Gilleen P. Borromeo
Alexander S. Ibrahim Jr.
EARIST
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APPROVAL SHEET
This Thesis entitled Optimization of Fly Ash for production of Geopolymer
Binder Prepared and submitted by; Adriano, Joyce Mari., Ayohan, Lenard A.,
Borromeo, Sweet Gilleen P. and Ibrahim, Alexander S. Jr, in partial fulfillment of the
degree Bachelor of Science in Chemical Engineering was examined and recommended
for oral examination
_______________________ _______________________
Engr. Alvin A. Talampas Engr. Nerissa M. De Guzman
Adviser Area Chairman, ChE Dept.
Approve in partial fulfillment of the requirements for the degree of BACHELOR
OF SCIENCE IN CHEMICAL ENGINEERING by the committee of ORAL
EXAMINATION on March 2014 with the rating of _____.
_______________________ _______________________
Accept in partial fulfillment of the requirement for the degree of Bachelor of
Science in Chemical Engineering.
_______________________
Dean, College of Engineering

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ACKNOWLEDGEMENT
After an intensive period of months, today is the day; writing this note of thanks is
the finishing touch on our thesis. It has been a period of intense learning for us, not only
in the scientific area, but also on a personal level. Writing this thesis has had a big impact
on us. We would like to reflect on the people who have supported and helped throughout
this period.
First, we would like to thank our God for giving one of us strength to finish this study
and always lead us.
We also admire the help and guidance of our Area-chairman, Engr. Nerissa M. De
Guzman for her always being concerned .Thank you for your support!
Our joy knows no bounds in expressing our cordial gratitude to R. Chem. Gether
Coloma, his keen interest and encouragement were a great help throughout the course of
this research work and to Engr. Apolinario Sollano, the Dean College of Engineering for
encouragement and constructive criticisms.
Lastly, we would also like to thank our venerated parents for their wise counsel and
sympathetic ear. We were not only able to support each other by deliberating over our
problems and findings, but also happily by talking about things other than just our papers.
We humbly extend our thanks to all concerned person who co-operated in this regard.
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Table of Contents
Tittle page i
Approval Sheet ii
Acknowledgement iii
Table of Contents iv
List of Tables vi
List of Figures vi
Abstract vii
1. Introduction 1
1.01 Background of the study 1
1.02 Statement of the problem 3
1.03 Objective of the Study 4
1.031General Objective 4
1.032Specific Objectives 4
1.04 Scope and Limitation 4
1.05 Significance of the Study 5
2. Review Related Literature 5
2.01Related Literature 6
2.02Theoretical Literature 15
3. Methodology 16
3.01 Research Design 16
3.02 Preparation of Materials 16
3.03 Fly ash 17
3.04 Sodium Silicate Solution 18

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3.05 Sodium Hydroxide Flakes 18
3.06 Preparation for Geopolymer binder 19
3.07 Mixture Proportion 20
4. Result and Discussion 21
4.01 SEM (Scanning Electron Microscopy) 21
4.02 Compressive Strength 23
4.03 NaOH Concentration 23
4.04 Alkaline Liquid to Fly Ash Ratio 29
4.05 Sodium Hydroxide Solution to Sodium Silicate Solution Ratio 37
5. Conclusion 44
6. Recommendation 45
7. References 46
8. Appendices 48
9. Appendix A. Figures 48
9.01 Appendix A. Fly Ash 48
9.02 Appendix B. Mixing of Alkaline Liquid 48
9.03 Appendix C. Preparation of Cube Mould 49
9.04 Appendix D. Mixing Geopolymer Binder 50
9.05 Appendix E. Casting 50
9.06 Appendix F. Fresh Geopolymer Binder 51
9.07 Appendix G. Compressive Strength Testing Machine 51
Calculation
Appendix 1 52
Appendix 2 64
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List of tables
Table 1 Chemical Composition of Fly Ash 17
Table 2 Chemical Composition of Sodium Silicate Solution 18
Table 3 Geopolymer Binder Mix Proportion 19
Table 4 Statistical analysis 23
List of Figures
Figure 1 Chemical Structure of polysialates 6
Figure 2 Chemical Structure of Geopolymer Binder 7
Figure 3 The Schematic Formation of Geopolymer Binder 7
Figure 4 Portland cement vs. geopolymer cement chemistry(Joseph Davidovits)13
Figure 5 Fly Ash 17
Figure 6 Sodium Silicate Solution 18
Figure 7 Sodium Hydroxide Flakes 18
Figure 8 Pure Fly Ash SEM x 2000 21
Figure 9 Geopolymer Binder SEM 22
Figure 10 -18 Compressive Strength vs. NaOH Concentration 23
Figure 19 - 30 Compressive Strength vs. Alkaline liquid to Fly Ash 29
Figure 30 42 Compressive Strength vs. NaOH/ Na2SiO3 37

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Abstract
Based on study, there are many issues on how does air pollution affect to our beloved
mother earth, particularly the effect of Carbon dioxide gas to atmosphere. The Carbon
dioxide gasses produce when fuel combustion is being done. Based on research one of
the most production that can produce tons of carbon dioxide nowadays is producing tons
of Ordinary Portland Cement (OPC). The purpose of this investigation is to produce a
binder out of coal combustion by-products that can be an alternative for Ordinary
Portland Cement. The main constituent material is Fly Ash from Coal-Fired Power Plant
of the National Power Corporation (NAPOCOR) in Calaca Batangas. The major factors
affecting geopolymerization are identified as the mass ratio of alkaline liquid to fly ash,
mass ratio of sodium hydroxide (NaOH) to sodium silicate (Na2SiO3) solution as alkaline
liquid and the concentration of sodium hydroxide (NaOH). The Scanning Electron
Microscopy (SEM) of the fly ash and geopolymer binder specimen is respectively shown
in figure 4.1.1 and 4.1.2. Respectively Alkaline liquid to Fly ash has a mass ratio of
3.2:10; Sodium hydroxide solution to Sodium silicate solution has a mass ratio of 2:1 and
the concentration of NaOH solution is 7 Molar in room temperature at 25C within 7 days
has highest compressive strength of Geopolymer binder approximately 61MPa (8820 psi)
Keywords: Fly Ash, Alkaline liquid, Sodium silicate solution, Sodium hydroxide
solution, Geopolymer binder, Carbon dioxide and Geopolymerization.

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Optimization of Fly Ash for Production of
Geopolymer Binder
Ordinary Portland Cement (OPC) is the most common raw material use for making
concrete. Ordinary Portland cement contains CaO, Al2O3, and SiO and raw materials come from
a variety of sources depending on availability and chemical composition. Limestone, chalk, or
oyster shells are sources of calcium and for alumina, shale, clay while and silica typically comes
from sand and clay. Coal Combustion By-products (CCBs) such us fly ash, bottom ash and boiler
slag. It is the unburned residue during CCBs and Fly ash is usually as alternative OPC and the
major source of geopolymer concrete.
Industrialized Countries like Japan, China, USA, Russia, London, Saudi Arabia and other
industrialized countries are need more OPC production for development of structures, houses,
roads, bridges, and building application for the progress economy. However, the more
production of OPC the more release through the air called greenhouse gases and result of
increase in temperature. Many engineers looking for possible alternative binder for concrete
rather than OPC from this waste such as fly ash, boiler slag, rice husk, and so on. Geopolymer is
the most suitable solution for this environmental issues and extensively emission of into air. The
source materials of Geopolymer which fly ash can reduce the emission of up to 80-90% into air
using by-product as source materials and the environmental issues regarding lack of storage in
coal power plant of disposing CCBs in landfills also utilize.
Geopolymer proposed by Joseph Davidovits in year 1978, Geopolymer produced in a
process of geopolymerization which is the synthesis of alkaline activator and source material.
Alkaline activator is a combination of Sodium Hydroxide and Sodium Silicate then the source
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material should be rich in Aluminum (Al) and Silicate (Si) which is natural minerals such as
kaolinite, clays, Meta-kaolin and by-product such as Silica fume, fly ash, Slag, and rice husk are
possible source materials. Fly Ash is the most appropriate source material in all coal combustion
by product for making Geopolymer binder and totally replacement to OPC. Geopolymer Binder
is more advantage to use because it will help a lot to lessen the emission of CO2 and the general
problem that coal company facing right now.
Ordinary Portland Cement (OPC) is the common raw material use for making concrete
which is the worlds most widely use man made material for building, bridges, roads and other
structures. Coal Combustion by-product (CCB's) such as fly Ash, boiler Slag and bottom ash are
solid by-product that produces during combustion of coal. Coal Power Plants generated almost
100 million tons of these Products every year. Besides, this by-product are being disposed into
landfills, only 45-50 % of this CCB's being used as a raw materials in different application in
construction industry including structural fills, agriculture, mining and so on. The remaining by
product causes environmental issues as the result of bad effect for our environment because
due to the production, every 1 ton of OPC directly generates 0.55 tons of and carbon fuel
requires for the combustion process which produced 0.40 approximately almost 1 tons of
released for every production of OPC that cause harmful effect to our environment and may
result of extreme global warming which we experience nowadays.
Statement of the problem. Ordinary Portland cement is commonly used as a binder for
concrete in terms of workability, compressive strength, and flexural strength. Ordinary Portland
cement is good enough as a binder for concrete and widely used for construction industry in
application for building columns, bridges highways, and flooring. In this research fly ash used as
main constituent materials as a binder instead of cement since fly ash also has a cementitious
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material which means in terms of characteristics they are similar. The fly ash content has rich in
silica oxide, aluminum oxide, ferrous oxide & calcium oxide, other minor and trace constituents.
The researchers found out that this chemical content is enough to attain the standard
compressive strength for Geopolymer binder. Therefore, fly ash is possible as a binder that can
be attain the standard compressive strength for ASTM specification in order to use as
alternative to Ordinary Portland cement in concrete. For different application and cost
effectiveness since fly ash is a coal combustion by-product from Coal Power Plant the
production of Geopolymer binder will be economical.
In terms of strength, it will depend on its characteristics such as workability, high silicate
content and chemical bonding of silicate and aluminates.
Objective of the study
General Objective. To optimize the fly ash for the production of geopolymer binder
Specific Objective. to find the optimum formulation for geopolymer binder, to
characterize the specimen using universal testing machine (UTM) or testing physical strength of
materials to reach the minimum compressive strength using fly ash accordance to ASTM C39,
and to compare the microstructure of Geopolymer binder to fly ash.

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Scope and Limitation
The scope of this investigation is to produce Geopolymer binder using by-Product which
is fly Ash. It serves as replacement to OPC (Ordinary Portland Cement) as binder. This by-Product
(Fly Ash) is being collected in coal combustion power plant at Calaca Batangas using electro
collector and also the process of making Geopolymer binder using fly ash as a main constituent.
The Research limits are the parameter of curing process such as temperature (room 35
degree temp.) and days of curing (at least 7 days) to observe carefully the significant of NaOH
concentration (4, 5, 6, and 7 molar), Fly Ash to Alkaline Liquid Ratio (0.3, 0.32 and 0.35) and
sodium Hydroxide Solution to sodium silicate solution ratio (2.5, 2 and 1.5) in Geopolymer
binder for compressive strength and also the application of Fly Ash in construction industry to
Geopolymer binder.
Significance of the study
This study focuses on producing Geopolymer Binder by using the waste product
produced from Coal Combustion. This waste is known as fly-ash, Bottom ash, and boiler slag. Fly
ash is the common by-product material used for making Geopolymer binder and as additives to
cement. Production of Ordinary Portland cement causes bad effect to our environment due to
emission of CO2 produced and the waste by-product being disposed into landfills. This is the
common problem that coal power plants used to deal with before Geopolymers havent been
created.
The researchers believe that this study would lessen the environmental issues brought
about by coal combustion through utilizing the by-product as Geopolymers. In addition, it will
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help communities which cant afford costly cement for making buildings, bridges, roads,
columns, and other infrastructures. Therefore, Geopolymer Binder is an alternative binder that
will lessen the need for production of ordinary Portland cement that causes different
environmental issues and costs high expenditures.
Review Related Literature
This part aim to provide related literature that will help and gave idea to be able to
perform this research entitled Optimization of Fly ash in production of Geopolymer Binder.
Related literature and theoretical literature aim to gather information that will enrich the idea
and the steps to be follow also to know the available materials which can be possible
replacement for OPC. This review made to have more knowledge about the concept of this
research and will serve to verify whether existing study is already reported.
Related Literature
The term Geopolymer was first introduced by Davidovits in 1978 to describe a family of
mineral binders with chemical composition similar to zeolites but with an amorphous
microstructure. He also suggested the use of the term poly (sialate) for the chemical
designation of Geopolymer based on silico-aluminate (Davidovits, 1988a, 1988b, 1991; van
Jaarsveld et. al., 2002a); Sialate is an abbreviation for silicon-oxo-aluminate. Poly(sialates) are
chain and ring polymers with Si4+ and AL3+ in IV-fold coordination with oxygen and range from
amorphous to semi-crystalline with the empirical formula:
Mn (-(SiO2) zAlO2) n. wH2O (2-1)
Where: z is 1, 2 or 3 or higher up to 32; M is a monovalent cation such as potassium or
sodium, and n is a degree of polycondensation (Davidovits, 1984, 1988b, 1994b, 1999).

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Davidovits (1988b; 1991; 1994b; 1999) has also distinguished 3 types of polysialates, namely the
Poly(sialate) type (-Si-O-Al-O), the Poly(sialate-siloxo) type (-Si-O-Al-O-Si-O) and the Poly(sialate-
disiloxo) type (-Si-O-Al-O-Si-O). The structures of these polysialates can be schematised as in
Figure 2.1.
Figure 1 Chemical structure of polysialates
Figure 2 Chemical structure of Geopolymer Binder
Geopolymerization involves the chemical reaction of alumina-silicate oxides (Si2O5,
Al2O2) with alkali polysilicates yielding polymeric Si O Al bonds. Poly-silicates are generally
sodium or potassium silicate supplied by chemical industry or manufactured fine silica powder
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as a by-product of Ferro-silicon metallurgy. Equation 2-2 shows an example of poly-
condensation by alkali into poly (sialatesiloxo).
Figure 3 the schematic formation of Geopolymer material
Unlike ordinary Portland/pozzolanic cements, geopolymers do not form calciumsilicate-
hydrates (CSHs) for matrix formation and strength, but utilize the poly-condensation of silica
and alumina precursors and a high alkali content to attain structural strength. Therefore,
Geopolymer are sometimes referred to as alkali activated alumina silicate binders (Davidovits,
1994a; Palomo et. al., 1999; Roy, 1999; van Jaarsveld et. al., 2002a). However, Davidovits (1999;
2005) stated that using the term alkali-activated could create significant confusion and
generate false granted ideas about geopolymer concrete. For example, the use of the term (-)
(Si2O5, Al2O2)n + nSiO2 + nH2O NaOH, KOH n(OH)3 -Si-O-Al-O-Si-(OH)3 (OH)2 (-) (-) n(OH)3 -Si-
O-Al-O-Si-(OH)3 NaOH, KOH (Na,K)(+) (-Si-O-Al-O-Si-O-) + nH2O (OH)2 O OO (2-2) 6 alkali-
activated cement or alkali-activated fly ash can be confused with the term Alkali-aggregate
reaction (AAR) , a harmful property well known in concrete.
The last term of Equation 2-2 indicates that water is released during the chemical
reaction that occurs in the formation of geopolymers. This water is expelled from the mixture
during the curing process.

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The two main constituents of Geopolymer namely the source materials and the alkaline
liquids the source materials for Geopolymer based on alumina-silicate should be rich in silicon
(Si) and aluminum (Al). These could be natural minerals such as kaolinite, clays, micas,
andalousite, spinel, etc. whose empirical formula contains Si, Al, and oxygen (O) (Davidovits,
1988c). Alternatively, by-product materials such as fly ash, silica fume, slag, rice-husk ash, red
mud, etc. could be used as source materials. Among the by-product materials, only fly ash and
slag have been proved to be the potential source materials for making Geopolymer. Fly ash is
considered to be advantageous due to its high reactivity that comes from its finer particle size
than slag. The choice of the source materials for making Geopolymer depends on factors such as
availability, cost, and type of application and specific demand of the end users. The alkaline
liquids are from soluble alkali metals that are usually Sodium or Potassium based. Low-calcium
(ASTM Class F) fly ash is preferred as a source material than high- calcium (ASTM Class C) fly ash.
The presence of calcium in high amount may interfere with the polymerization process and alter
the microstructure (Gourley 2003).
The most common alkaline liquid used in geopolymerization is a combination of sodium
hydroxide (NaOH) or potassium hydroxide (KOH) and sodium silicate or potassium silicate
(Davidovits 1999; Palomo et al. 1999; Barbosa et al. 2000; Xu and van Deventer 2000;
Swanepoel and Strydom 2002; Xu and van Deventer 2002). The use of a single alkaline activator
has been reported (Palomo et al. 1999; TeixeiraPinto et al. 2002),Palomo et al (1999) concluded
that the type of alkaline liquid plays an important role in the polymerization process. Reactions
occur at a high rate when the alkaline liquid contains soluble silicate, either sodium or
potassium silicate, compared to the use of only alkaline hydroxides. Xu and van Deventer (2000)
confirmed that the addition of sodium silicate solution to the sodium hydroxide solution as the
alkaline liquid enhanced the reaction between the source material and the solution.
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Furthermore, after a study of the geopolymerization of sixteen natural Al-Si minerals, they
found that generally the NaOH solution caused a higher extent of dissolution of minerals than
the KOH solution.
According to the American Concrete Institute (ACI) Committee 116R, Fly Ash is a
pulverized fuel ash form from Coal Combustion and collect by dust collection system either
mechanical or electrostatic precipitator before they discharge in the atmosphere. The fly ash
mainly composition of chemical elements Silicon Oxides (SiO), Aluminum Oxide (Al2O3), Iron
Oxide (FeO), and Calcium Oxide (CaO), where magnesium, sodium, potassium, titanium, and
sulphur are also presented in a lesser amount. The major composition of fly ash comes from a
type of coal which is the combustion of sub-bituminous coal. It contains more calcium but less
iron than fly ash from bituminous coal. (Malhotra and Ramezanianpour 1994).
Inorganic polymers are a unique classification of polymers. They contain inorganic
atoms in the main chain. Hybrids with organic polymers as well as those chains that contain
metals as pendant groups are considered in a special sub-classification as organo-metallic
polymers. The networks containing only inorganic elements in main chain are called inorganic
polymers. The silicone rubber is the most commercial inorganic polymer. The organo-metallic
and polymers have a different set of applications. The current paper is a review of current
applications of polymers with inorganic back bone-bone networks, especially focusing on Si and
Al based organic polymeric materials.
Inorganic polymers, by name, stand for many non-organic monomers/repeating units.
Distinguishing between inorganic and organometallic polymers depends on ones opinion.
Simply put, inorganic polymers contain only inorganic repeating units, while the organometallics
have an alternate organic linkage between the inorganic elements. Metal containing polymers
10
can be further classified as per the metal ion. The metal ions could be in the backbone of the
polymer, enmeshed into the chain or as pendent groups to an organic backbone chain. The most
common inorganic polymer is polydimethylsiloxane (PDMS), also called silicone rubber. The
main interest in this section of polymers arises due to their low temperature elastomeric
properties coupled with high temperature stability. Since the divide between inorganic between
the organometallics is very confusing, the polymers can hence be referred to as polymers with
non-organic elements. Futher, they can be classified as metal in backbone, metal enmeshed
polymers and metal ions in pendent groups. Inorganic polymers of this class are majorly
components of soil, mountains and sand. They are used in fire resistant panels, coatings, flame
resistant materials and construction materials. The most widely studied and developed
inorganic polymers are silicon based. Polysiloxanes are the most important inorganic polymers
with regard to commercial applications. Their applications range from medical to sealants, water
barriers, and cosmetics. PDMS (polymethylsiloxane) or silicone rubber is the most widely used.
Polysilanes are similar to polysiloxanes in structure. They contain only silicon in the backbone.
The applications of polysilanes are based on their property of electron mobility. Their current
uses are as photoresists and precursors to other silicon containing materials. (J. Davidovits,
1976; 2011).
My chemistry background had focused on organic polymer chemistry and in the
aftermath of various catastrophic fires in France Between 197072 which involved common
organic plastic research on nonflammable and noncombustible plastic materials became my
objective. In 1972, I founded the private research company Cordi SA, later called Cordi-
Gopolymre. In my pursuit to develop new inorganic polymer materials, I was struck by the
fact that the same simple hydrothermal conditions governed the synthesis of some organic
plastics in alkali medium, as well as mineral feldspathoids and zeolites. Thus, phenol and
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formaldehyde polycondense into the famous Bakelite invented by Bakeland at the beginning of
the 20th Century, one of the oldest man-made plastic (Figure 1.1). Figure 1.1: Phenoplast
polycondensation between phenol and formaldehyde, in alkali medium. On the other hand, the
aluminosilicate kaolinite reacts with NaOH at 100150C and polycondenses into hydrated
sodalite (a tectoaluminosilicate, a feldspathoid), or hydroxysodalite (Figure 1.2).. Introduction
Figure 1.2: Polycondensation of kaolinite Si2O5, Al2 (OH) 4 in alkali medium. synthesis of zeolites
and molecular sieves essentially in the form of powders it became clear that this
geochemistry had so far not been investigated for producing mineral binders and mineral
polymers. I proceeded therefore to develop amorphous to semi-crystalline three-dimensional
silico-aluminate materials, which I call in French "gopolymres", geopolymers (mineral
polymers resulting from geochemistry or geosynthesis). The first applications were building
products developed in 1973-1976, such as fire-resistant chip-board panels, comprised of a
wooden core faced with two geopolymer nanocomposite coatings, in which the entire panel
was manufactured in a one-step process (Davidovits, 1973). We coined it Siliface Process. An
unusual feature was observed to characterize the manufacturing process: for the first time, the
hardening of organic material of organic material (wood chips and organic resin based on urea-
formaldehyde aminoplast) occurred simultaneously with the setting of the mineral silico-
aluminate (Na-poly(sialate) / quartz nanocomposite), when applying the same thermosetting
parameters as for organic resin: 150-180C temperature (J. Davidovits, 1976; 2011).
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Figure 4 Portland cement vs. geopolymer cement chemistry (Joseph Davidovits)
Geopolymers are inorganic, typically ceramic, materials that form long-range, covalently
bonded, non-crystalline (amorphous) networks. Obsidian is an example of naturally occurring
geopolymer. Commercially produced geopolymers may be used for fire- and heat-resistant
coatings and adhesives, medicinal applications, high-temperature ceramics, new binders for fire-
resistant fiber composites, toxic and radioactive waste encapsulation and as cementing
components to make concrete. The properties and uses of geopolymers are being explored in
many scientific and industrial disciplines: modern inorganic chemistry, physical chemistry,
colloid chemistry, mineralogy, geology, and in other types of engineering process technologies.
Raw materials used in the synthesis of silicon-based polymers are mainly rock-forming minerals
of geological origin, hence the name: geopolymer. Joseph Davidovits coined the term in
1978 and created the nonprofit French scientific institution (Association Loi 1901) Institut
Gopolymre (Geopolymer Institute). (J. Davidovits, 1976; 2011).
Inorganic polymers are polymers with a skeletal structure that does not
include carbon atoms in the backbone. Polymers containing inorganic and organic components
are sometimes called hybrid polymers, and most so-called inorganic polymers are hybrid
polymers. One of the best known examples ispolydimethylsiloxane, otherwise known commonly
13
as silicone rubber. Inorganic polymers offer some properties not found in organic materials
including low temperature flexibility, electrical conductivity, and nonflammability. Inorganic
polymers focus on 1-dimensional polymers, not heavily crosslinked materials such as silicate
minerals. Inorganic polymers with tunable or responsive properties are sometimes called smart
inorganic polymers. Special classes of inorganic polymers are geopolymers, which may be
anthropogenic or naturally occurring. Inorganic polymers are a unique classification of polymers.
They contain inorganic atoms in the main chain. Hybrids with organic polymers as well as those
chains that contain metals as pendant groups are considered in a special sub-classification as
organo-metallic polymers. The networks containing only inorganic elements in main chain are
called inorganic polymers. The silicone rubber is the most commercial inorganic polymer. The
organo-metallic and polymers have a different set of applications. The current paper is a review
of current applications of polymers with inorganic back bone-bone networks, especially focusing
on Si and Al based organic polymeric materials. Inorganic polymers, by name, stand for many
non-organic monomers/repeating units. Distinguishing between inorganic and organometallic
polymers depends on ones opinion. Simply put, inorganic polymers contain only inorganic
repeating units, while the organometallics have an alternate organic linkage between the
inorganic elements. Metal containing polymers can be further classified as per the metal ion.
The metal ions could be in the backbone of the polymer, enmeshed into the chain or as pendent
groups to an organic backbone chain. The most common inorganic polymer is
polydimethylsiloxane (PDMS), also called silicone rubber. The main interest in this section of
polymers arises due to their low temperature elastomeric properties coupled with high
temperature stability. (J. Davidovits, 1976; 2011).
Theoretical literature. Fly ash is a pozzolanic material. It is a finely-divided amorphous
alumino-silicate with varying amounts of calcium, which when mixed with portland cement and
14
water, will react with the calcium hydroxide released by the hydration of portland cement to
produce various calcium-silicate hydrates (C-S-H) and calcium-aluminate hydrates. Fly ash is
used as a Supplementary Cementitious Material (SCM) in the production of Ordinary Portland
cement concrete since 1930s and fly ash has been use to concrete with level ranging 15% to
25% by mass of cemetitious material component. This ash is the unburned residue and collected
by either mechanical or electrostatic separator. Fly ash has two type which is class F and class C,
class F contain low calcium than class C and originates from anthracite and bituminous coals
while Class C is originates from sub-bituminous and lignite coals. SCM include pozzolan and
hydraulic material. Pozzolan is known as siliceous and aluminous material; also it chemically
reacts with calcium hydroxide with ordinary temperatures to form compounds having
cementitious properties. Xu and Deventer studied the alkali activation of a large number of
natural alumino silicate minerals and confirmed that source materials with a high reactivity are
required in order to synthesize a geopolymer with high compressive strength. They also
concluded that Si/Al ratio in the original mineral presents a correlation with mechanical strength
of the geopolymer. Fernandez et al. Fly ash when activated with soluble silicates (sodium or
potassium silicate), the reaction rates would be higher than that activated with hydroxides only
and quicker development of mechanical strength would be the result. Fernandez-Jimeneza et al.
geopolymers formed with sodium hydroxide activator showed more stable strength properties
than geopolymers formed with sodium silicate activator. (Joshi and Kadu.)
Methodology
Research Design
This type of research considered as experimental based on the investigation and the
articles we gathered from different premises. To pursue the objectives of these research the
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parameters of methodology must be done by experimentation and testing. It is important and
necessary to perform the require methodology to construct conclusion which is the main
purpose of the study.
The result of these depends on the quality of the product had made and after gathering
some studies we finally get the idea on how we carry out the methodology which help as to
make this research well.
Preparation of Materials
In this research material for making geopolymer binder the raw materials is fly ash low
calcium (Type F) and mixture of two alkaline liquid which is sodium silicate solution and sodium
hydroxide solution.
In preparation of materials the alkaline liquid need to prepare in advance before the day
of experiment which is sodium silicate and sodium hydroxide solution to makes sure that
alkaline liquid is well mixed.
Fly Ash low calcium content of fly ash (Type F) is used in this research from coal-fired
power plant of the National Power Corporation (NAPOCOR) in Calaca, Batangas. The chemical
composition of fly ash is indicated in table 3.2.1
Figure 5 Fly Ash Sample

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Table 1 Chemical Composition of Fly Ash
Content Percentage %
SiO2 57.9
Al2O3 19.3
Fe2O3 7.94
CaO 3.5
MgO 3.4
Content Percentage %
Na2O 11.81
Si2O 33.07
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Sodium H2O 55.12 Silicate
Solution the composition of
sodium silicate is indicated in table 3.2.2.1
Table 2 Chemical Composition of Sodium Silicate Solution
Figure 6 Sodium Silicate Sample
Sodium Hydroxide Flakes Concentration 99 % NaOH
Figure 7 Sodium Hydroxide Flakes Sample

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Preparation for Geopolymer Binder @ (4, 5, 6 &7 Molar)
Mixture Fly Ash Sodium Sodium

No. (FA) Hydroxide Silicate Curing
(Grams) Solution Solution
(Grams) (Grams)
Grams Molar Time Temp. method
(Day) (Celsius)
1 238 51 4 21 7 25 Room
2 238 48 4 24 7 25 Room
3 238 24 4 29 7 25 Room
4 235 54 4 21 7 25 Room
5 235 50 4 25 7 25 Room
6 235 45 4 30 7 25 Room
7 230 57 4 23 7 25 Room
8 230 53 4 27 7 25 Room
9 230 48 4 32 7 25 Room
10 238 51 5 21 7 25 Room
11 238 48 5 24 7 25 Room
12 238 24 5 29 7 25 Room
13 235 54 5 21 7 25 Room
14 235 50 5 25 7 25 Room
15 235 45 5 30 7 25 Room
16 230 57 5 23 7 25 Room
17 230 53 5 27 7 25 Room
18 230 48 5 32 7 25 Room
19 238 51 6 21 7 25 Room
20 238 48 6 24 7 25 Room
21 238 24 6 29 7 25 Room
22 235 54 6 21 7 25 Room
23 235 50 6 25 7 25 Room
24 235 45 6 30 7 25 Room
25 230 57 6 23 7 25 Room
26 230 53 6 27 7 25 Room
27 230 48 6 32 7 25 Room
28 238 51 7 21 7 25 Room
29 238 48 7 24 7 25 Room
30 238 24 7 29 7 25 Room
31 235 54 7 21 7 25 Room
32 235 50 7 25 7 25 Room
33 235 45 7 30 7 25 Room
34 230 57 7 23 7 25 Room
35 230 53 7 27 7 25 Room
36 230 48 7 32 7 25 Room
19
Table 3 Geopolymer Binder Mixture Proportion
Mixture proportion the mixture amount is in terms of grams:
The variable parameter. Alkaline Liquid / Fly Ash (0.3, 0.32 and 0.35), Sodium Hydroxide
/ Sodium Silicate (1.5, 2, and 2.5) and NaOH Concentration (4, 5, 6 and 7 Molar)
20
The constant parameter. Curing @ Room Temperature 25 Celsius and Curing Time 7
Days
Dissolving sodium hydroxide flakes in water for making sodium hydroxide solution. The
amount of NaOH Flakes in a solution varied depending on the desire concentration if 4, 5, 6, and
7 Molarity, For instance, 4 molar (M) of NaOH consisted of 4x40 = 160 grams of NaOH Flakes.
Molecular Weight of NaOH = 40 grams/gmole
Therefore for 160 grams of NaOH mixed to water the product is NaOH concentrated Solution.
Formula
()
Compressive strength = (2 ) Molarity =
Area = (side) 2
Result and Discussion
In this chapter, the compressive strength of specimen result is present and discuss. The
result of different variable parameter of geopolymer binder will discuss here such as effect of
NaOH Concentration, Alkaline Liquid to Fly Ash Ratio and Sodium Hydroxide and Sodium Silicate
Solution Ratio along the constant parameter which is temperature and days of curing are
present and discuss by graphically and table.

21
4.1 SEM (Scanning Electron Microscopy)
Figure 4.1.1 shows: The SEM (Scanning Electron Microscopy) of fly ash and geopolymer binder
Figure 8
Pure Fly Ash SEM x 2,000 (Mohd Mustafa Al Bakri Abdullah et al)
Figure 9
22
(a) (b)
(c) (d)
Geopolymer Binder SEM
In Figure 4.1-1 SEM of pure Fly Ash and Figure 4.1-2 SEM of geopolymer binder (a.) x
2000 (b.) x 5000 (c.) x 7500 and (d.) x 10000 the NaOH concentration in geopolymer binder is
7M. As shown in above, we have seen spores, micro crack, unreacted fly ash and incomplete
reaction came from specimen (Geopolymer binder).
Compressive Strength
The compressive strength of geopolymer binder in different mix proportion are shown
in figure below, with constant curing time and method which is at 7 days and 25 C temperature
(room temp.) and gives different results
Table 4 Statistical analysis
FA/AL Mean Compressive Strength (psi)

Mixture Ratio 23 S.D 23 S.D 23 S.D

= 2.5 =2 = 1.5
23
1 0.30 1672.5 1117.4 3075 1950.5 6365 895.3

2 0.32 2417.5 1343.7 4032.5 3239.4 6940 980.6
3 0.35 3092.5 1611.3 5042.5 1787.1 6122 640.3
NaOH Concentration
Figure10. Compressive Strength vs. NaOH Concentration (0.30)
3500
3000
Compressive Strength (psi)
2500
2000
1500
1000
500
0
4 5 6 7
NaOH Concentration
This graph shows that the sodium hydroxide concentration versus Compressive
Strength increases from 4 molar goes up to 7 molar with ratio of 0.3.
Figure 11. Compressive Strength vs. NaOH Concentration (0.32)

24
4500
4000
Compressive Strngth (psi)

3500
3000
2500
2000
1500
1000
500
0
4 5 6 7
NaOH Concenration
This graph shows that the compressive strength versus Sodium Hydroxide with a
ratio of 0.32 increases. From 4 molar up to 7 molar the compressive strength increases.
Figure 12. Compressive Strength vs. NaOH Concentration (0.35)
5000
4500
4000
3500
3000
2500
2000
1500
1000
500
0
4 5 6 7
NaOH Concentration
This graph shows that the compressive strength versus Sodium Hydroxide with a
ratio of 0.35 increases. From 4 molar to 5 molar and sudden increases when the line
connected to the 6 molar and 7 molar, the compressive strength increases but close each
of molar.
25
Figure 13. Compressive Strength vs. NaOH Concentration @ NaOH/Na2SiO3= 2
6000
5000
Compressive Strength (psi) 4000
3000
2000
1000
0
4 5 6 7
NaOH Concentration
This graph shows the compressive strength versus Sodium Hydroxide with ratio
of 0.30 increases. 4 molar and 5 molar and get the same result of compressive strength,
then 6 molar sudden increases and gets big difference from first two molar. The Molarity
of 7 molar gets the highest compressive strength among the three molar.
Figure 14. Compressive Strength vs. NaOH Concentration @ NaOH/Na2SiO3= 2

26
10000
9000
Compressive Stregth (psi)

8000
7000
6000
5000
4000
3000
2000
1000
0
4 5 6 7
NaOH Concentration
This graph shows that the compressive strength versus sodium hydroxide
concentration with a ratio of 0.32 increases. The compressive strength from 4 molar to 6
molar increases but the difference is close to each other and at 7 molar it sudden
increases.
Figure15. Compressive Strength vs. NaOH Concentration @ NaOH/Na2SiO3= 2
8000
7000
6000
5000
4000
3000
2000
1000
0
4 5 6 7
NaOH Concentration
27
This graph shows the Compressive Strength versus Sodium Hydroxide
concentration with a ratio of 0.35. From Molarity of 4 to Molarity of 7 the compressive
strength is rising.
Figure 16. Compressive Strength vs. NaOH Concentration @ NaOH/Na2SiO3= 1.5 (0.30)
8000
7000
6000
5000
4000
3000
2000
1000
0
4 5 6 7
NaOH Concentration
This graph shows the compressive strength versus sodium hydroxide
concentration with a ratio of 0.30 results different from the other graph. From 4 molar to
5 molar the strength increases while at 6 molar sudden decreases but the 7 molar is higher
than 6 molar. Thats why the graph gives zigzag line.

28
Figure 17. Compressive Strength vs. NaOH Concentration @ NaOH/Na2SiO3= 1.5
9000
8000

7000
6000
5000
4000
3000
2000
1000
0
4 5 6 7
NaOH Concentration
concentration with a ratio of 0.32. As shown above the strength of 4 molar and 5 molar
increases but not totally too far while from 6 molar to 7 molar the strength decreases.
Figure 18. Compressive Strength vs. NaOH Concentration @ NaOH/Na2SiO3= 1.5
7000
6000
5000
4000
3000
2000
1000
0
4 5 6 7
NaOH Concentration
29
concentration with a ratio of 0.35. As shown above the strength for each concentration
increases but sudden decreases at 7 Molar. From 4 molar up to 6 molar the compressive
strength gradually increasing but when it comes to 7 molar sudden decreases.
Alkaline Liquid to Fly Ash Ratio
Figure 19. Alkaline Liquid to Fly Ash Ratio 4 molar
900
800
700
600
500
400
300
200
100
0
0.3 0.32 0.35
Alkaline Liquid to Fly Ash
This graph shows that the compressive strength versus Alkaline liquid to Fly ash
in 4 molar, and also shows that at 0.3 to 0.35 the strength increase.

30
3500
3000
2500

2000
1500
1000
500
0
0.3 0.32 0.35
Alkaline Liquid yo Fly Ash
in 4 molar. The alkaline liquid ratio of 0.3 to 0.32 increases gradually, then the ratio of
0.35 sudden increases.
6200
6000
5800
5600
5400
5200
5000
4800
4600
0.3 0.32 0.35
31
This graph shows that the compressibility strength versus Alkaline liquid to Fly
ash in 4 molar. The alkaline liquid ratio of 0.3 to 0.32 increases to the high level while
increases gradually in ratio of 0.35.
3500
3000
2500
2000
1500
1000
500
0
0.3 0.32 0.35
This graph shows that the compressive strength versus Alkaline liquid to Fly ash in 5
molar. The ratio of alkaline liquid 0.3, 0.32, and 0.35 increases
Figure 23 Alkaline Liquid to Fly Ash Ratio 5 molar
4500
4000
3500
3000
2500
2000
1500
1000
500
0
0.3 0.32 0.35
32
This graph shows the compressive strength versus Alkaline liquid to Fly ash in 5
molar. The compressive strength of alkaline liquid to fly ash ratio 0.30 to 0.32 increases
but not too high and the strength at 0.35 different, as shown in figure increases much
higher.
7200
7000
6800
6600
6400
6200
6000
5800
5600
0.3 0.32 0.35
This graph shows the compressive strength versus Alkaline liquid to Fly Ash in 5
molar. This graph is not too close from other molar because the ratio of alkaline liquid
increases and decreases. The ratio of 0.3 gave a high compressive strength, and then at
0.32 ratio gave a lower strength and then the ratio of 0.35 gave higher than 0.32 but lower
than 0.30.
33
4500
4000

3500
3000
2500
2000
1500
1000
500
0
0.3 0.32 0.35
Alkaline Liquid o Fly Ash
in 6 molar. Shown the strength of the alkaline liquid ratio of 0.3, 0.32 and 0.35 is
increases.
Figure 26 Alkaline Liquid to Fly Ash Ratio 6 molar
7000
6000
5000
4000
3000
2000
1000
0
0.3 0.32 0.35
34
in 6 molar. The alkaline liquid ratio of 0.3 to 0.32 decreases but the ratio of 0.35 sudden
increases.
9000
8000
7000
6000
5000
4000
3000
2000
1000
0
0.3 0.32 0.35
in 6 molar. As shown the alkaline liquid ratio 0.3 got a result of high compressive
strength then the ratio of 0.32 increases higher, while the ratio of 0.35 sudden decreases.
35
Figure 28. Alkaline Liquid to Fly Ash Ratio 7molar
5000
4500

4000
3500
3000
2500
2000
1500
1000
500
0
0.3 0.32 0.35
This graph shows the compressive strength versus Alkaline liquid to Fly ash in 7
molar. The alkaline liquid ratio of 0.3, 0.32, and 0.35 graphs the compressive strength
start from high strength then increases higher.
10000
9000
8000
7000
6000
5000
4000
3000
2000
1000
0
0.3 0.32 0.35
36
in 7 molar. The alkaline liquid ratio at 0.3 to 0.32 increases and from the ratio of 0.32 to
0.35 decreases but little bit higher than 0.3.
9000
8000
7000
6000
5000
4000
3000
2000
1000
0
0.3 0.32 0.35
in 7 molar. The alkaline liquid ratio of 0.3 gave a higher strength, the ratio 0.32 increases
higher than 0.3 but not too high and ratio of 0.35 sudden decreases.
37
Sodium Hydroxide to Sodium Silicate Solution Ratio
Figure 31. Sodium hydroxide vs. Sodium silicate
6000
5000
4000
3000
2000
1000
0
2.5 2 1.5
Sodium Hydroxide to Sodium Silicate
This graph shows the compressive strength versus Sodium Hydroxide to sodium
Silicate in 4 molar. The compressive strength of alkaline liquid with a ratio of 2 is higher
than ratio of 2.5 and the ratio of 1.5 sudden increases. This figure showed the effect of
different ratio in Molarity of 4.
7000
6000
5000
4000
3000
2000
1000
0
2.5 2 1.5
38
Silicate in 4 molar. The compressive strength of alkaline liquid with a ratio of 2.5 to 2
increases, then the ratio of 1.5 sudden increases.
7000
6000
5000
4000
3000
2000
1000
0
2.5 2 1.5
Silicate in 4 molar. The compressive strength of alkaline liquid with a ratio of 2.5,2 and
1.5 continuously increases.

39
8000
7000

6000
5000
4000
3000
2000
1000
0
2.5 2 1.5
Sodium Hydroxide to Fly Ash
increases moderately, and then the ratio of 1.5 sudden increases.
7000
6000
5000
4000
3000
2000
1000
0
2.5 2 1.5
40
increases while, the ratio at 1.5 sudden increases.
7000
6000
5000
4000
3000
2000
1000
0
2.5 2 1.5
Silicate in 5 molar. The compressive strength of alkaline liquid with a ratio of 2.5,2 and

41
7000
6000

5000
4000
3000
2000
1000
0
2.5 2 1.5
Silicate in 6 molar. The compressive strength of alkaline liquid with a ratio of 2.5, 2 and
9000
8000
7000
6000
5000
4000
3000
2000
1000
0
2.5 2 1.5
42
Silicate in 5 molar. The compressive strength of alkaline liquid with a ratio of 2.5 to 2 is
increases but moderately, then the ratio of 1.5 sudden increases.
7000
6000
5000
4000
3000
2000
1000
0
2.5 2 1.5
Silicate in 6 molar. The compressive strength of alkaline liquid with a ratio 2 is increases
much compare to ratio of 2.5, and then the ratio of 1.5 also increases but gradually than
the first two ratios.

43
8000
7000
Compressive Strength (psi) 6000
5000
4000
3000
2000
1000
0
2.5 2 1.5
Silicate in 7 molar. The compressive strength of alkaline liquid with a ratio 2.5, 2 and 1.5
is continuously increases.
10000
9000
8000
7000
6000
5000
4000
3000
2000
1000
0
2.5 2 1.5
44
Silicate in 7 molar. The compressive strength of alkaline liquid with a ratio 2.5 to 2 is
sudden increases, and then the ratio of 1.5 gradually decreases.
8000
7000
6000
5000
4000
3000
2000
1000
0
2.5 2 1.5
Silicate in 7 molar. The compressive strength of alkaline liquid with a ratio 2.5 to 2 is
continuously increases, and then the ratio of 1.5 sudden decreases.
Conclusion
The importance of the research based on several test and thorough investigation,
researchers emphasized the factors to optimize the fly ash for the production of Geopolymer
binder and compressive strength depends on mixture proportion in producing geopolymer
binder. As the result, the highest compressive strength is attained at 7 Molar of NaOH
concentration solutions, alkaline liquid to fly ash ratio of 0.32 and sodium hydroxide to sodium
45
silicate solution ratio of 2 at constant condition of 7 days curing of specimen and room
temperature (25) that results 8820 psi approximately 61 MPa. Sodium hydroxide concentration
has significant for increasing and decreasing of compressive strength of geopolymer binder.
Therefore, the information given has the significance in producing Geopolymer binder
using fly ash. Since Ordinary Portland cement (OPC) production is responsible in producing tons
of Carbon Dioxide gas that can affect much to our environment. This research OPTIMIZATION
OF FLY ASH For PRODUCTION OF GEOPOLYMER BINDER has an advantage not only in the
construction industries and also in our environment.
Recommendation
Based on study, this research may contribute much to our environment. We highly
recommend fly ash as main substituent material in producing Geopolymer binder. By
considering Geopolymer Binder instead of Ordinary Portland cement (OPC), it will develop an
economically friendly environment and the application of Geopolymer binder used in concrete
or in other possible way.
Sodium hydroxide solution and sodium silicate solution commonly used in Geopolymer
but there are other alkaline liquid like lithium hydroxide solution and lithium silicate solution
also possible to use as alternative to potassium hydroxide and potassium silicate. Method of
curing temperature such as curing in steam condition, oven curing and also adjust the curing day
up to 28days.
References
Domingo, Mark Bryan S., Santos, Roger Owen P. &Somera, Justy Jos V. December 2013
Hamizi bin Yahya(1132010621) 2013

46
Omar A. Abdulkareem, A.M. Mustafa Al Bakri, H.Kamarudin& I. KhairulNizar 2013
Oscar Victor M. Antonio, Jr Mark Albert H. Zarco ,2007
Studies on Fly Ash-Based Geopolymer Concrete by Curtin University of Technology
(2005)
ASTM (American Society for Testing Materials)
C39-Standard Test Method for Compressive Strength of Cylindrical Concrete Specimens
Mustafa Al Bakri , H. Kamarudin , M. Bnhussain , I. Khairul Nizar , A. R.Rafiza
and Y. Zarina
Optimizing the Use of Fly Ash in Concrete By: Michael Thomas, Ph.D., P.Eng.,
Professor of Civil Engineering, University of New Brunswick
The processing, characterization, and properties of fly ash based geopolymer concrete
A.M.
Davidovits, Joseph (2013) Geopolymer Cement (a review)
Francesco Colangelo, Giuseppina Roviello, Laura Ricciotti, Claudio Ferone and Raffaele
Cioffi (2013). Preparation of Characterization of New Geopolymer-Epoxy Resin
Hybrid Mortars
47
Mohd Mustafa Al Bakri Abdullah, Kamarudin Hussin, Mohamed Bnhussain, Khairul
Nizar, Ismail, Zarina Yahya and Rafiza Abdul Razak. (Fly ash SEM)
Obonyo, Esther, Kamseu, Elle, Melo, Uphle C. and Leonelll, Christina (2011) Advancing
the use of Secondary Inputs in Geopolymer Binders for Sustainable Cementitious
Coposites
Madejska, Lucyna, Jarosinski, Andrzej, Zelazny, Sylwester, Kusnierova, Chachlowska,
Maria and Chachlowska, Monika (2011) Properties of Geopolymer Binder
Obtained From Fly Ash
Appendices
Appendix A
Fly Ash
48
Appendix B
Mixing of Alkaline Liquid
Weighing of Sodium Silicate Weighing of Sodium Hydroxide

49
Mixing of Sodium Silicate and Sodium Hydroxide
Apendix C
Preparation of Cube Mould
Spare parts of the molds arranging of the spare parts
Cube molds
Appendix D
Mixing of Geopolymer Binder

50
Appendix E
Casting
Putting of Geopolymer binder to the molds
Appendix F
Fresh Geopolymer Binder

51
Appendix G
Compressive Strength Testing using Universal Testing Machine (UTM)
Putting of geopolymer binder in UTM Preparing
Setting Actual result

52
Appendix 1
Calculation
Calculation for Molar Concentration of NaOH
Grams of NaOH Flakes in @ 4 molar
@ 4 molar NaOH Molecular Weight = 40 grams / moles NaOH
4 40 160 ()
=
1 1 1
Using Weighing Scale
Step 1 Formula of Solution

= 1215

= +

Step 2 substitute the value (1 Liter of solution operation)
1215 = 160 () +
= 1215 160
= 1055
Therefore every 1055 grams of water = 160 grams of NaOH
Step 3 how to calculate the amount of NaOH Flakes & Water Content @ Mix. No. 1
@ Mix. 1.30 NaOH Solution = 43 grams NaOH Solution
1055
43 ( ) 37.34
1215
53
160 ()
43 ( )
1215
5.66 ()
1055
45 ( ) 39.07
1215
160 ()
45 ( )
1215
5.93 ()
1055
48 ( ) 41.68
1215
160 ()
48 ( )
1215
6.32 ()
1055
48 ( ) 41.68
1215
160 ()
48 ( )
1215
6.32 ()
1055
50 ( ) 43.
1215
160 ()
50 ( )
1215
6.58 ()
54
@ Mix. 2.35 NaOH Solution = 53grams NaOH Solution
1055
53 ( ) 46.02
1215
160 ()
53 ( )
1215
6.98 ()
@ Mix.3.3 NaOH Solution = 51 grams NaOH Solution
1055
51 ( ) 44.28
1215
160 ()
51 ( )
1215
6.72 ()
1055
54 ( ) 46.89
1215
160 ()
54 ( )
1215
7.11 ()
1055
57 ( ) 49.49
1215
160 ()
57 ( )
1215
7.51 ()

55
5 40 200 ()
=
1 1 1

= 1215

= +

1215 = 200 () +
= 1215 200
= 1015
Therefore every 1015grams of water = 200 grams of NaOH
1015
43 ( ) 35.92
1215
200 ()
43 ( )
1215
7.08 ()
1015
45 ( ) 37.60
1215
56
200 ()
45 ( )
1215
7.40 ()
1015
48 ( ) 40.10
1215
200 ()
48 ( )
1215
7.90 ()
1015
48 ( ) 40.10
1215
200 ()
48 ( )
1215
7.90 ()
1015
50 ( ) 41.77
1215
200 ()
50 ( )
1215
8.23 ()
1015
53 ( ) 44.28
1215
57
200 ()
53 ( )
1215
8.78 ()
1015
51 ( ) 42.60
1215
200 ()
51 ( )
1215
8.40 ()
1015
54 ( ) 45.11
1215
200 ()
54 ( )
1215
8.89 ()
1015
57 ( ) 47.62
1215
200 ()
57 ( )
1215
9.38 ()

=

58
6 40 240 ()
=
1 1 1

= 1215

= +

1215 = 240 () +
= 1215 240
= 975
Therefore every 975 grams of water = 240 grams of NaOH
975
43 ( ) 34.51
1215
240 ()
43 ( )
1215
8.49 ()
975
45 ( ) 36.11
1215
240 ()
45 ( )
1215
8.89 ()
59
975
48 ( ) 38.52
1215
240 ()
48 ( )
1215
9.48 ()
975
48 ( ) 38.52
1215
240 ()
48 ( )
1215
9.48 ()
975
50 ( ) 40.12
1215
240 ()
50 ( )
1215
9.88 ()
975
53 ( ) 42.53
1215
240 ()
53 ( )
1215
10.47 ()
60
975
51 ( ) 40.93
1215
240 ()
51 ( )
1215
10.07 ()
975
54 ( ) 43.33
1215
240 ()
54 ( )
1215
10.67 ()
975
57 ( ) 45.74
1215
240 ()
57 ( )
1215
11.26 ()
7 40 280 ()
=
1 1 1

61

= 1215

= +

1215 = 280 () +
= 1215 280
= 935
Therefore every 935grams of water = 280 grams of NaOH
935
43 ( ) 33.10
1215
280 ()
43 ( )
1215
9.90 ()
935
45 ( ) 35.63
1215
280 ()
45 ( )
1215
9.37 ()
935
48 ( ) 36.94
1215
62
280 ()
48 ( )
1215
11.06 ()
935
48 ( ) 36.94
1215
280 ()
48 ( )
1215
11.06 ()
935
50 ( ) 38.48
1215
280 ()
50 ( )
1215
11.52 ()
935
53 ( ) 40.79
1215
280 ()
53 ( )
1215
12.21 ()
63
935
51 ( ) 39.25
1215
280 ()
51 ( )
1215
11.75 ()
935
54 ( ) 41.56
1215
280 ()
54 ( )
1215
12.44 ()
935
57 ( ) 43.86
1215
280 ()
57 ( )
1215
13.14 ()
64
Appendix 2
Calculation for Geopolymer Binder
Mixing 1
1.30.) Composition for 4 molar, 5 molar, 6 molar, and 7 molar of at particular
ratio for Alkaline Liquid/Fly Ash 3:10 and /2 33:2.
Geopolymer Binder = 310 grams per fresh specimen
Geopolymer Binder = Fly Ash (FA) + Alkaline Liquid (AL)
Alkaline Liquid = + 2 3
Ratio:

= 0.30 ; = 1.50
2 3
FA + AL = 310grams
AL = 0.30FA
0.30FA + FA = 310
FA 238 grams
AL = 310 - 238
AL = 72 grams
+ 2 3 = 72 grams
= 1.5(2 3)
1.5(2 3) + 2 3 = 72
2 3 29 grams
= 72 29
= 43 grams
65
Mixing 2
ratio for Alkaline Liquid/Fly Ash 3.2:10 and /2 33:2.
Ratio:

= 0.32 ; = 1.5
2 3
FA + AL = 310grams
AL = 0.32FA
0.32FA + FA = 310
FA 235 grams
AL = 310 - 235
AL = 75 grams
+ 2 3 = 75 grams
= 1.5(2 3)
1.5(2 3) + 2 3 = 75
2 3 = 30 grams
= 75 30
= 45 grams
66
Mixing 3

Ratio:

= 0.35 ; = 1.50
2 3
FA + AL = 310grams
AL = 0.35FA
0.35FA + FA = 310
FA 230 grams
AL = 310 - 230
AL =80 grams
+ 2 3 = 80 grams
= 1.5(2 3)
1.5(2 3) + 2 3 = 80
2 3= 32 grams
= 80 32
= 48 grams
67
Mixing 4
2.30) Composition for 4 molar, 5 molar, 6 molar, and 7 molar of at particular
Ratio:

= 0.30 ; =2
2 3
FA + AL = 310grams
AL = 0.30FA
0.30FA + FA = 310
FA 238 grams
AL = 310 - 238
AL = 72 grams
+ 2 3 = 72 grams
= 2(2 3)
2(2 3) + 2 3 = 72
2 3 = 24 grams
= 72 24
= 48 grams
68
Mixing 5
ratio for Alkaline Liquid/Fly Ash 3.2:10 and /2 3 2:1.
Ratio:

= 0.32 ; =2
2 3
FA + AL = 310grams
AL = 0.32FA
0.32FA + FA = 310
FA 235 grams
AL = 310 - 235
AL = 75 grams
+ 2 3 = 75 grams
= 2(2 3)
2(2 3) + 2 3 = 75
2 3 = 25 grams
= 75 25
= 50 grams
69
Mixing 6
ratio for Alkaline Liquid/Fly Ash 3.5:10 and /2 3 2:1.
Ratio:

= 0.35 ; =2
2 3
FA + AL = 310grams
AL = 0.35FA
0.35FA + FA = 310
FA 230 grams
AL = 310 - 230
AL = 80 grams
+ 2 3 = 80 grams
= 2(2 3)
2(2 3) + 2 3 = 80
2 3 27 grams
= 80 27
= 53 grams
70
Mixing 7
Ratio:

= 0.3 ; = 2.5
2 3
FA + AL = 310grams
AL = 0.3FA
0.3FA + FA = 310
FA 238 grams
AL = 310 - 238
AL = 72 grams
+ 2 3 = 72 grams
= 2.5(2 3)
2.5(2 3) + 2 3 = 72
2 3 21 grams
= 72 21
= 51 grams
71
Mixing 8
Ratio:

= 0.32 ; = 2.5
2 3
FA + AL = 310grams
AL = 0.32FA
0.32FA + FA = 310
FA 235 grams
AL = 310 - 235
AL = 75 grams
+ 2 3 = 75 grams
= 2.5(2 3)
2.5(2 3) + 2 3 = 75
2 3 21 grams
= 75 21
= 54 grams
72
Mixing 9
Ratio:

= 0.35 ; = 2.5
2 3
FA + AL = 310grams
AL = 0.35FA
0.35FA + FA = 310
FA 230 grams
AL = 310 - 230
AL = 80 grams
+ 2 3 = 80 grams
= 2.5(2 3)
2.5(2 3) + 2 3 = 80
2 3 23 grams
= 80 23
= 57 grams

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OPTIMIZATION OF FLY ASH FOR PRODUCTION

Optimization of Fly Ash for Production of Geopolymer Binder

Joyce Mari E. Adriano

Sweet Gilleen P. Borromeo

Alexander S. Ibrahim Jr.

This Thesis entitled Optimization of Fly Ash for production of Geopolymer

degree Bachelor of Science in Chemical Engineering was examined and recommended

for oral examination

Engr. Alvin A. Talampas Engr. Nerissa M. De Guzman

Adviser Area Chairman, ChE Dept.

Approve in partial fulfillment of the requirements for the degree of BACHELOR

OF SCIENCE IN CHEMICAL ENGINEERING by the committee of ORAL

EXAMINATION on March 2014 with the rating of _____.

Accept in partial fulfillment of the requirement for the degree of Bachelor of

Science in Chemical Engineering.

Dean, College of Engineering

and always lead us.

encouragement and constructive criticisms.

1.01 Background of the study 1

1.02 Statement of the problem 3

1.03 Objective of the Study 4

1.04 Scope and Limitation 4

1.05 Significance of the Study 5

2. Review Related Literature 5

3.01 Research Design 16

3.02 Preparation of Materials 16

3.03 Fly ash 17

3.04 Sodium Silicate Solution 18

3.06 Preparation for Geopolymer binder 19

3.07 Mixture Proportion 20

4. Result and Discussion 21

4.01 SEM (Scanning Electron Microscopy) 21

4.02 Compressive Strength 23

4.03 NaOH Concentration 23

4.04 Alkaline Liquid to Fly Ash Ratio 29

4.05 Sodium Hydroxide Solution to Sodium Silicate Solution Ratio 37

9.01 Appendix A. Fly Ash 48

9.02 Appendix B. Mixing of Alkaline Liquid 48

9.03 Appendix C. Preparation of Cube Mould 49

9.04 Appendix D. Mixing Geopolymer Binder 50

9.05 Appendix E. Casting 50

9.06 Appendix F. Fresh Geopolymer Binder 51

9.07 Appendix G. Compressive Strength Testing Machine 51

Table 1 Chemical Composition of Fly Ash 17

Table 2 Chemical Composition of Sodium Silicate Solution 18

Table 3 Geopolymer Binder Mix Proportion 19

Table 4 Statistical analysis 23

Figure 1 Chemical Structure of polysialates 6

Figure 2 Chemical Structure of Geopolymer Binder 7

Figure 3 The Schematic Formation of Geopolymer Binder 7

Figure 4 Portland cement vs. geopolymer cement chemistry(Joseph Davidovits)13

Figure 5 Fly Ash 17

Figure 6 Sodium Silicate Solution 18

Figure 7 Sodium Hydroxide Flakes 18

Figure 8 Pure Fly Ash SEM x 2000 21

Figure 9 Geopolymer Binder SEM 22

Figure 10 -18 Compressive Strength vs. NaOH Concentration 23

Figure 19 - 30 Compressive Strength vs. Alkaline liquid to Fly Ash 29

Figure 30 42 Compressive Strength vs. NaOH/ Na2SiO3 37

of Ordinary Portland Cement (OPC). The purpose of this investigation is to produce a

solution, Geopolymer binder, Carbon dioxide and Geopolymerization.