Development of Geopolymer Properties from Cement Industry Waste as Raw Material for Clay Pottery Products
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Abstract
This study demonstrates that cement industry waste (CCW) can be effectively utilized to produce high-performance clay–geopolymer hybrid ceramics with enhanced mechanical, physical, thermal, and durability properties. An optimum substitution of 20 wt% CCW achieved the highest compressive strength (42.5 MPa), compared with 31.4 MPa for the control, together with reduced porosity (22.1%) and water absorption (9.8%). These improvements are attributed to the combined effects of geopolymer reaction product development, improved particle packing, and microstructural densification, resulting in a dense and homogeneous matrix. Thermal and phase analyses suggest a progressive transition from geopolymer-dominated bonding to ceramic bonding during firing, with optimum densification at approximately 1050 °C, whereas firing at 1100 °C promoted over-fluxing and microstructural defects. The optimized composition also exhibited superior durability, retaining approximately 88% of its compressive strength after wet–dry cycling, and demonstrated good environmental compatibility, with heavy metal leaching below regulatory limits. In addition, CCW incorporation improved workability, reduced drying shrinkage from 6.5% to 4.0%, and enhanced surface quality while achieving comparable performance at lower firing temperatures than those typically required for conventional ceramics, suggesting the potential for reduced firing energy demand. Overall, the results demonstrate that CCW offers a promising and sustainable approach for producing durable, high-value ceramic materials while promoting waste valorization, resource efficiency, and circular economy practices.
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