Investigation of mechanical, microscopic, and leaching properties of coal-based solid waste geopolymer mortar activated by soda residue and phosphogypsum

In this study, coal-based solid waste geopolymer mortar (SWCB) was prepared by using granulated ground blast-furnace slag (GGBS) and coal gasification coarse slag (CGCS) as precursors, and soda residue (SR) and phosphogypsum (PG) as activators, with gangue sand (GS) utilized as an inert filler. The corresponding compressive strength, fluidity, ion leaching, and microstructure of the developed SWCB were systematically investigated under varying solid contents, binder-to-sand ratios, and activator ratios. The findings suggest that the incorporation of activators promoted the dissolution of the silicon-aluminum phase in GGBS and CGCS into Al(OH)4−, [SiO(OH)3]−, and [SiO2(OH)2]2−, which could subsequently react with the Ca2+ and SO42− released by PG, forming AFt and C-(A)-S-H, thereby playing a crucial role in enhancing matrix strength. AFt was the predominant hydration product in the early reaction stage. The morphology of the AFt phase evolved from needle-like or filamentous to fine and coarse rods as hydration progressed. Initially, the formation of C-(A)-S-H gel increased with rising activator content before decreasing. The optimal synergy between AFt and C-(A)-S-H was observed at an activator content of 30 %. However, the growth of gypsum crystals was hindered when the activator content surpassed 30 %, resulting in a plate-like or columnar morphology. C-(A)-S-H gel exhibited remarkable adsorption capability towards P atoms attributed to intermolecular Van der Waal's forces, enabling simultaneous physical encapsulation of P atoms, while Cl element immobilization was primarily attributed to the contribution of SiOH sites to Cl adsorption.