The development of an optimal low-calcium alkali-activated binder for high-temperature stability based on ferronickel slag, silica fume, potassium hydroxide, and potassium silicate was investigated based on Mixture Design of Experiment (Mixture DOE). Mass loss, shrinkage/expansion, and compressive and flexural strengths before and after exposure to a high thermal load (900 °C for two hours) were selected as performance markers. Chemical activator minimization was considered in the selection of the optimal mix to reduce CO2 emissions. Unheated 42-day compressive strength was found to be as high as 99.6 MPa whereas the 42-day residual compressive strength after exposure to the high temperature reached 35 MPa (results pertaining to different mixes). Similarly, the maximum unheated 42-day flexural strength achieved was 8.8 MPa, and the maximum residual flexural strength after extreme temperature exposure was 2.5 MPa. The binder showed comparable properties to other alkali-activated ones already studied and a superior thermal performance when compared to Ordinary Portland Cement. A quantitative X-ray diffraction analysis was performed on selected hardened mixes, and fayalite was found to be an important component in the optimal formulation. A life-cycle analysis was performed to study the CO2 savings, which corresponded to 55% for economic allocation.
Keywords: alkali-activated materials (AAM); design of experiment (DOE); life cycle assessment (LCA); response surface method (RSM).