1. Introduction
Transformation of industrial wastes into a resource is one of the pillars of the circular economy. The need of waste valorization is widely recognized, and a large amount of effort is focused on the research and development of industrial processing activities for reusing or recycling industrial wastes. The mine activities and metal extraction processes generate an enormous amount of tailings usually stored in tailing dumps [
1,
2]. The disadvantages of this practice are well recognized, and the industry is eager to find alternatives to landfill practice [
2,
3].
Geopolymer technology offers a valuable approach to reuse mine tailings as well as other types of industrial wastes by applying low CO
2 footprint processes. An advantage of the geopolymerization process is that the new composite materials could be obtained by fine tuning the precursor mixture containing low and high reactive silica and alumina to obtain a material with desired characteristics [
4,
5]. The blending of raw material mixtures allowed in some cases for the skipping of the activation step of low reactive precursors, thus ensuring eco-friendly process [
4]. Coal combustion byproducts, blast furnace slag, fly ash, glass fibers, metakaolin, etc. were studied as raw materials with high reactive Al and Si [
4,
5]. The thorough characterization of mine tailing is required in order to finely adjust the technology to the particular characteristics of raw materials. Due to the specific chemical composition and characteristics of mine tailings from different sources, a deep study is needed for each tailing source. The characterization strategy should include not only the required characteristics for the obtaining technology, but also the assessment of some parameters, taking into account the application of the final product as well as the generated flows into the environment during its production, usage and post-application fate.
Over 55 billion cubic meters of mine tailings (MTs) are stored globally, with a 23% increase by 2025 [
3]. Many storage facilities are vulnerable, with over 100 large dam collapses since 1960 causing death and environmental consequences [
6]. Utilizing mine tailings as a replacement can conserve natural resources for 4 to 5 years, reducing the use of virgin raw materials in concrete production. Zhang et al. [
7] explored the use of mine tailings as precursors for geopolymers, partially replacing fly ash (FA) with molybdenum tailings for cost-effective waste valorization. However, a higher percentage of FA substitution with MT leads to mechanical performance loss due to an increased macropore volume fraction. Qing et al. [
8] produced geopolymer concrete with a compressive strength of 47.6 MPa using the alkali-hydrothermal activation of quartz powder at 300 °C. Although it meets 42.5 cement standards, high temperatures may hinder its sustainability. Orozco et al. [
9] developed sustainable bricks by activating gold mine tailings with NaOH or (CaOH)
2 and curing at 80 °C. Opiso et al. [
10] found that adding 10% palm oil fuel ash to gold mine tailings-based geopolymer bricks improved their mechanical qualities and allowed for room-temperature curing, resulting in cost and CO
2 emission savings. However, creating geopolymers with suitable mechanical characteristics using MTs as raw materials is challenging due to the large number of nonreacting phases, particularly quartz. Vizureanu et al. [
6] also concluded that the properties of the geopolymers that use mine tailings as pre-cursors strongly depend on the characteristics of the raw materials. Next to the characteristics of the mine tailings, the activator parameters (type and concentration) and the curing conditions (temperature and time) will also affect the performance of the geopolymers. Krishna et al. [
5] found low reactivity of metallurgical tumbling in mine tailings for a geopolymer manufacture. They suggested a customized processing approach for each location and available MT, considering factors like raw material properties, activation parameters and end product type.
Geopolymers based on copper mine tailings with and without blending with additional sources of aluminosilicates have been proposed for potential use as construction materials (bricks, pavements, road construction, etc.) or as an approach for hazardous element encapsulation [
11,
12,
13,
14,
15,
16,
17,
18]. As copper tailings showed low reactivity [
12,
17], preliminary activation was proposed, such as mechanical activation [
16] or curing at elevated temperatures [
11,
13,
16]. Castillo et al. [
12] reported that heating at 90 °C promoted the dissolution of aluminosilicates in an alkaline medium and favored geopolymer hardening processes based on copper tailing. In contrast, Tian et al. [
13] found that moderate heating (80 °C) promoted the dissolution of aluminosilicates, whereas higher temperatures negatively influenced the microstructure of the obtained geopolymers. The optimal curing temperature should be established empirically for the given raw materials and should depend on their reactivity and alkali concentration [
11]. Geopolymer materials appropriate for low-strength applications were developed based on copper tailing and alkali activated fly ash or low-calcium slag as additional sources of reactive aluminosilicates [
14,
16]. High-calcium additives were reported to result in better characteristics of the obtained geopolymers [
17]. A geopolymer concrete based on copper tailing and blast furnace slag was reported to show promising behavior in marine-related environments [
18].
Mine tailing dumps in Bulgaria are well studied from a environmental or technological point of view. Some results on mine tailing valorization have been recently discussed in detail [
19,
20,
21]. However, the mine tailing potential for application as raw materials for geopolymer obtaining is scarcely reported. The main challenges for the incorporation of mine tailings into geopolymer manufacturing are related to heavy metal contaminations and leaching. Wang et al. [
22] reviewed the literature on geopolymers containing heavy metals and found that the process produces safe and long-lasting products through physical encapsulation, covalent bonding, ion exchange, and compound creation mechanisms. However, experimental validation is necessary due to the particularities of each mine tailing and geopolymer manufacturing method, especially when blended systems are researched.
The aim of the present study is characterization of copper mine tailing as a raw material for obtaining geopolymers with a low CO2 footprint. To achieve this goal, a specific algorithm for the chemical characterization of the item was developed to test not only the chemical composition parameters, but also the behavior of potentially hazardous components and their mobility. From a geopolymer technology point of view, the following parameters were studied: particle size distribution, chemical and mineralogical composition, characteristics of aqueous leachate, and alkaline reactivity. From an environmental point of view, the following characteristics were studied: heavy metal fractionalization, the composition of water leachate, and the mobility of hazardous components. The results revealed that the copper mine tailing from the Assarel Concentrator plant in Bulgaria has a great potential for valorization by using it as a precursor for obtaining geopolymers. This study presents for the first time a detailed characterization of copper mine tailing from Assarel, Bulgaria as a raw material for geopolymers obtained by alkali activation and low CO2 footprint technology.
4. Discussion
A detailed characterization of the Bulgarian copper mine tailing from Assarel-Medet as a precursor for geopolymer obtaining was reported for the first time. The chemical and mineralogical composition, leaching behavior, alkaline reactivity amd heavy metal distribution in the geochemical phases of mine tailing were studied. The conclusions drawn were focused on its utilization as a raw material for obtaining geopolymers.
The chemical composition of the studied copper mine tailings showed their perspective to be reused as raw materials for obtaining geopolymers (
Table 1). The high content in Si and significant content in Al-bearing minerals are favorable for the geopolymerization process [
37]. The ratio of Si/Al in the copper mine tailing was in the optimal ratio of 1–3 [
12,
24,
35,
49,
50] thus making the studied tailing a promising precursor for geopolymers. However, an additional source of Al could be added to enhance the geopolymerization process and improve the characteristics of the obtained products [
24,
51]. In a recent review, Lazorenko et al. summarized the chemical composition of various mine tailings used for geopolymers. The SiO
2 content in copper mine tailing from different sources varied between 28 and 65%, and for Al
2O
3 from 4 to 14% [
52]. Comparing the composition of the studied material, it could be concluded that it is a suitable precursor for geopolymerization, having the benefit of higher Al content.
The study of mineralogical composition proved the presence of alumosilicate minerals (muscovite, clinochlore), as well as SiO
2 in the zeolite and quartz phases. The presence of alumosilicates in the tailings could be expected to exert a neutralizing or pH buffering effect on generated leachates [
24], which will mitigate the environmental effect during rainfall. The study of the alkaline reactivity of copper mine tailing (
Figure 4) revealed that the alkali-leachable Si и Al were between 0.2 and 0.5% from the total content of SiO
2 and Al
2O
3 in the raw material. Hence, the low extent of dissolution of crystalline phases in the studied conditions 3, 6.5 and 10 M NaOH at different times up to 72 h was observed. The results were in support of the findings of Cristello et al., who demonstrated that crystalline phases in copper tailing were inert [
14]. The ratio of reactive Si and Al in copper tailing (
Table 6) was also studied, as it was known to influence the formation of geopolymer networks [
14,
15,
17]. However, a convincing answer for which ratio was optimal for designing a geopolymer product with the intended characteristics and application could not be found. The reason was that additional sources of reactive Si were added to the precursor mixture during the obtaining of geopolymer material: (i) sodium silicate and (ii) fly ash. Thus, the properties of the obtained materials depended on the complex combinations of parameters that govern the alkali activation process [
5,
15,
53]. It was observed that increasing the molarity of NaOH in activator solution resulted in a higher strength of the obtained geopolymer materials. The results were in line with previous studies [
12,
14,
15]. It could be explained only partially by the increased dissolution rate of aluminosilicates, and accordingly, the concentrations of reactive Si and Al, as fly ash addition, could positively influence the development of the geopolymer network [
5,
14].
Additionally, the studied mine tailing contained fine particles; hence, the mine tailing possessed a potential to be an appropriate raw material for geopolymerization.
The results from sequential extraction demonstrated the low potential environmental risk, as it was found that the main part of hazardous heavy metals was immobilized in the non-labile phase. It could be concluded that the copper mine tailing is a promising precursor for obtaining building products based on the geopolymerization process. Additionally, due to the encapsulation of heavy metals and other environmentally contaminants in the geopolymer matrix, the mobility of hazardous compounds could be expected to be lower in the final geopolymer product [
40].
The chemical composition, the behavior in alkaline media, the leaching characteristics of the studied copper mine tailing, as well as the fractionalization of the potential environmental contaminants demonstrated its high potential for the valorization of the tailings in the form of geopolymer products for building engineering.
5. Conclusions
Copper mine tailings from the Assarel Concentrator Plant (Bulgaria) can be successfully used as precursors for geopolymers. The replacement of 25 wt.% of fly ash with mine tailings promoted better compressive strength. By increasing the replacement of FA with MT to 50 wt.%, a significant decrease in compressive strength can be observed, especially for the mixture with a Na to Al ratio of 1.
From the three mixtures of raw materials, three different liquid-to-solid ratios, and three different Na-to-Al ratios, the system with 75 wt.% FA, 25 wt.% MT, a liquid-to-solid ratio of 0.7, and a Na-to-Al ratio of 1 exhibits the highest compressive strength at 28 days of curing. From a flexural strength point of view, the system with 50 wt.% MT, a liquid-to-solid ratio of 0.7, and a Na-to-Al ratio of 0.75 was optimum, but at a very low difference from the system that also exhibited the highest compressive strength. Therefore, from all nine mixtures, it can be considered that the one that had the highest compressive strength is optimal from a mechanical properties point of view.
The microstructural analysis showed a clear relationship between the homogeneity of the matrix and the mechanical performance of the mixture. Accordingly, it was observed that compact matrixes with fewer cracks and unreacted particles would perform better.