Environmental risks and upcycling potential in ternary geopolymer development for oily sludge pyrolysis byproducts

Zhong C. Luan C. Guo X. Lin F. Li J. Yan B. Cheng Z. Mamurovich E.A. Bigalievich B.A. Chen G.
April 2026 Elsevier Ltd

Journal of Environmental Chemical Engineering
2026 #14 Issue 2

This study develops a ternary geopolymer system combining fly ash (FA), pyrolysis residue (PR), and ground granulated blast furnace slag (GGBS), designed to simultaneously enhance solidification performance and resource utilization. Unlike conventional binary FA-GGBS or PR-GGBS systems, the deliberate incorporation of PR (silica-rich, lamellar, and organically coated) enables complementary reactivity and microstructural densification, yielding a more robust immobilization matrix. Using a one-step dry-mix alkali activation route, hazardous FA and PR were converted into structural materials exhibiting high contaminant stabilization, including > 99 % Pb immobilization, while maintaining strong early mechanical strength (47.85 MPa at 7 days). Durability testing confirmed resistance to aggressive environments, even at 30 % waste substitution. Life-cycle analysis demonstrated reduced carbon emissions and net economic advantages relative to conventional disposal-based approaches. Mechanistic analysis indicates that the ternary system promotes synergistic stabilization through compact C-(A)-S-H gel formation, physical encapsulation, ion exchange, and metal–silicate bonding. These findings demonstrate that the FA-PR-GGBS ternary framework provides a scalable, low-carbon pathway that simultaneously addresses hazardous waste management and infrastructure sustainability.

Geopolymer , Hydration mechanisms , Material properties , Oily sludge , Solidification/stabilization

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School of Environmental Science and Engineering, Tianjin University/Tianjin Key Lab of Biomass/Wastes Utilization, Tianjin, 300072, China
School of Energy and Power Engineering, Shandong University/Shandong Key Laboratory of Energy Carbon Reduction and Resource Utilization, Jinan, 250014, China
Tashkent Institute of Chemical Technology, Yangiyer Branch, Yangiyer, 123456, Uzbekistan
Institute of Ecological and Biological Resource Sustainability, National University of Kazakhstan, Almaty, 050040, Kazakhstan
School of Mechanical Engineering, Tianjin University of Commerce, Tianjin, 300134, China

School of Environmental Science and Engineering
School of Energy and Power Engineering
Tashkent Institute of Chemical Technology
Institute of Ecological and Biological Resource Sustainability
School of Mechanical Engineering

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