Preparation a High-Performance of Gangue-Based Geopolymer Backfill Material: Recipes Optimization Using the Taguchi Method

Abstract

The strip filling method in underground reservoir needs high strength to achieve the requirements of water storage. In order to address the challenges associated with costly and weak filling materials, this study aimed to develop an economically efficient and high-strength gangue-based geopolymer backfill material (GBGBM). To achieve this, the Taguchi method was employed to design a series of 25 experiments, each consisting of four factors and five levels. This study focused on investigating the effects of different gangue gradation levels, sand ratios, water binder ratios (w/b), and aggregate binder ratios (a/b) on the working characteristics and unconfined compressive strength (UCS) of the GBGBM. The optimal combination of the GBGBM was determined by employing a signal-to-noise ratio (S/N)-based extreme difference and variance analysis. The results revealed that the w/b ratio exerted the most substantial influence on both the slump and UCS. Specifically, when employing a gradation of 50%, a sand ratio of 55%, an a/b ratio of 2.5, and a w/b ratio of 0.64, the slump measured 251.2 mm, the UCS at 3d reached 5.27 MPa, and the UCS at 28d amounted to 17.65 MPa. These findings indicated a remarkable improvement in early UCS by 131.14% and the late UCS by 49.45% compared to gangue-based cement backfill material (GBCBM). Additionally, this study examined the hydration products and microstructures of both GBGBM and GBCBM using X-ray diffraction (XRD), scanning electron microscopy (SEM), and mercury intrusion porosimetry (MIP) analyses. Significantly, the GBGBM exhibited notable advantages over the GBCBM, including a 78.16% reduction in CO2 emissions, a 73.45% decrease in energy consumption, and a 24.82% reduction in cost. These findings underscore the potential of GBGBM as a sustainable and cost-effective alternative to GBCBM.