The recycling of SiC sludge material is crucial for resource reutilization and environmental protection. In the current study, the effect of the mass ratio between the Na₂SiO₃ and sodium hydroxide (NaOH) solutions (NS/SS ratio) and the effect of SiC sludge on metakaolin geopolymers was comprehensively investigated to determine the underlying performance of the geopolymerization system. During thermal evolution, the second exothermic peak of 1.6NS10SCS (NS/SS ratio: 1.6, 10% SiC sludge) showed a heat evolution value of 990.6 W/g, which was the highest among other geopolymers. Additionally, the 1.6NS10SCS sample after 28 days of curing showed the highest flexural strength (6.42 MPa), compared to that of the others, and the DTA/TG (differential thermal analysis/thermogravimetry) results showed that the weight loss percentage increased to 14.62% from 400 to 750 °C. For the ²⁹Si nuclear magnetic resonance deconvolution, 1.6NS10SCS exhibited high fractions of Q⁴(3Al) (33.63%), Q⁴(2Al) (23.92%), and Q⁴(1Al) (9.70%). Thus, the geopolymer with the optimal SiC-sludge replacement level and NS/SS ratio contained more macropores and geopolymer gels, which benefit structural development. The experimental results indicated that SiC-sludge can potentially serve as a partial replacement for metakaolin and exhibited favorable mechanic characteristics.

This study uses metakaolin, sodium hydroxide, sodium metasilicate, and water content as the reaction variables in the application of the design of experiment (DOE) method. At the same time, the various component factors and their interactions were analyzed to understand how these factors affect the mechanical properties of a metakaolin-based geopolymer incorporated with SiC sludge (SCSGPs). The results of the statistical analysis showed that the compressive strength of SCSGPs was affected by the Na/Si molar ratio (NSR) (p-level = 0.000 <0.05), the Na/Al molar ratio (NAR) (p-level= 0.000 <0.05), and the interaction between the dissolution rate of Si (DRA). Within the design scope of this study, the maximum compressive strength of SCSGPs and the coefficients of the NSR, the NAR, and the DRA of SCSGPs was evaluated. The multiple regression analysis and the tested coefficient of r² were also studied. The multiple regression analysis models provide an effective reference for the application of SCSGPs.

There are considerable resource reuse and environmental concerns regarding SiC sludge (SiCS) that results from cutting silicon ingots into wafers. In the current study, the effect of the Na₂SiO₃ solution/sodium hydroxide solution (NS/SS) mass ratio and SiCS amount on metakaolin geopolymers was found during geopolymerization system performance. The results indicate that while NS/SS ratio was relatively low, increasing the NaOH content resulted in a sufficient amount of OH⁻ in the system to increase the solubility and hinder polycondensation, as indicated by the bulk density and setting-time results; since the polycondensation was inhibited, the mechanical strength was reduced. This study demonstrated that a geopolymer can be formed from a substitution of 10% SiCS and with an NS/SS ratio of 1.6, and that this geopolymer is a feasible material.