This study explores the fabrication, structural characteristics, and performance of an innovative porous geopolymer membrane made from waste natural zeolite powder for Pb(II) removal, with potential applications in wastewater treatment. A hybrid geopolymer membrane incorporating polyvinyl acetate (PVAc) (10, 20, and 30 wt.%) was synthesized and thermally treated at 300 °C to achieve a controlled porous architecture. Characterization techniques, including Fourier-transform infrared spectroscopy (FTIR), revealed the disappearance of characteristic C=O and C-H stretching bands (~1730 cm⁻¹ and ~2900 cm⁻¹, respectively), confirming the full degradation of PVAc. Thermogravimetric analysis (TG) and differential scanning calorimetry (DSC) indicated a total mass loss of approximately 14.5% for the sample with PVAc 20 wt.%, corresponding to PVAc decomposition and water loss. Energy-dispersive spectroscopy (EDS) elemental mapping showed the absence of carbon residues post-annealing, further validating complete PVAc removal. X-ray diffraction (XRD) provided insight into the crystalline phases of the raw zeolite and geopolymer structure. Once PVAc removal was confirmed, the second phase of characterization assessed the membrane’s mechanical properties and filtration performance. The thermally treated membrane, with a thickness of 2.27 mm, exhibited enhanced mechanical properties, measured with a nano-indenter, showing a hardness of 1.8 GPa and an elastic modulus of 46.7 GPa, indicating improved structural integrity. Scanning electron microscopy (SEM) revealed a well-defined porous network. Filtration performance was evaluated using a laboratory-scale dead-end setup for Pb(II) removal. The optimal PVAc concentration was determined to be 20 wt.%, resulting in a permeation rate of 78.5 L/(m²·h) and an 87% rejection rate at an initial Pb(II) concentration of 50 ppm. With increasing Pb(II) concentrations, the flux rates declined across all membranes, while maximum rejection was achieved at 200 ppm. FTIR and EDS analyses confirmed Pb(II) adsorption onto the zeolite-based geopolymer matrix, with elemental mapping showing a uniform Pb(II) distribution across the membrane surface. The next step is to evaluate the membrane’s performance in a multi-cation water treatment environment, assessing the sorption kinetics and its selectivity and efficiency in removing various heavy metal contaminants from complex wastewater systems.

This study investigated the attenuation and release behaviour of copper ions using a standard kaolin-silt slurry as the synthetic tailings in a high solids/high salinity application before and after inline flocculation. A homogenous, synthetic tailings slurry was prepared in a 0.6 M NaCl solution and treated in a low-shear mixer by adding Magnafloc^® 336 flocculant. Following the evaluation of morphological properties of both the untreated (UT) and polymer-treated tailings (PT), identical equilibrium tests were performed via the bottle-point method constant concentration technique. The maximum copper ions uptake capacity of polymer-treated tailings was 25% more than the untreated slurry at the equilibrium state in a chemisorption process in which the ions had the capability of binding onto one location on the sorbent, which could be influencing other binding sites on the same sorbent. Polymer treatment resulted in a highly porous structure that exhibited an increased capacity to adsorb and retain copper ions compared to the UT materials. This behaviour indicates the strong binding between the copper ions and active site of the treated tailings particles with greater capability of this material for preserving heavy metal ions within their structure across a wide pH range (2–10) compared to the UT materials. The results advance the fundamental understanding of how inline flocculation can considerably improve the sorption capacity of high solids/high salinity tailings favouring potential long-term rehabilitation purposes at mine closure and the role of sorption and desorption of heavy metal ions’ behaviour play to achieve this goal.

This study examines the geotechnical and hydro-mechanical behaviour of a model slurry used in high-solids, high-salinity applications, both before and after inline flocculation with an anionic polyacrylamide. Initial evaluations showed untreated tailings (UT) with a water content of 107%, void ratio of 2.6, and dry density of 0.711 t/m³, compared to polymer-amended tailings (PAT) with 53% water content, a void ratio of 1.6, and a dry density of 1.069 t/m³. Post-flocculation consolidometer tests revealed a distinct consolidation mode, with PAT showing 60% less settlement within the first 48 h and achieving 50% more free water drainage. Polymer treatment improved consolidation parameters, yielding a lower compressibility index (Cc of 0.74 vs. 1.05 for raw slurry), a higher coefficient of consolidation (Cv of 0.005 cm²/s for PAT vs. 0.0009 cm²/s for raw slurry), and an increased water retention capacity. Additionally, PAT demonstrated a final void ratio of 0.62 compared to 0.51 for the UT sample and an internal porosity characterised by discrete voids, supporting enhanced stability for long-term rehabilitation. These findings underscore the potential of inline flocculation to improve tailings management in saline conditions.