Techno-economic analysis of geopolymer production from the coal fly ash with high iron oxide and calcium oxide contents

•The low acid resistance of geopolymer was related to the high iron oxide content.•The heat resistance of geopolymer was better than that of OPC.•Geopolymer production (material use) design improves the economics of the process.•Profitability boundaries were identified regarding geopolymer and Na2SiO3 prices. In this work, we firstly examined the technical feasibility of geopolymer synthesis from the coal fly ash with high iron oxide (48.84 wt.%) and calcium oxide (22.15 wt.%) contents. The heat resistance of geopolymer was represented by the dry weight loss which ranged from 2.5 to 4.9% and was better than that (11.7%) of OPC. However, the high iron oxide content made the acid resistance (13–14%) of geopolymer inferior to OPC. The economics of geopolymer production changes significantly upon the variation in the arrangement of material use and geopolymer price. The costs of Na2SiO3 and NaOH and the benefit of geopolymer selling were the major factors affecting the economic feasibility of geopolymer production. When the Na2SiO3 price was around 400 USD/ton, the geopolymer production will be profitable even if the geopolymer price was as low as 50 USD/ton. It is possible to improve the economics of geopolymer production by varying the arrangement of material use while not impairing the performance of geopolymer.