Synthesis of metakaolin-based geopolymer foamed materials using municipal solid waste incineration fly ash as a foaming agent

[Display omitted] •Municipal solid waste incineration fly ash was used to synthesize geopolymer foamed materials.•Municipal solid waste incineration fly ash addition improved the properties of foamed materials.•Stabilizing agent was needed to trap the foam and refine the cells in geopolymer foamed materials.•The high compressive strength of geopolymer foamed materials (4.3–11.9 MPa) was obtained. The existence of metallic aluminum in municipal solid waste incineration fly ash (MSWIFA) makes it challenging to recycle MSWIFA into cement materials because expansion occurs in the resultant matrices. Geopolymer-foamed materials (GFMs) are gaining attention in the field of porous materials due to their high-temperature stability, low thermal conductivity and low CO2 emission. This work aimed to utilize MSWIFA as a foaming agent to synthesize GFMs. The physical properties, pore structure, compressive strength and thermal conductivity were analyzed to assess different GFMs which were synthesized with various MSWIFA and stabilizing agent dosages. X-ray diffraction (XRD) and Fourier transform infrared spectroscopy (FTIR) analysis were conducted to characterize the phase transformation of the GFMs. Results showed that when MSWIFA content was increased from 20 to 50%, the porosity of GFMs increased from 63.5 to 73.7%, and bulk density decreased from 890 to 690 kg/m3. The addition of stabilizing agent could trap the foam, refine the cell size, and homogenize the cell size range. With the stabilizing agent increase from 0 to 4%, the porosity increased from 69.9 to 76.8%, and the bulk density decreased from 800 to 620 kg/m3. The thermal conductivity decreased with increasing MSWIFA from 20 to 50%, and stabilizing agent dosage from 0 to 4%. Compared with the collected data from references, a higher compressive strength can be obtained at the same level of thermal conductivity for GFMs synthesized with MSWIFA as a foaming agent. Additionally, the foaming effect of MSWIFA results from the H2 release. The addition of MSWIFA changed both the crystal phase and gel composition, whereas the stabilizing agent dosage had little impact on the phase composition.