Cement Particle Deagglomeration using Power Ultrasonics
Ultrasonic deagglomeration using probe-type sonicators offers a superior alternative by overcoming these issues. This method eliminates the need for grinding media, simplifies the process by removing the need for post-process filtration and intensive cleaning, and provides efficient particle size reduction in the fine particle range. Additionally, it reduces the reliance on dispersants and utilizes more compact, energy-efficient equipment, making it a highly advantageous solution for cement particle dispersion and deagglomeration.
The Advantages of Ultrasonic Deagglomeration of Cement Particles
Cement is one of the most essential materials in construction, widely used for its binding properties. However, achieving optimal performance requires uniform particle distribution, as agglomerated particles can adversely affect the cement performance. Ultrasonic deagglomeration has emerged as a powerful technique to address this challenge.
Industrial sonicators for high-throughput cement particle deagglomeration.
- Enhanced Particle Dispersion: Ultrasonic deagglomeration effectively disperses cement particles, ensuring a uniform particle size distribution. This uniformity is crucial for achieving consistent strength and durability in cementitious materials.
- Improved Hydration: The increased surface area of deagglomerated particles enhances the hydration process, leading to better bonding and higher strength in the final product. Improved hydration also reduces the risk of incomplete reactions and weak spots in the cement matrix.
- Increased Workability: Well-dispersed cement particles result in a more workable mixture, making it easier to mix, pour, and finish. This improved workability can lead to faster construction times and reduced labor costs.
- Enhanced Mechanical Properties: Ultrasonic deagglomeration contributes to the development of a denser and more homogeneous microstructure in cement-based materials. This results in enhanced mechanical properties such as compressive and tensile strength.
- Reduction in Additive Usage: By achieving better dispersion through ultrasonic deagglomeration, the need for chemical dispersants and other additives can be minimized. This not only reduces costs but also decreases the environmental impact of cement production.
- Cost-Effectiveness: Regardless of the initial investment in an industrial-grade ultrasonicator, the long-term benefits of improved product quality, reduced additive usage, and enhanced performance make it a cost-effective solution for the cement industry.
| Comparative Aspect | Ball Milling for Cement Particles | Ultrasonic Deagglomeration for Cement Particles |
|---|---|---|
| Method | Uses steel or silica balls as grinding media | Uses high-intensity ultrasonic waves to create acoustic cavitation and sonomechanical shear forces |
| Grinding Media Replacement | Frequent replacement of steel or silica balls | No grinding media, eliminating replacement costs |
| Post-Process Filtration | Required to filter out grinding media | Not necessary, simplifying the process |
| Cleaning Requirements | Labor-intensive and time-consuming cleaning of milling media and chamber | Minimal cleaning, ultrasonic probes are easier to maintain |
| Efficiency in Fine Particle Range | Inefficient for particles in the 0 – 100 µm range, time-consuming | Highly effective for fine particle sizes, including the 0 – 100 µm range |
| Dispersant Requirement | High amount of dispersant needed | Reduced need for dispersants due to powerful cavitation and shear forces |
| Equipment Characteristics | Large, bulky, energy-inefficient, requires extensive maintenance and cleaning | Compact, energy-efficient, less maintenance, easier to handle and safe to operate |
Case Study: Microfine Cement Grout Dispersion with Ultrasonic Mixers
The research team led by Draganović presents a comprehensive investigation into the dispersion of microfine cement grout using ultrasound technology in comparison with conventional laboratory dissolvers. The study specifically focuses on the performance of the sonicator UP400St relative to traditional grout dispersion methods.
The researchers conducted a series of experiments employing various dispersion techniques to assess the particle size distribution (PSD) and zeta potential of microfine cement particles. The techniques evaluated include ultrasound treatment with the UP400St sonicator, high-speed laboratory dissolvers, and a combination of both methods.
The findings reveal that ultrasound dispersion using the UP400St sonicator significantly enhances particle size distribution compared to conventional laboratory dissolvers. The sonicator UP400St effectively mitigates the agglomeration of microfine cement particles, producing a more homogeneous and stable grout suspension. Ultrasound treatment improves the distribution of smaller particles, resulting in a narrower particle size distribution range.
The ultrasonic homogenizer UP400St is compared regarding dispersion efficiency of cement grout with an ordinary laboratory mixer equipped with a disk, and using the rotor-stator technique. The study showed that ultrasonic dispersion is not only an effective method but is even better than a mixer using the rotor-stator technique.
(study and graphic: © Draganović et al., 2020)
Furthermore, combining ultrasound with conventional laboratory dissolvers enhances dispersion efficiency, achieving an even finer particle size distribution than ultrasound treatment alone. This combination allows for improved control over the PSD and zeta potential of microfine cement grout in batch operations. In continuous flow systems, the particle suspension automatically passes through the cavitational hot spot zone, rendering additional stirring unnecessary.
The study underscores the superior performance of the sonicator UP400St in dispersing microfine cement grout. Ultrasound treatment, especially when combined with conventional laboratory dissolvers, offers an effective and efficient method for achieving a uniform and stable suspension of microfine cement particles.
This research provides a detailed comparison between ultrasound and conventional dispersion methods, highlighting the superior efficacy of sonication in grout dispersion.
(cf. Draganović et al., 2020)
Compared Dispersion methods: Vma-Getzmann Dispermat CV-3 dissolver equipped with a 90-mm disk and a rotor-stator (R/S) system. Hielscher UP400St sonicator equipped with an H22 sonotrode.<br/>(Study and pictures: ©Draganovic et al., 2020)
Probe-type sonicator UP400ST for micro-fine cement grout dispersion
(Study and image: ©Draganovic et al., 2020)
Applications of Sonicators in the Cement Industry
Utilizing the advantageous effects of high-power ultrasound in cement particle and grout deagglomeration opens numerous application fields in the cement industry allowing for improved material characteristics and final product quality.
- Wet-Milling of Cement Particles: Probe-type sonication is a highly effective and energy-efficient method to mill cement particles. Read more about ultrasonic wet-milling of cement!
- Production of High-Performance Concrete: Probe-type sonicators are used to produce high-performance concrete by ensuring uniform dispersion of fine cement particles and supplementary cementitious materials like fly ash and silica fume. This leads to concrete with superior mechanical properties and durability.
- Development of Nanocomposites: In research and development, probe-type sonicators facilitate the incorporation of nanoparticles into cement matrices, creating nanocomposites with enhanced properties such as increased strength, toughness, and resistance to environmental degradation.
- Optimization of Additive Performance: Ultrasonic deagglomeration helps in optimizing the performance of chemical additives, such as superplasticizers and air-entraining agents, by ensuring their uniform distribution in the cement matrix. This leads to improved workability and performance of the final product.
High-Performance Sonicators for Cement Particle Dispersion and Deagglomeration
Ultrasonic deagglomeration using probe-type sonicators offers significant advantages for the cement industry. By enhancing particle dispersion, improving hydration, and increasing workability, these devices contribute to the production of high-quality cementitious materials. The precise control, scalability, and versatility of probe-type sonicators make them valuable tools for both research and industrial applications, driving innovation and efficiency in cement production.
Hielscher Ultrasonic supplies high-performance sonicators at any power level for processing cement particles and cement grout from smaller lots for Research + Development to high-throughputs for industrial cement deagglomeration on production scale.
- high efficiency
- state-of-the-art technology
- reliability & robustness
- adjustable, precise process control
- batch & inline
- for any volume
- intelligent software
- smart features (e.g., programmable, data protocolling, remote control)
- easy and safe to operate
- low maintenance
- CIP (clean-in-place)
Design, Manufacturing and Consulting – Quality Made in Germany
Hielscher ultrasonicators are well-known for their highest quality and design standards. Robustness and easy operation allow the smooth integration of our ultrasonicators into industrial facilities. Rough conditions and demanding environments are easily handled by Hielscher ultrasonicators.
Hielscher Ultrasonics is an ISO certified company and put special emphasis on high-performance ultrasonicators featuring state-of-the-art technology and user-friendliness. Of course, Hielscher ultrasonicators are CE compliant and meet the requirements of UL, CSA and RoHs.
The table below gives you an indication of the approximate processing capacity of our ultrasonicators:
| Batch Volume | Flow Rate | Recommended Devices |
|---|---|---|
| 0.5 to 1.5mL | n.a. | VialTweeter |
| 1 to 500mL | 10 to 200mL/min | UP100H |
| 10 to 2000mL | 20 to 400mL/min | UP200Ht, UP400St |
| 0.1 to 20L | 0.2 to 4L/min | UIP2000hdT |
| 10 to 100L | 2 to 10L/min | UIP4000hdT |
| 15 to 150L | 3 to 15L/min | UIP6000hdT |
| 15 to 150L | 3 to 15L/min | UIP6000hdT |
| n.a. | 10 to 100L/min | UIP16000 |
| n.a. | larger | cluster of UIP16000 |
Contact Us! / Ask Us!
Hielscher Ultrasonics manufactures high-performance ultrasonic homogenizers for mixing applications, dispersion, emulsification and extraction on lab, pilot and industrial scale.
Literature / References
- Almir Draganović, Antranik Karamanoukian, Peter Ulriksen, Stefan Larsson (2020): Dispersion of microfine cement grout with ultrasound and conventional laboratory dissolvers. Construction and Building Materials, Volume 251, 2020.
- Peters, Simone (2017): The Influence of Power Ultrasound on Setting and Strength Development of Cement Suspensions. Doctoral Thesis Bauhaus-Universität Weimar, 2017.
- N.-M. Barkoula, C. Ioannou, D.G. Aggelis, T.E. Matikas (2016): Optimization of nano-silica’s addition in cement mortars and assessment of the failure process using acoustic emission monitoring. Construction and Building Materials, Volume 125, 2016. 546-552.
- Mahmood Amani, Salem Al-Juhani, Mohammed Al-Jubouri, Rommel Yrac, Abdullah Taha (2016): Application of Ultrasonic Waves for Degassing of Drilling Fluids and Crude Oils Application of Ultrasonic Waves for Degassing of Drilling Fluids and Crude Oils. Advances in Petroleum Exploration and Development Vol. 11, No. 2; 2016.
- Amani, Mahmood; Retnanto, Albertus; Aljuhani, Salem; Al-Jubouri, Mohammed; Shehada, Salem; Yrac, Rommel (2015): Investigating the Role of Ultrasonic Wave Technology as an Asphaltene Flocculation Inhibitor, an Experimental Study. Conference: International Petroleum Technology Conference 2015.
Facts Worth Knowing
What is Cement?
Cement is a fine, powdery substance that acts as a binding agent in construction. When mixed with water, it undergoes a chemical reaction called hydration, hardening into a solid material. It is primarily composed of limestone, clay, shells, and silica, and is a key ingredient in concrete, mortar, and other building materials. The ability of cement to harden and bind other materials makes it essential for constructing buildings, roads, bridges, and other infrastructure. The most common type of cement is Portland cement, which is widely used due to its strength and versatility.
Why is the Deagglomeration of Cement Particles Important?
The deagglomeration of cement particles is important because it ensures a uniform particle size distribution, which enhances the performance and quality of cement-based materials. Proper deagglomeration improves hydration efficiency, leading to stronger and more durable concrete. It also enhances the workability of cement mixtures, making them easier to mix, pour, and finish. Additionally, well-dispersed particles reduce the need for chemical additives, lower production costs, and minimize environmental impact. Overall, effective deagglomeration is crucial for achieving optimal mechanical properties and long-term durability in construction projects.
How are Cement Particles Deagglomerated?
Cement particles are deagglomerated using various methods, with ultrasonic deagglomeration being one of the most effective techniques. In this process, high-frequency ultrasonic waves are emitted by a probe immersed in the cement slurry. These waves create intense cavitation bubbles that collapse with high energy, producing powerful shear forces and shock waves. These forces break apart the agglomerated cement particles, ensuring uniform dispersion. Other methods include mechanical mixing, milling, and the use of dispersing agents, but ultrasonic deagglomeration is favored for its efficiency and ability to achieve fine, consistent particle distribution.
What Role plays Water in Cement Processing?
Water plays a pivotal role in cement processing. It hydrates various minerals in the clinker, which provides the necessary fluidity to the cement paste. However, managing water content is a delicate balance. Excessive water can lead to issues such as bleeding (where water separates from the mix) and reduced compressive strength. Conversely, insufficient water can decrease workability, making the cement mix difficult to handle and resulting in weaker products.
How Do Probe-Type Sonicators Work?
Probe-type sonicators are a specific class of ultrasonic devices designed for dispersing and deagglomerating particles in various suspensions, including cement. These devices use a probe or horn that emits ultrasonic waves directly into the medium, creating cavitation bubbles that implode with high energy, leading to particle deagglomeration.
Probe-type sonicators operate by generating ultrasonic waves typically in the range of 20 to 30kHz. The probe, also called sonotrode, is a rod made from materials like titanium that is immersed into the cement slurry. When activated, the probe vibrates at ultrasonic frequencies, producing intense acoustic cavitation. This cavitation involves the formation and violent collapse of microscopic bubbles in the slurry, which generates powerful shear forces and shock waves. These forces break apart agglomerated particles and promote uniform dispersion.
Hielscher Ultrasonics manufactures high-performance ultrasonic homogenizers from lab to industrial size.