Cement Particle Wet-Milling Using Probe-Type Sonicators
Cement particle wet milling is a crucial process in the production of high-quality cement. The objective is to reduce the particle size to enhance the properties of cement, such as its reactivity and strength. Traditional milling techniques, such as ball milling, have been widely used for this purpose. However, since the significant advantages of ultrasonic wet-milling were discovered, particularly probe-type sonicators replace conventional milling methods. Outperforming other milling techniques, Hielscher sonicators are successfully operated from research at bench-top scale to industrial high-throughput cement production.
Comparison of Cement Dispersion Methods: Vma-Getzmann Dispermat CV-3 dissolver, a rotor-stator (R/S) system and the Hielscher UP400St sonicator.
(Study and pictures: ©Draganovic et al., 2020) Read more about this comparative study here!
Sonicator UIP16000 for milling and dispersing construction materials such as cement, geopolymers or concrete.
Ultrasonic Cement Particle Milling with Probe-Type Sonicators
Probe-type sonicators, also known as ultrasonic homogenizers, utilize high-intensity ultrasound to induce acoustic cavitation in a liquid medium, e.g. a cement slurry. Ultrasonic cavitation generates intense micro-jets, shock waves and shear forces that break down cement particles efficiently. The key advantages of ultrasonic milling include:
- Enhanced Efficiency: Ultrasonic milling is highly efficient in particle size reduction. Acoustic cavitation provides intense local forces that can rapidly disintegrate cement particles without the need for excessive mechanical energy.
- Temperature Control: During ultrasonic wet-milling, the process temperature can be precisely monitored and controlled. This is particularly important for cement particles, as excessive heat can alter their properties.
Read more about temperature control during ultrasonic processing! - Uniform Particle Distribution: Ultrasonic milling ensures a more uniform particle size distribution, improving the quality and performance of the final product.
- No Milling Media: Since ultrasonic milling does not rely on grinding media, there is no need to clean and replace milling beads or balls.
- Scalability: Ultrasonic milling using probe-type sonicators can be scaled completely linearly to any throughput. Available at various power ratings – from bench-top models for research to large industrial ultrasonic homogenizers for high-throughput production – Hielscher Ultrasonics can offer you the ideal sonicator for your wet-milling application.
Comparison of Ultrasonic Milling, Bead Milling, Rotor-Stator Mixers, and High-Shear Blade Mixers for Cement Particle Size Reduction
| Feature | Ultrasonic Milling (Probe Type Sonicators) | Bead Milling | Rotor-Stator Mixers | High-Shear Blade Mixers |
|---|---|---|---|---|
| Efficiency | High | Moderate | Moderate | Low |
| Heat Generation | Low | High | High | High |
| Particle Size Uniformity | High | Moderate | Moderate | Low |
| Contamination Risk | Low (no grinding media) | High (due to grinding media) | Moderate | Low |
| Scalability | High (available in various sizes) | Moderate | Moderate | Low |
| Maintenance | Low (few moving parts, no grinding media) | High (wear and tear of media) | Moderate | Low to Moderate |
| Speed of Processing | Fast | Moderate to Slow | Moderate | Moderate |
| Energy Consumption | Moderate | High | Moderate | Moderate |
| Flexibility | High (various applications) | Moderate (specific to particle size reduction) | Moderate (mixing and emulsifying) | Low (mixing only) |
| Industrial Application | High (widely applicable) | Moderate | Moderate | Low |
Influence of Power Ultrasonication (PUS) on Compressional Strength of Mortar Prisms
High-Performance Sonicators for Cement Particle Wet-Milling
Hielscher high-performance sonicators are ideal for cement wet-milling due to their superior efficiency in reducing particle size through ultrasonic cavitation, ensuring a uniform particle distribution. With precise process control, you can optimize the ultrasonic milling process to your target cement particle size and highest energy efficiency. Additionally, Hielscher sonicators are scalable and versatile, available in both benchtop and industrial models, making them suitable for various production scales from research to high-throughput industrial applications.
Hielscher sonicators are the most sophisticated ultrasonic homogenizers on the market. Take advantage of Hielscher sonicators!
Bench-top sonicator UIP1000hdT for wet-milling of cement particles
- 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 |
|---|---|---|
| 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 |
Probe-type sonicator for micro-fine cement grout dispersion
(Study and image: ©Draganovic et al., 2020)
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 binding material used in construction, composed of a mixture of calcareous, siliceous, aluminous, and ferriferous materials. When mixed with water, it forms a paste that hardens over time, providing structural strength and stability. Cement particles are the finely ground, powdered form of cement that results from milling processes. These particles play a crucial role in the hydration process, which leads to the hardening and strength development of cement in construction applications.
Why is Wet-Milling of Cement Particles Important?
Wet-milling of cement particles is important because it reduces the particle size, enhancing the reactivity and strength of cement. This process improves the uniformity and quality of the cement, leading to better performance in construction applications.
What is Mortar?
A mortar prism is a rectangular test specimen made from a mixture of cement, sand, and water, commonly used in testing the strength and durability of mortar. These prisms are typically created to standardized dimensions and tested in laboratory conditions to determine the compressive and flexural strength of the mortar mix.
What is a Mortar Prism?
Mortar is a construction material composed of cement, sand, and water. Cement acts as the primary binding agent in mortar, giving it adhesive properties when mixed with sand and water. Mortar is used to bond building materials such as bricks, stones, and concrete blocks, filling the gaps between them and providing structural stability. The cement in the mortar hardens and gains strength over time through hydration, creating a solid and durable matrix that holds the other components together.
Hielscher Ultrasonics manufactures high-performance ultrasonic homogenizers for mixing applications, dispersion, emulsification and extraction on lab, pilot and industrial scale.
Hielscher Ultrasonics manufactures high-performance ultrasonic homogenizers from lab to industrial size.