Sonication Enhanced Geopolymerisation
Geopolymers present a promising alternative to traditional cement-based materials, offering environmental, mechanical, and durability advantages. Ultrasonic dispersing is a highly efficient technique to produce geopolymers with excellent material characteristics. Sonication represents a highly efficient mixing method enabling the economical production of high-performance geopolymers in large quantities.
Enhanced Geopolymerization by Power Ultrasound
Geopolymerization necessitates meticulous and vigorous mixing to ensure optimal contact among its components, facilitating complete polymerization. The application of power ultrasound induces intense shear forces, thereby fostering the necessary mixing and homogenization, while concurrently supplying energy conducive to prompt and thorough geopolymerization. Power ultrasound has enhances geopolymerization kinetics by promoting better dispersion of reactants and facilitating the breakdown of agglomerates, leading to improved reaction rates and product quality.
MultiSonoReactor with 16kW ultrasound power for inline geopolymerization on production scale
Ultrasonic mixing and dispersing can promote geopolymerization through several mechanisms:
These ultrasonically induced mechanisms collectively contribute to the enhancement of geopolymerization kinetics and the development of geopolymer materials with improved properties.
Power-Ultrasound for Improved Manufacturing of Construction Materials
Power ultrasound has emerged as a reliable technology for the manufacturing of building and construction materials, including cement, concrete, geopolymers, and other constriction matrials. Ultrasonic processing involves the application of low-frequency ultrasound waves to a liquid or slurry medium, leading to a range of beneficial effects on the material properties and processing characteristics. Researchers and industry professionals have increasingly recognized the potential of ultrasound to improve the performance, efficiency, and sustainability of construction materials. This introduction provides an overview of the applications and advantages of power ultrasound in the manufacturing of building and construction materials.
- Cement: Ultrasonic treatment can enhance the hydration kinetics of cementitious materials by promoting the dissolution of clinker phases and accelerating the formation of hydration products. This results in shorter curing times, improved early strength development, and enhanced durability of concrete structures. Additionally, ultrasound can facilitate the dispersion of additives and supplementary cementitious materials, such as fly ash and slag, leading to more sustainable and environmentally friendly cement compositions.
Read more about ultrasonically accelerated setting and early strength development of concrete! - Concrete: Ultrasonic mixing and curing techniques can improve the workability, strength, and durability of concrete mixtures. Sonication promotes the dispersion of aggregates and reinforcement fibers, reduces the presence of air voids and defects, and enhances the bonding between cementitious matrix and aggregates. This results in concrete with higher compressive strength, enhanced resistance to cracking and degradation, and improved long-term performance in various environmental conditions.
Learn more about the beneficial effects of sonication on the hydration in cement! - Geopolymers: Ultrasonic processing plays a crucial role in the synthesis and curing of geopolymers, which are eco-friendly alternatives to traditional cement-based materials. Sonication promotes the dissolution of aluminosilicate precursors, accelerates the polymerization of silicate species, and enhances the homogenization of reactants, leading to faster curing and superior mechanical properties of geopolymer products. Additionally, ultrasound can improve the rheological properties and workability of geopolymer slurries, enabling the fabrication of complex shapes and structures.
- Other Construction Materials: Power ultrasound has diverse applications in the manufacturing of various construction materials, including mortar, grouts, plaster, and insulation products. Sonication can improve the dispersion of additives, fillers, and reinforcing agents, optimize the microstructure and porosity of materials, and enhance their thermal and mechanical properties. Especially when it comes to the uniform incorporation of nanomaterials, ultrasonic dispersing and geagglomeration contribute to the quality and performance of construction materials in architectural and infrastructure applications.
Read more about the superior dispersion of nanomaterials using sonication!
High-Performance Sonicators for Geoppolymer Production
Hielscher sonicators are capable of producing intense acoustic cavitation, which leads to the formation and collapse of microscopic bubbles in the liquid medium. This process results in highly efficient mixing and homogenization of the geopolymer precursor materials, ensuring uniform distribution of reactants and improving the quality of the final product. Hielscher Ultrasonics industrial ultrasonic processors can deliver very high amplitudes. Amplitudes of up to 200µm can be easily continuously run in 24/7 operation. The continuous processing using an ultrasonic flow cell allows to sonicate large volumes under precisely controlled conditions guaranteeing continuously high quality geopolymerization.
Ultrasound-Dispersers for Geopolymer Synthesis at Any Scale: Hielscher offers a range of ultrasonic equipment with varying power capacities and processing volumes, allowing for scalability and customization according to the specific requirements of geopolymer manufacturing processes. Whether it is laboratory-scale experimentation in batches or industrial-scale inline production, Hielscher sonicators can be adapted to meet the needs of different applications.
Strengths of ultrasonic processing – including enhanced homogenization, accelerated reaction kinetics, particle size reduction, improved mechanical properties, and scalability – make Hielscher a powerful technique for optimizing geopolymer synthesis and advancing the development of sustainable construction materials. Offering strong advantages for geopolymer manufacturing, Hielscher sonicators bring you to the forefront of geopolymer production.
Sonicator UIP16000 for dispersing construction materials such as geopolymers or cementitious materials.
- 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 |
|---|---|---|
| 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 |
| 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
- Feng, D.; Tan, H.; van Deventer, J.S.J. )2004): Ultrasound enhanced geopolymerisation. Journal of Materials Science 39, 2004. 571–580.
- 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.
- Szelag M. (2017): Mechano-Physical Properties and Microstructure of Carbon Nanotube Reinforced Cement Paste after Thermal Load. Nanomaterials 7(9), 2017. 267.
- Peters, S.; Kraus, M.; Rößler, Christiane; Ludwig, H.-M. (2011): Workability of cement suspensions Using power ultrasound to improve cement suspension workability. Betonwerk und Fertigteil-Technik/Concrete Plant and Precast Technology. 77, 2011. 26-33.
- M.G. Hamed, A.M. El-Kamash & A. A. El-Sayed (2023): Selective removal of lead using nanostructured chitosan ion-imprinted polymer grafted with sodium styrene sulphonate and acrylic acid from aqueous solution. International Journal of Environmental Analytical Chemistry, 103:17, 5465-5482.
Facts Worth Knowing
What are Geopolymers and what are they used for?
Geopolymers are inorganic polymers or aluminosilicate materials that are typically synthesized by the alkaline activation of aluminosilicate precursors such as fly ash, slag, metakaolin, or natural materials like volcanic ash. They are formed through a polymeric network of aluminum and silicon oxides, with the alkaline activator playing a crucial role in initiating the geopolymerization reaction.
These materials have gained attention as a sustainable alternative to traditional Portland cement-based concrete due to their environmentally friendly properties and excellent engineering performance.
Geopolymers are used in various applications, including:
Geopolymers – A Green Alternative to Concrete
Geopolymers offer a green alternative to traditional concrete due to several environmentally friendly characteristics. The major advantages of geopolymer as building material in construction include reduced carbon emissions, the utilization of industrial by-products, conservation of energy and water, and its recyclability and durability. As awareness of environmental issues continues to grow worldwide, geopolymers are increasingly recognized as a viable solution for reducing the environmental footprint of construction materials. Sonication is a highly effective mixing technique that allows to produce high-performence geolpolymers economically at large volumes.
- Reduced Carbon Footprint: Geopolymers typically have a lower carbon footprint compared to traditional Portland cement-based concrete. The production of Portland cement involves high-temperature kiln processes, which emit significant amounts of carbon dioxide (CO2). In contrast, geopolymers can be synthesized at much lower temperatures, sometimes at room temperature, resulting in reduced energy consumption and CO2 emissions during manufacturing.
- Utilization of Industrial By-Products: Geopolymers often utilize industrial by-products such as fly ash, slag, and metakaolin as precursors. These materials are often considered waste products from other industries and would otherwise require disposal, contributing to environmental burdens. By incorporating these by-products into geopolymers, not only are they diverted from landfills, but they also reduce the demand for virgin raw materials, further reducing environmental impact.
- Lower Energy Consumption: The production of geopolymers typically requires lower energy input compared to Portland cement. Geopolymerization processes can occur at lower temperatures and may not require the extensive calcination process involved in cement production. This results in reduced energy consumption and associated greenhouse gas emissions.
- Durability and Longevity: Geopolymers can exhibit excellent durability properties, including high compressive strength, low permeability, and resistance to chemical corrosion. As a result, structures made from geopolymers may require less maintenance and repair over their lifespan compared to traditional concrete. This longevity reduces the need for frequent reconstruction or replacement, thereby conserving resources and reducing overall environmental impact.
- Reduced Water Usage: Geopolymer production typically requires less water compared to traditional concrete. The mixing process for geopolymers often involves minimal water content, leading to lower water consumption and less strain on water resources.
- Recyclability and Reusability: Geopolymer materials can often be recycled or reused at the end of their service life. Unlike traditional concrete, which may require significant energy-intensive processing for recycling or disposal, geopolymers can be broken down and repurposed with lower environmental impact.
Hielscher Ultrasonics manufactures high-performance ultrasonic homogenizers from lab to industrial size.