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Xi măng hạt Deagglomeration sử dụng 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.

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MultiSonoReactor MSR-5 equipped with 5x 4kW sonicators for the high-throughput processing of cement and calcite particles for reliable deagglomeration.

Industrial sonicators for high-throughput cement particle deagglomeration.

Ultrasonic cement deagglomeration utilizes high-power ultrasound waves to break down particle clusters, offering numerous advantages:

  • 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 Overview: Ball Milling vs. Ultrasonic Deagglomeration for Cement Particles

Comparative Aspect Ball Milling for Cement Particles Ultrasonic Deagglomeration for Cement Particles
phương pháp 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 0100 µm range, time-consuming Highly effective for fine particle sizes, including the 0100 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.
 

Đồng nhất siêu âm cho kết quả tốt nhất cho sự phân tán bệnh gút xi măng Portland khi so sánh với máy trộn phòng thí nghiệm được trang bị đĩa và máy trộn rôto-stato.

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.
(nghiên cứu và đồ họa: © Draganović và cộng sự, 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.
(xem Draganović và cộng sự, 2020)
 

Vữa xi măng siêu mịn là hiệu quả nhất và phân tán đáng tin cậy bằng cách sử dụng sonicator Hielscher UP400S. Trong nghiên cứu so sánh, sonicator loại đầu dò rõ ràng vượt trội so với bộ phân tán rôto-stato và bộ hòa tan đĩa.

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)

 

Vữa xi măng có thể được phân tán hiệu quả đến quy mô nano bằng cách sử dụng sonicator loại đầu dò UP400St.

Probe-type sonicator UP400ST for micro-fine cement grout dispersion
(Nghiên cứu và hình ảnh: ©Draganovic et al., 2020)

 

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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.

Contact us now for detailed information, technical data and case studies! Our technical staff will gladly consult you regarding your process goals!
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Thiết kế, sản xuất và tư vấn – Chất lượng Sản xuất tại Đức

Hielscher ultrasonicators nổi tiếng với chất lượng cao nhất và tiêu chuẩn thiết kế của họ. Mạnh mẽ và hoạt động dễ dàng cho phép tích hợp trơn tru của ultrasonicators của chúng tôi vào các cơ sở công nghiệp. Điều kiện khắc nghiệt và môi trường đòi hỏi dễ dàng được xử lý bởi Hielscher ultrasonicators.

Hielscher Ultrasonics là một công ty được chứng nhận ISO và đặc biệt nhấn mạnh vào ultrasonicators hiệu suất cao có công nghệ tiên tiến và thân thiện với người dùng. Tất nhiên, Hielscher ultrasonicators là CE tuân thủ và đáp ứng các yêu cầu của UL, CSA và RoHs.

Bảng dưới đây cung cấp cho bạn một dấu hiệu về khả năng xử lý gần đúng của ultrasonicators của chúng tôi:

Khối lượng hàng loạt Tốc độ dòng chảy Thiết bị được đề xuất
0.5 đến 1,5mL N.A. LọTweeter
1 đến 500mL 10 đến 200ml / phút UP100H
10 đến 2000mL 20 đến 400ml / phút UP200Ht, UP400ST
0.1 đến 20L 0.2 đến 4L / phút UIP2000hdT
10 đến 100L 2 đến 10L / phút UIP4000hdt
15 đến 150L 3 đến 15L / phút UIP6000hdT
15 đến 150L 3 đến 15L / phút UIP6000hdT
N.A. 10 đến 100L / phút UIP16000
N.A. Lớn Cụm UIP16000

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Siêu âm cắt cao homogenizers được sử dụng trong phòng thí nghiệm, băng ghế dự bị, thí điểm và chế biến công nghiệp.

Hielscher Ultrasonics sản xuất homogenizers siêu âm hiệu suất cao cho các ứng dụng trộn, phân tán, nhũ tương hóa và khai thác trên phòng thí nghiệm, thí điểm và quy mô công nghiệp.



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Xi măng là gì?

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.


Siêu âm hiệu suất cao! Phạm vi sản phẩm Hielscher bao gồm toàn bộ quang phổ từ ultrasonicator phòng thí nghiệm nhỏ gọn trên các đơn vị băng ghế dự bị đến các hệ thống siêu âm công nghiệp đầy đủ.

Hielscher Ultrasonics sản xuất homogenizers siêu âm hiệu suất cao từ phòng thí nghiệm đến quy mô công nghiệp.

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