Search Results (8)

This study investigates the effects of varying filler content on the thermal and mechanical performance of metakaolinite-based geopolymer composites designed for thermal energy storage applications. The composites were formulated using a geopolymer binder, combined with a thermally stable filler (ground chamotte) and a thermal energy storage filler (waste steel chips) in different proportions. Chamotte content within the binder matrix (binder + chamotte) ranged from 20 to 40 wt.%, while steel chip content varied from 0 to 40 wt.% of the total composite mass. The thermal properties of the composites were evaluated at room temperature and compared with conventional reference materials, including Ultraboard, chamotte brick, and magnetite brick. Mechanical performance, specifically flexural and compressive strength, was evaluated at room temperature and after exposure to elevated temperatures (800 and 1100 °C), followed by two cooling regimes, slow furnace cooling and rapid water quenching. Microstructural characterization via optical microscopy was used to examine filler dispersion and matrix–filler interactions. The results showed that the thermal effusivity of the optimized composites exceeded that of chamotte brick by more than 50%. The highest flexural (12.68 MPa) and compressive (86.18 MPa) strengths were achieved in the composite containing 20 wt.% steel chips, prior to thermal exposure. Microstructural observations revealed the diverse geometry of the steel chips and arrangement of the chamotte particles. These findings highlight the potential of incorporating metallic waste materials into geopolymer systems to develop multifunctional composites with improved thermal storage capacity and mechanical resilience. Full article

In the present work, the development of geopolymeric materials with Na or K based on industrial kaolin samples, with variable kaolinite content and alkaline silicates, is studied. XRF, XRD, FTIR and SEM-EDS have been used as characterization techniques. Three ceramic kaolin samples, two from Algeria and one from Charente (France), have been considered. In particular, chemical and mineralogical characterization revealed elements distinct of Si and Al, and the content of pure kaolinite and secondary minerals. Metakaolinite was obtained by grinding and sieving raw kaolin at 80 μm and then by thermal activation at 750 °C for 1 h. This metakaolinite has been used as a base raw material to obtain geopolymers, using for this purpose different formulations of alkaline silicates with NaOH or KOH and variable Si/K molar ratios. The formation of geopolymeric materials by hydroxylation and polycondensation characterized with different Si/Al molar ratios, depending on the original metakaolinite content, has been demonstrated. Sodium carbonates have been detected by XRD and FTIR, and confirmed by SEM-EDS, in two of these geopolymer materials being products of NaOH carbonation. Full article

Geopolymers offer a potential alternative to ordinary Portland cement owing to their performance in mechanical and thermal properties, as well as environmental benefits stemming from a reduced carbon footprint. This paper endeavors to build upon prior atomistic computational work delving deeper into the intricate relationship between pH levels and the resulting material’s properties, including pore size distribution, geopolymer nucleate cluster dimensions, total system energy, and monomer poly-condensation behavior. Coarse-grained Monte Carlo (CGMC) simulation inputs include tetrahedral geometry and binding energy parameters derived from DFT simulations for aluminate and silicate monomers. Elevated pH values may can alter reactivity and phase stability, or, in the structural concrete application, may passivate the embedded steel reinforcement. Thus, we examine the effects of pH values set at 11, 12, and 13 (based on silicate speciation chemistry), investigating their respective contributions to the nucleation of geopolymers. To simulate a larger system to obtain representative results, we propose the numerical implementation of an Octree cell. Finally, we further digitize the resulting expanded structure to ascertain pore size distribution, facilitating a comparative analysis. The novelty of this study is underscored by its expansion in both system size, more accurate monomer representation, and pH range when compared to previous CGMC simulation approaches. The results unveil a discernible correlation between the number of clusters and pores under specific pH levels. This links geopolymerization mechanisms under varying pH conditions to the resulting chemical properties and final structural state. Full article

The present study focused on investigating the differences in properties between calcined and milled aluminosilicates with different particle size distributions. Two types of clay, i.e., kaolin and kaolinitic claystone, were subjected to calcination at 750 °C, and subsequent milling to obtain different fractions with distinct particle size distributions. These fractions were then combined with a potassium alkaline activator and quartz sand in a 50:50 weight ratio to form a geopolymer composite. The geopolymer binders were then characterized using a mercury intrusion porosimeter (MIP), scanning electron microscopy (SEM), and a rotary rheometer. Mechanical tests were conducted on the geopolymer composites prepared from aluminosilicates with varying particle size distributions. The findings indicated that aluminosilicates with a finer particle size distribution exhibited higher levels of dissolved aluminum (10,000 mg/kg) compared to samples with coarser particle size distributions (1000 mg/kg). Additionally, as the particle size distribution decreased, the dynamic viscosity of the geopolymer binders increased, while the average pore size decreased. Finally, the mechanical properties of the geopolymer composites derived from both tested aluminosilicates demonstrated a decline in performance as the mean particle size increased beyond 10 µm. Full article

This work presents a 3D off-lattice coarse-grained Monte Carlo (CGMC) approach to simulate the nucleation of alkaline aluminosilicate gels, their nanostructure particle size, and their pore size distribution. In this model, four monomer species are coarse-grained with different particle sizes. The novelty is extending the previous on-lattice approach from White et al. (2012 and 2020) by implementing a full off-lattice numerical implementation to consider tetrahedral geometrical constraints when aggregating the particles into clusters. Aggregation of the dissolved silicate and aluminate monomers was simulated until reaching the equilibrium condition of 16.46% and 17.04% in particle number, respectively. The cluster size formation was analyzed as a function of iteration step evolution. The obtained equilibrated nano-structure was digitized to obtain the pore size distribution and this was compared with the on-lattice CGMC and measurement results from White et al. The observed difference highlighted the importance of the developed off-lattice CGMC approach to better describe the nanostructure of aluminosilicate gels. Full article

In this study, the effect of different types of aluminosilicates on the thermo-mechanical properties of metakaolinite-based geopolymer binders and composites was examined. The metakaolinite-based geopolymer binders and composites were produced from three different types of aluminosilicates (one metakaolin and two calcined claystones) and a potassium alkaline activator. Chamotte was added as a filler, amounting to 65% by volume, to create geopolymer composites. Geopolymer binders were characterized by X-ray diffraction, rotary rheometer and scanning electron microscopy. The mechanical properties, thermal dilatation and thermal conductivity were investigated on geopolymer composites with three different aluminosilicates before and after exposure to high temperatures (up to 1200 °C). The results showed that the geopolymer binders prepared from calcined claystones had a lower dynamic viscosity (787 and 588 mPa·s) compared to the geopolymer binders prepared from metakaolin (1090 mPa·s). Geopolymer composites based on metakaolin had lower shrinkage (0.6%) and higher refractoriness (1520 °C) than geopolymers from calcined claystones (0.9% and 1.5%, 1500 °C and 1470 °C). Geopolymers based on calcined kaolinitic claystones are a promising material with higher compressive (95.2 and 71.5 MPa) and flexural strength (12.4 and 10.7 MPa) compared to geopolymers based on metakaolin (compressive strength 57.7 MPa). Full article

A metakaolinite-based geopolymer binder was prepared by using calcined claystone as the main raw material and potassium as the alkaline activator. Chamotte was added (65 vol%) to form geopolymer composites. Potassium hydroxide (KOH) was used to adjust the molar ratio of K/Al and the effect of K/Al on thermo-mechanical properties of geopolymer composites was investigated. This study aimed to analyze the effect of K/Al ratio and exposure to high temperatures (up to 1200 °C) on the compressive and flexural strengths, phase composition, pore size distribution, and thermal dilatation. With an increasing K/Al ratio, the crystallization temperature of the new phases (leucite and kalsilite) decreased. Increasing content of K/Al led to a decline in the onset temperature of the major shrinkage. The average pore size slightly increased with increasing K/Al ratio at laboratory temperature. Mechanical properties of geopolymer composites showed degradation with the increase of the K/Al ratio. The exception was the local maximum at a K/Al ratio equal to one. The results showed that the compressive strength decreases with increasing temperature. For thermal applications above 600 °C, it is better to use samples with lower K/Al ratios (0.55 or 0.70). Full article

Metakaolinite-based geopolymer binder was prepared at room temperature by mixing calcined claystone and potassium alkaline activator. Various granular inorganic fillers were added, amounting to 65 vol % to form geopolymer composites. The effect of four types of fillers (sand quartz, chamotte, cordierite, and corundum) on the thermo-mechanical properties of metakaolinite-based geopolymer composites were investigated. The samples were also examined by an X-ray diffraction method to determine their phase composition. The pore size distributions were determined by a mercury intrusion porosimeter. The XRD revealed the crystallization of new phase (leucite) after thermal exposure at 1000 °C and higher. Geopolymer binders had low mechanical properties (flexural strength 2.5 MPa and compressive strength 45 MPa) and poor thermo-mechanical properties (especially high shrinkage—total shrinkage 9%) compared to geopolymer composites (flexural strength up to 13.8 MPa, compressive strength up to 95 MPa and total shrinkage up to 1%). The addition of fillers reduced the shrinkage of geopolymers and improved their mechanical properties. The results have shown that the compressive strength tested in situ and after exposure to high temperature are in conflict. Geopolymer composites with the addition of chamotte had the best mechanical properties before and after thermal exposure (compressive strength up to 95 MPa). The average pore size diameters increased with the increasing temperature (from 10 nm to approx. 700 nm). The fillers addition decreased the pore volume (from 250 mm³/g to approx. 100 mm³/g). Full article