Porous geopolymer insulation materials and ceramics
Innovative porous geopolymer materials offering fireproof insulation up to 1000°C, with applications in high-temperature environments. Scalable synthesis and reinforcement options with particulates or fibers enhance mechanical properties.
Overview
Porous geopolymer insulation materials and ceramics are cutting-edge solutions designed to offer superior thermal insulation and fire resistance. These materials are made from alumino-silicate geopolymers, which are synthesized like cement but behave like ceramics. The resulting compositions are intumescent, fireproof, and stable up to 1000°C. Beyond this threshold, they transform into crystalline ceramics with melting points ranging from 700°C to 1693°C, depending on the specific composition. The materials can be reinforced with various particulates or fibers, making them suitable for a range of high-temperature applications.
Technical specifications
Porous geopolymers are created by mixing alkali solutions with aluminosilicate metakaolin clay or halloysite, followed by the addition of minor additives to induce porosity. These materials can be further reinforced with sand, mineral fibers, or chopped basalt fibers. The synthesis is scalable and conducted under ambient temperatures, achieving inorganic polymerization within 1-3 days. The composite pastes are robust, outperforming traditional cements, and can be aerated using conventional methods to enhance their properties. Key features include:
- Fireproof and intumescent up to 1000°C
- Ability to transform into crystalline ceramics beyond 1000°C
- Reinforcement options with basalt or wollastonite fibers for enhanced strength
- Scalable production process suitable for large-scale applications
Technology readiness level
The development of these porous geopolymer materials is at Technology Readiness Level 4, indicating that laboratory validation has been achieved. The focus is on optimizing thermal insulation properties and mechanical performance through composite development. Further validation will explore various aerating additives and methods to meet the demanded insulation and mechanical property trade-offs.
About Keanetech, LLC
Keanetech, LLC is a research-based consulting firm specializing in platform technologies that leverage inorganic ceramic-based materials. Founded in 2004 and based in Champaign, Illinois, the company focuses on transitioning fundamental scientific research from the University of Illinois Urbana-Champaign (UIUC) into practical, commercial applications. Their technical expertise encompasses low-energy ceramic powder synthesis, geopolymer design, and the development of high-tech ceramics for various industrial and environmental use cases. Operating a dedicated research and fabrication facility, the team consists of researchers and materials scientists focused on sustainable innovation.
The company's work addresses critical industrial and environmental challenges, such as reducing carbon dioxide emissions, promoting the circular economy, and enhancing agricultural productivity. They develop prototype materials and technologies, including fire-resistant geopolymers for construction, Li-ion battery components, and agricultural supplements like their Gelizer seed booster, which is designed to increase crop yields. By utilizing industrial waste materials as precursors and aiming for low-energy production methods, Keanetech provides sustainable alternatives to traditional materials, serving partners and industries interested in cost-effective, environmentally conscious engineering solutions.
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