Developing a hollow glass microsphere/geopolymer thermal insulation composite for hot metal surface coating

Abstract

Manufacturing inorganic thermal insulation materials with superior properties such as low thermal conductivity (k < 0.1 W/mK) and high mechanical properties in terms of adhesion strength is critical for energy efficiency in energy-intense industries. Geopolymer-based composites composing of hollow glass microspheres (HGMs), waste fly ash (FA), and metakaolin (MK) were successfully applied on hot (T similar to 300 degrees C) metal surfaces via spray deposition technique. The effect of Si/Al and Na/Al mole ratios and HGM loading on geopolymer composites' physical, microstructural, thermal, and adhesion strength properties were explored. The best composite composition was obtained when Si/Al mole ratio, Na/Al mole ratio, and HGM loading were 2.5, 1.0, and 10 wt %, respectively. This composition achieved an HGM/geopolymer composite material with low thermal con-ductivity (k similar to 0.05 W/mK), high adhesion strength (similar to 5.0 MPa), and high stability under immersion in water and vibration environments (particularly exposed to water). The results showed that HGM/geopolymer composites could be used as a thermal insulation material in energy-intense industries.