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Received: 15 December 2021 Revised: 12 January 2022 Accepted: 12 January 2022

DOI: 10.1111/ijac.14028

REVIEW ARTICLE

A review on the porous geopolymer preparation for


structural and functional materials applications

Haoyang Yu1 Meng-xue Xu2 Chaoni Chen1 Yan He1 Xue-min Cui1

1 Guangxi Key Lab of Petrochemical

Resource Process and Process Abstract


Intensification Technology, School of Geopolymer (also called inorganic polymers) is a kind of amorphous gel mate-
Chemistry and Chemical Engineering,
rial with a 3D structure consisting of SiO4 and AlO4 tetrahedra. It has drawn
Guangxi University, Nanning, P. R. China
2 Guangxi Academy of Sciences, Nanning, international attention due to its environmental friendliness and excellent per-
P. R. China formance. This review covers raw materials, preparation methods, and appli-
cations of porous geopolymer materials with micropore, mesopore, or macrop-
Correspondence
Xue-min Cui, Guangxi Key Lab of Petro- ore. The preparation methods can be divided into five categories: (i) self-forming
chemical Resource Process and Process method, (ii) direct foaming method, (iii) adding filler method, (iv) particles stack-
Intensification Technology, School of
ing method, and (v) other methods. In this paper, different raw materials and
Chemistry and Chemical Engineering,
Nanning, 530004, P. R. China. applications were combined with the preparation methods, and some general
Email: cui-xm@tsinghua.edu.cn conclusions of porous geopolymer were summarized. The applications of porous
geopolymer materials in building materials, adsorbents, porous ceramics, mem-
Funding information
Chinese Natural Science Fund, brane separation, catalyst, pH regulator, and other fields were introduced as well.
Grant/Award Number: 51772055; Guangxi
Natural Science Fund, Grant/Award Num- KEYWORDS
ber: 2016GXNSFGA380003 geopolymer, porous, preparation, structural and functional materials

1 INTRODUCTION materials of the geopolymer, but its rationality is justi-


fied by the comprehensive analysis of leaching experi-
The term geopolymer was introduced by Davidovits in 1978 ments, nuclear magnetic resonance and scanning electron
to describe a cementitious material made from a mixture microscope.6,7
of dolomite, limestone, metakaolin, and alkaline solution, The raw materials used for preparing geopolymer
initially describing the formation process of such materi- could be natural, synthetic aluminosilicate minerals
als similar to the geological diagenesis.1–3 In accordance like metakaolin, clay, bentonite clay, volcanic ash, tuff,
with the theories of Davidovits,2,4 the formation5 process diatomaceous earth, illite, and montmorillonite, or indus-
of geopolymer can be divided into four stages: (i) alumi- trial byproducts such as fly ash, slag, biomass fly ash,
nosilicate mineral powder dissolves in alkaline solution; red mud, waste-glass, bottom ash, and catalyst residue.8–10
(ii) the silicon tetrahedral and the aluminum tetrahedron During the reaction, the mechanical property, thermal sta-
diffuse from the surface of the solid particles to fluid; (iii) bility, acid, alkali resistance, and so forth of the geopolymer
the silicon tetrahedra and aluminum tetrahedral polymer- material improved owing to the unceasing occurrence of
ize to gel; (iv) the remaining reactants dissolve in the gel depolymerization-condensation reaction, many outstand-
phase and the gel phase solidifies into geopolymer after ing performances also gradually manifest. Because of its
rearrangement of particles and dehydration. The polymer- excellent mechanical, structural, chemical, and thermal
ization mechanism has some limitations, for instance, it properties, geopolymer has received extensive attention
fails to explain the real structure of geopolymer, nor can during the last decades, widely used in ceramics, cement,
it demonstrate the existential structure of the unreacted concretes, fireproof materials and high thermal shock

Int J Appl Ceram Technol. 2022;19:1793–1813. wileyonlinelibrary.com/journal/ijac © 2022 The American Ceramic Society. 1793
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1794 YU et al.

refractories, building materials, adhesives, radiation, and porous structure, such as SFM,48–51 DFM (H2 O2 ),26,52–54
toxic waste solidification.10–13 DFM (Others),55,56 AFM,57–59 and so forth. Its appli-
Porous geopolymer is a type of geopolymer, and it has cations involve adsorption mental ions,23,60 building
specific preparation methods and application fields own- lightweight,56,61 building insulation,62,63 adsorption
ing to its internal pore structure. Porous materials are pro- ammonium,64,65 and so on. Metakaolin can also be com-
posed relative to dense materials, a material with a net- bined with fly ash,66,67 biomass ash,30,68 waste glass,69
work structure composed of interpenetrating or closed slag,70,71 and zeolite72 to prepare porous geopolymer
pores and skeletons. It is characterized by low density, low materials.
thermal conductivity, large specific surface area, high spe-
cific strength, large porosity, and light weight. Its poros-
ity is based on the original material to play the unique- 2.2 Fly ash
ness of the porous structure.14 In this paper, the prepara-
tion methods of porous geopolymer can be divided into Fly ashes are fine residues from the combustion of coal
five types: (i) self-forming method (SFM), (ii) direct foam- during the operation of thermal power plants.73,74 Note
ing method (DFM), (iii) adding filler method (AFM), (iv) that 50% of fly ash produced was globally utilized, with the
particle stacking method (PSM), and (v) other methods rest dumped into the sea or landfills.28 The particle sizes in
(OM). The characteristics and applications of different fly ash vary from < 1 µm up to more than 100 µm and the
preparation methods were analyzed. In turn, the prepara- surface area is typically 300–500 m2 /kg.75,76
tion methods in different applications were analyzed and When fly ash was the only source of aluminosili-
so were the effects of different preparation methods on cate reactive materials, there were many methods to
the properties of materials. Currently, porous geopolymer prepare its porous structure, such as SFM,77–80 DFM
is used in constructions15–17 as an alternative to cement (Al),81–83 DFM (H2 O2 ),84,85 PSM,86,87 and so forth. Its
because it can reduce the CO2 emission in cement man- applications involve building lightweight,20,88 adsorp-
ufacturing by 80%.18,19 Porous geopolymers are produced tion mental ions,89,90 building insulation,91 perme-
at temperatures lower than 100◦ C but has the same prop- able concrete,92 and so on. Fly ash can also be used
erties as porous glass and porous ceramics which are pro- with slag,93,94 metakaolin,95,96 red mud,97 biomass
duced at temperatures higher than 900◦ C.20 It can also ash,98 and zeolite 99 to prepare porous geopolymer
be applied to adsorbents,21–23 porous ceramics,24,25 mem- materials.
brane filtration,26,27 catalysts,28,29 pH regulators,30,31 and
other fields.
There have been many reviews of geopolymers in recent 2.3 Slag
years,32–36 and some of them focus on the porous geopoly-
mer. However, the existing reviews of porous geopolymer Slag is also called granulated blast furnace slag, which is
are mostly based on the foam concrete37,38 or the adsorp- a glassy granular material formed when molten blast fur-
tion and immobilization of heavy metals.39–43 Bai et al.44 nace slag is rapidly cooled, usually by immersing in water
summarized porous geopolymer (porosity ≥ 50 vol%) thor- and then ground to improve its reactivity.100,101 It shows
oughly, but mainly analyzed foam geopolymer. So far, the primarily cementitious performance (latent hydraulic
preparations of porous geopolymer and their porous appli- activity) but may show some pozzolanic traits (reaction
cations have not been reviewed. with lime) as well.102 Slag is often used as the admix-
ture to replace part of cement to produce blast furnace
slag cement,103,104 and has a major market share in many
2 RAW MATERIALS OF POROUS countries.105
GEOPOLYMER Slag is rarely used as the only source of porous geopoly-
mer materials. Its porous structure is mainly formed by
2.1 Metakaolin SFM106,107 and DFM (H2 O2 ),108,109 which can be used for
adsorption mental ions110,111 and building lightweight.112,113
Metakaolin is a pozzolanic material which had been used Slag is often used with other geopolymers, such as fly
since 1962 when it was incorporated into concrete for Jupia ash,114–116 metakaolin,117 red mud,16,118 clay,119 and so on,
Dam in Brazil.45 It is generated by the calcination of kaoli- especially with fly ash. This is because the fly ash slag
nite clay at temperatures ranging from 500–800◦ C depend- geopolymer system will form aluminum modified cal-
ing on the purity and crystallinity of the precursor clay.46,47 cium silicate hydrate gels, coexist with aluminum silicate
When metakaolin is the only source of aluminosilicate hydrate gels,120,121 and improve mechanical properties and
reactive materials, there are many ways to prepare its microstructures.122,123
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YU et al. 1795

2.4 Biomass fly ash after foaming by FE-SEM and Brunauer–Emmett–Teller.


In the photo, the geopolymer is transformed into NaA
Biomass ash is the residual ash after biomass combus- zeolite, and the cubic zeolite particles and the zeolite
tion, including rice husk ash,21,98 wood forest ash,68,124 itself are porous.151 Many geopolymer materials have their
coconut ash,125 palm oil fuel ash,126 and so on. Soltan- own porous structure, and porous geopolymer prepared
Hassan et al.125 used only coconut ash by DFM (Al) to pre- by OM usually still own the porous structure.26 However,
pare porous geopolymer insulation material. In other stud- due to the addition of other substances, more and larger
ies, the biomass ash was used with metakaolin,17,127,128 fly pores are produced and carried out relevant applications,
ash,98,129 volcanic ash,130 and the other geopolymer to pre- while ignoring the porous structure of the geopolymer
pare porous materials, which possibly caused by the fact itself. The porous geopolymer prepared by this method
that they are difficult to prepare materials with good prop- has low porosity and small pore size and is often used in
erties separately. adsorption,110,153 and membrane filtration applications.154
DFM, as shown in Figure 1B, has a porous structure due
to the direct addition of foaming agents or surfactants or
2.5 Others both of them, producing or retaining foam inside it, so
it was called DFM. The pore diameter prepared by this
Other aluminosilicates raw materials include natural, method is relatively large and can be directly observed.155
synthetic aluminosilicate minerals such as chamotte Because of surface tension, the surface has a small number
clay,131 clay,73 bentonite clay,132 tuff,133 diatomaceous of circular pores. The internal bubbles may be different in
earth,134 illite and montmorillonite,55 and industrial size and shape due to the squeezing of each other.85 For dif-
byproducts such as red mud,16,135,136 waste glass,137,138 vol- ferent foaming agents, DFM is divided into chemical foam-
canic ash,139,140 bottom ash,141,142 catalyst residue,143,144 ing and physical foaming methods. The chemical foaming
and mining tailing waste sludge residue,137,145,146 The method is divided into DFM (H2 O2 ), DFM (Al), and DFM
sources and types of raw materials are continuously (Others) because of the different substances added, which
widened by scientific studies.147 The selection of suitable respectively represent H2 O2 , Al, or other substances to pro-
raw materials is very important for the properties.18 In gen- duce gas. The physical foaming method is represented by
eral, suitable materials are characterized by the content of DFM (Physics), which means that foam or surfactant is
a sufficient amount of reactive silica and alumina.148 In added instead of producing a gas substance and the foam
some cases, a combination of two minerals, as well as vari- or gas mixed by physical stirring is retained in the mate-
ous preprocessing such as energetic grinding or preheating rial. The porous geopolymer prepared by DFM has a lower
of the starting materials, would be beneficial to improve density, larger porosity, and smaller thermal conductivity,
the reactivity and achieve desired properties.149,150 and is often used in building insulation,70,156 and building
lightweight.113,157
AFM, as shown in Figure 1C, has a porous structure
3 PREPARATION OF POROUS because of added porous filler or materials, so it was called
GEOPOLYMER add filler method. The porous structure in this method is
the pores structure of the filler itself, rather than the forma-
There are five methods to prepare porous geopolymer, as tion of geopolymer or between the filler and geopolymer.
schematically illustrated in Figure 1: (i) SFM, (ii) DFM, (iii) The method can select different fillers with excellent prop-
AFM, (iv) PSM, and (v) OM. The pores sources are respec- erties and mix them with geopolymer to improve proper-
tively, between the particles themselves, the introduction ties. It is widely used in different fields because of the dif-
of gas, the addition of materials, free space after accumu- ferent properties of mixed fillers.158,159
lation, and so forth. PSM, as shown in Figure 1D, its porous structure is
SFM, as shown in Figure 1A, is called SFM because formed due to the stacking of particles; geopolymer can-
its porous structure is self-contained and no substance is not occupy all space outside the aggregate. The porous
added. The porous geopolymer prepared by this method is structure is formed in geopolymer or between aggre-
difficult to directly observe its porous structure due to its gate and geopolymer. The pore diameter is related to
small pore size. When observed by electron microscopy, it the size of aggregate added, which is generally large and
can be seen that the material is composed of many regu- can be observed directly.87,160 Aggregates can be large
lar or irregular particles. Deng et al.152 used field-emission or small, one kind or more, and the amount of aggre-
scanning electron microscopy (FE-SEM) to observe the gate can affect the structure of the pore. The porous
mesoporous structure in the geopolymer material, and geopolymer prepared by this method is generally with
Tang et al.108 also compared the geopolymer before and good permeability and good mechanical properties and
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1796 YU et al.

FIGURE 1 Schematic diagram and photos of the preparation method of porous geopolymer26,63,87,151

is mostly used in porous pavement161 and permeable


concrete.118
In addition to the traditional preparation methods of
porous geopolymers mentioned above, the methods that
have emerged in recent years are classified as OM, includ-
ing 3D printing technology,24,162 adding water-soluble
pore-forming agent,163 the mixing of several methods,164
and so forth. Note that 3D printing technology can be
used to generate complex, non-random pore structures,
adding a water-soluble pore-forming agent can easily form
an open pore structure, which cannot be obtained by tra-
ditional techniques.
Preparation of porous geopolymer spheres has become
a new alternative to bulk porous geopolymer.14,165 Porous
spheres have the advantages of large specific surface area
and low flow resistance due to their unique structure.108 F I G U R E 2 Raw material and room temperature process to
Compared with the difficulty of separation of powder and reduce energy consumption125
the small specific surface area of bulk, microspheres have
more application advantages in adsorption. The prepara-
tion method of porous spheres is mainly based on the used primary power, and 75% of electric power genera-
suspension and solidification method, and the main for- tion come from the building industry,167,168 which brings
mation of the porous structure is SFM and DFM. Shan resources, energy, and environmental issues and becomes
et al.166 used amino acid as a pore-forming agent to prepare a serious obstacle to sustainable development. Contrary
enzyme-loaded porous geopolymer spheres, and its degra- to the manufacturing of traditional Portland cement, the
dation rate for Congo Red reached 94.78%. At the same production of geopolymer is not energy-intensive and con-
time, the geopolymer spheres exhibited good reusability in sumes minimal natural resources.169 Raw materials are
the degradation cycles. Novais et al.30 pored geopolymer usually selected from landfill waste materials170 and natu-
spheres by DFM and used it as pH buffer material. ral minerals, and the manufacturing process is conducted
at ambient or slightly elevated temperatures, with great
4 POROUS GEOPOLYMER potential to reduce CO2 emissions and natural resources
APPLICATIONS consumption,171,172 as shown in Figure 2.
In construction fields, the main preparation methods are
4.1 Building field DFM, AFM, and PSM. Application in the field of build-
ing, air pores of porous geopolymer significantly reduce
Traditional Portland cement is widely used in the build- the thermal conductivity and sound velocity through the
ing field. Note that 50% of total CO2 emissions, 40% of walls and act as a thermal and sound insulator.173 Lighter
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YU et al. 1797

F I G U R E 4 Thermal conductivity-density for building


F I G U R E 3 Thermal conductivity-compression strength for insulation56,62,63,66,68,70,85,91,97,112–114,125,129,137,139,143,144,156–158,169,178,181–187
building insulation56,62,63,66,68,70,85,91,112–114,125,129,137,139,143,144,156–158,169,
178,181–185

position of H2 O2 can be an unrestrained reaction in a


highly alkaline environment of geopolymer resulting in
building decreases the dead load of the building and a porous matrix with undesirable coarse voids,62 which
reduces the construction periods and costs.173–175 Com- affects the durability, mechanical properties, and thermal
bined with the aggregate, the porous geopolymer contains insulation properties of samples. Therefore, many papers
continuous pores and has high water permeability to form have explored the pore size distribution and uniformity
permeable concrete. of DFM (H2 O2 ).128,188 Because the foam will be layered
Globally, buildings constructions should be responsi- according to density, the foams on the top are lighter and
ble for approximately 40% of total world annual energy the pores are larger, while the foams at the bottom are heav-
consumption.176 Space heating and cooling are the main ier and the pores are smaller. The ultrasonic pulse velocity
energy end-uses.177 An attractive option is the incor- in different directions of cubic samples is used to compare
poration of thermal insulating materials which signifi- the uniformity of pore distribution.62 In Figure 4, the data
cantly reduces energy consumption and improves energy of DFM (H2 O2 ) are basically distributed near the yellow
efficiency.178 Polymer materials such as polystyrene and line. It means that when H2 O2 is used as a foaming agent,
polyethylene are very popular materials for insulation and the thermal conductivity and density have a greater corre-
make up almost half of the market.137 The lower ther- lation. Pores increase will reduce the density and affect the
mal conductivity of organic materials such as polystyrene thermal conductivity. But different materials, opening and
(0.029 W/(m•K)) and polyurethane (0.026 W/(m•K)),179 closing pores, and the size of pores also influence the ther-
has limited the application of inorganic insulating mate- mal conductivity which indicates that density is not the
rials. However, organic materials have a long service life only variable affecting it.
and limited options for reuse. They are usually land-filled DFM (Al) has no obvious rule in Figure 4. There
or incinerated63 to decompose toxic components and pol- are many data above and below the yellow line, which
lute the environment. is widely distributed. However, in the red box area of
Geopolymer thermal insulation material is usually pre- Figure 3, many DFM (Al) test data are distributed. On the
pared by DFM or AFM. According to the Knudsen effect,180 one hand, it means that many DFM (Al) samples have
the smaller the pore sizes are, the lower the thermal con- high thermal conductivity. On the other hand, it means
ductivity is. Generally, the air thermal conductivity is 0.002 that many samples do not have good compressive strength
W/(m•K) within the pore sized <50 nm, 0.015 W/(m•K) when the thermal conductivity is high. However, Lynch133
within the pore size between 50 nm and 50 µm, and 0.026 found that DFM (Al) found better pore size distribution
W/(m•K) within the pore sized >50 µm 85 . than DFM (H2 O2 ) for zeolite-based geopolymer. The pore
It is generally believed that H2 O2 has better performance structure of DFM (Al) is similar to that of DFM (H2 O2 ), and
than other foaming agents.91 Therefore, DFM (H2 O2 ) has there may be different choices from different perspectives.
been mentioned in many articles, and its thermal conduc- Aluminum powder is commonly used in traditional con-
tivity is less than 0.5 W/(m•K). In Figure 3, the data of crete. Compared with concrete, in the geopolymer system,
DFM (H2 O2 ) are widely distributed and irregular. Decom- the reaction is faster and more efficient, and more bubbles
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1798 YU et al.

are entrapped in the fresh material.144 Adding aluminum superb workability and lighter weight of building struc-
powder can reduce the time of reaching the peak temper- tures. The less amount of binder and fillers used, the
ature and cure faster, which is important for production, lower transportation costs and construction time is.134
transportation, and storage.178 Due to the high environ- Lightweight porous cement materials have been used as
mental and economic impact of aluminum powder, a ton of substitutes for normal weight concrete for more than
pure aluminum requires 15 000 kWh of heat and electrical 100 years.113 At present, large-scale lightweight building
energy and produces 5 tons of residues, so residual metallic materials and components prepared by lightweight porous
aluminum is chosen as a substitute to further reduce CO2 cement have been widely used in many civil and structural
emissions.143,144 Aluminum powder and residual metallic engineering fields.157 Compared with lightweight porous
aluminum are classified as DFM (Al). cement-based materials, geopolymer lightweight materials
In addition to H2 O2 and Al, foaming agents such as Si, should have more promising application prospects because
SiC, silica fume, and sodium silicate can also be used to of the low production energy consumption and CO2 emis-
prepare porous thermal insulation materials by chemical sions.
reactions. A few articles have used them and they are rep- The main preparation methods of making Lightweight
resented in DFM (Others) in Figures 3 and 4. geopolymer are DFM (H2 O2 ), DFM (Al), DFM (Others),
In Figure 3, the two green box areas are obviously dis- DFM (Physics), and AFM.63,129,158,181 As shown in Figure 6,
tributed with a lot of test data prepared by DFM (Physics). DFM (H2 O2 ), DFM (Al), and DFM (Physics) are densely
The green box areas indicate that the samples prepared distributed in black, red and green boxes, which mean that
by DFM (Physics) have lower compressive strength or the density and compressive strength of samples prepared
higher thermal conductivity than those prepared by OM. by their methods increase gradually in general. The sam-
In Figure 4, many samples prepared by DFM (Physics) ples prepared by AFM are greatly influenced by aggre-
are distributed in the green box areas, which means that gates, but the compressive strength of samples prepared
the thermal conductivity of the samples prepared by DFM by appropriate lightweight aggregates is higher than that
(Physics) is higher than those of OM and may be less suit- of samples prepared by OM with the same density, shown
able for the preparation of thermal insulating materials. in the pink box.
In DFM (Physics), surfactants with a typical amphiphilic There are many factors affecting the density of materials.
structure are used, which reduces surface tension and pro- On the one hand, it depends on the nature of raw materials
motes interfacial formation.189 A large amount of gas is of geopolymer. On the other hand, the density of materi-
mixed into the interface by mechanical stirring. The bub- als can be changed to some extent by the means of differ-
ble size formed by this method is changed by slurry den- ent kinds and quantities of activators, DFM and AFM. In
sity, interfacial tension, amount of introduced gas, and DFM, the addition of foam decreases the density owing to
other factors, most of which are closed pores with uniform the pore volume.129 Sanjayan found that using more liquid
size.190 However, due to the demand for more water, the alkali activators could make the material achieve a lower
performance is relatively poor and the strength is low.91 density.194 DFM (Physics) can be used for the load-bearing
AFM is used to prepare thermal insulation materials wall because of its low bubble volume and relatively high
by adding some aggregates, such as cork,158 sawdust,97 strength. Therefore, the lightweight geopolymer material
polystyrene particles,181 expanded polystyrenes,63 highly is not the lower density, the better, and should be com-
porous siliceous materials,134 and so on. The lowest ther- bined with compressive strength and application. Accord-
mal conductivity geopolymer insulation material is pre- ing to the actual needs, materials with different densities
pared by AFM,181 as shown in Figure 5. The insula- and compressive strength are selected. In AFM, the selec-
tion materials produced by AFM have better compressive tion of lightweight aggregates such as recycle lightweight
strength at the same thermal conductivity, shown as the block,195 expanded polystyrene,63 cold bonded lightweight
data in the pink circle in Figure 3. This is because the added aggregate,196 and oil palm shell197,198 can effectively reduce
aggregate itself may have excellent thermal insulation the density. The density and compressive strength of the
properties. Expanded polystyrene has low thermal con- materials prepared by different methods are analyzed.
ductivity, high durability, and low cost. Waste expanded Pervious concrete is a special concrete prepared by PSM
polystyrene is difficult to decompose and recycle but can that contains continuous voids and possesses high water
be reused as filler.63 In the case of using cork as aggregate, permeability compared to normal concrete 160 . Generally,
the thermal conductivity of the heat insulation material is it consists of a binder, water, and coarse aggregates. The
only 0.072 W/(m•K).158 size of connected pores is 2–8 mm, with void content
The density of lightweight porous materials is usu- between 15% and 35%, and compressive strength ranges
ally 10–50 % of that of compact materials.157 Lightweight from 2.8 to 28.0 Mpa.160 Geopolymer binder can replace
porous materials not only have low density but also with cement that releases a large amount of greenhouse gas
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YU et al. 1799

FIGURE 5 Prepare thermal insulation materials by adding filter method (AFM)

aggregates, the relationships are similar to those of conven-


tional pervious concrete, but there are significant losses in
strength.160
Pervious material is applied to the road by PSM to
reduce the risk of flash floods199 and is initially treated
by filtration to improve the quality of rainwater. It can
be used as a part of an effective stormwater management
strategy200 to collect, store, treat, redistribute and recycle
water.201 Compared to cement pervious concrete, the 28d
compressive strength of the geopolymer-based ones was
only lower by 5%, while the removal of heavy metal ions
increased by 33%–120% by good adsorption.118 As a novel
and environment-friendly surface material, the rainwater
is preliminarily treated through filtration which is trans-
ferred to the underground, and conduct secondary treat-
F I G U R E 6 Density-compressive strength for building
insulation produced using different preparation method15,16,56,
ment below the surface phytoremediation via the extensive
62,63,66,68,70,85,91,97,112–114,125,126,128,129,137,139,141,143,144,156–158,169,178,181–187,191–194 rooting systems of trees,161 as shown in Figure 7.
When a porous geopolymer material is used for sound
adsorption after sound waves enter into it, diffuse reflec-
to the atmosphere to prepare a geopolymer-based per- tion or refraction is enhanced and the vibration of the
vious concrete. The relationships between the density- pore wall increases, so the sound waves are attenuated
void content, compressive strength-density, and compres- effectively.202,203 Therefore, the higher the open void ratio
sive strength-void content were formulated and similar to is, in general, the greater sound adsorption coefficients
those of the conventional pervious concrete, and could in the whole range of frequencies.204 It can be prepared
be used for fabricating pervious concrete with geopoly- by DFM, AFM, and PSM. Interlocked needle-like mul-
mer binder.87 Replacing natural aggregates with recycled lite crystals not only enhance the porosity but also enable
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1800 YU et al.

FIGURE 7 Preparation of pervious geopolymer pavers161

the pores to constitute a good network structure and metal ions in water, so this part is about the adsorption
improve the sound-adsorption performance of the porous of metal ions by geopolymer. The methods of removing
materials.205 After the addition of silica fume, the bubbles metal ions in water include precipitation as hydroxides,
were formed and attempted to escape from the paste to electro-dialysis, coagulation-sedimentation, reverse osmo-
the air, resulting in expansion, producing a porous struc- sis, ion-exchange, ultra-filtration, and adsorption.209,210
ture, improving the open void porosity, and increasing the The adsorption method has been widely used because of
sound adsorption. Increasing the temperature can shorten its low cost, ease to use, simple equipment, high efficiency,
the solidification time, increase the porosity and improve and environmental protection.211,212 However, the most
the sound adsorption.205 Using a coarser aggregate, its widely used adsorbent, activated carbon, has the shortcom-
irregular surface develops a more tortuous internal struc- ings of limited adsorption capacity and high cost.213 There-
ture, forms tortuous paths, dissipates sound energy, and fore, researchers are looking for low-cost adsorbents with
increases the sound adsorption effect.86 high adsorption capacity.214,215 In recent years, more and
more attention has been paid to effective adsorption90,206
and immobilization216,217 of metal ions by geopolymers.
4.2 Adsorbent field In Figure 8, recent studies on metal ion adsorption by
geopolymer are summarized. It is found that the adsorp-
4.2.1 Adsorption metal ions tion of metal ions by geopolymers is more concentrated
on Cu and Pb ions. But in general, the adsorbed ions
Heavy metal pollution has been at a critical level with are widely distributed in the main-group I, II, IV, and
the rapid development of industrial society.206 Excess V, sub-group I, II, VI, VII and eight-group of the peri-
heavy metals in water and soil can enter the human body odic table of elements. It shows that geopolymer mate-
through food and water207 and accumulate, causing dam- rials can be widely used to adsorb different ions, but it
age to the kidney, liver, and nervous system.208 In practical also means that geopolymer adsorbents may not have good
processes, it is necessary to remove excessive non-heavy adsorption selectivity. Because of the great difference in the
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YU et al. 1801

F I G U R E 8 Adsorption of metal ions with different FIGURE 9 Adsorption of metal ions with different shapes
pore-forming methods13,23,60,71,72,90,108,110,111,115,132,140,146,153,210,218–234 13,23,60,71,72,90,108,110,111,115,132,140,146,153,210,218–234

relative atomic mass of different atoms, the elements have


a great influence on the adsorption quality. Therefore, the
molar adsorption capacity is used to compare different ele-
ments in Figure 8. Although there are great differences in
raw materials and environments used in different articles,
there are still no obvious rules for several ions with larger
adsorption moles, such as Ca, Mg, Cu, Pb, and Ni, which
also indicates that geopolymer adsorbents may not have
good adsorption selectivity.
As adsorbents for porous geopolymer, there are two
methods to form the porous structure in the literature,
SFM and DFM (H2 O2 ), as shown in Figure 8. Most of
them use SFM to adsorb, and a few articles use DFM. The
adsorptive properties of different pore-forming methods
vary greatly and show no distinct disciplines.
Adsorption capacity is affected by many factors, such as
the amounts of adsorbents, pH, temperature, time, con-
centration, the flow rate of dynamic adsorption, and so
on. Apart from these factors, how can we prepare adsor-
bents with larger adsorption capacity? Fly ash90,146,222 and
slag108,110,111 are often used as raw materials in the reference
with large molar adsorption. Different sizes of geopoly-
F I G U R E 1 0 Porous geopolymer microspheres for the
mers were obtained by ball milling. Beniz et al.222 found
adsorptive removal of Pb2+108
that the smaller the particle size of geopolymer is, the
higher the surface activity and the better adsorption perfor-
mance are. However, in Figure 9, through the summary of lem of continuous wastewater treatment, but as a result
the adsorptive moles of different shapes of adsorbents, no of the contact with wastewater during membrane filtra-
rule was found that the smaller the adsorbent is, the greater tion, a large number of active sites cannot be used.234
the adsorptive capacities are. It is estimated that due to Tang et al.108 prepared microspheres by suspension disper-
many factors affecting adsorption, the same materials will sion solidification method, which can be used for contin-
have a better comparison in the same environment. For uous treatment of wastewater and have good adsorption
different forms of adsorbents, in practical applications, the performance, and the Desorption ratio and regeneration
powder samples cannot be treated continuously because of ratio of adsorbents were 62% and 51% for EDTA-2Na. as
their small particle size, which is difficult to separate and shown in Figure 10. Ge et al.206 compared porous geopoly-
recover.108 Membrane materials are used to solve the prob- mer spheres with other commercial adsorbents and found
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1802 YU et al.

F I G U R E 1 2 Adsorption capacity and removal rate after


FIGURE 11 Adsorption of dye with different pore-forming multiple regeneration cycles124
methods

ity of methyl violet 10B dye was 276.9 mg/g, the adsorp-
that geopolymers showed stronger adsorption capacity for tion capacity of other materials for different dyes was
Cu(II). 10–60 mg/g. Novais et al. found that when the porosity
Through the studies of different geopolymer raw mate- increased, the adsorption capacity could even be increased
rials and metal ions, scholars generally believe that by three times. The adsorbent could be regenerated cycli-
the adsorption kinetics accords with the pseudo-second- cally without affecting the performance.124
order kinetic model.23,71,108,111,206,210,226,230 It means that The formation of dyes adsorbed by porous geopolymer
the adsorption rate is controlled by the adsorption is similar to that of metal ion adsorbent, mostly SFM or
mechanism.108 The adsorption isotherm conforms to DFM (H2 O2 ). Shu Yan et al. used AFM to improve the
the Langmuir isotherm model.23,108,206,210,226,230,233 This adsorption performance by adding porous gangue micro-
means that the adsorption process can be described spheres, but the adsorption capacity of methylene blue was
as a monolayer surface adsorption, all adsorption sites only 24.6 mg/g.243 However, Yi Liu et al. applied fly ash by
are the same, and the adsorbed ions are completely DFM (H2 O2 ) to prepare samples, and the adsorption capac-
independent.236 For desorption of adsorbents, the solution ity of methylene blue reached 50.7 mg/g.192 For different
containing Na ion has a better desorption effect.60,108,210 forms of geopolymers adsorbing different dyes, this part
includes powder, bulk, sphere, and cylinder adsorbents.
Novais et al. used fly ash as raw material by DFM (H2 O2 )
4.2.2 Adsorption of dye as bulk and spherical materials to adsorb methylene blue
dye. The adsorption capacity of spherical geopolymer was
Dyes are widely used in textiles, pharmaceuticals, food, 30.1 mg/g244 was significantly higher than that of bulk
plastics, tires, automobiles, electroplating, and other geopolymer, which was 15.4 mg/g124 and the adsorption
industries.237 When dye-containing wastewater is dis- removal rate is not lower than 83% in nine cycles, as shown
charged improperly, the wastewater will pass through the in Figure 12.
water treatment stations and pollute natural waters. Toxic The results of adsorption kinetics and isotherms are con-
and usually carcinogenic dyes will cause extensive damage sistent with those of metal ion adsorption. The adsorption
to the human body.238 Removal methods of dyes include kinetics accords with pseudo-second-order kinetic model
aerobic and anaerobic microbial degradation, coagulation and adsorption isotherm accord with Langmuir isotherm
and chemical oxidation, membrane separation, electro- model.240,241,243 Salehi and Kani242 found that the higher
chemistry, softening and reverse osmosis, filtration, and the degree of order of Si-O-Si bond in its molecular struc-
adsorption.239 Adsorption is considered to be one of the ture is, the lower the negative charge density is, and the
most effective, simplest, and most economical methods.124 higher adsorption selectivity for OH– is, the stronger the
In Figure 11, recent studies on dye adsorption by adsorption capacity of geopolymer materials for cationic
geopolymer are summarized. Geopolymers have good elements and cationic dyes is. The regeneration of geopoly-
adsorption for methyl violet,21 methylene blue,240 crys- mer adsorbents after the adsorption of dyes shows that
tal violet,241 basic violet, and malachite green oxalate they still have good adsorption capacity. Even if the maxi-
dyes.242 Barbosa et al.21 found that the adsorption capac- mum adsorption capacity of recycled material is 20.5 mg/g,
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YU et al. 1803

it is larger than the adsorption capacity of 15.4 mg/g when ety of applications.139 However, the cost of raw materi-
used the first time.124 The authors believe that the heat als of porous ceramic is high, and almost all the tradi-
treatment in the process of regeneration will lead to an tional fabrication methodologies involve high-temperature
increase in permeability, porosity, and active sites. At the treatment.253 Therefore, the high cost limits the applica-
same time, Salehi and Kani242 believe that the higher tions. The natural porosity of geopolymer and the simplic-
adsorption capacity after regeneration is related to the pore ity of synthesis methods254 make geopolymers an econom-
structure and the Si-O-Si bond of the materials. At present, ical porous ceramic material.255,256
there is still no convincing evidence about the structure of Geopolymer has the advantages of low-temperature cur-
geopolymer and their influence on adsorption. ing and no sintering, but in high-temperature applica-
tions, high-temperature sintering is still needed to pre-
pare geopolymer-based porous ceramics. Because chem-
4.2.3 Adsorption of other substances ical reaction (alkaline activation) and consolidation can
partially replace the sintering process, the preparation
Fossil fuel combustion increases atmospheric CO2 and temperature of porous geopolymer ceramics may be lower
produces the greenhouse effect, so it is necessary and than that of ordinary materials.139 Geopolymer itself has
urgent to take actions to reduce CO2 emissions or cap- a pore structure, and there is no need to add any addi-
ture CO2 in the atmosphere.245 Capturing CO2 is a fea- tives or fillers in the preparation of its porous ceram-
sible measure to reduce the greenhouse effect because ics. However, pore size or porosity can be increased by
it can be accomplished downstream without substantial adding pore-forming or other materials. By adding pore-
changes to existing processes and facilities.246,247 Geopoly- forming agents, the geopolymer-based porous ceramic
mer has been applied to CO2 adsorption because of its low has a pore size of 300–500 µm,25 which is much larger
cost and excellent adsorption performance. The adsorp- than 10–30 µm without any pore-forming.69 By combin-
tion capacity of metakaolin-based geopolymer for CO2 is ing with organic polymer materials, geopolymer ceram-
obviously better than that of other light gases. The selec- ics can obtain more morphology and porosity, and also
tivity of adsorption is CO2 /N2 = 200 and CO2 /CH4 = 100 broaden the applications of heat treatment by adding
in the adsorption test.245 Composite materials were pre- ceramic fillers,252 as shown in Figure 14. Romero24 found
pared by mixing metakaolin with zeolite Na13X. Due to the that the alkali ions in the porous ceramics can affect its
huge interaction between phases, the adsorption capac- chemical and thermal stability, and its function can be fur-
ity of CO2 was larger than the average adsorption capac- ther improved by ion exchange. The alkali ions can also
ity of the two components.159 The blocks with sufficient be ion-exchanged with ammonium ions to form alkali-free
mechanical strength, retractable, porous, and easy to han- ceramics.
dle are prepared by the same method, which can adsorb up
to 3.1% CO2 .248
Nitrogen is the main factor of water nutrition.249 Aque- 4.4 Membrane separation field
ous nitrogen generally exists in the form of ammonium
(NH4 + ), which is likely to be the most serious kind of nitro- Membrane separation processes have found wide appli-
gen from the viewpoint of eutrophication.65 Using fly ash cations in various fields, using the membrane to selec-
as raw material to synthesize P1 zeolite, the adsorption of tively separate two or more components through driv-
NH4 + can reach 22.9 mg/g.250 Luukkonen et al.65,249 took ing force (pressure, concentration, temperature, or elec-
advantage of metakaolin-based geopolymers to remove trical potential gradient).107 It holds many advantages,
ammonium from water, as shown in Figure 13, even in con- such as simple operation, high efficiency, no phase tran-
tinuous small-scale field experiments of landfill leachate, sition, energy conservation, convenient use, small equip-
further demonstrated that the material removed NH4 + in ment size, low pollution, and continuous operation.257–259
the presence of competitive ions and at low temperatures. Compared with organic membranes, inorganic ones are
capable of withstanding high temperature, chemical corro-
sion, organic solvents, long service life, high strength, and
4.3 Porous ceramics field good antimicrobial properties. However, due to the unfa-
vorably high manufacturing cost and difficulties in han-
Porous ceramics display good insulating properties, resis- dling, the industrial utility of inorganic membranes is rare
tance to aggressive environments,251 and organic solvents. in water treatment.260 The geopolymer membrane has the
Furthermore, they demonstrate high-temperature resis- advantages of inorganic ones and is easy to prevail at a
tance, excellent mechanical strength, and good structural larger scale for their low raw material cost and mild prepa-
stability,252 making them the first choice for a wide vari- ration conditions.26
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1804 YU et al.

F I G U R E 1 3 The landfill leachate ammonium removal field tests. (Solid line-removal%; Dashed line-NH4 + concentration) (Site
A-higher organic matter and metal concentrations; Site B-lower than Site A)

FIGURE 14 Preparation of porous ceramic foam using commercial polyurethane foam252

There is an obvious porous structure inside the geopoly- 4.5 Catalyst field
mer, which provides a food channel for the permeation
of water.234 Metakaolin and sodium silicate as raw mate- Porous geopolymers prepared by SFM or AFM can be
rials, a green liquor treatment separation membrane with used as a porous heterogeneous catalyst after grinding,
internal porous structure was prepared at 60◦ C. Its amor- and applied in photocatalytic degradation of dyes,29,145
phous gels have a strong ability to immobilize heavy metal Friedel−Crafts benzylation reactions of benzene and
ions. When the concentration of Ni2+ is 300 mg/L and other substituted aromatics,28 cleaning of tar in biomass-
pH at 5, because of the combined actions of the adsorp- derived gas,261 solar photoproduction of hydrogen,29 Beck-
tion and rejection, membranes can effectively remove 96.37 mann rearrangement reaction (cyclohexanone oxime ɛ-
% of Ni2+ , from low-concentration wastewater, as shown caprolactam),262 nitrogen oxides by ammonia and total
in Figure 15. Their structures are zeolite-like, a class of oxidation of volatile hydrocarbons.117 There is only one
aluminosilicate materials, and can obtain zeolite struc- study addressing porous geopolymers for biodiesel synthe-
ture with small molecular size and uniform pores by sis by OM.263
hydrothermal processes.27 Took slag as raw material, a sim-
ple method was used to fabricate zeolite membrane for per-
vaporation separation of ethanol/water mixture (90%), and 4.6 pH regulator field
the maximum selectivity was 2579.48.107 Some polymer
fibers are easily degraded by alkaline hydrolysis, allow- The geopolymer framework contains leachable free
ing them to be removed chemically without heat treat- alkalis,264 which can be used as pH buffer by control-
ment. The diameter and interconnectivity of the pore can ling alkali leaching and pH regulator during anaerobic
be controlled by the amount and diameter of the fibers digestion. In this application, porous geopolymers were
to provide higher permeability.59 The resistance of self- prepared by DFM. Novais et al.30,31,135 prepared geopoly-
supporting homogeneous membrane is excessively large. mer blocks or spheres using metakaolin, fly ash, or red
Therefore, a developed composite membrane can have the mud as raw materials, measured the release of OH– over
separation performance of the separation membrane and time to evaluate its pH buffer capacity and found that the
low resistance, thus producing a larger volume of output use of porous geopolymer showed high alkali leaching,
economically.26,151 up to 0.0317 mol/dm3 •g. Ascensao et al.265 found that
17447402, 2022, 4, Downloaded from https://ceramics.onlinelibrary.wiley.com/doi/10.1111/ijac.14028 by Universidad Autonoma del Estado de Morelos, Wiley Online Library on [30/04/2023]. See the Terms and Conditions (https://onlinelibrary.wiley.com/terms-and-conditions) on Wiley Online Library for rules of use; OA articles are governed by the applicable Creative Commons License
YU et al. 1805

FIGURE 15 Energy spectrum analysis of the upper and lower surfaces of membranes after Ni adsorption234

the larger the opening pore size, the less pH fluctuation. such as building insulation, building lightweight, and
Therefore, porous geopolymer is more suitable as a pH adsorption mental ions, we summarized the following
regulator. conclusions. AFM can provide porous geopolymer with
excellent properties by adding filler with better perfor-
mance. The material prepared by DFM (Physics) has rela-
4.7 Other applications tively high thermal conductivity, poor thermal insulation,
high density, and relatively good compressive strength,
There are many other applications of porous geopoly-
so it can be applied to load-bearing walls. In general,
mer, moisture management,266 evaporative cooling,51,127
the density of lightweight geopolymer prepared by DFM
air purification,99,267 and so forth. There are relatively few
is DFM (Physics) > DFM (Al) > DFM (H2 O2 ). Porous
studies and references. geopolymer can be used to adsorb a variety of metal
ions, but its selective adsorption is poor. Due to the dif-
5 SUMMARY ference in adsorption ions, raw material, morphology,
and environments, no obvious adsorption discipline was
This paper summarized the raw materials, preparation found.
methods, and applications of porous geopolymer. Raw
materials involve metakaolin, fly ash, slag, and biomass AC K N OW L E D G M E N T S
fly ash. The methods and applications of preparing porous This work was supported by the Chinese Natural Science
geopolymer from different raw materials and the mixing Fund (grant: 51772055) and the Guangxi Natural Science
methods with other geopolymers as raw material were ana- Fund (grant: 2016GXNSFGA380003).
lyzed. Preparation methods of porous geopolymer mainly
include SFM, DFM, AFM, and PSM. The morphologies, ORCID
pores, and applications prepared by different methods Xue-min Cui https://orcid.org/0000-0003-1818-8470
were analyzed. The applications of porous geopolymer in
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