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<p>Geopolymer-based refractories enhanced with engineered nanomaterials are emerging as sustainable alternatives to energy-intensive conventional ceramics. Their ability to develop dense, thermally stable aluminosilicate networks at low processing temperatures provides significant reductions in embodied energy and CO<sub>2</sub> emissions while enabling high-temperature performance suitable for demanding industrial environments. This review provides a critical, integrated assessment of how nanosilica, nanoalumina, TiO<sub>2</sub>, ZnO, carbon nanotubes, graphene derivatives, and layered nanoclays modify geopolymer chemistry, microstructure, and thermomechanical behavior. The analysis reveals that nanomaterials act as nucleation centers, crack-bridging reinforcements, pore refiners, and gel-structure stabilizers, leading to enhanced strength retention (70–85% above 1000 − 1200 <sup>ο</sup>C), reduced thermal shrinkage, improved thermal shock resistance, and refined ITZ densification. The review also evaluates synthesis routes including sol–gel, hydrothermal, co-precipitation, and mechanical milling, and advanced dispersion techniques such as ultrasonication, surfactants, zeta-potential control, and hybrid multi-step strategies, highlighting their influence on nanoparticle reactivity, phase evolution, and long-term stability under cyclic heating. Despite these advances, large-scale implementation remains constrained by nanoparticle agglomeration, precursor variability, curing sensitivities, high cost of nanomaterials, inconsistent mix designs, safety concerns, and the absence of geopolymer-specific high-temperature testing standards. A forward-looking roadmap is developed to bridge these gaps, emphasizing hybrid nanocomposite engineering, AI- and machine-learning-driven mix optimization, digitally controlled additive manufacturing, and comprehensive life-cycle and techno-economic assessments to balance performance benefits with environmental and economic impacts. Collectively, this review establishes the mechanistic foundations, methodological requirements, and industrial considerations necessary to transition nano-enhanced geopolymers from laboratory-scale innovation to reliable, energy-efficient, and industrially viable refractory solutions for next-generation high-temperature applications.</p>

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Nanomaterials in Geopolymers for Refractory Applications: Trends, Mechanisms, and Challenges

  • 期刊论文

  • 出版模式：

    开放获取

  • 发表日期：

    2026年3月19日

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  • Said A. Saeid,
  • Makungu M. Madirisha,
  • Bolanle D. Ikotun

摘要

Geopolymer-based refractories enhanced with engineered nanomaterials are emerging as sustainable alternatives to energy-intensive conventional ceramics. Their ability to develop dense, thermally stable aluminosilicate networks at low processing temperatures provides significant reductions in embodied energy and CO2 emissions while enabling high-temperature performance suitable for demanding industrial environments. This review provides a critical, integrated assessment of how nanosilica, nanoalumina, TiO2, ZnO, carbon nanotubes, graphene derivatives, and layered nanoclays modify geopolymer chemistry, microstructure, and thermomechanical behavior. The analysis reveals that nanomaterials act as nucleation centers, crack-bridging reinforcements, pore refiners, and gel-structure stabilizers, leading to enhanced strength retention (70–85% above 1000 − 1200 οC), reduced thermal shrinkage, improved thermal shock resistance, and refined ITZ densification. The review also evaluates synthesis routes including sol–gel, hydrothermal, co-precipitation, and mechanical milling, and advanced dispersion techniques such as ultrasonication, surfactants, zeta-potential control, and hybrid multi-step strategies, highlighting their influence on nanoparticle reactivity, phase evolution, and long-term stability under cyclic heating. Despite these advances, large-scale implementation remains constrained by nanoparticle agglomeration, precursor variability, curing sensitivities, high cost of nanomaterials, inconsistent mix designs, safety concerns, and the absence of geopolymer-specific high-temperature testing standards. A forward-looking roadmap is developed to bridge these gaps, emphasizing hybrid nanocomposite engineering, AI- and machine-learning-driven mix optimization, digitally controlled additive manufacturing, and comprehensive life-cycle and techno-economic assessments to balance performance benefits with environmental and economic impacts. Collectively, this review establishes the mechanistic foundations, methodological requirements, and industrial considerations necessary to transition nano-enhanced geopolymers from laboratory-scale innovation to reliable, energy-efficient, and industrially viable refractory solutions for next-generation high-temperature applications.