Process for the production of geopolymer or geopolymer composite

Process for the production of a geopolymer or geopolymer composite, comprising

• a) mixing of precursor for aluminate and silicate in alkaline solution, comprising sodium silicate, sodium aluminate, sodium disilicate, sodium phosphoaluminate, or a mixture thereof, to form a sol-gel,
• b) optionally adding of one or more additives to the sol-gel, to form a filled sol-gel,
• c) adding water to the sol-gel or filled sol-gel, to form a diluted sol-gel or diluted filled sol-gel,
• d) mixing of the diluted sol-gel or diluted filled sol-gel, to form geopolymer or geopolymer composite, without curing drying and milling of the geopolymer or of the geopolymer composite,
• e) obtaining a suspension of the geopolymer or of the geopolymer composite,
• wherein step e) comprises
• e1) decanting, wherein step e1) comprises
• e1a) applying high shear mixing and ultrasound with high energy to induce cavitation,
• e1b) optionally adding acid,
• e1c) decanting, and
• e1d) optionally membrane filtering, and precipitate cake washing
• or
• e2) adding an organic phase, emulsifying and stripping of the organic phase, wherein
• step e2) comprises
• e2a) adding an organic phase,
• e2b) emulsifying the sol-gel,
• e2c) applying high shear mixing and ultrasound with high energy, to induce cavitation,
• e2d) steam stripping to remove the organic phase, and
• e2e) dispersing the geopolymer or the geopolymer composite in water;
• f) reducing the content of sodium cation within the structure of the geopolymer or geopolymer composite, and
• g) obtaining the geopolymer or geopolymer composite,
• wherein the geopolymer or geopolymer composite has a sodium content of less than 200 ppm, measured according to PN-ISO 9964-1:1994+Apl:2009 and calculated on dry mass.