Comparative Analysis of Porous Alkali-Activated Composites Modified with Commercial and Laboratory-Prepared Phase...

This study presents a comparative evaluation of geopolymer foams incorporating either commercially available shape-stabilized phase change materials (PCMs) or laboratory-developed diatomite-paraffin PCM granules with controlled particle size fractions ranging from <1.6 mm to >2.5 mm. All PCM variants were incorporated at a constant dosage of 7.5 wt.% to isolate the influence of PCM type on the properties of the resulting composites. The commercial materials comprised PX-4, PX15, and PX20 (Rubitherm Technologies GmbH), whereas the laboratory-developed PCM consisted of paraffin immobilized within a porous diatomite matrix to produce granular shape-stabilized composites. The experimental program included the determination of bulk density, total porosity, pore size distribution, thermal conductivity (λ), thermal resistance (R), specific heat capacity (Cp), and compressive strength. The pore structure was characterized by mercury intrusion porosimetry (MIP), while the morphology and dispersion of PCM particles within the geopolymer matrix were investigated using scanning electron microscopy (SEM). All mixtures were produced using the same alkali-activated matrix and identical curing conditions, with the PCM content maintained at 7.5 wt.%. The results demonstrated that the type of PCM significantly affected the microstructure and thermophysical performance of the geopolymer foams. The laboratory-developed diatomite-paraffin PCM provided the most favorable thermal insulation performance, exhibiting the lowest thermal conductivity (0.095 W/m·K) together with the highest thermal resistance (0.278 m²·K/W). In contrast, the commercial PX15 and PX20 materials exhibited the highest specific heat capacities (1.740 and 1.778 kJ/kg·K, respectively), indicating superior thermal energy storage capability. In addition, the estimated production cost of the laboratory-developed PCM (2.5-4.0 EUR/kg) was substantially lower than that of the commercial PX materials (approximately 20 EUR/kg), highlighting its potential as a cost-effective alternative for sustainable, energy-efficient building materials. These findings demonstrate that both commercial and laboratory-developed PCM systems can effectively enhance the functionality of geopolymer foams, although they provide different balances between thermal insulation, heat storage capacity, and production cost.