6/26/2011

Development of Blended Cement using Ac

Development of Blended Cement using Activated Sintered Fly Ash

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Abstract SFBM Plotter Computer Aided Structural Design Relational Database Design Distributed Database Design Finite Element Analysis Matrix Analysis of Framed Structure Development of Blended Cement Introduction Raw Material Preparation Testing Result Advantages Conclusion

Abstract
Investigations have been made to develop flyash blended cements using flyash in activated form. Activated flyash has been mixed in 20%, 30%, 40% and 50% by replacing portland cement clinker and cements have been prepared by grinding in ball mill with 4% of gypsum. Different physical properties of the cements thus prepared have been examined. It has been found that up to 40% flyash in activated form can be used for manufacturing blended cements as per Indian standard.
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Introduction
For civil engineering construction different types of portland cements, slag cement, portland pozzolana cement etc. are used. The basic material for above cements, portland cement clinker, normally produced using lime stone and clay in the raw mix and the second material in use is slag or any pozzolanic material. In the present investigation in place of direct use of pozzolanic material, activated flyash in different percentage has been used. Coal is the largest fossil fuel resource of the country, which needs to be utilised in an efficient and environmentally sound manner. Thermal power plant in India currently utilises noncooking coal containing 35-40% ash. During combustion, some clinkers are formed from the residue which drop and collect at the buttom of the furnace. This clinker with the help of clinker grinder are broken down to smaller pieces which constitute about 20% of the coal ash and is termed as bottom ash. The finer fraction, the balance part of the residue is carried by the flue gas in suspension and is collected in electronic precipitator. This finer fraction, about 80% of the coal ash is FLYASH. The flyash, which is by-product of coal based thermal power plants amounts to be approximately 60 million tons per year at present in the country and will increase with the expansion of thermal power generation. By the end of 2007, it has been estimated that total flyash production shall reach a staggering figure of almost 175 million tons per year. Such huge generation of ash from the thermal power station become an alarming dimension so far as availability of land for dumping and hazardous pollution are concerned. For disposal of huge amount of flyash generated (I 75 million tons per year by the end of 2007) 1,00,000 acres of valuable land will be required in the construction of ash storage ponds. If utilisation of flyash can be targeted at least at least to an extent of 40-50% in different field, a large portion of bricks are needed for housing construction, in urban and rural area, which consumes 160 million tons of top soil, making barren of 30.50 hectares of fertile land. Flyash generation from thermal power plant in posing a great threat to the atmosphere. Since most of the thermal power plants are not equipped with pollution control equipments, huge amounts of particulate matter (flyash)
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Development of Blended Cement using Ac

is emitted into the atmosphere, causing serious problem to air pollution. Therefore in the present investigation attempts have been made to use this waste material of thermal power plants in the form of activated flyash in blended cement, which will help in saving a considerable area of fertile land. The flyash of Indian thermal power plants contains considerable amount of crystalline compounds like quartz, mullite, magnetite etc. Quartz and mullite particles are stable phases of ea ash and they show very weak reactivity to lime and cement. The combustible carbon particles present in the flyash causes deterioration in the strength of cement and concrete. The above -factors stand as barrier for high percentage use of flyash in cement concrete.In order to materialize the direct bulk use of flyash as blending material in cement and concrete some investigations have been made by mechanical, chemical and thermal means to improve the pozzolanic activities of flyash. The thermochemical activities of coal tly ash has been increased to a considerable extent by adopting draft sintering technique. By this technique activated sintered flyash aggregate (ASFA) are manufactured by incorporating lime and iron bearing waste materials and sintering at temperature polymeric phases of quartz such as tridimide any crystoballite calciumalumino silicates. Mullite originally present in flyash is being transformed to calcium and iron bearing mineral compounds Besides it also contains 50-60% non crystalline phases. And the presence of polymer forms of lower elementary silica, calcium, iron containing silicates and other amorphous phases maintains the lime reactivity value of ASFA to as 7Mpa. Generally the reactivity values of Indian flyash are in lower side, around 4Mpa, which prevents it direct use in blended cement Activated flyash on the other hand which has high reactivity values of around 7Mpa duo to the presence of polymer forms of lower elementary silica calcium, iron containing silicates and other amorphous phases has been successfully used in high percentage in blended cement by replacing cement clinker gives better strength of cements than inactivated flyash. In the present content use of ASFA along with portland cement clinker has been examined and investigations have been carried out as regards their suitability as per National and International Standards.
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Raw Material (Industrial Waste) for Blended Cement

Portland cement clinker and activated flyash are used as the main ingredient for the preparation of blended cements: a) Activated flyash: Typical flyash from thermal power plant of Orissa containing 57.82% SiO2, 24.130/OA1203, 5.120/oFe2O3, 1.49%TiO2, 0-85%CaO, 0-50%MgO, 0.67%Na2O, 0.63%K20, 0.650/OP205, and 7.50"/oLIO is used to prepare activated flyash aggregate by agglomeration technique. The powdery flyash of 75% is mixed with 10% lirnesludge waste, 10% semiplastic clay and 5% coke breeze powder and granulated in a disc granulator using water as a binder. Pellets below 15mm size are prepared. The granulated pellets are sintered in a portgrate furnace, which operates on the principle of chain grate sintering system commonly adopted for agglomeration of iron ore fines in steel plants. A laboratory setup (4OOx4OO) mm cross section and 500mrn height sinter pot has been used to produce about 30kg of activated flyash aggregate by sintering at 1260' temperature. Solid carbon present in the charge acts as fuel for sintering. b) Portland cement: Clinkers manufactured by rotary kiln process is collected for mineralogical study, the cement clinker contains 58% tricalcium silicate (C3S), 27% dicalcium silicate and interstitial phases of tricalcium aluminate (C3A), tetracalcium aluminofertite (C4AF) and glass of 155. Chemically the cement clinker contains 20.6% SiO2, 5.1% MgO, 0.3% S03, 63.0% CaO, 5.6% A1203, and 0.8% alkalines (mainly K20 and N20). This cement clinker is used as control cement. which is prepared by grinding in a ball mill in presence of 3% by-product gypsum.
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Preparation of Blended Cement

Cement clinker, activated flyash, and by-product gypsum are mixed and ground in the laboratory ball mill to prepare blended cements. Four different mix proportions (Table-2) were made to prepare 6 kg. cement keeping cement fineness constant about 3000 sq. cm /gm . Gypsum has been kept 3% in all the cement to keep uniform content Of S03 . In order to study the effect of flyash, a blended cement of cement clinker 80% fly ash, 20% by-product gypsum 3% is prepared by similar fineness.
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Development of Blended Cement using Ac

Testing Procedure
The sintered materials are subjected to sieve analysis to determine percentage of different size fractions. Representative sintered sample from each type is ground to powder for chemical analysis. Different mineral phases present in sintered aggregate were examined in a Phillips Make XRD using Cu ka radiation. Physical properties such as specific gravity, bulk density, porosity and strength of the aggregate have been determined following BIS specification. Refractoriness of different sintered products containing alumina was determined using Lica Make heating microscope.
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Result and Discussion

Flyash collected from thermal power plant is highly crystalline in nature which contains quartz and mullites the major mineral phases and hematite, magnetite were present as accessory mineral phases. Presence of some glass (non-crystalline) particles was also observed through microscope. Residual carbon present in the flyash is 6 %. About 94% particles of flyash are below 90-micron sizes. Activated tlv ash prepared using this flyash in presence of line bearing material bv sintering at 1260'C temperature contains 56.30% SiO2, 23.45% Al2O3, 5.58 % FeO3, 7.60 CaO, and 2.28 %LOI. Mineralogical character of the lime activated flyash is shown in fig.5. The activated flyash contains mostly calcium bearing complex silicate mineral phases. It is revealed that formation of calcium aluminosilicate, calcium iron silicate phase have increased where as free quarts and mullite phases have been decreased in the activated flyash. Since the flyash is poor in lime (around 0.8%), the formation of lime bearing compounds in the activated flyash is almost negligible as observed from XRD pattern. It is observed that mineralogical phases in activated flyash have been influenced greatly by the addition of excess lime and high temperature. Generally lime and lime bearing complex silicate phases impart better pozzolanic property than crystalline quartz and mullite (3AI203SiO2). Blended cement of different composition MIX- I, MIX-2, MIX-3 and MIX4 have been prepared replacing cement clinker by 50%, 40%, 30% and 20% respectively by activated flyash (table-1). 3% by-product gypsum has been used as set retarder in all the samples. The control cement prepared from clinker containing 97% clinker and 3% gypsum, physical properties of control cement and of the 4 blended cement have been shown in Table-1. It is observed that normal consistency and setting time of blended cements increase with increase of activated flyash from 20 to 50%. However these values are well within the standard specification. Le-chartelier expansion of the blended cements are very much negligible showing less that 1mm expansion where as the same control cements shows expansion up to 5mm. Compressive strength of blended cement cubes in 1:3 mortar ratio have been determined up to 90 days. It shows that with increase of activated flyash addition from 20 to 50%, strength gradually decreases. The blended cements are marginally lower than the control cement without flyash. But it is interesting to note that all the blended cements shows remarkably increase in strength at 60 to 90 days of curing . But in case of controlled cement, the strength gain after 28 days is very much marginal. The blended cements of activated flyash show gradual increase in strength as observed up to 90 days of curing.
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Advantages
Compressive strength of blended cement using 20% flyash has been shown in fig. It is observed that the strength achieved in direct flyash blended cement are much lower than activated flyash blended cement. The strength of blended cements of 40% activated flyash is almost similar to 20% flyash blended cement. It is clear that activated flyash contents lime activated silicate phase which enhance better hydraulic property than the normal [ 26 flyash. Use of activated flyash in making blended cement appears to be very much promising. Fig shows blended cement of 20%, 300/o, 40% of activated flyash are quite satisfactory to meet the specification as recommended in BIS .But 50 % of activated flyash cement is almost marginal to 33 grade from strength point of view.
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Conclusion
From the present investigation following conclusions are drawn.
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Development of Blended Cement using Ac

1. Normal flyash contains quartz and mullite as the major mineral phases with hematite, magnetite and orthoclase
as the minor mineral phases.

2. Activated flyash contains calcium bearing complex silicate phases as the major constituents with quartz and
mullite

3. Presence of lime bearing complex silicate as the phases minor phases imparts better pozzolanic property than
due to the presence of crystalline quartz and mulliate phases.

4. In activated form flyash can replace cement clinker up to 50% in blended cement preparation which gives
similar strength to the blended cement with 20% normal flyash.

5. Up to 40% substitution of activated flyash in blended cement results are quite satisfactory as per BIS
specification. However, blended cement with

6. Preparation of blended cement using activated flyash is one of the successful attempts in waste utilization
programme.

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