Search results for: cement production

Authors: Krzysztof Zieliński, Dariusz Kierzek

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The addition of a small amount of alumina cement to Portland cement results in immediate setting, a rapid increase in the compressive strength and a clear increase of the adhesion to concrete substrate. This phenomenon is used, among others, for the production of liquid floor self-levelling compounds. Alumina cement is several times more expensive than Portland cement and is a component having a significant impact on prices of products manufactured with its use. For the production of liquid floor self-levelling compounds, low-alumina cement containing approximately 40% Al₂O₃ is normally used. The aim of the study was to determine the impact of Portland cement with the addition of alumina cement on the basic physical and mechanical properties of cement slurries and mortars. CEM I 42.5R and three types of alumina cement containing 40%, 50% and 70% of Al₂O₃ were used for the tests. Mixes containing 4%, 6%, 8%, 10% and 12% of different varieties of alumina cement were prepared; for which, the time of initial and final setting, compressive and flexural strength and adhesion to concrete substrate were determined. The analysis of the obtained test results showed that a similar immediate setting effect and clearly better adhesion strength can be obtained using the addition of 6% of high-alumina cement than 12% of low-alumina cement. As the prices of these cements are similar, this can give significant financial savings in the production of liquid floor self-levelling compounds.

Keywords: alumina cement, immediate setting, compression strength, adhesion to substrate

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Authors: Hamisu Idi

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The present study focuses on studying the impact of influencer recommendation in the quality of cement production. Exploratory research was done on monthly basis, where data were obtained from secondary source i.e. the record kept by an automated recompilation machine. The machine keeps all the records of the mills downtime which the process manager checks for validation and refer the fault (if any) to the department responsible for maintenance or measurement taking so as to prevent future occurrence. The findings indicated that the product of the Ashaka Cement Plc. were considered as qualitative, since all the production processes were found to be in control (preset specifications) with the exception of the natural cause of variation which is normal in the production process as it will not affect the outcome of the product. It is reduced to the bearest minimum since it cannot be totally eliminated. It is also hopeful that the findings of this study would be of great assistance to the management of Ashaka cement factory and the process manager in particular at various levels in the monitoring and implementation of statistical process control. This study is therefore of great contribution to the knowledge in this regard and it is hopeful that it would open more research in that direction.

Keywords: cement, quality, variation, assignable cause, common cause

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Authors: Adem Atmaca

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More than 500 million COVID-19 cases were noted in February 2022 in Turkey. The country is one of the most impacted countries all around the world with twenty million cases. The cement industry in Turkey ranks among the most energy-intensive sectors with huge production capacities among the biggest exporter countries. The purpose of this paper is to clarify the effects of the pandemic on the cement industry in Turkey by showing the changes in manufacturing capacities and export rates of all facilities in the country. The investigation has revealed that the epidemic has slight effects on the factory production capacities and export rates. Even though the capacity usage rates of the factories decreased dramatically in 2019, it seems that Turkish cement companies turned the pandemic to their advantage by increasing their production capacities, capacity usage rates and export rates gradually by reaching new markets during the pandemic.

Keywords: energy, emissions, cement industry, COVID-19

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Authors: M. Sedlmajer, J. Zach, J. Hroudova, P. Rovnaníkova

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There are several possibilities of reducing the required amount of cement in concrete production. Natural zeolite is one of the raw materials which can partly substitute Portland cement. The effort to reduce the amount of Portland cement used in concrete production is brings both economical as well as ecological benefits. The paper presents the properties of concrete containing natural zeolite as an active admixture in the concrete which partly substitutes Portland cement. The properties discussed here bring information about the basic mechanical properties and frost resistance of concrete containing zeolite. The properties of concretes with the admixture of zeolite are compared with a reference concrete with no content of zeolite. The properties of the individual concretes are observed for 360 days.

Keywords: concrete, zeolite, compressive strength, modulus of elasticity, durability

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Authors: Hang Tran, Victor Brial, Luca Sorelli, Claudiane Ouellet-Plamondon, David Conciatori, Laurent Birry

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Spend pot lining (SPL) is a by-product generated from primary aluminum production. SPL consists of two parts, the first cut is rich in carbonaceous materials, and the second cut is rich in aluminum and silicon oxides. After treating by the hydrometallurgical Low Caustic Leaching and Liming process, the refractory part of SPL becomes an inert material, called LCLL ash in this project. LCLL ash was calcined at different temperatures (800 and 1000°C) and Calcined LCLL ash ground as fines of cement and replacement a part of cement in concrete production. The effect of LCLL ash on the chemical properties, mechanical properties and fresh behavior of concrete was evaluated by isothermal calorimetry, compressive test, and slump test. These results were compared to the reference mixture.

Keywords: spend pot lining, concrete, cement, compressive strength, calorimetry

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Authors: O. Zimbili, W. Salim, M. Ndambuki

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Construction and Demolition (C&D) wastes contribute the highest percentage of wastes worldwide (75%). Furthermore, ceramic materials contribute the highest percentage of wastes within the C&D wastes (54%). The current option for disposal of ceramic wastes is landfill. This is due to unavailability of standards, avoidance of risk, lack of knowledge and experience in using ceramic wastes in construction. The ability of ceramic wastes to act as a pozzolanic material in the production of cement has been effectively explored. The results proved that temperatures used in the manufacturing of these tiles (about 900 ⁰C) are sufficient to activate pozzolanic properties of clay. They also showed that, after optimization (11-14% substitution), the cement blend performs better, with no morphological differences between the cement blended with ceramic waste, and that blended with other pozzolanic materials. Sanitary ware and electrical insulator porcelain wastes are some wastes investigated for usage as aggregates in concrete production. When optimized, both produced good results, better than when natural aggregates are used. However, the research on ceramic wastes as partial substitute for fine aggregates or cement has not been overly exploited as the other areas. This review has been concluded with focus on investigating whether ceramic wall tile wastes used as partial substitute for cement and fine aggregates could prove to be beneficial since the two materials are the most high-priced during concrete production.

Keywords: blended, morphological, pozzolanic, waste

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Authors: S. Al-Fadala, J. Chakkamalayath, S. Al-Bahar, A. Al-Aibani, S. Ahmed

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Globally, the use of pozzolan in blended cement is gaining great interest due to the desirable effect of pozzolan from the environmental and energy conservation standpoint and the technical benefits they provide to the performance of cement. The deterioration of concrete structures in the marine environment and extreme climates demand the use of pozzolana cement in concrete construction in the Gulf region. Also, natural sources of cement clinker materials are limited in the Gulf region, and cement industry imports the raw materials for the production of Portland cement, resulting in an increase in the greenhouse gas effect due to the CO₂ emissions generated from transportation. Even though the Gulf region has vast deposits of natural pozzolana, it is not explored properly for the production of high performance concrete. Hence, an optimum use of regionally available natural pozzolana for the production of blended cement can result in sustainable construction. This paper investigates the effect of incorporating natural pozzolan sourced from the Gulf region on the performance of blended cement in terms of heat evolution and strength development. For this purpose, a locally produced Ordinary Portland Cement (OPC) and pozzolan-incorporated blended cements containing different amounts of natural pozzolan (volcanic ash) were prepared on laboratory scale. The strength development and heat evolution were measured and quantified. Promising results of strength development were obtained for blends with the percentages of Volcanic Ash (VA) replacement varying from 10 to 30%. Results showed that the heat of hydration decreased with increase in percentage of replacement of OPC with VA, indicating increased retardation in hydration due to the addition of VA. This property could be used in mass concreting in which a reduction in heat of hydration is required to reduce cracking in concrete, especially in hot weather concreting.

Keywords: blended cement, hot weather, hydration, volcanic ash

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Authors: M. B. Ahmadi, A. A. Kaffash B., B. Mobaraki

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Slump loss, which refers to the gradual reduction of workability and the amount of slump in fresh concrete over time, is one of the significant challenges in the ready-mixed concrete industry. Therefore, having accurate knowledge of the factors affecting slump loss is a crucial solution in this field. In this paper, an attempt was made to investigate the effect of cement produced by different units on the slump of concrete in a laboratory setting. For this purpose, 12 cement samples were prepared from 6 different production units. Physical and chemical tests were performed on the cement samples. Subsequently, a laboratory concrete mix with a slump of 13 ± 1 cm was prepared with each cement sample, and the slump was measured at 0, 15, 30, 45, and 60 minutes. Although the environmental factors, mix design specifications, and execution conditions—factors that significantly influence the slump loss trend—were constant in all 12 laboratory concrete mixes, the slump loss trends differed among them. These trends were categorized based on the results, and the relationship between the slump loss percentage in 60 minutes, the water-cement ratio, and the LOI and K2O values of different cements were introduced.

Keywords: concrete, slump loss, portland cement, efficiency

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Authors: Mohammad Ashraf, Kawther Mohamed

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This research tackles a new kind of additions (Nano Clay) and its effect on the features of concrete and both fresh and hardened cement mortar, as well as setting an optimal percentage of adding it to achieve the desired results and obtain on a strong concrete and mortar can be used for skyscrapers. The cementations additions are mineral materials in the form of a fine powder, added to concrete or cement mortar as partly cement substitutes, which means to be added instead of an equivalent amount of cement in order to improve and enhance some features of concrete or both the newly made and hardened cementations materials.

Keywords: nano clay in structure engineering, nanotechnology in construction industry, advanced additions in concrete, special concrete for skyscrapers

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Authors: Rodrigo D. S. Oliveira, Sarah David-Muzel, Maristela Gava, Victor A. De Araujo, Glaucia A. Prates, Juliana Cortez-Barbosa

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Improper disposal of treated wood waste is a problem of the timber sector, since this residue is toxic, due to the harmful characteristics of the preservative substances. An environmentally friendly alternative is the use of this waste for the production of cement-wood composites. The aim of this work was to study the possibility of using wood treated with CCA (Chromated Cooper Arsenate) in cement-wood. Specimens of Pinus sp. and Eucalyptus sp. were produced with wood raw in natura and treated with CCA. A test was performed to determine the parallel shear stress of samples after 14 days of drying, according to the Brazilian Standard NBR-7215/97. Based on the analyzed results it is concluded that the use of wood treated with CCA is not feasible in cement-wood production, because the composite samples of treated wood showed lower mechanical strength in shear stress than those with wood in natura.

Keywords: waste recovery, wood composites, cement-wood, wood preservation, chromated copper arsenate

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Authors: Eva Ujaczki, Rama Krishna Chinnam, Ronan Courtney, Syed A. M. Tofail, Lisa O'Donoghue

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Concrete is the second most widely used material in the world and is made of cement, sand, and aggregates. Cement is a hydraulic binder which reacts with water to form a solid material. In the cement manufacturing process, the right mix of minerals from mined natural rocks, e.g., limestone is melted in a kiln at 1450 °C to form a new compound, clinker. In the final stage, the clinker is milled into a fine cement powder. The principal cement types manufactured in Ireland are: 1) CEM I – Portland cement; 2) CEM II/A – Portland-fly ash cement; 3) CEM II/A – Portland-limestone cement and 4) CEM III/A – Portland-round granulated blast furnace slag (GGBS). The production of eco-efficient, blended cement (CEM II, CEM III) reduces CO₂ emission and improves energy efficiency compared to traditional cements. Blended cements are produced locally in Ireland and more than 80% of produced cement is blended. These eco-efficient, blended cements are a relatively new class of construction materials and a kind of geopolymer binders. From a terminological point of view, geopolymer cement is a binding system that is able to harden at room temperature. Geopolymers do not require calcium-silicate-hydrate gel but utilize the polycondensation of SiO₂ and Al₂O₃ precursors to achieve a superior strength level. Geopolymer materials are usually synthesized using an aluminosilicate raw material and an activating solution which is mainly composed of NaOH or KOH and Na₂SiO₃. Cement is the essential ingredient in concrete which is vital for economic growth of countries. The challenge for the global cement industry is to reach to increasing demand at the same time recognize the need for sustainable usage of resources. Therefore, in this research, we investigated the potential for Irish wastes to be used in geopolymer cement type applications through a national stakeholder workshop with the Irish construction sector and relevant stakeholders. This paper aims at summarizing Irish stakeholder’s perspective for introducing new secondary raw materials, e.g., bauxite residue or increasing the fly ash addition into cement for eco-efficient cement production.

Keywords: eco-efficient, cement, geopolymer, blending

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Authors: Azadeh Askarinejad, Parham Hayati, Reza Parchami, Parisa Hayati

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One of the most important industries and building operations causing carbon dioxide emission is the cement and concrete related industries so that cement production (including direct fuel for mining and transporting raw material) consumes approximately 6 million Btus per metric-ton, and releases about 1 metric-ton of CO2. Reducing the consumption of cement with simultaneous utilizing waste materials as cement replacement is preferred for reasons of environmental protection. Blended cements consist of different supplementary cementitious materials (SCM), such as fly ash, silica fume, Ground Granulated Blast Furnace Slag (GGBFS), limestone, natural pozzolans, etc. these materials should be chemically activated to show effective cementitious properties. The present review article reports three different methods of nanofabrication that were used for activation of two types of SCMs.

Keywords: nanofabrication, cement replacement materials, activation, concrete

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Authors: C. S. Paglia, E. Ginercordero, A. Jornet

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Environmental pollution, along with the depletion of natural resources, is among the most serious global challenges in our times. The construction industry is one of the sectors where a relevant reduction of the environmental impact can be achieved. Thus, the cement production will play a key role in sustainability, by reducing the CO₂ emissions and energy consumption and by increasing the durability of the structures. A large number of investigations have been carried out on blended cements, but it exists a lack of information on the Portland cement limestone - silica fume system. Mortar blends are optimized in the mix proportions for the different ingredients, in particular for the dosage of the silica fume. Portland cement and the new binder-based systems are compared with respect to the fresh mortar properties, the mechanical and the durability behaviour of the hardened specimens at 28 and 90 days. The use of this new binder combination exhibits an interesting hydration development with time and maintain the conventional characteristics of Portland cementitious material. On the other hand, it will be necessary to reproduce the Portland Limestone Cement-silica fume system within the concrete. A reduction of the CO₂ production, energy consumption, and a reasonable service life of the concrete structures, including a maintenance free period, will all contribute to a better environment.

Keywords: binder, cement, limestone, silica fume

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Authors: Mulubrhan Berihu

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Due to the design versatility, availability, and cost efficiency, concrete continues to be the most used construction material on earth. However, the production of Portland cement, the primary component of concrete mix is causing to have a serious effect on environmental and economic impacts. This shows there is a need to study using of supplementary cementitious materials (SCMs). The most commonly used supplementary cementitious materials are wastes, and the use of these industrial waste products has technical, economic, and environmental benefits besides the reduction of CO2 emission from cement production. This paper aims to document the effect on the strength property of concrete due to the use of low cement by maximizing supplementary cementitious materials like fly ash. The amount of cement content was below 250 kg/m3, and in all the mixes, the quantity of powder (cement + fly ash) is almost kept at about 500 kg. According to this, seven different cement content (250 kg/m3, 195 kg/m3, 150 kg/m3, 125 kg/m3, 100 kg/m3, 85 kg/m3, 70 kg/m3) with different amount of replacement of SCMs was conducted. The mix proportion was prepared by keeping the water content constant and varying the cement content, SCMs, and water-to-binder ratio. Based on the different mix proportions of fly ash, a range of mix designs was formulated. The test results showed that using up to 85 kg/m3 of cement is possible for plain concrete works like hollow block concrete to achieve 9.8 Mpa, and the experimental results indicate that strength is a function of w/b. The experiment result shows a big difference in gaining of compressive strength from 7 days to 28 days and this obviously shows the slow rate of hydration of fly ash concrete. As the w/b ratio increases, the strength decreases significantly. At the same time, higher permeability was seen in the specimens which were tested for three hours than one hour.

Keywords: efficiency factor, cement content, compressive strength, mix proportion, w/c ratio, water permeability, SCMs

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Authors: Kumator Taku, Bilkisu Amartey

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This research used Grid indentation technique to investigate the effect of the addition of Coconut Shell Ash (CSA) on the nanomechanical properties of the main phases of the hydrated cement paste. Portland cement was partially replaced with 15% CSA at a water-binder ratio of 0.5 and cubes casted and cured for 28 days after which they were polished to reduce surface roughness to the barest minimum. The result of nanoindentation shows that addition of 15% CSA to cement paste transforms portlandite to C-S-H by the pozzolanic reaction. More so, there is reduced porosity and a reduction in the volume of CH by the addition of the CSA. Even though the addition of 15% CSA does not drastically change the average values of the hardness and elastic modulus of the two phases of the C-S-H, it greatly modifies their relative proportions, leading to the production of more HD C-S-H. Overall, incorporating 15%CSA to cement mortar improves the Nanomechanical properties of the four main phases of the hydrated cement paste.

Keywords: Coconut Shell Ash, Elastic Modulus, Hardness, Nanoindentation, Porosity

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Authors: Khalid M. Albarkoly, Kenneth S. Park

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The substantial development of the construction industry has forced the cement industry, its major support, to focus on achieving maximum productivity to meet the growing demand for this material. Statistics indicate that the demand for cement rose from 1.6 billion metric tons (bmt) in 2000 to 4bmt in 2013. This means that the reliability of a production system needs to be at the highest level that can be achieved by good maintenance. This paper studies the extent to which the implementation of RCM is needed as a strategy for increasing the reliability of the production systems component can be increased, thus ensuring continuous productivity. In a case study of four Libyan cement factories, 80 employees were surveyed and 12 top and middle managers interviewed. It is evident that these factories usually breakdown more often than once per month which has led to a decline in productivity, they cannot produce more than 50% of their designed capacity. This has resulted from the poor reliability of their production systems as a result of poor or insufficient maintenance. It has been found that most of the factories’ employees misunderstand maintenance and its importance. The main cause of this problem is the lack of qualified and trained staff, but in addition, it has been found that most employees are not found to be motivated as a result of a lack of management support and interest. In response to these findings, it has been suggested that the RCM strategy should be implemented in the four factories. The paper shows the importance of considering the development of maintenance strategies through the implementation of RCM in these factories. The purpose of it would be to overcome the problems that could reduce the level of reliability of the production systems. This study could be a useful source of information for academic researchers and the industrial organisations which are still experiencing problems in maintenance practices.

Keywords: Libyan cement industry, reliability centred maintenance, maintenance, production, reliability

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Authors: R. Ziaie Moayed, S. P. Emadoleslami Oskoei, S. D. Beladi Mousavi, A. Taleb Beydokhti

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There have been many reports of the destructive effects of cement on the environment in recent years. In the present research, it has been attempted to reduce the destructive effects of cement by replacing silica fume as adhesive materials instead of cement. The present study has attempted to improve the mechanical properties of cement slurry by using waste material from a glass production factory, located in Qazvin city of Iran, in which accumulation volume has become an environmental threat. The chemical analysis of the waste material indicates that this material contains about 94% of SiO₂ and AL₂O₃ and has a close structure to silica fume. Also, the particle grain size test was performed on the mentioned waste. Then, the unconfined compressive strength test of the slurry was performed by preparing a mixture of water and adhesives with different percentages of cement and silica fume. The water to an adhesive ratio of this mixture is 1:3, and the curing process last 28 days. It was found that the sample had an unconfined compressive strength of about 300 kg/cm² in a mixture with equal proportions of cement and silica fume. Besides, the sample had a brittle fracture in the slurry sample made of pure cement, however, the fracture in cement-silica fume slurry mixture is flexible and the structure of the specimen remains coherent after fracture. Therefore, considering the flexibility that is achieved by replacing this waste, it can be used to stabilize soils with cracking potential.

Keywords: cement replacement, cement slurry, environmental threat, natural pozzolan, silica fume, waste material

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Authors: Gustave Semugaza, Anne Zora Gierth, Tommy Mielke, Marianela Escobar Castillo, Nat Doru C. Lupascu

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The generation of Construction and Demolition Waste (CDW) has globally increased enormously due to the enhanced need in construction, renovation, and demolition of construction structures. Several studies investigated the use of CDW materials in the production of new concrete and indicated the lower mechanical properties of the resulting concrete. Many other researchers considered the possibility of using the Hydrated Cement Powder (HCP) to replace a part of Ordinary Portland Cement (OPC), but only very few investigated the use of Recycled Concrete Powder (RCP) from CDW. The partial replacement of OPC for making new concrete intends to decrease the CO₂ emissions associated with OPC production. However, the RCP and HCP need treatment to produce the new concrete of required mechanical properties. The thermal treatment method has proven to improve HCP properties before their use. Previous research has stated that for using HCP in concrete, the optimum results are achievable by heating HCP between 400°C and 800°C. The optimum heating temperature depends on the type of cement used to make the Hydrated Cement Specimens (HCS), the crushing and heating method of HCP, and the curing method of the Rehydrated Cement Specimens (RCS). This research assessed the quality of recycled materials by using different techniques such as X-ray Diffraction (XRD), Differential Scanning Calorimetry (DSC) and thermogravimetry (TG), Scanning electron Microscopy (SEM), and X-ray Fluorescence (XRF). These recycled materials were thermally pretreated at different temperatures from 200°C to 1000°C. Additionally, the research investigated to what extent the thermally treated recycled cement could partially replace the OPC and if the new concrete produced would achieve the required mechanical properties. The mechanical properties were evaluated on the RCS, obtained by mixing the Dehydrated Cement Powder and Recycled Powder (DCP and DRP) with water (w/c = 0.6 and w/c = 0.45). The research used the compressive testing machine for compressive strength testing, and the three-point bending test was used to assess the flexural strength.

Keywords: hydrated cement powder, dehydrated cement powder, recycled concrete powder, thermal treatment, reactivation, mechanical performance

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Authors: S. Šupić, M. Malešev, V. Radonjanin, M. Radeka, M. Laban

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The production of low cost and environmentally friendly products represents an important step for developing countries. Biomass is one of the largest renewable energy sources, and Serbia is among the top European countries in terms of the amount of available and unused biomass. Substituting cement with the ashes obtained by the combustion of biomass would reduce the negative impact of concrete industry on the environment and would provide a waste valorization by the reuse of this type of by-product in mortars and concretes manufacture. The study contains data on physical properties, chemical characteristics and pozzolanic properties of obtained biomass ashes: wheat straw ash and mixture of wheat and soya straw ash in Serbia, which were, later, used as supplementary cementitious materials in preparation of mortars. Experimental research of influence of biomass ashes on physical and mechanical properties of cement mortars was conducted. The results indicate that the biomass ashes can be successfully used in mortars as substitutes of cement without compromising their physical and mechanical performances.

Keywords: biomass, ash, cementitious material, mortar

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Authors: Muzeyyen Balcikanli, Selma Ozaslan, Osman Sahin, Burak Uzal, Erdogan Ozbay

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In this study, the effect of nano-CaCO3 replacement with cement on the nano-mechanical properties of cement paste was investigated. Hydrophobic and hydrophilic characteristics Two types of nano CaCO3 were replaced with Portland cement at 0, 0.5 and 1%. Water to (cement+nano-CaCO3) ratio was kept constant at 0.5 for all mixtures. 36 indentations were applied on each cement paste, and the values of nano-hardness and elastic modulus of cement pastes were determined from the indentation depth-load graphs. Then, by getting the average of them, nano-hardness and elastic modulus were identified for each mixture. Test results illustrate that replacement of hydrophilic n-CaCO3 with cement lead to a significant increase in nano-mechanical properties, however, replacement of hydrophobic n-CaCO3 with cement worsened the nano-mechanical properties considerably.

Keywords: nanoindenter, CaCO3, nano-hardness, nano-mechanical properties

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Authors: M. Tazky, R. Hela, P. Novosad, L. Osuska

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This paper deals with the possibility of safe incorporation fluidised bed combustion fly ash (waste material) into cement matrix together with next commonly used secondary raw material, which is high-temperature fly ash. Both of these materials have a very high pozzolanic ability, and the right combination could bring important improvements in both the physico-mechanical properties and the better durability of a cement composite. This paper tries to determine the correct methodology for designing green concrete by using modern methods measuring rheology of fresh concrete and following hydration processes. The use of fluidised bed combustion fly ash in cement composite production as an admixture is not currently common, but there are some real possibilities for its potential. The most striking negative aspect is its chemical composition which supports the development of new product formation, influencing the durability of the composite. Another disadvantage is the morphology of grains, which have a negative effect on consistency. This raises the question of how this waste can be used in concrete production to emphasize its positive properties and eliminate negatives. The focal point of the experiment carried out on cement pastes was particularly on the progress of hydration processes, aiming for the possible acceleration of pozzolanic reactions of both types of fly ash.

Keywords: high temperature fly ash, fluidized bed combustion fly ash, pozzolan, CaO (calcium oxide), rheology

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Authors: Mohamed. A. Saad

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The paper represents a case study regarding the conversion of Electro-Static Precipitators (ESP`s) into Fabric Filters (FF). Seven cement production companies were established in Egypt during the period 1927 to 1980 and 6 new companies were established to cope with the increasing cement demand in 1980's. The cement production market shares in Egypt indicate that there are six multinational companies in the local market, they are interested in the environmental conditions improving and so decided to achieve emission reduction project. The experimental work in the present study is divided into two main parts: (I) Measuring Efficiency of Filter Fabrics with detailed description of a designed apparatus. The paper also reveals the factors that should be optimized in order to assist problem diagnosis, solving and increasing the life of bag filters. (II) Methods to mitigate dust emissions in Egyptian cement plants with a special focus on converting the Electrostatic Precipitators (ESP`s) into Fabric Filters (FF) using the same ESP casing, bottom hoppers, dust transportation system, and ESP ductwork. Only the fan system for the higher pressure drop with the fabric filter was replaced. The proper selection of bag material was a prime factor with regard to gas composition, temperature and particle size. Fiberglass with PTFE membrane coated bags was selected. This fabric is rated for a continuous temperature of 250 C and a surge temperature of 280C. The dust emission recorded was less than 20 mg/m3 from the production line fitted with fabric filters which is super compared with the ESP`s working lines stack.

Keywords: Engineering Electrostatic Precipitator, filtration, dust collectors, cement

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Authors: Nkiru I. Ibeakuzie, Paul D. J. Watson, John F. Pescatore

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In roadway construction, the cost of soil-cement stabilization per unit area is significantly influenced by the binder content, hence the need to optimise cement usage. This research work will characterize the influence of soil fractal geometry on properties of cement-stabilized soil, and strive to determine a correlation between mechanical proprieties of cement-stabilized soil and the mass fractal dimension Dₘ indicated by particle size distribution (PSD) of aggregate mixtures. Since strength development in cemented soil relies not only on cement content but also on soil PSD, this study will investigate the possibility of reducing cement content by changing the PSD of soil, without compromising on strength, reduced permeability, and compressibility. A series of soil aggregate mixes will be prepared in the laboratory. The mass fractal dimension Dₘ of each mix will be determined from sieve analysis data prior to stabilization with cement. Stabilized soil samples will be tested for strength, permeability, and compressibility.

Keywords: fractal dimension, particle size distribution, cement stabilization, cement content

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Authors: Zhihao Zhao, Ali El-Nagger, Johnson Kau, Chris Olson, Douglas Tomlinson, Scott X. Chang

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One strategy to reduce CO₂ emissions from cement production is to reduce the amount of Portland cement produced by replacing it with supplementary cementitious materials (SCMs). Biochar is a potential SCM that is an eco-friendly and stable porous pyrolytic material. However, the effects of biochar addition on the performances of Portland cement composites are not fully understood. This meta-analysis investigated the impact of biochar addition on the 7- and 28-day compressive strength of Portland cement composites based on 606 paired observations. Biochar feedstock type, pyrolysis conditions, pre-treatments and modifications, biochar dosage, and curing type all influenced the compressive strength of Portland cement composites. Biochars obtained from plant-based feedstocks (except rice and hardwood) improved the 28-day compressive strength of Portland cement composites by 3-13%. Biochars produced at pyrolysis temperatures higher than 450 °C, with a heating rate of around 10 °C/min, increased the 28-day compressive strength more effectively. Furthermore, the addition of biochars with small particle sizes increased the compressive strength of Portland cement composites by 2-7% compared to those without biochar addition. Biochar dosage of < 2.5% of the binder weight enhanced both compressive strengths and common curing methods maintained the effect of biochar addition. However, when mixing the cement, adding fine and coarse aggregates such as sand and gravel affects the concrete and mortar's compressive strength, diminishing the effect of biochar addition and making the biochar effect nonsignificant. We conclude that appropriate biochar addition could maintain or enhance the mechanical performance of Portland cement composites, and future research should explore the mechanisms of biochar effects on the performance of cement composites.

Keywords: biochar, Portland cement, constructure, compressive strength, meta-analysis

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Authors: Mojebullah Wahidy, Murat Olgun

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In this study, four different types of cement are used to investigate the permeability of DMC (Deep Mixing Column) in the clay. The clay used in this research is in the kaolin group, and the types of cement are; CEM I 42.5.R. normal portland cement, CEM II/A-M (P-L) pozzolan doped cement, CEM III/A 42.5 N blast furnace slag cement and DMFC-800 fine-grained portland cement. Firstly, some rheological tests are done on every cement, and a 0.9 water/cement ratio is selected as the appropriate ratio. This ratio is used to prepare the small-scale DMCs for all types of cement with %6, %9, %12, and %15, which are determined as the dry weight of the clay. For all the types of cement, three samples were prepared in every percentage and were kept on curing for 7, 14, and 28 days for permeability tests. As a result of the small-scale DMCs, permeability tests, a %12 selected for big-scale DMCs. A total of five big scales DMC were prepared by using a %12-cement and were kept for 28 days curing for permeability tests. The results of the permeability tests show that by increasing the cement percentage and curing time of all DMCs, the permeability coefficient (k) is decreased. Despite variable results in different cement ratios and curing time in general, samples treated by DMFC-800 fine-grained cement have the lowest permeability coefficient. Samples treated with CEM II and CEM I cement types were the second and third lowest permeable samples. The highest permeability coefficient belongs to the samples that were treated with CEM III cement type.

Keywords: deep mixing column, rheological test, DMFC-800, permeability test

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Authors: Zhuomin Zou, Thijs Van Landeghem, Elke Gruyaert

Abstract:

Using supplementary cementitious materials, such as blast-furnace slag and limestone, to replace cement clinker is a promising method to reduce the carbon emissions from cement production. To efficiently use slag and limestone, it is necessary to carefully select the particle size distribution (PSD) of the binders. This study investigated the effects of the PSD of binders on the performance of slag-limestone ternary cement. The Portland cement (PC) was prepared by grinding 95% clinker + 5% gypsum. Based on the PSD parameters of the binders, three types of ternary cements with a similar overall PSD were designed, i.e., NO.1 fine slag, medium PC, and coarse limestone; NO.2 fine limestone, medium PC, and coarse slag; NO.3. fine PC, medium slag, and coarse limestone. The binder contents in the ternary cements were (a) 50 % PC, 40 % slag, and 10 % limestone (called high cement group) or (b) 35 % PC, 55 % slag, and 10 % limestone (called low cement group). The pure PC and binary cement with 50% slag and 50% PC prepared with the same binders as the ternary cement were considered as reference cements. All these cements were used to investigate the mortar performance in terms of workability, strength at 2, 7, 28, and 90 days, carbonation resistance, and non-steady state chloride migration resistance at 28 and 56 days. Results show that blending medium PC with fine slag could exhibit comparable performance to blending fine PC with medium/coarse slag in binary cement. For the three ternary cements in the high cement group, ternary cement with fine limestone (NO.2) shows the lowest strength, carbonation, and chloride migration performance. Ternary cements with fine slag (NO.1) and with fine PC (NO.3) show the highest flexural strength at early and late ages, respectively. In addition, compared with ternary cement with fine PC (NO.3), ternary cement with fine slag (NO.1) has a similar carbonation resistance and a better chloride migration resistance. For the low cement group, three ternary cements have a similar flexural and compressive strength before 7 days. After 28 days, ternary cement with fine limestone (NO.2) shows the highest flexural strength while fine PC (NO.3) has the highest compressive strength. In addition, ternary cement with fine slag (NO.1) shows a better chloride migration resistance but a lower carbonation resistance compared with the other two ternary cements. Moreover, the durability performance of ternary cement with fine PC (NO.3) is better than that of fine limestone (NO.2).

Keywords: limestone, particle size distribution, slag, ternary cement

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Authors: Peloriadi Konstantina, Fakis Dimitris, Grammelis Panagiotis

Abstract:

Methods for carbon capture and storage (CCS) can play a key role in the reduction of industrial CO₂ emissions, especially in the cement industry, which accounts for 7% of global emissions. Cement industries around the world have committed to address this problem by reaching carbon neutrality by the year 2050. The aim of the work to be presented was to contribute to the decarbonization strategy by integrating the 1st generation oxyfuel technology in cement production plants. This technology has been shown to improve fuel efficiency while providing one of the most cost-effective solutions when compared to other capture methods. A validated simulation of the cement plant was thus used as a basis to develop an oxyfuel retrofitted cement process. The process model for the oxyfuel technology is developed on the ASPEN (Advanced System for Process Engineering) PLUSTM simulation software. This process consists of an Air Separation Unit (ASU), an oxyfuel cement plant with coal and alternative solid fuel (ASF) as feedstock, and a carbon dioxide processing unit (CPU). A detailed description and analysis of the CPU will be presented, including the findings of a literature review and simulation results, regarding the effects of flue gas impurities during operation. Acknowledgment: This research has been conducted in the framework of the EU funded AC2OCEM project, which investigates first and the second generation oxyfuel concepts.

Keywords: oxyfuel technology, carbon capture and storage, CO₂ processing unit, cement, aspen plus

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Authors: Olonade, K. A., Jaji, M. B., Rasak, S. A., Ojo, B. A., Adefuye, O. E.

Abstract:

Different brands of cement are used in Nigeria by local contractors for various works without prior knowledge of their performance. Qualities of common cement brands in Southwestern Nigeria were investigated. Elephant, Dangote, Gateway, Purechem, Burham and Five Star cements were selected for the study. Fineness, setting times, chemical composition, compressive and flexural strengths of each of the cement brands were determined. The results showed that all the cement brands contained major oxides in amount within the acceptable values except that the sulphite content of Gateway fell outside the range. Strength comparison indicated that Burham had highest flexural and compressive strength, followed by Elephant and then Dangote while Gateway had the lowest strength at 28 days. It was observed that Dangote cement set earlier than other cement brands. The study has shown that there were differences in performance of the selected cement brands and concluded that the choice of cement brand should be based on the expected performance.

Keywords: cement brand, compressive strength, flexural strength, local construction industries

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Authors: Hamoud Al-Hadrami, Hossein Emadi, Athar Hussain

Abstract:

Green hydrogen is quickly emerging as a new source of renewable energy for the world. Hydrogen production using water electrolysis is deemed as an environmentally friendly and safe source of energy for transportation and other industries. However, storing a high volume of hydrogen seems to be a significant challenge. Abandoned hydrocarbon reservoirs are considered as viable hydrogen storage options because of the availability of the required infrastructure such as wells and surface facilities. However, long-term wellbore integrity in these wells could be a serious challenge. Hydrogen reduces the compressive strength of a set cement if it gets in contact with the cement slurry. Also, mixing hydrogen with cement slurry slightly increases its density and rheological properties, which need to be considered to have a successful primary cementing operation.

Keywords: hydrogen, well bore integrity, clean energy, cementing

Procedia PDF Downloads 174

Authors: K. Arroudj, M. Lanez, M. N. Oudjit

Abstract:

The introduction of siliceous mineral additions in cement production allows, in addition to the ecological and economic gain, improvement of concrete performance. This improvement is mainly due to the fixing of Portlandite, released during the hydration of cement, by fine siliceous, forming denser calcium silicate hydrates and therefore a more compact cementitious matrix. This research is part of the valuation of the Dune Sand (DS) in the cement industry in Algeria. The high silica content of DS motivated us to study its effect, at ground state, on the properties of mortars in fresh and hardened state. For this purpose, cement pastes and mortars based on ground dune sand (fine quartz) has been analyzed with a replacement to cement of 15%, 20% and 25%. This substitution has reduced the amount of heat of hydration and avoids any risk of initial cracking. In addition, the grinding of the dune sand provides amorphous thin populations adsorbed at the surface of the crystal particles of quartz. Which gives to ground quartz pozzolanic character. This character results an improvement of mechanical strength of mortar (66 MPa in the presence of 25% of ground quartz).

Keywords: mineralogical structure, pozzolanic reactivity, Quartz, mechanical strength

Procedia PDF Downloads 249