Search results for: metakaolin and blast furnace slag

Authors: Eskinder Desta Shumuye, Jun Zhao, Zike Wang

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This paper summarizes the results of experimental studies carried out at Zhengzhou University, School of Mechanics and Engineering Science, research laboratory, on the performance of concrete produced by combining Ordinary Portland Cement (OPC) with Ground-Granulated Blast Furnace Slag (GGBS). Concrete specimens cast with OPC and various percentage of GGBS (0%, 30%, 50%, and 70%) were subjected to high temperature exposure and extensive experimental test reproducing basic freeze-thaw cycle and a chloride-ion attack to determine their combined effects within the concrete samples. From the experimental studies, comparisons were made on the physical, mechanical, and microstructural properties in compassion with ordinary Portland cement concrete (OPC). Further, durability of GGBS cement concrete, such as exposure to accelerated carbonation, chloride ion attack, and freeze-thaw action in compassion with various percentage of GGBS and ordinary Portland cement concrete of similar mixture composition was analyzed. The microstructure, mineralogical composition, and pore size distribution of concrete specimens were determined via Scanning Electron Microscopy (SEM) analysis and X-Ray Diffraction (XRD). The result demonstrated that when the exposure temperature increases from 200 ºC to 400 ºC, the residual compressive strength was fluctuating for all concrete group, and compressive strength and chloride ion exposure of the concrete decreased with the increasing of slag content. The SEM and EDS results showed an increase in carbonation rate with increasing in slag content.

Keywords: accelerated carbonation, chloride-ion, concrete, ground-granulated blast furnace slag, GGBS, high-temperature

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Authors: Kunal Krishna Das, Eddie S. S. Lam

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Preplaced Aggregate Concrete (PAC) is produced by first placing the coarse aggregate into the formwork, followed by injection of grout to fill in the voids in between the coarse aggregates. In this study, tests were carried out to determine the effects of supplementary cementitious materials on the properties of PAC. Cement was partially replaced by ground granulated blast furnace slag (GGBS) and silica fume (SF) at different proportions. Grout properties were determined by the flow cone test and compressive strength test. Grout proportion was optimized statistically. It was applied to form PAC. Hardened properties of PAC, comprising compressive strength, splitting tensile strength, chloride-ion penetration and drying shrinkage, were evaluated. GGBS enhanced the flowability of the grout, whereas SF enhanced the strength of PAC. Both GGBS and SF improved the resistance to chloride-ion penetration with the drawback of increased drying shrinkage. Nevertheless, drying shrinkage was within the range to be classified as low shrinkage concrete.

Keywords: factorial design, ground granulated blast furnace slag, preplaced aggregate concrete, silica fume

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Authors: Biswajit Seal, Dushyant Kumar, Shambhu Nath, A. B. Raju

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Extension of blast furnace campaign life is highly desired for blast furnace operators mainly because of reduction of operating cost and to avoid capital expenditure cost. Tata Steel Ltd, Jamshedpur plant operates seven blast furnaces with combination of old and new technologies. The focus of Tata Steel Ltd is to push for increasing productivity with good quality product and increasing campaign life. This has been challenging for older furnaces because older furnaces are generally equipped with less automation, old design and old equipment. Good operational practices, appropriate remedial measures, and regular planned maintenance helps to achieve long campaign life of old furnaces. Good operating practices like stable and consistent productivity, control of burden distribution, remedial measures like stack gunning and shotcreting for protection of stack wall, enhanced cooling system, and intermediate stack repair helps to achieve long campaign life of old blast furnaces. This paper describes experiences with the current old equipment and design of Tata Steel’s D Blast Furnace for campaign life extension.

Keywords: blast furnace, burden distribution, campaign life, productivity

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Authors: L. Rozumová, J. Seidlerová

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The aim of this paper was to study the sorption properties of a blast furnace sludge used as the sorbent. The sorbent was utilized for reduction of content of lead and zinc ions. Sorbent utilized in this work was obtained from metallurgical industry from process of wet gas treatment in iron production. The blast furnace sludge was characterized by X-Ray diffraction, scanning electron microscopy, and XRFS spectroscopy. Sorption experiments were conducted in batch mode. The sorption of metal ions in the sludge was determined by correlation of adsorption isotherm models. The adsorption of lead and zinc ions was best fitted with Langmuir adsorption isotherms. The adsorption capacity of lead and zinc ions was 53.8 mg.g^-1 and 10.7 mg.g^-1, respectively. The results indicated that blast furnace sludge could be effectively used as secondary material and could be also employed as a low-cost alternative for the removal of heavy metals ions from wastewater.

Keywords: blast furnace sludge, lead, zinc, sorption

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Authors: Amiya Kumar Thakur, Dinesh Ganvir, Prem Pal Bansal

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Industrial by product utilization has been encouraged due to environment and economic factors. Since electric arc furnace slag aggregate is a by-product of steel industry and its storage is a major concern hence it can be used as a replacement of natural aggregate as its physical and mechanical property are comparable or better than the natural aggregates. The present study investigates the effect of partial and full replacement of natural coarse aggregate with coarse EAF slag aggregate and partial replacement of cement with ground granulated blast furnace slag (GGBFS) on the mechanical and durability properties of roller compacted concrete pavement (RCCP).The replacement level of EAF slag aggregate were at five levels (i.e. 0% ,25% ,50%,75% & 100%) and of GGBFS was (0 % & 30%).The EAF slag aggregate was stabilized by exposing to outdoor condition for several years and the volumetric expansion test using steam exposure device was done to check volume stability. Soil compaction method was used for mix proportioning of RCCP. The fresh properties of RCCP investigated were fresh density and modified vebe test was done to measure the consistency of concrete. For investigating the mechanical properties various tests were done at 7 and 28 days (i.e. Compressive strength, split tensile strength, flexure strength modulus of elasticity) and also non-destructive testing was done at 28 days (i.e. Ultra pulse velocity test (UPV) & rebound hammer test). The durability test done at 28 days were water absorption, skid resistance & abrasion resistance. The results showed that with the increase in slag aggregate percentage there was an increase in the fresh density of concrete and also slight increase in the vebe time but with the 30 % GGBFS replacement the vebe time decreased and the fresh density was comparable to 0% GGBFS mix. The compressive strength, split tensile strength, flexure strength & modulus of elasticity increased with the increase in slag aggregate percentage in concrete when compared to control mix. But with the 30 % GGBFS replacement there was slight decrease in mechanical properties when compared to 100 % cement concrete. In UPV test and rebound hammer test all the mixes showed excellent quality of concrete. With the increase in slag aggregate percentage in concrete there was an increase in water absorption, skid resistance and abrasion resistance but with the 30 % GGBFS percentage the skid resistance, water absorption and abrasion resistance decreased when compared to 100 % cement concrete. From the study it was found that the mix containing 30 % GGBFS with different percentages of EAF slag aggregate were having comparable results for all the mechanical and durability property when compared to 100 % cement mixes. Hence 30 % GGBFS can be used as cement replacement with 100 % EAF slag aggregate as natural coarse aggregate replacement.

Keywords: durability properties, electric arc furnace slag aggregate, GGBFS, mechanical properties, roller compacted concrete pavement, soil compaction method

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Authors: Ayad Salih Sabbar, Amin Chegenizadeh, Hamid Nikraz

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Utilizing waste materials in civil engineering applications has a positive influence on the environment by reducing carbon dioxide emissions and issues associated with waste disposal. Granulated blast furnace slag (GBFS) is a by-product of the iron and steel industry, with millions of tons of slag being annually produced worldwide. Slag has been widely used in structural engineering and for stabilizing clay soils; however, studies on the effect of slag on sandy soils are scarce. This article investigates the effect of slag content on shear strength parameters through direct shear tests and unconsolidated undrained triaxial tests on mixtures of Perth sand and slag. For this purpose, sand-slag mixtures, with slag contents of 2%, 4%, and 6% by weight of samples, were tested with direct shear tests under three normal stress values, namely 100 kPa, 150 kPa, and 200 kPa. Unconsolidated undrained triaxial tests were performed under a single confining pressure of 100 kPa and relative density of 80%. The internal friction angles and shear stresses of the mixtures were determined via the direct shear tests, demonstrating that shear stresses increased with increasing normal stress and the internal friction angles and cohesion increased with increasing slag. There were no significant differences in shear stresses parameters when slag content rose from 4% to 6%. The unconsolidated undrained triaxial tests demonstrated that shear strength increased with increasing slag content.

Keywords: direct shear, shear strength, slag, UU test

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Authors: Vibha Venkataramu, B. V. Venkatarama Reddy

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Natural river sand is the most preferred choice as fine aggregate in masonry mortars. Uncontrolled mining of sand from riverbeds for several decades has had detrimental effects on the environment. Several countries across the world have put strict restrictions on sand mining from riverbeds. However, in countries like India, the huge infrastructural boom has made the local construction industry to look for alternative materials to sand. This study aims at understanding the suitability of granulated blast furnace slag (GBS) as fine aggregates in masonry mortars. Apart from characterising the material properties of GBS, such as particle size distribution, pH, chemical composition, etc., of GBS, tests were performed on the mortars with GBS as fine aggregate. Additionally, the properties of five brick tall, stack bonded masonry prisms with various types of GBS mortars were studied. The mortars with mix proportions 1: 0: 6 (cement: lime: fine aggregate), 1: 1: 6, and 1: 0: 3 were considered for the study. Fresh and hardened properties of mortar, such as flow and compressive strength, were studied. To understand the behaviour of GBS mortars on masonry, tests such as compressive strength and flexure bond strength were performed on masonry prisms made with a different type of GBS mortars. Furthermore, the elastic properties of masonry with GBS mortars were also studied under compression. For comparison purposes, the properties of corresponding control mortars with natural sand as fine aggregate and masonry prisms with sand mortars were also studied under similar testing conditions. From the study, it was observed the addition of GBS negatively influenced the flow of mortars and positively influenced the compressive strength. The GBS mortars showed 20 to 25 % higher compressive strength at 28 days of age, compared to corresponding control mortars. Furthermore, masonry made with GBS mortars showed nearly 10 % higher compressive strengths compared to control specimens. But, the impact of GBS on the flexural strength of masonry was marginal.

Keywords: building materials, fine aggregate, granulated blast furnace slag in mortars, masonry properties

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Authors: Kianoosh Samimi, Farhad Estakhr, Mahdi Mahdikhani, Faramaz Moodi

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Due to their fluidity and simplicity of use, self-compacting concretes (SCCs) have undeniable advantages. In recent years, the role of metakaolin as a one of pozzolanic materials in concrete has been considered by researchers. It can modify various properties of concrete, due to high pozzolanic reactions and also makes a denser microstructure. The objective of this paper is to examine the influence of three type of Portland cement and metakaolin on fresh state, compressive strength and sulfuric acid attacks in self- consolidating concrete at early age up to 90 days of curing in lime water. Six concrete mixtures were prepared with three types of different cement as Portland cement type II, Portland Slag Cement (PSC), Pozzolanic Portland Cement (PPC) and 15% substitution of metakaolin by every cement. The results show that the metakaolin admixture increases the viscosity and the demand amount of superplasticizer. According to the compressive strength results, the highest value of compressive strength was achieved for PSC and without any metakaolin at age of 90 days. Conversely, the lowest level of compressive strength at all ages of conservation was obtained for PPC and containing 15% metakaolin. According to this study, the total substitution of PSC and PPC by Portland cement type II is beneficial to the increasing in the chemical resistance of the SCC with respect to the sulfuric acid attack. On the other hand, this increase is more noticeable by the use of 15% of metakaolin. Therefore, it can be concluded that metakaolin has a positive effect on the chemical resistance of SCC containing of Portland cement type II, PSC, and PPC.

Keywords: SCC, metakaolin, cement type, durability, compressive strength, sulfuric acid attacks

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Authors: K. Y. Lin, W. H. Lee, T. W. Cheng, S. W. Huang

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Basic Oxygen Furnace (BOF) Slag is a by-product of iron making. It has great engineering properties, such as, high hardness and density, high compressive strength, low abrasion ratio, and can replace natural aggregate for building materials. However, the main problem for BOF slag is expansion, due to it contains free lime or free magnesium. The purpose of this study was to stabilize the BOF slag by using geopolymeric technology, hoping can prevent BOF slag expansion. Geopolymer processes contain a large amount of free silicon. These free silicon can react with free-lime or free magnesium oxide in BOF slag, and thus to form stable compound, therefore inhibit the expansion of the BOF slag. In this study for the successful preparation of geopolymer mortar with BOF slag, and their main properties are analyzed with regard to their use as building materials. Autoclave is used to study the volume stability of these geopolymer mortar. Finally, the compressive strength of geopolymer mortar with BOF slag can be reached 33MPa in 28 days. After autoclave testing, the volume expansion does not exceed 0.2%. Even after the autoclave test, the compressive strength can increase to 35MPa. According to the research results can be proved that using geopolymer technology for stabilizing BOF slag is very effective.

Keywords: BOF slag, autoclave test, geopolymer, swell behavior

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Authors: Maryam Ghareh Chaei, Masuzyo Chilwesa, Ali Akbarnezhad, Arnaud Castel, Redmond Lloyd, Stephen Foster

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Cement hydration is an exothermic chemical reaction generally leading to a rise in concrete’s temperature. This internal heating of concrete may, in turn, lead to a temperature difference between the hotter interior and the cooler exterior of concrete and thus differential thermal stresses in early ages which could be particularly significant in mass concrete. Such differential thermal stresses result in early age thermal cracking of concrete when exceeding the concrete’s tensile strength. The extent of temperature rise and thus early age differential thermal stresses is generally a function of hydration heat intensity, thermal properties of concrete and size of the concrete element. Both hydration heat intensity and thermal properties of concrete may vary considerably with variations in the type cementitious materials and other constituents. With this in mind, partial replacement of cement with supplementary cementitious materials including fly ash and ground granulated blast furnace slag has been investigated widely as an effective strategy to moderate the heat generation rate and thus reduce the risk of early age thermal cracking of concrete. However, there is currently a lack of adequate literature on effect of partial replacement of cement with fly ash and/or ground granulated blast furnace slag on the thermal properties of concrete. This paper presents the results of an experimental conducted to evaluate the effect of addition of varying percentages of fly ash (up to 60%) and ground granulated blast furnace slag (up to 50%) on the heat capacity and thermal conductivity of early age cement paste. The water to cementitious materials ratio is kept 0.45 for all the paste samples. The results of the experimental studies were used in a numerical analysis performed using Comsol Multiphysics to highlight the effects of variations in the thermal properties of concrete, due to variations in the type of aggregate and content of supplemenraty cementitious materials, on the risk of early age cracking of a concrete raft.

Keywords: thermal diffusivity, early age thermal cracking, concrete, supplementary cementitious materials

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Authors: Festus A. Olutoge, Ahmed A. Akintunde, Anuoluwapo S. Kolade, Aaron A. Chadee, Jovanca Smith

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Geopolymer concrete's (GPC) compressive strength was investigated. The GPC was incorporated with rice husk ash (RHA) and ground granulated blast furnace slag (GGBFS), which may have potential in the construction industry to replace Portland limestone cement (PLC) concrete. The sustainable construction binders used were GGBFS and RHA, and a solution of sodium hydroxide (NaOH) and sodium silicate gel (Na₂SiO₃) was used as the 12-molar alkaline activator. Five GPC mixes comprising fine aggregates, coarse aggregates, GGBS, and RHA, and the alkaline solution in the ratio 2: 2.5: 1: 0.5, respectively, were prepared to achieve grade 40 concrete, and PLC was wholly substituted with GGBFS and RHA in the ratios of 0:100, 25:75, 50:50, 75:25, and 100:0. A control mix was also prepared which comprised of 100% water and 100% PLC as the cementitious material. The GPC mixes were thermally cured at 60-80ºC in an oven for approximately 24hrs. After curing for 7 and 28 days, the compressive strength test results of the hardened GPC samples showed that GPC-Mix #3, comprising 50% GGBFS and 50% RHA, was the most efficient geopolymer mix. The mix had compressive strengths of 35.71MPa and 47.26MPa, 19.87% and 8.69% higher than the PLC concrete samples, which had 29.79MPa and 43.48MPa after 7 and 28 days, respectively. Therefore, geopolymer concrete containing GGBFS incorporated with RHA is an efficient method of decreasing the use of PLC in conventional concrete production and reducing the high amounts of CO₂ emitted into the atmosphere in the construction industry.

Keywords: alkaline solution, cementitious material, geopolymer concrete, ground granulated blast furnace slag, rice husk ash

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Authors: Abdulkarim Mohammed Iliyasu, Mahmud Abba Tahir

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Freezing and thawing are considered to be one of the major causes of concrete deterioration in the cold regions. This study aimed at assessing the freezing and thawing of concrete within the cover zone by monitoring the formation of ice and melting at different temperatures using electrical measurement technique. A multi-electrode array system was used to obtain the resistivity of ice formation and melting at discrete depths within the cover zone of the concrete. A total number of four concrete specimens (250 mm x 250 mm x 150 mm) made of ordinary Portland cement concrete and ordinary Portland cement replaced by 65% ground granulated blast furnace slag (GGBS) is investigated. Water/binder ratios of 0.35 and 0.65 were produced and ponded with water to ensure full saturation and then subjected to freezing and thawing process in a refrigerator within a temperature range of -30 ⁰C and 20 ⁰C over a period of time 24 hours. The data were collected and analysed. The obtained results show that the addition of GGBS changed the pore structure of the concrete which resulted in the decrease in conductance. It was recommended among others that, the surface of the concrete structure should be protected as this will help to prevent the instantaneous propagation of ice trough the rebar and to avoid corrosion and subsequent damage.

Keywords: concrete, conductance, deterioration, freezing and thawing

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Authors: Basant Kumar Singh, S. Subhachandhar, Vineet Ranjan Tripathi, Amit Kumar Singh, Uttam Singh, Santosh Kumar Lal

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Productivity of Blast Furnace is largely impacted by fuel efficiency and controlling heat loss is one of the enabling parameters for achieving lower fuel rate. 'I' Blast Furnace is the latest and largest Blast Furnace of Tata Steel Jamshedpur with working volume of 3230 m³ and with rated capacity of 3.055 million tons per annum. Optimizing heat losses in Belly and Bosh zone remained major challenge for blast furnace operators after its commissioning. 'I' Blast has installed Cast Iron & Copper Staves cooling members where copper staves are installed in Belly, Bosh & Lower Stack whereas cast iron staves are installed in upper stack area. Stave cooled Blast Furnaces are prone to higher heat losses in Belly and Bosh region with an increase in coal injection rate as Bosh gas volume increases. Under these conditions, managing gas flow pattern through proper burden distribution, casting techniques & by maintaining desired raw material qualities are of utmost importance for sustaining high injection rates. This study details, the burden distribution control by Ore & Coke ratio adjustment at wall and center of Blast Furnace as the coal injection rates increased from 140 kg/thm to 210 kg/thm. Control of blowing parameters, casting philosophy, specification for raw materials & devising operational practice for controlling heat losses is also elaborated with the model that is used to visualize heat loss pattern in different zones of Blast Furnace.

Keywords: blast furnace, staves, gas flow pattern, belly/bosh heat losses, ore/coke ratio, blowing parameters, casting, operation practice

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Authors: W. H. Lee, T. W. Cheng, K. Y. Lin, S. W. Huang, Y. C. Ding

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Basic Oxygen Furnace (BOF) Slag and electric arc furnace (EAF) slag is the by-product of iron making and steel making. Each of slag with produced over 100 million tons annually in Taiwan. The type of slag has great engineering properties, such as, high hardness and density, high compressive strength, low abrasion ratio, and can replace natural aggregate for building materials. However, no matter BOF or EAF slag, both have the expansion problem, due to it contains free lime. The purpose of this study was to stabilize the BOF and EAF slag by using geopolymer technology, hoping can prevent and solve the expansion problem. The experimental results showed that using geopolymer technology can successfully solve and prevent the expansion problem. Their main properties are analyzed with regard to their use as building materials. Autoclave is used to study the volume stability of these specimens. Finally, the compressive strength of geopolymer mortar with BOF/FAF slag can be reached over 21MPa after curing for 28 days. After autoclave testing, the volume expansion does not exceed 0.2%. Even after the autoclave test, the compressive strength can be grown to over 35MPa. In this study have success using these results on ready-mixed concrete plant, and have the same experimental results as laboratory scale. These results gave encouragement that the stabilized and reutilized BOF/EAF slag could be replaced as a feasible natural fine aggregate by using geopolymer technology.

Keywords: BOF slag, EAF slag, autoclave test, geopolymer

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Authors: Sebastiano Candamano, Antonio Iorfida, Patrizia Frontera, Anastasia Macario, Fortunato Crea

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Alkali-activated materials are promising binders obtained by an alkaline attack on fly-ashes, metakaolin, blast slag among others. In order to guarantee the highest ecological and cost efficiency, a proper selection of precursors and alkaline activators has to be carried out. These choices deeply affect the microstructure, chemistry and performances of this class of materials. Even if, in the last years, several researches have been focused on mix designs and curing conditions, the lack of exhaustive activation models, standardized mix design and curing conditions and an insufficient investigation on shrinkage behavior, efflorescence, additives and durability prevent them from being perceived as an effective and reliable alternative to Portland. The aim of this study is to develop alkali-activated cements mortars containing high amounts of industrial by-products and waste, such as ground granulated blast furnace slag (GGBFS) and ashes obtained from the combustion process of forest biomass in thermal power plants. In particular, the experimental campaign was performed in two steps. In the first step, research was focused on elucidating how the workability, mechanical properties and shrinkage behavior of produced mortars are affected by the type and fraction of each precursor as well as by the composition of the activator solutions. In order to investigate the microstructures and reaction products, SEM and diffractometric analyses have been carried out. In the second step, their durability in harsh environments has been evaluated. Mortars obtained using only GGBFS as binder showed mechanical properties development and shrinkage behavior strictly dependent on SiO2/Na2O molar ratio of the activator solutions. Compressive strengths were in the range of 40-60 MPa after 28 days of curing at ambient temperature. Mortars obtained by partial replacement of GGBFS with metakaolin and forest biomass ash showed lower compressive strengths (≈35 MPa) and shrinkage values when higher amount of ashes were used. By varying the activator solutions and binder composition, compressive strength up to 70 MPa associated with shrinkage values of about 4200 microstrains were measured. Durability tests were conducted to assess the acid and thermal resistance of the different mortars. They all showed good resistance in a solution of 5%wt of H2SO4 also after 60 days of immersion, while they showed a decrease of mechanical properties in the range of 60-90% when exposed to thermal cycles up to 700°C.

Keywords: alkali activated cement, biomass ash, durability, shrinkage, slag

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Authors: H. Higashiyama, M. Sappakittipakorn, M. Mizukoshi, O. Takahashi

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Ceramic waste aggregates (CWAs) were made from electric porcelain insulator wastes supplied from an electric power company, which were crushed and ground to fine aggregate sizes. In this study, to develop the CWA mortar as an eco–efficient, ground granulated blast–furnace slag (GGBS) as a supplementary cementitious material (SCM) was incorporated. The water–to–binder ratio (W/B) of the CWA mortars was varied at 0.4, 0.5, and 0.6. The cement of the CWA mortar was replaced by GGBS at 20 and 40% by volume (at about 18 and 37% by weight). Mechanical properties of compressive and splitting tensile strengths, and elastic modulus were evaluated at the age of 7, 28, and 91 days. Moreover, the chloride ingress test was carried out on the CWA mortars in a 5.0% NaCl solution for 48 weeks. The chloride diffusion was assessed by using an electron probe microanalysis (EPMA). To consider the relation of the apparent chloride diffusion coefficient and the pore size, the pore size distribution test was also performed using a mercury intrusion porosimetry at the same time with the EPMA. The compressive strength of the CWA mortars with the GGBS was higher than that without the GGBS at the age of 28 and 91 days. The resistance to the chloride ingress of the CWA mortar was effective in proportion to the GGBS replacement level.

Keywords: ceramic waste aggregate, chloride diffusion, GGBS, pore size distribution

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Authors: M. Boháč, R. Novotný, F. Frajkorová, R. S. Yadav, T. Opravil, M. Palou

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Properties of Portland cement mixtures with various fractions of metakaolin were studied. 10 % of Portland cement CEM I 42.5 R was replaced by different fractions of high reactivity metakaolin with defined chemical and mineralogical properties. Various fractions of metakaolin were prepared by jet mill classifying system. There is a clear trend between fineness of metakaolin and hydration heat development. Due to metakaolin presence in mixtures the compressive strength development of mortars is rather slower for coarser fractions but 28-day flexural strengths are improved for all fractions of metakaoline used in mixtures compared to reference sample of pure Portland cement. Yield point, plastic viscosity and adhesion of fresh pastes are considerably influenced by fineness of metakaolin used in cement pastes.

Keywords: calorimetry, cement, metakaolin fineness, rheology, strength

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Authors: V. Revathi, J. Thaarrini, M. Venkob Rao

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This paper presents a study on use of alkali activated bottom ash (BA) and ground granulated blast furnace slag (GGBS) blend in paver blocks. A preliminary effort on alkali-activated bottom ash, blast furnace slag based geopolymer (BA-GGBS-GP) mortar with river sand was carried out to identify the suitable mix for paver block. Several mixes were proposed based on the combination of BA-GGBS. The percentage ratio of BA:GGBS was selected as 100:0, 75:25, 50:50, 25:75 and 0:100 for the source material. Sodium based alkaline activators were used for activation. The molarity of NaOH was considered as 8M. The molar ratio of SiO2 to Na2O was varied from 1 to 4. Two curing mode such as ambient and steam curing 60°C for 24 hours were selected. The properties of paver block such as compressive strength split tensile strength, flexural strength and water absorption were evaluated as per IS15658:2006. Based on the preliminary study on BA-GGBS-GP mortar, the combinations of 25% BA with 75% GGBS mix for M30 and 75% BA with 25% GGBS mix for M35 grade were identified for paver block. Test results shows that the combination of BA-GGBS geopolymer paver blocks attained remarkable compressive strength under steam curing as well as in ambient mode at 3 days. It is noteworthy to know BA-GGBS-GP has promising future in the construction industry.

Keywords: bottom ash, GGBS, alkali activation, paver block

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Authors: Nils Mueller, Gregor Herz, Erik Reichelt, Matthias Jahn

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In the context of climate change, the reduction of greenhouse gas emissions in all economic sectors is considered to be an important factor in order to meet the demands of a sustainable energy system. The steel industry as one of the large industrial CO₂ emitters is currently highly dependent on fossil resources. In order to reduce coke consumption and thereby CO₂ emissions while still being able to further utilize existing blast furnaces, the possibility of including a direct reduction process (DRP) into a fully integrated steel mill was investigated. Therefore, a blast furnace model, derived from literature data and implemented in Aspen Plus, was used to analyze the impact of DRI in the blast furnace process. Furthermore, a state-of-the-art DRP was modeled to investigate the possibility of substituting the reducing agent natural gas with hydrogen. A sensitivity analysis was carried out in order to find the boundary percentage of hydrogen as a reducing agent without penalty to the DRI quality. Lastly, the two modeled process steps were combined to form a route of producing pig iron. By varying boundary conditions of the DRP while recording the CO₂ emissions of the two process steps, the overall potential for the reduction of CO₂ emissions was estimated. Within the simulated range, a maximum reduction of CO₂ emissions of 23.5% relative to typical emissions of a blast furnace could be determined.

Keywords: blast furnace, CO₂ mitigation, DRI, hydrogen

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Authors: Chayan Gupta, Arun Prasad

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The quick evolution of industrialization causes the scarcity of precious land. Thus, it is vital need to influence the R&D societies to achieve sustainable, economic and social benefits from huge utilization of waste for universal aids. The current study promotes the influence of steel industries waste i.e. ground granulated blast furnace slag (GGBS) in geotechnical properties of jarosite waste (solid waste residues produced from hydrometallurgy operations involved in extraction of Zinc). Numerous strengths tests (unconfined compression (qu) and splitting tensile strength (qt)) are conducted on jarosite-GGBS blends (GGBS, 10-30%) with different curing periods (7, 28 & 90 days). The results indicate that both qu and qt increase with the increase in GGBS content along with curing periods. The increased strength with the addition of GGBS is also observed from microstructural study, which illustrates the occurrence of larger agglomeration of jarosite-GGBS blend particles. The Freezing-Thawing (F-T) durability analysis is also conducted for all the jarosite-GGBS blends and found that the reduction in unconfined compressive strength after five successive F-T cycles enhanced from 62% (natural jarosite) to 48, 42 and 34% at 7, 14 and 28 days curing periods respectively for stabilized jarosite-GGBS samples containing 30% GGBS content. It can be concluded from this study that blending of cementing additives (GGBS) with jarosite waste resulted in a significant improvement in geotechnical characteristics.

Keywords: jarosite, GGBS, strength characteristics, microstructural study, durability analysis

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Authors: L. Pu, C. Unluer

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MgO cements have the potential to sequester CO2 in construction products, and can be partial or complete replacement of PC in concrete. Construction block is a promising application for reactive MgO cements. Main advantages of blocks are: (i) suitability for sequestering CO2 due to their initially porous structure; (ii) lack of need for in-situ treatment as carbonation can take place during fabrication; and (iii) high potential for commercialization. Both strength gain and carbon sequestration of MgO cements depend on carbonation process. Fly ash and ground granulated blast-furnace slag (GGBS) are pozzolanic material and are proved to improve many of the performance characteristics of the concrete, such as strength, workability, permeability, durability and corrosion resistance. A very limited amount of work has been reported on the production of MgO blocks on a large scale so far. A much more extensive study, wherein blocks with different mix design is needed to verify the feasibility of commercial production. The changes in the performance of the samples were evaluated by compressive strength testing. The properties of the carbonation products were identified by X-ray diffraction (XRD) and scanning electron microscopy (SEM)/ field emission scanning electron microscopy (FESEM), and the degree of carbonation was obtained by thermogravimetric analysis (TGA), XRD and energy dispersive X-ray (EDX). The results of this study enabled the understanding the relationship between lab-scale samples and scale-up blocks based on their mechanical performance and microstructure. Results indicate that for both scaled-up and lab-scale samples, MgO samples always had the highest strength results, followed by MgO-fly ash samples and MgO-GGBS had relatively lowest strength. The lower strength of MgO with fly ash/GGBS samples at early stage is related to the relatively slow hydration process of pozzolanic materials. Lab-scale cubic samples were observed to have higher strength results than scaled-up samples. The large size of the scaled-up samples made it more difficult to let CO2 to reach inner part of the samples and less carbonation products formed. XRD, TGA and FESEM/EDX results indicate the existence of brucite and HMCs in MgO samples, M-S-H, hydrotalcite in the MgO-fly ash samples and C-S-H, hydrotalctie in the MgO-GGBS samples. Formation of hydration products (M-S-H, C-S-H, hydrotalcite) and carbonation products (hydromagnecite, dypingite) increased with curing duration, which is the reason of increasing strength. This study verifies the advantage of large-scale MgO blocks over common PC blocks and the feasibility of commercial production of MgO blocks.

Keywords: reactive MgO, fly ash, ground granulated blast-furnace slag, carbonation, CO₂

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Authors: S. Jursová, P. Pustějovská, S. Brožová, J. Bilík

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The paper deals with possibilities of interpretation of iron ore reducibility tests. It presents a mathematical model developed at Centre ENET, VŠB–Technical University of Ostrava, Czech Republic for an evaluation of metallurgical material of blast furnace feedstock such as iron ore, sinter or pellets. According to the data from the test, the model predicts its usage in blast furnace technology and its effects on production parameters of shaft aggregate. At the beginning, the paper sums up the general concept and experience in mathematical modelling of iron ore reduction. It presents basic equation for the calculation and the main parts of the developed model. In the experimental part, there is an example of usage of the mathematical model. The paper describes the usage of data for some predictive calculation. There are presented material, method of carried test of iron ore reducibility. Then there are graphically interpreted effects of used material on carbon consumption, rate of direct reduction and the whole reduction process.

Keywords: blast furnace technology, iron ore reduction, mathematical model, prediction of iron ore reduction

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Authors: Zhuomin Zou, Thijs Van Landeghem, Elke Gruyaert

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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

Procedia PDF Downloads 92

Authors: Ali Shubbar, Hassnen M. Jafer, Anmar Dulaimi, William Atherton, Ali Al-Rifaie

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This research represents experimental work for investigation of the influence of utilising Ground Granulated Blast Furnace Slag (GGBS) and High Calcium Fly Ash (HCFA) as a partial replacement for Ordinary Portland Cement (OPC) and produce a low carbon cementitious material with comparable compressive strength to OPC. Firstly, GGBS was used as a partial replacement to OPC to produce a binary blended cementitious material (BBCM); the replacements were 0, 10, 15, 20, 25, 30, 35, 40, 45 and 50% by the dry mass of OPC. The optimum BBCM was mixed with HCFA to produce a ternary blended cementitious material (TBCM). The replacements were 0, 10, 15, 20, 25, 30, 35, 40, 45 and 50% by the dry mass of BBCM. The compressive strength at ages of 7 and 28 days was utilised for assessing the performance of the test specimens in comparison to the reference mixture using 100% OPC as a binder. The results showed that the optimum BBCM was the mix produced from 25% GGBS and 75% OPC with compressive strength of 32.2 MPa at the age of 28 days. In addition, the results of the TBCM have shown that the addition of 10, 15, 20 and 25% of HCFA to the optimum BBCM improved the compressive strength by 22.7, 11.3, 5.2 and 2.1% respectively at 28 days. However, the replacement of optimum BBCM with more than 25% HCFA have showed a gradual drop in the compressive strength in comparison to the control mix. TBCM with 25% HCFA was considered to be the optimum as it showed better compressive strength than the control mix and at the same time reduced the amount of cement to 56%. Reducing the cement content to 56% will contribute to decrease the cost of construction materials, provide better compressive strength and also reduce the CO₂ emissions into the atmosphere.

Keywords: cementitious material, compressive strength, GGBS, HCFA, OPC

Procedia PDF Downloads 174

Authors: M. Al-Majidi, A. Lampropoulos, A. Cundy

Abstract:

Geopolymer (cement-free) concrete is the most promising green alternative to ordinary Portland cement concrete and other cementitious materials. While a range of different geopolymer concretes have been produced, a common feature of these concretes is heat curing treatment which is essential in order to provide sufficient mechanical properties in the early age. However, there are several practical issues with the application of heat curing in large-scale structures. The purpose of this study is to develop cement-free concrete without heat curing treatment. Experimental investigations were carried out in two phases. In the first phase (Phase A), the optimum content of water, polycarboxylate based superplasticizer contents and potassium silicate activator in the mix was determined. In the second stage (Phase B), the effect of ground granulated blast furnace slag (GGBFS) incorporation on the compressive strength of fly ash (FA) and Slag based geopolymer mixtures was evaluated. Setting time and workability were also conducted alongside with compressive tests. The results showed that as the slag content was increased the setting time was reduced while the compressive strength was improved. The obtained compressive strength was in the range of 40-50 MPa for 50% slag replacement mixtures. Furthermore, the results indicated that increment of water and superplasticizer content resulted to retarding of the setting time and slight reduction of the compressive strength. The compressive strength of the examined mixes was considerably increased as potassium silicate content was increased.

Keywords: fly ash, geopolymer, potassium silicate, slag

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Authors: Amol Rakhunde, Namdeo Hedaoo

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Cold bituminous emulsion mixes (CBEM) are preferred due to their low cost for the construction of low volume roads in India. Due to the low strength of CBEM’s, the strength is generally increased by the addition of Ordinary Portland Cement (OPC) and hydrated lime. To improve the performance of CBEM’s, the use of industrial waste material is also an alternative. Steel slag is by product of steel industry which is sustainable construction material. Due to limited modes of practice of utilization steel slag, huge amount of steel slag dumped in yards of each steel industry and engaging of important agricultural land and gave pollution to whole environment. The effective use of steel slag as additives in CBEM’s has ultimate benefits such improvement in strength of CBEM’s, waste disposal steel slag, saving natural aggregate and lowering cost of roadways. Studies carried out in the past have shown a significant improvement in the strength of CBEM’s prepared with the replacement of natural aggregate with industrial waste materials such as fly ash and ground granulated blast furnace slag. In this study, effect of modified mix which is mixes prepared with steel slag compared with the control mix and the mixes prepared with OPC. Experimental work was carried out on the sample of control mix, OPC mix, and modified mix. For modified mix, aggregate was replaced with steel slag by 10%, 20%, 30% and 40% of weight of aggregate of same size as of steel slag in aggregate gradation. For OPC mix, filler was replaced by 1%, 2% and 3% of weight of total aggregate with OPC. Optimum emulsion content of each mix obtained by using Marshall stability test and comparison of stability values were carried out. Marshall stability, indirect tensile strength test, and retained stability tests are performed on control mixes, OPC mixes and modified mixes. Significant improvement in Marshall stability retained stability and indirect tensile strength of modified mix compared to control mix and OPC mix.

Keywords: CBEM, indirect tensile strength test, Marshall stability test, OPC, optimum emulsion content, retained stability test, steel slag

Procedia PDF Downloads 125

Authors: Sulaem Musaddiq Laskar, Sudip Talukdar

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Sustainable supplementary cementitious material is the prime need in the construction industry. Geopolymer has strong potential for replacing the conventional Portland cement used in mortar and concrete in the industry. This study deals with experimental investigations performed on geopolymer mixes prepared from both ultra-fine ground granulated blast furnace slag and fly ash in a certain proportion. Geopolymer mixes were prepared with alkali activator composed of sodium hydroxide solution and varying amount of superplasticizer. The mixes were tested to study fresh and hardened state properties such as setting time, workability and compressive strength. Influence of concentration of alkali activator on effectiveness of superplasticizer in modifying the properties of geopolymer mixes was also investigated. Results indicated that addition of superplasticizer to ultra-fine slag-fly ash based geopolymer is advantageous in terms of setting time, workability and strength performance but up to certain dosage level. Higher concentration of alkali activator renders ineffectiveness in superplasticizer in improving the fresh and hardened state properties of geopolymer mixes.

Keywords: ultra-fine slag, fly ash, superplasticizer, setting time, workability, compressive strength

Procedia PDF Downloads 160

Authors: Bing Song, Kexi Han, Xuewei Lv

Abstract:

Titania slag is a high quality raw material containing titanium in the subsequent process of titanium pigment. The effects of cooling approaches of granulating, water cooling, and air cooling on chemical, phases, and acidolysis of Panzhihua titania slag were investigated. Compared to the original slag which was prepared by the conventional processing route, the results show that the titania slag undergoes oxidation of Ti³⁺during different cooling ways. The Ti₂O₃ content is 17.50% in the original slag, but it is 16.55% and 16.84% in water cooled and air-cooled slag, respectively. Especially, the Ti₂O₃ content in granulated slag is decreased about 27.6%. The content of Fe₂O₃ in granulated slag is approximately 2.86% also obviously higher than water (<0.5%) or air-cooled slag (<0.5%). Rutile in cooled titania slag was formed because of the oxidation of Ti³⁺. The rutile phase without a noticeable change in water cooled and air-cooled slag after the titania slag was cooled, but increased significantly in the granulated slag. The rate of sulfuric acid acidolysis of cooled slag is less than the original slag. The rate of acidolysis is 90.61% and 92.46% to the water-cooled slag and air-cooled slag, respectively. However, the rate of acidolysis of the granulated slag is less than that of industry slag about 20%, only 74.72%.

Keywords: cooling approaches, titania slag, granulating, sulfuric acid acidolysis

Procedia PDF Downloads 211

Authors: A. Q. Sobia, M. S. Hamidah, I. Azmi, S. F. A. Rafeeqi

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Fibre-reinforced polymer (FRP) strengthened reinforced concrete (RC) structures are susceptible to intense deterioration when exposed to elevated temperatures, particularly in the incident of fire. FRP has the tendency to lose bond with the substrate due to the low glass transition temperature of epoxy; the key component of FRP matrix.  In the past few decades, various types of high performance cementitious composites (HPCC) were explored for the protection of RC structural members against elevated temperature. However, there is an inadequate information on the influence of elevated temperature on the ultra high performance fibre-reinforced cementitious composites (UHPFRCC) containing ground granulated blast furnace slag (GGBS) as a replacement of high alumina cement (HAC) in conjunction with hybrid fibres (basalt and polypropylene fibres), which could be a prospective fire resisting material for the structural components. The influence of elevated temperatures on the compressive as well as flexural strength of UHPFRCC, made of HAC-GGBS and hybrid fibres, were examined in this study. Besides control sample (without fibres), three other samples, containing 0.5%, 1% and 1.5% of basalt fibres by total weight of mix and 1 kg/m³ of polypropylene fibres, were prepared and tested. Another mix was also prepared with only 1 kg/m³ of polypropylene fibres. Each of the samples were retained at ambient temperature as well as exposed to 400, 700 and 1000 °C followed by testing after 28 and 56 days of conventional curing. Investigation of results disclosed that the use of hybrid fibres significantly helped to improve the ambient temperature compressive and flexural strength of UHPFRCC, which was found to be 80 and 14.3 MPa respectively. However, the optimum residual compressive strength was marked by UHPFRCC-CP (with polypropylene fibres only), equally after both curing days (28 and 56 days), i.e. 41%. In addition, the utmost residual flexural strength, after 28 and 56 days of curing, was marked by UHPFRCC– CP and UHPFRCC– CB2 (1 kg/m³ of PP fibres + 1% of basalt fibres) i.e. 39% and 48.5% respectively.

Keywords: fibre reinforced polymer materials (FRP), ground granulated blast furnace slag (GGBS), high-alumina cement, hybrid, fibres

Procedia PDF Downloads 265

Authors: Junhai Liao, Yansong Shen, Aibing Yu

Abstract:

A 3D numerical model is developed to simulate the complicated in-furnace combustion phenomena in the lower part of an ironmaking blast furnace (BF) while using pulverized coal injection (PCI) technology to reduce the consumption of relatively expensive coke. The computational domain covers blowpipe-tuyere-raceway-coke bed in the BF. The model is validated against experimental data in terms of gaseous compositions and coal burnout. Parameters, such as coal properties and some key operational variables, play an important role on the performance of coal combustion. Their diverse effects on different combustion characteristics are examined in the domain, in terms of gas compositions, temperature, and burnout. The heat generated by the combustion of upgraded Victorian brown coal is able to meet the heating requirement of a BF, hence making upgraded brown coal injected into BF possible. It is evidenced that the model is suitable to investigate the mechanism of the PCI operation in a BF. Prediction results provide scientific insights to optimize and control of the PCI operation. This model cuts the cost to investigate and understand the comprehensive combustion phenomena of upgraded Victorian brown coal in a full-scale BF.

Keywords: blast furnace, numerical study, pulverized coal injection, Victorian brown coal

Procedia PDF Downloads 211