What Is Clinker Factor In Cement?

What Is Clinker Factor In Cement
Clinker. An intermediate product in cement manufacturing produced by decarbonizing, sintering, and fast- cooling ground limestone. Clinker factor. The percentage of clinker in cement (according to the WBCSD-CSI Cement CO2 and Energy Protocol).

What is cement clinker ratio?

Status of the technology and its future market potential – While slag cement use is miniscule in contrast with portland cement use, it has been around for a while. In fact, it was used in the building of both the Paris underground system and the Empire State Building.

According to the Slag Cement Association, slag cement can replace up to 50% of portland cement in most common concrete mixtures, and up to 80% “in massive concrete elements and other specialized structures.” Not only does its use cut down CO 2 emissions, it also helps save energy. In many countries, slag is being used for cement production, such as in China, where nowadays, steel slag is a useful resource rather than a “waste”, since extensive applications of slag have been developed.

At the same time, the Government of China encourages the use of coal ash powder to produce low quanlity cement through tax refunds. China merits special attention because of its high share of world production and its production technology. Thus far, inefficient vertical shaft kilns dominate in China, but the country’s capacity base is changing quickly.

  1. In developed countries, such as the U.S., the generally declining trend in the U.S.
  2. Output of iron and steel implies future overall supply constraints from domestic sources, especially as existing stockpiles get drawn down.
  3. This is especially true for the long-term availability of air-cooled slag, given the continuing decline in the number of operating blast furnaces In the long term, new cement types may be developed that do not use limestone as a primary resource.

These new types are called synthetic pozzolans. The technological feasibility, economics and energy effects of such alternative cementsremain speculative (IEA 2008). Admixtures help create “high-performance cements” basedon mechanochemical activation of certain ratios of clinker, gypsum,admixture, and optionally, a mineral additive of industrialor natural origin that imparts a high strength and extreme durabilityto the concrete or mortar made from it.

Why is clinker used in cement?

Use of Clinker: Conversion to Cement – Clinker, combined with additives and ground into a fine powder, is used as a binder in cement products. Different substances are added to achieve specific properties in the produced cement. Gypsum added to and ground with clinker regulates the setting time and gives the most important property of cement, compressive strength.

It also prevents agglomeration and coating of the powder at the surface of balls and mill wall. Some organic substances, such as Triethanolamine (used at 0.1 wt.%), are added as grinding aids to avoid powder agglomeration. Other additives sometimes used are ethylene glycol, oleic acid, and dodecyl-benzene sulphonate.

The most notable type of cement produced is Portland cement, but certain active ingredients of chemical admixtures may be added to clinker to produce other types of cement, such as:

  • ground granulated blast furnace slag cement
  • pozzolana cement
  • silica fume cement

Clinker is primarily used to produce cement. Since it can be stored in dry condition for several months without noticeable deterioration, it is traded internationally in large amounts. Cement manufacturers buy clinker for their cement plants in areas where raw materials for cement are scarce or unavailable.

How can we reduce the clinker factor of cement?

One approach to reducing carbon footprint is to use supplementary cementitious materials (SCMs) to lower the clinker factor of cement. Each 1% drop in clinker factor can reduce emitted CO 2 by 8-9 kg/cement tonne.

What is clinker quality?

Introduction – In module 2 of the course we are going to focus on the quality and composition of cement clinker. Perhaps we should first define quality as it relates to cement clinker. Primarily clinker quality is judged by the hydraulic performance of cement made from the clinker. Hydraulic performance of cement covers strength development, setting characteristics, workability and durability and the consistency of those hydraulic performance characteristics. The clinker quality and composition affects all these hydraulic characteristics of the cement, although setting and workability can be adjusted or controlled in the finish milling of the cement. Durability of concrete made from cement is certainly determined by the clinker quality and composition. The clinker must be combined to a low residual free lime (<2.5%) and not contain more than 5% MgO. However, presuming adequate combination, the strength development of the cement made from the clinker is the primary measure of clinker quality. The strength development of cement, and concrete made from cement, is determined by the silicate content of the cement in the minerals C3S and C2S. The higher the silica modulus (SM) of clinker the greater the silicate content, but we have seen in Module 1 that if the SM exceeds 4.0 then there are difficulties in combining the clinker. The early strength of cement derives primarily from the C3S, the higher the lime saturation (LSF) of the clinker the higher will be the C3S content, up to the maximum of 100% lime saturated. The raw materials in kiln feed can be proportioned to high LSF and SM targets to maximise silicate and C3S content, but what does lime saturation actually mean? Will the real clinker mineralogy correspond with the target from the proportioning? Will strength development of the C3S and C2S be as expected? Is strength development only dependent on the amount of the C3S and C2S present? Or is the C3S and C2S in some clinkers better at strength development than others? What is the role of minor compounds and constituents in the clinker? How can the strength development of the C3S and C2S be controlled and predicted? These are the questions we will try to answer in this Module 2 of the course. We will certainly not be able to answer these questions without an understanding of CaO-SiO2-Al2O3-Fe2O3 (CSAF) quaternary system. The CaO-SiO2-Al2O3-Fe2O3 (CSAF) quaternary system is where we will start in the next session of the course. There is no exercise associated with this session 1 of module 2, however, I recommend trying Quiz 2.1 to assess your current knowledge before studying the rest of the sessions, then repeating later as self-assessment.

What is clinker formula?

The amount of C 3 A in high sulphur clinker could be calculated by the following formula: % of C 3 A = 2.65 × (%Al 2 O 3 – (%Al 2 O 3 ( Silicate phases ) ) −1.692 × %Fe 2 O 3. C 3 A = 2.65 × ( % Al 2 O 3 − ( 0.469 × % SO 3 + 0.15 ) ) − 1.692 × % Fe 2 O 3.

What is the percentage of clinker?

Clinker Substitution – Cembureau

Clinker can be blended with a range of alternative materials, including pozzolans, finely ground limestone and waste materials or industrial by-products. The clinker-to-cement ratio (percentage of clinker compared to other non-clinker components) has an impact on the properties of cement so standards determine the type and proportion of alternative main constituents that can be used. To ensure the future use of other constituents, the cement industry is dependent on the local supply of these materials.

The use of other constituents in cement and the reduction of the clinker-to-cement ratio means lower emissions and lower energy use. Ordinary Portland cement can contain up to 95% clinker (the other 5% being gypsum). The current average clinker-to-cement ratio over all cement types in the EU27 is 73.7%.

  1. Different cement types have different properties, including hardening time, early and late strength, resistance to salty conditions and chemically aggressive environments, heat release during curing, colour, viscosity and workability.
  2. The importance and relevance of these qualities depend on the desired application of the cement and concrete.

There is a need to ensure that all the cement manufactured is safe and durable as it will be used in structures that are made to last at least 50 years or more. Thus, high durability of the final product concrete is a key property for sustainable construction.

Natural pozzolans, such as clays, shale and certain types of sedimentary rocks. Limestone (finely ground), which can be added to clinker (without being heated and transformed into lime). Silica fume, a pozzolanic material and a by-product in the production of silicon or ferrosilicon alloys. Granulated blastfurnace slag (GBFS), a by-product of the pig-iron/steel production process. Fly ash, dust-like particles from flue gases of coal-fired power stations.

The availability of alternative materials that can be used as other constituents varies considerably. For example, granulated blastfurnace slag availability depends on the location and output of blastfurnaces for pig-iron production equipped with slag granulation facilities, whilst fly ash use is dependent on supply from sufficiently close coal-fired power plants.

The availability of pozzolans depends on the local situation and only a limited number of regions have access to this material for cement production. Limestone is abundant worldwide and is easily accessible to most cement plants. Cement standards serve to guarantee the performance of each cement type.

The use of other constituents has an impact on the way the cement will perform in both the short and long term. The success of cements with a low clinker-to-cement ratio will also depend on market acceptance. Quality is crucial for building stability and, as such, a matter of public safety, e.g.

  • Bridges, sky scrapers as well as for the sustainability of investments into infrastructures and buildings.
  • A global clinker-to-cement ratio of 78% in 2006 meant that about 550-600 million tonnes of constituents other than clinker were used.
  • The International Energy Agency (IEA) estimated that in 2005, there were around 1,215 million tonnes of material suitable for clinker substitution globally (excluding pozzolan and limestone).

On this basis, it seems that the use of other constituents could be doubled. However, this scenario is only hypothetical because it does not take into account that these quantities do not necessarily reflect the required quality or local market situation.

There is also uncertainty regarding the future availability of clinker substitutes as well as the impact of environmental policy and regulation. For example, the future decarbonisation of the power sector could limit the availability of fly ash, or the application of Nitrogen Oxide(s) abatement techniques in coal-fired power stations could mean that the fly ash may be unusable as a constituent in cement due to higher NH3 (ammonia) concentrations.

Furthermore, some of these materials are already used in concrete, rather than cement, production. Finally, a life cycle cost analysis needs to be done to ensure that policies are based on the entire life cycle in order to avoid focusing solely on intermediate material impact.

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Low-clinker cements can offer both environmental benefits as well as favourable product characteristics. Nevertheless, it is important that a whole life cycle approach is applied to public procurement rather than simply focusing on product footprinting or intermediate product impacts. Facilitate access to raw materials and enhancing waste and by-products recycling policies. Provide support for and access to R&D funding. In addition, a strong industry focus on innovative cements and concretes has the potential to respond to the requirements of sustainable and resource-efficient production and construction.

F or the purposes of meaningful reporting, the definition of cement used in the GNR database differs slightly from that in common use. In this document, cement and cementitious products are considered equivalent, Source: Source: Development of State of the Art Techniques in Cement Manufacturing: Trying to Look Ahead (CSI/ECRA- Technology Papers), State of the Art Paper No 4: Reduction of clinker content in cement: long-term perspective : Clinker Substitution – Cembureau

Why is it called clinker?

Dutch origin – Clinker bricks used to form family initials on the, a 1700s Dutch house in, Clinker brick closeup of bricks in the so-called Clinker building on Barrow street in Greenwich Village, New York City. Clinker is sometimes spelled “klinker” which is the contemporary word for the brick.

What is the size of clinker?

Cement clinker is a solid material produced in the manufacture of Portland cement as an intermediary product. Clinker occurs as lumps or nodules, usually 3 millimetres (0.12 in) to 25 millimetres (0.98 in) in diameter. It is produced by sintering (fusing together without melting to the point of liquefaction ) limestone and aluminosilicate materials such as clay during the cement kiln stage.

What is called clinker?

Clinker is the backbone of cement production. It is essentially a mix of limestone and minerals that have been heated in a kiln and have been transformed by this heat.

Why is clinker important?

Use of Cement Clinker: Conversion to Cement – Cement Clinker, combined with additives and ground into a fine powder, is used as a binder in cement products. Different substances are added to achieve specific properties in the produced cement. Gypsum added to and ground with clinker regulates the setting time and gives the most important property of cement, compressive strength.

  • It also prevents agglomeration and coating of the powder at the surface of balls and mill wall.
  • Some organic substances, such as Triethanolamine (used at 0.1 wt.%), are added as grinding aids to avoid powder agglomeration.
  • Other additives sometimes used are ethylene glycol, oleic acid, and dodecyl-benzene sulphonate.

The most notable type of cement produced is Portland cement, but certain active ingredients of chemical admixtures may be added to clinker to produce other types of cement, such as:

  • ground granulated blast furnace slag cement
  • pozzolana cement
  • silica fume cement

Clinker is primarily used to produce cement. Since it can be stored in dry condition for several months without noticeable deterioration, it is traded internationally in large amounts. Cement manufacturers buy clinker for their cement plants in areas where raw materials for cement are scarce or unavailable.

What is low clinker cement?

Lower clinker cements Lower clinker cements have been developed over several years and this is where a cementitious material is used to partially substitute the clinker. In the past, fly ash from coal-fired power stations and slag from blast furnaces have been used.

These material sources will diminish in the future and alternative materials such as calcined clay and carbonated concrete fines are being researched. The use of other constituents in cement and the reduction of the clinker-to-cement ratio means lower emissions and lower energy use. Innovative clinker and cement products are being developed which will reduce the CO2 emissions during their manufacture due to their different formulations.

Examples of these include Sulpho-Aluminate Clinker (SAC), Ferro-Aluminate Clinker (FAC), Belite-Ye’elimite-Ferrite Clinker, Calcium Aluminate Clinker and Amorphous Clinker (X-Clinker). : Lower clinker cements

How can I improve my clinker quality?

3. Coal Fines – Many cement plants use bituminous coal as the fuel of rotary kiln, so the ash content, volatile matter, calorific value, fineness, and moisture of coal fines will affect the clinker calcination process in the kiln. What Is Clinker Factor In Cement Coal fines Coal fines are usually prepared by air swept coal mill or vertical mill, In order to produce high-quality clinker, the fineness of coal fines should be controlled at about 12%, and its moisture content should be controlled within 1.0%. The machines that are usually used to dry the coal fines are rotary dryers,

According to the data statistics obtained in the actual production, the coal ash infiltration in the process of calcination will cause the lime saturation factor in the clinker to be reduced by 0.04 ~ 0.16, the silicon ratio to be reduced by 0.05 ~ 0.20, and the aluminum ratio to be increased by 0.05 ~ 0.30.

Therefore, in normal production, it is necessary to make the ash and volatile matter of coal fines adapt to the proportioning of raw meal. For example, a high lime saturation factor of raw meal and a low ash content of coal fines will make the f-CaO content of the clinker hard to control.

What is the Colour of clinker?

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Home Blog Tips What are the colors of clinker brick? Clinker brick – Colors, textures, forms

Tuesday, 20 July 2021 / Published in Tips Contrary to what the term “clinker brick” is usually associated with, the colors of this precious material include not only various shades of red and brown. Apart from that, there is a rich palette of gray, white, black, as well as returning in fashion beige colors, which are perfect for modern interiors and not only.

Do you want to get to know them better? Read the article and see what the colors of clinker brick are. Clinker brick – First note: Color vs texture Before giving you a detailed answer on what colors of clinker bricks are, we must make three introductory notes. Firstly, thinking of the effect of clinker brick in an interior or on a building, the color must be considered in relation to the texture – smooth, rough, perhaps even carved.

The clinker’s interaction with light (with or without reflections and delicate or expressive chiaroscuro as well) can change the perception of the base color. Therefore brick, especially the one for interior use, should be selected taking into account the context in which it will be placed as well as the natural and artificial lighting conditions.

  1. Clinker brick – Second note: The color is not always uniform Another important point is that the color of clinker bricks from one line is strictly uniform.
  2. Whereas faces of each item shimmer with shades (e.g., similar tones of red or brown) or even colors (e.g., red blends with beige or black, yellow is crossed with brown lines, etc.).

In the next ones, it varies within the batch on purpose so that the finished brick wall gains visual lightness, an expressive character or intrigues the observer. There are great design possibilities. The only thing has to be remembered: not any single brick could always be a color sample – at least a photo of a larger fragment of a ready layout pattern (e.g.

on a clinker manufacturer’s website) is necessary to get a realistic idea of the final effect. Clinker brick – Third note: Color depends on context Finally, the context is extremely important in terms of the result of using clinker brick, from the proximity of other materials used in the arrangement to the particularly important color of the grout.

The use of the latter can completely change the character of the brick layout pattern (e.g. the same red brick can gain a rustic or loft character. On the other hand, a mustard shade of the yellow brick can be emphasized or toned down). Therefore it’s worth remembering about it and trying to “experiment” with colors before making the final call.

With the use of our Configurator various options for combining bricks (and brick mixes) as well as joints can be checked. Colors of clinker brick: The palette of yellow, orange and red colors That being said, let’s move on to present the available clinker brick colors, starting with the warm shades of burnt clay.

There is extremely fashionable mustard yellow, available in a pure shade and with a smooth face (Sahara) or dimmed, with additional brown lines of “patina” randomly located in the brick batch, which additionally has a delicate texture (Solaris). There are also the orange colors (Ochra), the more saturated red Alfa and Starobrowarna.

  • Among hand-formed bricks with obvious texture and irregular edges, the vibrant colors of the Lima and Lauda bricks combine orange color with pale coral red, however, there are also black bricks in the batch of the latter.
  • In contrast, much softer, bleached red colors, the kind known from old brickworks revealed from beneath the plaster, are represented by Nevel, which is fairly uniform in layout pattern, and by Salsa and Mooi, which differ in qualities.
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Within the bricks with a smooth face, your attention may attract the Classic line that consists of red-orange bricks with metallic burnt spots. It is distinguished by, just as the name suggests, its classic harmony of many shades coming together in a consistent brick layout pattern.

  1. The Gotika brick provides a similar effect with its irregular edges typical for brickworks with centuries of history.
  2. The dark red Etna stands out for its low-key red colors, and the cherry Luna for its expressive shading.
  3. The spectacular Alt Deco brick combines dark terracotta with brown.
  4. The latter color is also associated with a texture whose character may be associated with the corten so eagerly used these days.

Colors of clinker brick: The palette of brown colors Especially in the case of clinker work, red colors are strictly connected with fantastically diverse brown colors. The clinker brick category includes wonderful rustic shades with metallic burnt spots and slags, the example of which is the Rustika brick, even more deeply textured than the Alt Deco brick, and many more.

We can also easily find reddish brown colors represented by bricks such as Alt Classic or the “patinated” Antika, as well as chocolate brown colors – with a smooth face (Toba) or textured historical style (Alt Tessin). Colors of clinker brick: The palette of white, gray, graphite and black colors A very attractive range of gray colors is still popular – from silver shade (Syriusz cieniowany, Sotis) to graphite (Tybet cieniowany) or anthracite (Galaxy).

The saturated color of the latter is emphasized by the smooth face of the brick, which at the same time gently captures the light. In the case of the Galaxy brick it’s even a delicate shimmering. The milky-white Wenus brick, as well as the stunning Carbon model – black and raw, impressing with its unusual color are also similar to that range.

What are the different types of clinker?

Cement Clinker: Its Composition, Types & Uses? Clinker is a nodular material produced during the furnace phase during the production of cement and is used as a binder in many cement products. Clinker nodes or nodules are usually 3–25 mm in diameter and dark brown.

  • Composition of clinker:
  • The structure of the clinker is tested in two different ways
  • Mineralogical analysis, using petrographic microscopy and / or X-ray diffraction analysis method.
  • Chemical analysis, most accurately by X-ray fluorescence spectrometry method
  • The clinker has four main components:
  • Alite: approximately tri- calcium silicate (usually about 65% of the total)
  • Belite: Approximately di-cillium silicate (usually about 15% of the total)
  • Aluminate: A very high amount of tetra-calcium aluminate(usually about 7% of the total)
  • Ferrite: very nearly tetra-calcium aluminoferrite (usually about 8% of the total)
  • Other substances may be present in small amounts:
  • Salt phases – various combinations of sodium, potassium and calcium with sulfate and chloride ions, such as:
  • Arcanite – K2SO4
  • Calcium Langbeinite – K2Ca2 (SO4) 3
  • Aphthitalite – K3Na (SO4) 2
  • Sylvite – KCl
  • Low-temperature phases – various intermediate chemical species that have survived further thermal processing, such as:
  • Spurrite : Ca5 (SiO4)2 (CO3)
  • Ternesite: Ca5 (SiO4)2 (SO4)
  • Ellestadite: Ca10 (SiO4)3 (SO4)3 (OH)2
  • Ye’elimite: Ca4 (AlO 2)6 (SO4)
  • Chemical analysis of the clinker is usually given in the form of oxide, as follows (oxide weight in%):

Free lime = 1.0% CaO The balance is made by small amounts of oxides of alkali sulfate and minor impurities, such as titanium, manganese, phosphorus, and chromium.The amount of different components varies depending on the desired properties of the clinker produced.

  1. Thermochemistry of clinker The raw material entered into the kiln is transported to room temperature.
  2. Inside the kiln, the temperature continues to rise and when it reaches its peak, the production of clinker cools rapidly.
  3. Although the reaction stages often overlap, they can be expressed in the following acutely-defined sequence: 1,65–125 ° C: Free water evaporates: latent heat needs to be supplied.

Pure heat input: 2145 kJ / kg clinker.2,400–650 ° C: Clays decompose endothermically, and alkalis react with kiln atmosphere to form liquid sulfates. Net heat input: 42.2 kJ / kg clinker.3.500–650 ° C: Dolomite decomposes endothermically. Net energy input rate: 19.7 kJ.4.650–900 ° C: Calcium carbonate combines endothermically with silica to form an “incipient belite”.

  • Net heating input: 722.5 kJ 5.700–900 ° C: Calcium carbonate reacts reactively with alumina, and iron oxide to form incipient alumina and ferrite.
  • Pure heat input rate: 207.2 kJ 6,900–1050 ° C: When all the available silica, alumina and iron oxide have reacted, the remaining calcium carbonate decomposes endothermically to calcium oxide.

Heat input requirement: 601.9 kJ / kg clinker.7.1300–1425 ° C: Aluminate, ferrite, and benite is melted endothermically, and the belite react with calcium oxide to form alite.8.1425–1300 ° C: After the peak temperature passes, the melt begins to re-freeze exothermically to aluminate,ferrite and belite.

  1. 1. Sulfate resistant clinker
  2. 2. Low Heat Clinker
  3. 3. White Clinker
  4. 4. Low Alkali Clinker
  5. 5. Belite Calcium sulfoaluminate Ternesite (BCT)
  6. 1. Sulfate resistant clinker

It contains 76% Alite, 5% Belite, 2% Tricalcium aluminate, 16% Tetracalcium Alumino-ferrite and 1% Free Calcium Oxide. Its production has decreased in recent years as sulfate resistance can be easily achieved by using granular blast furnace slag in cement production.2.

Low heat clinker It contains 29% Alite, 54% Belite, 2% Tricalcium aluminate and 15% Tetracalcium Alumino-ferrite with very little free lime. It is no longer produced because cement produced from ordinary clinker and ground granular blast furnace slag has excellent low heat properties.3. White clinker It contains 76% Alite, 15% Belite, 7% Tricalcium aluminate, no Tetracalcium Alumino-ferrite, and 2% free lime, but the composition can vary widely.

The white clinker produces white cement that is used for aesthetic purposes in construction. The majority of white cement goes into factory-manufactured pre-cast concrete applications.

  • 4. Low-alkali clinker
  • The reduction of the alkali content in the clinker is done either by replacing the raw-mix alumina source with another component (thus obtaining a more expensive material from a more distant source), or “bleeding from alkali” is established, Which includes some kiln systems with high temperature gases (which contain alkali as fume), resulting in some heat dissipation.
  • 5. Belite Calciumsulfo-aluminate Ternesite (BCT)

This concept is used to produce a type of clinker with 30% less carbon dioxide emissions. Energy efficiency improves and electricity costs are reduced by about 15% for the manufacturing process. Use of clinker: conversion to cement Clinker,added with additives and grounded in the form of fine powder that is used as a binder in cement products.

The produced cement combines various substances to obtain specific properties. Gypsum is added with clinker regulates the setting time and gives the most important property of cement, compressive strength. It also prevents the agglomeration and coating of powder on the surface of balls and mill wall. Some organic materials, such as triethanolamine (used at 0.1 wt.%), are added as a grinding aid to avoid powder agglomeration.Other additives sometimes used are ethylene glycol, oleic acid and dodecyl-benzene sulphonate.

The most notable type of cement produced is Portland cement, but some special chemical ingredients can be added to the clinker to produce some other types of cement, such as:

  1. • Ground granulated blast furnace slag cement
  2. • Pozzolana Cement
  3. • Silica Fume Cement

Clinker is mainly used to produce cement. Since it can be stored in dry condition for several months without noticeable deterioration, it is traded internationally in large quantities. Cement manufacturers purchase clinkers for their cement plants in areas where raw material for cement is scarce or unavailable. ALSO READ: : Cement Clinker: Its Composition, Types & Uses?

What is flux in clinker?

Abstract – A flux for cement comprises mainly wollastonite. By adding the flux 1-10% in preparing a cement raw material, the firing temperature may be reduced, the firing time may be shortened, coal consumption may be decreased and the productivity of cements may be improved.

What is silica cement ratio?

Silica Ratio (SR) – The Silica Ratio (also known as the Silica Modulus) is defined as: SR = SiO 2 /(Al 2 O 3 + Fe 2 O 3 ) A high silica ratio means that more calcium silicates are present in the clinker and less aluminate and ferrite. SR is typically between 2.0 and 3.0.

What is the density of clinker?

They are shipped in such ungrounded form; semi-manufactured material, so as to avoid the difficulties of carrying cement powder. Bulk density: 1,190 – 1,639 kg/m 3.

What has the highest percentage of clinker?

Portland cement clinker has highest weight percentage of.

What is flux in cement?

US5183506A – Modified flux composition for cement – Google Patents This is a continuation-in-part of application Ser. No.07/578,902, filed Sep.7, 1990, now abandoned, which in turn is a continuation-in-part of application Ser. No.07/234,125, filed Aug.19, 1988, now abandoned. BACKGROUND OF THE INVENTION

1. Field of the InventionFlux composition additives for manufacturing cements.2. Description of the Prior Art

_ SKALNY 4,135,941 JOHNSON et al.4,377,415 VOTAVA 4,337,316 KURZ 4,087,285 LOWE 3,879,214 Japan 71/22,765 Japan 55-158,238 _ “Advantages of Wollastonite”, CA79(2):9202F USSR, SADUAKASOV, A.S. “Cement and Concrete Product”. O Bannon Dictionary of Ceramic Science and Engr.

  • 1984) pp 109,261 and 278.
  • SUMMARY OF THE INVENTION A flux composition for manufacturing cement comprising mainly low grade wollastonite.
  • The flux is added during the preparation of the cement raw materials and comprises 1-10% of the admixture.
  • Thus, the firing temperature may be reduced, the firing time may be shortened and coal consumption decreased, while enhancing manufacturing productivity.

As a result, the compression strength and the binding strength of the cement are correspondingly enhanced. DESCRIPTION OF THE PREFERRED EMBODIMENTS This invention relates to flux compositions for manufacturing cements. In order to accelerate the formation of cement clinker, a small quantity of mineralizer is often added to the raw materials of cement.

A composite mineralizer comprised of gypsum and fluorite has been developed in recent years which lowers the melting point of the cement raw materials. However, this composite mineralizer mixture may give rise to manufacturing defects, such as the “ring formation”, and may also produce fluctuations in cement quality.

Wollastonite is a mineral which has gained widespread application in various manufacturing processes, for example, it has been used as a component of ceramic material to greatly reduce firing temperature and firing time. To date, no one has attempted to use wollastonite as a main component of the composite mineralizer for cements.

  • An object of the invention is to develop a new mineralizer employing low-grade wollastonite so as to reduce the firing temperature of cement and shorten its firing time.
  • This results in energy savings when manufacturing cements and improves overall productivity.
  • For purposes of the present application, “low-grade wollastonite” contains 25%-70% by weight of calcium silicate minerals (CaSiO 3 ) which does not meet standard application requirements in industry.
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In other words, “low-grade wollastonite” is treated as waste in the prior art. “Low-grate wollastonite” is available on the market. Wollastonite belongs to the class of calcium silicate minerals (CaSiO 3 ), having the chemical composition Ca 3 (Si 3 )O 9 ) wherein CaO is 48.3% and SiO 2 is 51.7% by weight.

  • Since wollastonite has a needle structure, it may improve the strength of a ceramic body by improving the compression strength.
  • Based on the successful application of wollastonite in ceramic use, the present invention utilizes wollastonite and compounds such as gypsum and fluorite, to develop novel fluxes for cement with the following compositions: 1.

wollastonite 50-99%, tremolite 1-50%; 2. wollastonite 50-65%, fluorite 5-15%, gypsum 30-35%; 3. wollastonite 50-98%, fluorite 1-20%, slag 1-30%. The individual flux components are crushed and ground into the desired particle sizes ranging from 60 to 160 mesh.

  1. In the preferred embodiment, particle sizes will range from 80 to 100 mesh.
  2. According to the present invention, the flux is added to raw materials of cement.
  3. The flux, when admixed or blended with the cement raw materials, comprises 1-10% of the cement-flux admixture.
  4. Preferably, the flux will average 3-5% of the admixture.

The strength of the cement will vary depending on the amount of flux added to the cement. The concentration of free CaO in the flux-cement admixture may be measured to determine the optimal percent value of flux to be added to the cement raw materials.

  • A first embodiment of invention was based on composition 2 above of the flux for cement, utilized the percentage of individual compounds as listed in Table 1.
  • Clinker raw materials were ground to pellet sizes ranging from 15 to 30 mm in diameter, preferably 25 mm.
  • The pellets were fired in an electric oven for 20 minutes at 1350° C.

This firing temperature was approximately 100° C. lower than conventional firing temperatures. Further, the amount of time required to keep constant temperature throughout the firing period was reduced by 30%. The resultant clinker was then analyzed for its chemical composition, including mineral content (%).

  1. The results are shown in Table 2.
  2. The slag cement was prepared using the clinker formed hereinabove.
  3. The weight ratio among clinker, slag and gypsum was set as: clinker; slag; gypsum=50:50:2.
  4. The physical properties of the resultant cement are shown in Table 3.
  5. A second embodiment of the present invention utilized composition 3 (see above) of the flux for cement.

The percentages of individual compounds are listed in Table 4. The raw material pellets were prepared as described hereinabove. In this second embodiment of the invention, the percent of both limestone and slag was held constant, while percent concentrations were adjusted for fluorite, gypsum and wollastonite, Firing time was again reduced to approximately 20 minutes at a high temperature.

  1. The general chemical composition and mineral content of the resultant clinker is shown in Table 5.
  2. The clinker, as prepared above, required only 20 minutes of firing, a reduction of 30% in firing time.
  3. This in turn conserved the amount of coal consumed during the firing process.
  4. The ratio for the cement mixture was: clinker prepared: gypsum=100: 4, and in preparing the slag cement the ratio was: clinker: slag: gypsum=50:50:4.

The physical properties of the cement are listed in Table 6. The distinguished effectiveness of the embodiments in comparison with the prior art is shown in Table 7. Therefore, using the flux of the invention in the production of cement may not only shorten the firing time, reduce the amount of coal consumption, improve the discharge of flue gas and reduce the “ring formation” in the oven but, also, increase the compression strength of the cement by approximately 100Kg/cm2 or more, and increase the binding strength of the cement by 10Kg/cm2 or more.

Based on the above Composition 1 of the flux for cement, (wollastonite 50-99%, tremolite 1-50%), the percentages of individual compounds are listed in Table 8. The raw material pellets were prepared in sizes ranging from 12 to 14 mm in diameter. The pellets were fired in a kiln. The general chemical composition and mineral content of the resultant clinker is shown in Table 9, in comparison with a control example in which no flux of the invention was used.

Table 10 shows the physical properties of the clinker. TABLE 1 _ Rate of Design ignition SIO.sub.2 Al.sub.2 O.sub.3 Fe.sub.2 O.sub.3 CaO MgO CaF.sub.2 SO.sub.2 Other Total Component % loss % % % % % % % % % % _ Limestone 66.50 28.74 0.86 0.15 0.05 36.08 0.49 0.13 66.50 Clay 12.50 0.90 8.26 1.90 0.78 0.05 0.31 0.30 12.50 Iron powder 2.00 0.25 0.06 1.35 0.10 0.06 0.18 2.00 Coal 13.00 9.96 1.69 0.83 0.24 0.17 0.06 0.05 13.00 Flux 6.00 0.94 0.72 0.03 0.01 2.16 0.03 0.76 1.26 0.09 6.00 Total 100 40.54 11.78 2.97 2.43 38.56 0.95 0.76 1.26 0.75 100 Raw Material Clinker 100 19.81 4.99 4.09 64.85 1.60 1.28 2.12 1.26 100 _ Black Raw Material Rate: KH = 0.98, N = 2.18, P = 1.22 Note: KH-Saturation coefficient of lime N-Rate of silice acid P-Rate of iron TABLE 2 _ (%) Rate of ignition loss SiO.sub.2 Al.sub.2 O.sub.3 Fe.sub.2 O.sub.3 CaO MgO Total f-CaO KH n p C.sub.3 S C.sub.2 S C.sub.3 A C.sub.4 AF _ 1.76 20.32 6.17 4.69 65.85 1.25 100.00 2.02 0.91 1.87 1.32 56.37 15.75 8.40 14.26 _ TABLE 3 _ Water quantity Compression Bending Specific added at stan- set time strength (kg/cm.sup.2) strength (kg/cm.sup.2) surface Fineness dard consistency Initial Ending 3 7 28 3 7 28 (cm.sup.2 /g) (%) (%) (hr, min) (hr, min) Safety day day day day day day _ 3160 7 21.5 1.30 3.20 Acceptable 307 523 648 59.00 74.50 89.50 _ TABLE 4 _ Rate of Design ignition SIO.sub.2 Al.sub.2 O.sub.3 Fe.sub.2 O.sub.3 CaO MgO CaF.sub.2 SO.sub.3 Other Total Component % loss % % % % % % % % % % _ Limestone 67.50 28.25 1.04 0.49 0.16 36.21 0.37 0.98 67.50 Slag 17.00 3.11 8.16 3.08 0.82 0.87 0.24 0.72 17.00 Coal 8.00 6.08 1.05 0.49 0.10 0.07 0.06 0.14 8.00 Flux 7.50 0.87 0.48 0.02 0.01 2.47 0.07 0.60 1.39 1.59 7.50 Total 100 38.31 10.73 4.09 1.09 39.62 0.74 0.60 1.39 3.43 100 Raw Material Clinker 100 17.40 6.63 1.77 64.22 1.20 0.97 2.25 5.56 100 _ Black Raw Material Rate: KH = 1.06, N = 2.07, P = 3.74 Note: KH-Saturation coefficient of lime N-Rate of silice acid P-Rate of iron TABLE 5 _ (%) nnn SiO.sub.2 Al.sub.2 O.sub.3 Fe.sub.2 O.sub.3 CaO MgO Sum f-CaO KH n p C.sub.3 S C.sub.2 S C.sub.3 A C.sub.4 AF _ 1.32 18.82 5.85 2.02 63.94 1.18 93.13 3.44 0.95 2.39 2.90 60.78 8.10 12.07 6.14 _ TABLE 6 _ Water quantity Compression Bending Specific added at stan- set time strength (kg/cm.sup.2) strength (kg/cm.sup.2) surface Fineness dard consistency Initial Ending 3 7 28 3 7 28 material (cm.sup.2 /g) (%) (%) (hr, min) (hr, min) Safety day day day day day day _ Clinker 3310 65 22.5 2.10 4.31 Acceptable 342 484 646 59 68 85 slag 3215 7 22.5 2.50 5.42 Acceptable 129 256 462 33 61 82 _ TABLE 7 _ No.

Title Unit Prior Art Embodiment Note _ 1. Heat consumption kcal/kg 1174 754 Reduction 35.7% 2. Ignition loss % 40 36 Average reduction 4% 3. Firing time of Min 30 20 Less clinker at high 33.3% temperature 4. Strength kg/cm.sup.2 Compressing strength Compressing strength Increasing 119 527 646 Increasing 17 Bending strength 68 Bending strength 85 5.

Kiln sintering Ring forming and Hardly lumping lumping easily 6. Draining of flue Black White with black gas 7. Time period for Day 15 7 Less 8 days settling safety 8. Grindability Solid and compact, Fragile, grinding hard for grinding easily _ TABLE 8 _ Rate of ignition SiO.sub.2 Al.sub.2 O.sub.3 Fe.sub.2 O.sub.3 CaO MgO Other Total Component loss % % % % % % % % _ Limestone 30.36 1.99 0.22 0.15 38.88 0.39 1.21 73.2 Clay 0.33 4.43 0.72 0.36 0.07 0.06 0.03 6.00 Iron 0.11 0.88 0.19 1.53 0.04 0.03 0.22 3.00 powder Coal 7.49 4.00 2.31 0.63 0.08 0.11 0.18 14.80 Flux 0.16 1.34 0.01 0.02 1.06 0.24 0.17 3.00 Total Raw 39.22 12.19 4.13 2.62 40.13 0.83 1.81 100 Material Clinker 0 20.06 6.79 4.31 66.03 1.37 _ Black Raw Material Rate: KH = 0.95, N = 1.8, P = 1.8 Note: KH-Saturation coefficient of lime N-Rate of silice acid P-Rate of iron TABLE 9 _ (%) Flux of the Rate of invention ignition added loss SiO.sub.2 Al.sub.2 O.sub.3 Fe.sub.2 O.sub.3 CaO MgO Total f-CaO KH KH.sup.- n p C.sub.3 S C.sub.2 S C.sub.3 A C.sub.4 _ AF 0 0.42 19.37 6.21 4.62 64.51 0.98 98.15 2.92 0.94 0.89 1.79 1.34 49.32 18.32 8.62 14.04 3 0.45 19.98 5.81 4.53 65.13 0.97 98.65 1.79 0.94 0.91 1.93 1.28 55.42 15.46 7.71 13.77 _ TABLE 10 _ Compression Bending strength strength Flux of the Specific set time (kg/cm.sup.3) (kg/cm.sup.3) invention surface Fineness consistency initial Ending 3 7 28 3 7 28 added (%) (cm.sup.3 /g) (%) (%) (hr, min) (hr, min) Safety day day day day day day _ 0 3030 5 23.50 1:56 3:01 Unacceptable 275 406 582 57 68 80 3 3210 5 23.75 3:15 4:20 Acceptable 437 592 756 75 90 97 _ : US5183506A – Modified flux composition for cement – Google Patents

What is the meaning of 1 2 4 ratio of concrete?

Free ST 22: Geotechnical Engineering 20 Questions 20 Marks 15 Mins Concept: Mix design can be defined as the process of selecting suitable ingredients of concrete and determining their relative proportions with the object of producing concrete of certain minimum strength and durability as economically as possible.

  • The purpose of designing as can be seen from the above definitions is two-fold.
  • The first object is to achieve the stipulated minimum strength and durability.
  • The second object is to make the concrete in the most economical manner.
  • The proportion is used for showing the amount of cement, sand, and coarse aggregate in the concrete.

The specification should also say if those proportions are by weight or volume. In mix design the proportion 1: 2:4 means, 1 part of cement is mixed with 2 part of sand and 4 part of coarse aggregate. Latest GPSC Assistant Engineer Updates Last updated on Oct 1, 2022 The GPSC Assistant Engineer notification has been released for 225 vacancies (Civil, and Mechanical) in the Gujarat Water Supply & Sewerage Board.

What is clinker capacity?

Clinker production from 3.50 MTPA to 7.00 MTPA & Cement production from: 3.90 MTPA to 7.40 MTPA by. Enhancement of capacity of Unit – IV (Under Implementation) by. Clinker Production from 1.75 MTPA to 3.5 MTPA, Cement production from 1.75 MTPA to 3.5 MTPA.

What is the standard ratio of cement?

What is cement mix? – A cement mix is a preparation of concrete for construction. It is a mixture of cement, stones, sand, and water. The mix is created with the proper ratio of substances, which is eventually used for building purposes. Cement, in this mix, acts as a binder and offers compressive strength. What Is Clinker Factor In Cement What Is Clinker Factor In Cement