Strength Enhancement for Portland Limestone Cements

Transcription

1 Strength Enhancement for Portland Limestone Cements Steve Farrington Principal Scientist, Admixture Systems Development PCA Manufacturing Committee Fall Technical Session August 25, 2014

2 Presentation synopsis Motivation Approach Testing Results Summary 2

3 Company overview BASF The Chemical Company The world s leading chemical company Serves all major industries 380 production facilities; i 6 Verbund sites World-class, innovative, high-value products Intelligent, sustainable system solutions 2013 Sales: 74 Billion Employees: 112,000 We create chemistry for a sustainable future 3

4 BASF: a global supplier of cement additives Why? existing global presence, infrastructure, coverage and customer access innovation focus and R&D capacity to drive new technologies technological competence in mineralogy, materials, cement hydration global access to technologies and chemistries throughout BASF 4

5 From request to product: 8-step approach to a tailored solution 3. Formulation of additives 1. Materials to BASF 2. Milling in lab ball mill 4. Mortar testing (additives w/ mix H 2 O) 8. Mortar and/or concrete testing (plant and/or BASF) 7. Plant trial 6. Mortar and/or concrete testing ti 5. Milling in lab (with additives) 5

6 Why focus on Portland Limestone Cement? Sustainable development Regulation Climate change legislation Portland limestone cements (5-15% limestone) recognized by Canadian standards in 2008 Type IL Portland limestone cement category included in 2013 version of ASTM C595 Cement producers have made limestone cements under ASTM C1157 6

7 PLC and additive formulation approach General approach for production of PLC is to grind the cement to a higher Blaine fineness to try to match the early strength of OPC longer grinding time = lower mill production longer grinding time = higher energy requirement focus on early-age strength can reduce late-age strength Formulation target: efficient grinding aid improve hydration process to improve early strength development with innovative chemistry include chemistry for late strength development Allow for higher mill production by achieving the early strength without a large Blaine fineness increase 7

8 Summary of tests done with a PCA member company New MasterCem performance enhancing cement additive was tested on three different days in one of the finish mills producing Type IL cement Type IL, 0.09% by mass cement Production increase >15% compared to Type IL with amine acetate grinding g aid Cement properties also compared to Type I with amine acetate as grinding aid 8

9 Finish mill production Date Time Type Limestone Additive -325, % Blaine, cm 2 /g Production, tph 1-day cube strength, psi 28-day cube strength, psi 6/19/ :30 IL 14.2% MasterCem /19/ :30 IL 14.1% MasterCem /19/ :00 IL 15.0% MasterCem /19/ :30 IL 13.9% amine acetate

10 Cement testing results: cube strength Type IL Blaine target:

11 Results from concrete tests: ASTM C465 certification of MasterCem Concrete data Type IL (sample 1) Type IL (sample 2) ASTM MasterCem % difference % difference C465 w/c Slump (in) Air (%) Concrete compressive strength testing Type IL (sample 1) Type IL (sample 2) ASTM MasterCem % difference % % difference % C465 3-day day day Average % min. 11

12 Conclusions from first industrial trials of MasterCem Use of MasterCem performance enhancing additive allowed for 15% improvement of finish mill production of Type IL cement Use of MasterCem performance enhancing cement additive allowed Type IL cement to have a similar strength profile to Type I cement During one of the trials, samples were collected for certification of the MasterCem additive under ASTM C465 ASTM C465 certification ca (plant-specific) c) of a MasterCem product was achieved 12

13 BASF Cement Additives team Matt McGlone: Business Segment Manager, Cement Additives Julissa Hidalgo: Product Manager, Cement Additives Bryan Patterson: Market Development Manager, Cement Additives Questions? CEMENTIUM. Cementing a better future. 13

14 INTERN 14

15 Phase [ma.-%] Klinker Aug08 Mergelstetten C3S Alite C 2S Belite 10.5 C3A total 10.0 C 3A cub. : orthor. 90 : 10 C4(A,F) Ferrite 7.1 K2SO4 Arcanite 0.0 K 3Na(SO 4) 2 Aphthitalite 0.5 K2Ca2(SO4)3 Ca-Langbeinite 0.0 CaO Free Lime 0.0 MgO Periclase 1.0 CaCO3 Calcite 0.3 SiO2 Quartz 0.1 Ca(OH)2 Portlandite 0.0 density (total) Solid state chemistry (XRF, fused bead): Klinker Aug08 Mergelstetten Sulfate SO 3 [wt.-%] 0.44 Calcium CaO [wt.-%] Potassium K2O [wt.-%] 0.36 Sodium Na 2O [wt.-%] 0.03 Silicon SiO2 [wt.-%] Iron Fe2O3 [wt.-%] 2.80 Aluminium Al 2O 3 [wt.-%] Magnesium MgO [wt.-%] 0.96 Manganese Mn 3O 4 [ppm] 529 Chromium Cr2O3 [ppm] 127 Titanum TiO2 [ppm] 2959 Tin SnO [ppm] 26 Chlorine Cl [ppm] <NWG Phosphorus P 2O 5 [ppm] 1880 L.O.I. (1050 C) [wt.-%] 0.38 Trocknungsverlust (120 C) [wt.-%] 0.28 Moduli: Klinker Aug08 Mergelstetten Natriumequivalent 0.27 Kalkstandard (not relevant in cement) 98 Sulfatisierungsgrad (not relevant in cement) 127 Silicatmodul Tonerdemodul 1.93 Summ Silicates ratio C3S/C2S 6.71 Summ Aluminates ratio C3A/C4AF 1.41 ratio Silicates/Aluminates 4.75