constructive solutions

FOSROC
CGA APPLICATION
Venue : PT Semen Bosowa Maros

Fosroc International Limited

Date: 30th August 2018 Presenter : Azhan Abdul Aziz
Introduction constructive solutions

 This training will covers :

 Clinker minerology
 Typical Clinker Minerology
 Gypsum & General Principal
 Cement with Cementitious metarial
 What a grinding Process Engineer should know
 Effect of limestone on cement
 Comparison of Fly Ash & Limestone cement
 Cement Additives
 Grinding Process is inefficient
 Agglomerates are formed during comminution
 Mechanisms during comminution
 Grinding/Comminution Process
 Comminution Theory
 Grinding Aid Mechanism
 Ball mill efficiency with and without grinding aids
 Separator performance with and without grinding aids
 Additives affect the cement properties in various ways
 Use of grinding aids / quality improvers in VRM
 FOSROC products
Clinker Minerology constructive solutions

Mineral Phases Reactivity Influence on

Clinker Phases Alite High Strength
C3S (early)

Belite Low Strength

C2S (late)

Aluminoferrite Very low

C4AF

Aluminate High/very high Stiffening, Setting

C3A, cubic/orthorhombic (early strength)

Alkali Sulfates Very high Stiffening, Setting

(also included in kiln dust) (early strength)

Calcium Sulfate Gypsum Medium

Addition Stiffening, Setting
Anhydrite Low (strength)

Hemihydrate High
(partly dehydrated gypsum)
Typical Clinker Minerology constructive solutions
Gypsum (Calcium Sulfate) & General
Principals constructive solutions

 Calcium sulfate is added to cement to control the reaction of

cement with water. The added amount is limited by the cement
standards
– Excess of sulfate leads to Ettringite formation even after hardening,
causing expansion and damages in concrete
=> Cement Standards define maximum sulfate, but no minimum fixed
 It affects:
– Rheology of mortar and concrete
 Water demand, workability, stiffening
 Compatibility with additives in concrete
– Setting
 Initial and final setting time (set retarders)
– Hardening
 Strength development

=> Need for sulfate optimization to obtain optimum properties

 constructive solutions

 Calcium sulfate phases

– Gypsum CaSO4 * 2 H2O
– Hemihydrate CaSO4 * 0.5 H2O
– Anhydrite CaSO4
 Dehydration of gypsum
– Induced by temperature
– Degree of dehydration as function
of mill temperature
– Intensive dehydration in ball mills
particularly in cements with high
fineness
– Depending on:
 Temperature profile through the
mill
 Mill retention time for gypsum
 Humidity of the venting air inside
the mill and the separator
 Storage temperature and period in
cement silo
 constructive solutions

 Water/cement ratio plays a major role in the hydration reaction

 From all main clinker phases, C3A is responsible for the initial
cement reaction with water, which is determined by its amount
and reactivity
 C3A has a significant impact on the early hydration and
rheology of cement and concrete
=> Inappropriate reaction might lead to fast setting and loss of
workability
=> In order to control the reaction and overcome problems, the
calcium sulfate added to cement needs to be optimized with
regard to its content and quality and must be ideally adjusted
to the given quantity and reactivity of C3A
 Fineness of the cement itself is also very important for
hydration reaction with added calcium sulfate
 constructive solutions

 Optimum sulfate content/mixing ratio depends on:

– Clinker quality used in cement, especially mineralogical phases
and amount
 Different lab cements 1, 2 and 3 with the same SO3 content (3.0%)
show different setting times
 constructive solutions

 Optimum sulfate content/mixing ratio to be adjusted:

– depending on the C3A amount
 Low C3A content in cement responds positively to a wide range of sulfate
sources including anhydrite (less soluble) as set control agents
 High C3A amount in cement demands higher sulfate inputs

 RED = LOW C3A

 BLUE = HIGH C3A
 constructive solutions

–depending on the reactivity of the C3A

At higher alkali content of clinker, alkalis are incorporated into the
C3A, modifying the crystal phase from the less reactive cubic to the
more reactive orthorhombic phase depending on the degree of
sulfatization
=> more easily soluble sulfate is needed
Cement with Cementitious Materials (CM)
constructive solutions

 Slag
– Presence of anhydrite is very important for slag-containing cements. As
it is slower in terms of solubility, it does not completely take part in the
setting process performed by the faster soluble hemihydrate and
dehydrate. It remains available for catalyzing the latent hydraulic slag
and boosting the late strength of the cement.

 Pozzolana
– Contrary to the reaction with latent hydraulic constituents, anhydrite has
no effect on strength development of pozzolana-containing cements.

 Limestone
– Anhydrite has no advantage while adding limestone to the cement.
What a Grinding Process Engineer
should also know constructive solutions

 Causes for Pre-Hydration of Cement, Consequences and

Preventive Measures
– Sources of water:
 From dehydration of gypsum
 From water injection into the mill for cooling purposes
 From wet constituents fed at too low temperature in the first mill chamber
– Consequences:
 False set due to formation of secondary gypsum
 Pre-hydration of clinker minerals leading to strength reduction
 Formation of lumps in the cement, coating in the silo (formation of
Syngenite) and obstruction of silo extraction
– Preventive measures*:
 No water injection/wet constituents in the first chamber when < 100 °C
 No water injection in last chamber if mill discharge temperature < 110 °C
 Venting of mill to keep dew point after mill below approx. 70 °C
 Possibly, cooling of cement before storage
* Reference: Effect of mill venting arrangements on cement quality, by S.W. Jørgensen.
SUMMARY
constructive solutions

 Amount of calcium sulfate strongly influences setting time and

compressive strength
 Cements with high alkali content require at same C3A content
more soluble calcium sulfate than those with low alkali content
 Compatibility of sulfate optimized cement and admixtures
makes cement less sensitive to variations in concrete and more
competitive on the market
Effect of limestone on cement constructive solutions

 As a minor addition (<5%) limestone reacts to form hydrate phases, which

reduce porosity and increase strength

 Limestone increase the hydration velocity of cement by accelerating alite

hydration

 At higher replacement levels (>5%) limestone does not contribute strength

development and limestone cements have lower early and late strength

 The fineness of the limestone determines its influence on strength and

workability
Comparison of Fly ash and Limestone
Cements constructive solutions
Agglomerates are formed during
comminution

 Electrovalent bonds are broken during comminution resulting in unbalanced

valence forces

 Grinding media not only fractures, but compresses groups of particles

already formed resulting in the formation of agglomerates
Mechanisms during comminution

 Amount of energy required to produce a new surface is reduced if the surface energy
is reduced by the addition of a surface active additive

 Effects are due to changes in the electronic states near the surface and also defect
caused by adsorption of the additive on the surface

 Prevention of the formation of agglomerates and control of flow

 In real grinding systems, the energy efficiency of a grinding process

decreases as the particle size decreases

:
 Agglomerative forces between particles increase as the particles become
smaller, thus resulting in a fine cohesive powder
Grinding Aid Mechanism - Separation constructive solutions

 By preventing or minimizing the level of agglomeration the air separator rejects

are cleaner resulting in fewer fines being returned to the mill which is normally
become over grind and causing super fine product

 This results in an improvement in the air separator operation and consequently

the quantity of super fines in the final product is reduced

 The degree of dry dispersion during the comminution does affect mill retention
time and consequently this may affect mill operating efficiency and particle size
distribution of the finished product

 This effect can be observed, however, only if the grinding aid is added in such a
way that the flowability of the material being classified can change significantly

 .
Cement Additives constructive solutions

Grinding Aids –
The principal application concerns mill output and dry cement
handling

Performance Enhancers –
In addition to a grinding aid effect, there is an intentional influence
on the cement performance properties, such as setting time and
strength development

Special Additives –
The additive imparts a specific property, such as air entrainment in
masonry cement or chromium reduction
CGA Mechanism

+
+ -+
+- -
++ -
+ - -
+- +
-
+ - - + - +
- + + -
+ - + - -
- + +- +
+- -
-- + - +- +- +
+ - +
+ - Ca++ O -
-+ + + -
-
+ - -
- + +- +
+- +- -
+ - +- +- +
CGA adsorbs
into small CGA
Neutralized
cracks neutralizes
particles -
clinker, electrostatic
CGA, highly reduce
saturate the charges on
polar organic, agglomeration
charges and newly formed
adsorbs onto between
reduce the cement
clinker cement
surface energy particle
particles
forces. surfaces
Ball mill efficiency with and without
grinding aids

Influence of Mill Exit Fineness on Ball Mill Efficiency

35

30
Mill Efficiency (cm2/joule)

25
With additive

20

No Additive

15

Increased Grinding Efficiency

10
50 100 150 200 250 300 350 400 450 500 550

Mill Exit Fineness (m2/kg)

Separator performance with and without
grinding aids

S e p a ra to r P e rfo rm a n c e
C o a r s e G r a d e E f f ic ie n c y - T r o m p c u r v e

100

90

80
C o a r s e G r a d e E ffic ie n c y (% )

70

60

50

40
No additive

30
Reduced by-Pass
Reduced fines
agglomeration
20

With additive
10 (same circ. load)

0
0 .1 1 10 100 1000

P a r t ic le S iz e
Additives affect the cement properties
in various ways

 Cement additives are used for a diverse range of applications and potential
improvement benefits include:

Property Range of improvement

Increase Mill Output 5 - 30%

Produce Narrower PSD Increase n By 0.02 – 0.05

(RRSB)
Reduce 45-micron residue By 1-3% points

Reduce Concrete Water Demand 2 – 5%

Increase Concrete Slump +20 – 70mm (@75mm initial slump)

Shorten Set Time By 10 – 40 Minutes

Extend Set Time By 10 - 40 Minutes

Increase Late Strength 5 – 15% 2 – 10 MPa

Increase Early Strength 10 – 30% 2 – 10 MPa
Use of grinding aids / quality improvers in
VRM

 Additives can also be used on VRMs

 Mechanisms involved are similar to ball mills e.g. deagglomeration and

dispersion

 However, their action in the mill is very different

 Unlike on ball mill systems the primary benefit is not mill output, but cement
performance and composition benefits

 Also bring some addition benefits specific to this type of equipment e.g.
stabilization of the bed
Conclusions constructive solutions

 Action of grinding aids is essentially a change in the properties of the particulate

bulk material and in conditions of load action

 This results mainly in the:

 Elimination/reduction of coating on the walls of the mill and on the grinding media
 Increase in axial transport velocity
 Better dispersion of the particulates in air separation
 Reduction of agglomeration formation
 constructive solutions

FOSROC PRODUCT

A) GRINDING AIDS
B) PERFORMANCE ENHANCERS
CEMAX Grinding Aids

Grinding Aids

• Reduced Agglomeration
CEMAX 300 • Reduced Pack Set
• Increased mill output
Series • Improved overall strength
CEMAX Grinding Aids

Grinding Aids Application

Reduced
setting time
Reduced
Pack Set Increased
Index early
strength
< 10

Increased CEMAX Dosage

mill output 300 0.02-0.05%
8 – 15% Series
CEMAX Performance Enhancers

Performance Enhancers

Performance CEMAX 200 –

Enhancers Early Strength Enhancer

CEMAX 400 –
Overall Strength Enhancer

CEMAX 600 –
Late Strength Enhancer
CEMAX Performance Enhancers

Application

Dosage between
CEMAX 0.05% - 0.25%
200
Series Increased early Reduced setting time
strength up to 20 minutes
5% - 15%

Increased mill output improved cement flow

8% - 15% ability during transport
CEMAX Performance Enhancers

Application

Dosage between 0.025% - 0.045%

CEMAX
400
Increased mill output
Series 8% - 20%

Increased late strength

5% - 10%

Increased early strength

5% - 10%
CEMAX Performance Enhancers

Application

Dosage between
CEMAX 0.02% - 0.05%
600
Series Increased Mill Output
8% - 15%

Increased Late Strength

5% - 12%
constructive solutions