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Use of Recycled Aggregates for Cement Production

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Use of Recycled Aggregates for Cement Production 21 January 2021 SeRaMCo Digital final conference Use of recycled aggregates for cement production André LECOMTE Laury BARNES-DAVIN Cécile DILIBERTO Amor BEN-FRAJ Breffni BOLZE Romain TRAUCHESSEC Nacef TAZI Arnaud DELHAY Hichem KROUR Outline Introduction I. Laboratory experiments II. Industrial production III. Durability Conclusion 2 Introduction Clinker Natural materials Cement raw meal (CRM) Recycled aggregates Firing 3 Introduction SiO 2 Max incorporation rate 10-12% Varies widely (10 à 94)% Recycled aggregates incorporation 12-15% rate1,2 10% 15-20% Impacted by the Silicium-Calcium couple 20-30% 30-50% >50% Depends also on: Cement raw meal • Type of cement plant quarries 94% • Chemical composition of natural materials CaO + Al2O3 + MgO Fe2O3 • Type of clinker/cement produced 10% of calculations ► < 5% Incorporation rate of at least 5% is possible for 73% of calculations ► 10 to 30% 17% of calculations ► > 30% 90% of calculations 1. H. Krour et al, (2020) «Incorporation rate of recycled aggregates in cement raw meals » Construction and Building Materials. 4 2. H. Krour, (2020) «Incorporation des déchets de construction et de démolition dans le cru cimentier » PhD Thesis (in French). I. Laboratory experiments Laboratory synthesis of cement raw meals (CRM) Ref GM1-N CT 40 Compared to reference CRM 30 Reduced burnability (EDTA, %) (EDTA, 20 40 Highest free lime 37 36 35 34 32 Changes on intermediate 31 31 content 28 contenct 10 19 20 21 phases 0 100 Free lime lime Free 1000 °C 1050 °C 1100 °C 1200 °C Ref 60 80 ) GM1-N u.a CT 50 60 40 40 Alum. Fer. (Rietveld, %) (Rietveld, Lower belite ( Intensity Geh. 30 20 content 50 53 50 50 ontent 44 43 45 44 0 20 36 37 34 30 31 32 33 34 35 Belite Belite 10 2θ (°) 0 5 1000 °C 1050 °C 1100 °C 1200 °C I. Laboratory experiments Laboratory synthesis of cement raw meals (CRM) 18 Higher belite contents 16 Ref GBR GM RB-CT 14 Reference 100% CaO 12 Variation of CRM Ferrite 10 80% Aluminate 16 burnability 8 15 15 16 60% 6 Alite 40% 4 8 7 6 6 5 20% 2 3 4 4 3 3 2 2 Bélite Free lime content (EDTA, %) (EDTA, content lime Free 0 0% 1200 °C 1300 °C 1400 °C 1450 °C 1200 1300 1400 1450 Firing temperature Temperature (°C) GBR GM RB-CT 100% 100% 100% CaO Ferrite CaO Ferrite CaO Ferrite 80% Aluminate 80% Aluminate 80% Aluminate 60% 60% 60% Alite Alite Alite 40% 40% 40% 20% 20% 20% Bélite Bélite Bélite 0% 0% 0% 1200 1300 1400 1450 1200 1300 1400 1450 1200 1300 1400 6 1450 Temperature (°C) Temperature (°C) Temperature (°C) I. Laboratory experiments Study of the cement raw meals fineness Residu @125 µm Residu @40 µm 40 30 20 Same fineness for all raw Wt. (%) Wt. 37 31 34 35 35 34 34 34 meals 10 9 11 10 10 9 10 10 10 0 Ref GBR-T GBR-V GM1-T GM-V GM1-N RB CT 7 Quartz>40 µm (%) Feldspaths>40 µm (%) Mullite>40 µm (%) 6 5 1,0 2,0 1,6 1,9 2,2 4 2,8 2,2 0,4 High quartz and feldspars 3 contents 2 4,3 0,2 3,8 3,6 3,3 3,3 2,5 2,6 1 1,9 0 7 Ref GBR-T GBR-V GM1-T GM-V GM1-N RB CT I. Laboratory experiments Study of the reactivity of quartz and feldspars in the kiln Feldspars in cement raw meal Recycled aggregates used for the first industrial trial contain high proportions of quartz and K-feldspars Silicium Potassium Calcium 8 I. Laboratory experiments Study of the reactivity of quartz and feldspars in the kiln Quartz in cement raw meal @ 1200 °C Feldspar in cement raw meal @ 1200 °C Belite Belite WollastoniteIntermediate + liquid phase Quartzamorphous phase Feldspar C2S CS + liquid C2S + liquid Amorphous phase CaO Quartz CaO CaO Feldspar CaO Both minerals are still present @ 1200 °C = Modification of raw meal burnability 9 I. Laboratory experiments Characterization of industrial clinkers Reference Alite Belite Ferrite Aluminate tricalcium 60 40 Wt. % Wt. 70 66 68 20 6 14 11 3 13 11 14 12 3 0 Reference First trial Second trial First trial Same mineralogical composition 100 Alite Belite 80 60 40 74,1 51,0 48,6 43,7 52,1 Second trial 20 29,0 0 Mean diameter (µm) diameter Mean Reference First trial Second trial Regular size of alite and belite grains 10 I. Laboratory experiments Characterization of industrial cements 300 Reference First trial Second trial 250 200 150 261 249 248 Cement paste 238 234 100 219 171 Cumulative heat (J/g) heatCumulative 157 50 151 68 61 60 Similar hydraulic0 12 24 48 72 Age (hours) reactivity400 Reference First trial Second trial 350 300 250 200 150 Cement mortars Cumulative heat (J/g) heatCumulative 100 50 0 12 24 48 72 96 120 144 168 Age (hours) I. Laboratory experiments Characterization of industrial cements 12 10 Reference 8 6 First trial 4 Flexural strengthFlexural(MPa) Second trial 2 0 1 2 7 28 90 180 365 Similar mechanical Age (days) 90 80 properties 70 Reference 60 50 First trial 40 30 Second trial 20 Compressive strength (MPa) strengthCompressive 10 0 1 2 7 28 90 180 365 Age (days) Conclusion Laboratory experiments →Industrial trials and laboratory synthesis confirm clinker quality but … Use of RAs at high incorporation rate = higher quartz and feldspars content in the raw meal for (d>40 µm) ✓ Study for better understanding of quartz and feldspars reactivity in the kiln C2S CS + liquid C2S + liquid Amorphous phase CaO Quartz CaO CaO Feldspar CaO Both minerals are still present @ 1100-1200 °C = Modification of raw meal burnability 13 II. Industrial production VICAT cement plant in Créchy, France 14 II. Industrial production (Créchy cement plant) Last cement plant greenfield in 70 workers France Raw material substitution : Open 24/7 Built in 1968 The plant is substituing 10% of natural ressources (limestone and marl) thanks to the valorisation of mineral by-products coming from other industries Leader in reducing the consumption of 2018 Innovation fossil fuel Commisioning of a > 80% of the energy gasifier needed for the burning is A world first!!! produced thanks to alternative fuel Raw materials Fuels Natural Alternative Fossil Alternative • Limestone • Foundry sand • Charcoal • Waste wood • Marl/ clay • Ashes • Petcoke • Bauxite • Iron oxydes • Oil / Solvents • Heavy oil • Iron ore • Excavated soil • Animal meal • Gas • Gypsum • Plasterboard • Tires • Etc. • Dried sewage sludge • Etc. 10 4 8 2 6 3 5 7 9 1 • 1: Quarry • 6: Kiln • 2: Pre-homogenisation pile • 7: Cooling • 3: Raw feed mill • 8: Storage • 4: Storage • 9: Cement mill • 5: Pre-heater Tower • 10: Storage, packing, loading Créchy cement plant Alternative raw materials: Alternative fuels: Créchy cement plant 2 full-scale trials ➢1st trial, September 2018, production of 3,000 t of clinker ➢ Raw materials included 14.2% of recycled aggregates ➢ Over-consumption of energy (~20%) ➢ Impact on the quality of the clinker ➢ Production of 5 t of cement for SERAMCO partners ➢2nd trial, July 2019, Production of 2,500 t of clinker ➢ Raw materials included 5.2% of recycled aggregates ➢ No over-consumption of energy ➢ Good quality clinker ➢ Production of 55 t of cement for SERAMCO partners 18 ➢ Stacking of raw material including 4.6% “mixed fines” delivered by TRADECOWAL (271 tons), equivalent to an annual consumption of ~50 kt/yr ➢ Pre-homogenisation Costa et al, Jan 07 Reserchgate 19 ➢Milling of the pre- homogenisation pile ➢Final adjustment of the chemistry by adding bauxite and iron oxide ➢Storage and homogenisation of the raw feed ➢Firing of the raw feed 20 ➢Production of 2,500 t of clinker ➢ Good quality clinker ➢ No over-consumption of energy ➢ 65% C3S ➢ 1.67% free lime ➢Storage in Créchy before transfer to VICAT R&D pilot center in Chambéry, France 21 • R&D ball mill pilot ➢ Same sulfate source and VICAT R&D plant in Chambéry, France content (former cement plant) ➢ Comparable fineness: measurement of Blaine fineness and PSD • Production of 55 t of CEM I 52,5 N : ➢35 t PREFER ➢14.5 t BETON BETZ ➢3 t TU KL ➢2 t TU Delft ➢0.4 t Uni Liège ➢0.2 t Uni Lorraine 22 III. Durability 23 III. Durability Mechanical properties of concrete 24 III. Durability Durability parameters of concrete 25 Thanks for your attention! Questions? 26.
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