Preparation, development and study of chemical, physical and mechanical properties of new formulations of blended cement

LC3 Cement Representation

2. Preparation, development and study of chemical, physical
and mechanical properties of new formulations of
blended cement
Submitted By
Mohamed Ali Medan Taha
M.Sc. (Applied Chemistry), 2016
Al-azharUniversity
Faculty of science
Chemistry department

3. Supervised by
Prof. Dr.
Mohamed Abdelsamea El-Nwaway
Prof.of inorganic chemistry
Faculty of science
AL-azhar University
Prof. Assistant Dr.
Mohamed El-ShahatSaraya
Prof. Assistant of applied chemistry
Faculty of science
Al-Azhar University
Dr.
Mohamed El-Sayed Sultan
Lecturer of inorganic applied Chemistry
Faculty of science
AL-azhar University

4. Representation Agenda
Our hypothesis
Methodology
Work Roadmap
4

6. Inthepresentscenario,urbanizationisacceleratingatan
exponentialrateallaroundtheworldandapproximately70%
populationisexpectedtobelivinginurbanareasby2030.This
rapidurbanizationhascreatedachallengebeforeconstruction
sectortodevelopsustainableanddurablebuildingmaterialswith
minimalemissionofGreenHouseGases(CO2)duringtheir
productionwithoutcompromisingtheirperformance.
6

7. Thecementsectoristhethird-largestindustrialenergyconsumer,
comprising7%oftheglobalindustrialenergyuse.
Cementproductioninvolvesthedecompositionoflimestone(calcium
carbonate),whichrepresentsabouttwo-thirdsofthetotalCO2emissions
generatedintheprocess,withtheremainderofCO2emissionsbeing
duetocombustionoffuels.
7

8. 8
Contribution of cement to CO2emissions
0.00
5.00
10.00
15.00
20.00
25.00
30.00
China India
European Union United States Saudi Arabia
Japan Brazil Russia Vietnam Turkey Iran Egypt
Indonesia South Korea
Pakistan Mexico Thailand Germany Nigeria Italy Taiwan Malaysia Canada France
South Africa Argentina Poland
United Kingdom
Australia
Countries ranked by CO2emission from cement production
%overall CO2 from cement
World average

9. 9
CO2roadmap
The ambitionis to reduce CO2intensity of cement by 2050

10. 10
EvolutionofClinkersubstitution,CSIdata
2%4%5%5%6%6%6%6%6%7%7%7%4%
4%
4%4%5%5%5%5%5%5%5%5%
1%
2%
3%3%3%4%4%4%4%4%4%4%
1%
2%
2%2%2%2%2%2%2%2%2%2%
4%
2%
1%1%
1%1%1%1%1%1%1%1%
0%
5%
10%
15%
20%
25%
199020002005200620072008200920102011201220132014
Limestone
Slag
Fly ash
Puzzolana
Others
•Almostnoprogressinlast5years
•Only3substitutesusedinquantity

11. 11
Toreducetheimpactofcementindustry,thereisnomagicsolution!
§BlendedwithSCMswillbebestsolutionforsustainablecementsfor
foreseeablefuture
§Blendcontainingcombinationofcalcinedclayandlimestoneare
particularlyinteresting:EPFLledLC3projectsupportedbySDC.
Started2013

12. What are the SCMs
12

13. Supplementarycementitiousmaterials(SCMs)are
materialsthatmayreplacetheclinkerincement
productionasitsusedasadditives.
13

14. Supplementarycementitiousmaterials(SCMs)
LimestoneFly ashSlagNatural pozzolanCalcined Clay
Noncalcined
limestonedoesnot
provideadditional
strenght
Flyashgenerated
incoalfired
furnaces.Coal
firedpowerplants
aresettodecrease
inthefuture.
Highvariable
quality&max
35%
Slagwill
decreaseasthe
sectorwillshift
fromblast
furnacetomore
energyefficient
scrapbased
electricarc
furnace.
Naturalpozzolan
availabilityand
reactivityvaries
widelyfromregion
14

15. Hypothesis
15

16. Production of a new cement named ternary
cement (LC3) with a properties similar to the
OPC
16

17. What is LC3
LC3 is not just a blended cement like the others
•50%lessclinker
•30%lessCO2•SimilarstrengthasOPC
•Betterchlorideresistance
•AlkaliSilicaResistant
17

18. 18
Blend containing combination of calcined clay and limestone are
particularly interesting: Started 2013

19. 19
SynergyinLC3cements
Theaddedsynergyfromthereactionofcalcinedclayswithlimestoneproducing
carboaluminatephasesimprovesthestrengthanddurabilityofthecement.

20. 20
Compressive strength of LC3 versus OPC
LC3developsultimatestrengthscomparabletoOPCs
Whycanwegetsuchhigh
replacementlevels?Calcined
kaolinite(metakaolin)ismuch
morereactivethanglassy
SCMs

21. Three main sequences were used to cover
this work
Methodology
21

22. •Collectionofrawmaterials(Kaolin,
metakaolin,redclay,andlimestone)
fromdifferentsitesinEgypt.
•Preparationofrawmaterialstobe
readytouse.
•Characterizationofrawmaterials.
Raw Materials Collection
•PreparationofLC3
withdifferentraw
mixdesign.
Preparation of LC3 cement
•Theproducedcement
willbecharacterized
accordingtothe
relevantstandards
Characterization of the produced cement

23. Raw materials
collection
Raw materials preparation
The raw materials
crushing, grinding and
calcination for kaolinite
Raw materials
characterization
Raw mix designMixing of clinker with the
selected raw materials in
different proportions
LC3CharacterizationXRF & XRD
Chemical and
physical properties
TGA
Heat of hydration
ESMApplication
TGA
XRF &
XRD
ESM
Chemical and physical
properties
Saini
Aswan
Helwan
Almenya

24. ThechemicalandphysicalpropertiesoftheproducedLC3cementswerecarriedoutaccordingtothe
followingtable
PropertyRelevant Standard
Fineness –BlaineEN 196 –6/2018
Sieve AnalysisEN 196 –6/2018
Standard ConsistencyEN 196 –3/2016
Setting TimeEN 196 –3/2016
Soundness –Expansion EN 196 –3/2016
Compressive and Flexural StrengthEN 196 –1/2016
Loss on Ignition (LOI)EN 196 –2/2016
Insoluble Residue (IR)EN 196 –2/2016
Free Calcium Oxide -CaOfreeBS EN 451 –1/2003

25. Three main sequences were used to cover
this work
Work roadmap
25

26. Month
Task1-23-1010-1212-1616-2222-28etc.
literature survey……….…………………………………
Collection and preparation
of raw materials……….
Experimental work..…….………
Analysis and testing of
samples………
Writing and publishing of
the obtained data ………
Preparing the thesis……………..