New Generation Idea Cement Additives (PAAF Group) ! Energy Saving in Grinding Prosess and Enhancement in Concrete Performance! Cemtech MEA 2014 Dubai İdea New Group Cement Additives (PAAF); Cemtech MEA 2014 1 PAAF Grubu Çimento Kimyasalları ! Preamble:! ! Cement Additives General: ! !According to EN 197-1:! !Cement additives are added to improve the manfacture or the !properties of the cement and the percentage should be less than 1 !% by mass. ! İdea New Group Cement Additives (PAAF); Cemtech MEA 2014 2 PAAF Grubu Çimento Kimyasalları ! Preamble:! ! Cement Additives General: ! ! Liquid Products, Added during grinding! ! Dosages between 200 grams/ton cement to 3000 grams/ton! ! Treated Cement percentages:! ! 85 - 95 % in USA! ! 70 – 80 % in Europa! ! 55 - 65 % in Asia! ! 50 - 60% in Middle East! ! 20- 30 % in Afrika ! İdea New Group Cement Additives (PAAF); Cemtech MEA 2014 3 PAAF Grubu Çimento Kimyasalları ! Preamble:! ! Achievements with Cement Additives:! ! Output increase ( 5 – 10 % )! ! Initial strength improvement ( 2 – 5 Mpa)! ! Final Strength improvement ( 2 – 10 Mpa)! ! Adjusting setting times ( 20 – 60 Minutes)! ! Clinker replacement by filler ( 3 – 10 %)! ! Chromium VI Reduction ! İdea New Group Cement Additives (PAAF); Cemtech MEA 2014 4 PAAF Grubu Çimento Kimyasalları SUMMARY ! Summary ! ! Laboratory works in Idea and Siegen University ! ! Pre Laboratory works! ! Advanced Laboratory works ! ! Field Trials ! ! Results ! ! Works will be completed in the near future ! ! Sources! İdea New Group Cement Additives (PAAF); Cemtech MEA 2014 5 PAAF Grubu Çimento Kimyasalları SUMMARY! Changes in Concrete Properties! Changes in Cement Properties! Lab trials! Field trials! The works for reducing water demand in concrete! The works for improving workability in concrete! Energy Saving! Changes in PSD! Changes in Morphology! 6! PAAF Grubu Çimento Kimyasalları SUMMARY! Developments in Building Technologies! Improvements in Concrete Technologies! Changes in Cement Production ! The effects of Cements on Concrete! 7! PAAF Grubu Çimento Kimyasalları SUMMARY! With PAAF Group developed by Idea İdea: ! 30 % Energy Saving with equal or better strengths ! Better workability in concrete Where did the works have been done: ! İdea labs, Siegen University labs, Cement Plants and Ready Mix Concrete Plants in Turkey 8 PAAF Grubu Çimento Kimyasalları SUMMARY! Cement production with traditional cement additives at high blaine values Coarser cement production with PAAF (10 milyon kWh energy saving in one cement plant) 9 PAAF Grubu Çimento Kimyasalları SUMMARY! Cement Cement Additives and PAAF Group The Effects of PAAF on cement Cement produced with PAFF and concrete 10 PAAF Grubu Çimento Kimyasalları SUMMARY Investments in Cement Industry! Developments in Cement and Building Technologies! High Performance Cements! Daha Yüksek Dayanımlı Çimentolar:! ! Higher MPa! ! Higher Blaine! ! Higher Production Cost and Competition! Daha Yüksek Dayanımlı Betonlar:! ! High Performance Concrete! ! Lower water/cement ratio! ! New concrete admixtures! ! Competition! 11! PAAF Grubu Çimento Kimyasalları SUMMARY! Clinker quality! High Performance Cement Production! Finer grinding! Cement Additives! 12! PAAF Grubu Çimento Kimyasalları Water/Cement ratio is constant in cement tests (0,50)! Beton’da ! Water/Cement ration is not constant in concrete which is lower as far as possible! CONCRETE! CEMENT! Cement and Concrete! 13! PAAF Grubu Çimento Kimyasalları The results of more fine grinding ! !Higher water demand ! ! !Unhydrated particules without bonding capacity and additional !water demand! ! !Increase of heat of hydration and cracks in high temperature in !concrete! 14 PAAF Grubu Çimento Kimyasalları 20 years ago, Blaine values! Today, Blaine values! = = 3000 ± 200 ! 4000 ± 200! Increase of 100 Blaine = 1 kWh! That means we need 10 kWh excess energy! If cement production is 90 million tonnes! We spent +900 million kWh excess electricity! 15! PAAF Grubu Çimento Kimyasalları Cement! More fine grinding;! ! Strengths, ! ! kWh/ton values,! ! Production Costs! are increasing! Concrete! Concrete produced by more fine cement;! ! Strength sometimes is not high enouhg,! ! Because of cement PSD, water/cement ratio is higher than expected! ! Higher heat of hydration and some problems in hot weather! Cement and Concrete with PAAF! ! Energy saving in cement production, ! ! PSD optimization, ! ! Improving in cement strengths, ! ! Higher workability and strengths in concrete produced cements treated by PAAF.! 16! PAAF Grubu Çimento Kimyasalları SUMMARY! Cement production with traditional cement additives! ! %10-15 Output increase! Cement production with PAAF ! ! %20–40 Output increase, ! ! PSD optimization, ! ! Higher strengths! ! Higher workability and strengths in concrete! 17! PAAF Grubu Çimento Kimyasalları LABORATORY WORKS IN TURKEY! ! !Initial lab tests were performed in Idea Laboratories in Istanbul with !7 !different clinkers. ! ! ! ! !Gypsum and lime stone was from 1 source in Marmara region. ! !Before grinding all raw materials were crashed in the lab.! 18! PAAF Grubu Çimento Kimyasalları LABORATORY WORKS IN TURKEY! Cement Tests! Table 1 & 2! Flow Tests! Table 3! Micro Concrete Works! Table 4! Concrete Tests! Table 5! 19! PAAF Grubu Çimento Kimyasalları LABORATORY WORKS IN TURKEY, Table 1! Fineness, Blaine and PSD Results! Lab. Mill Revolution! 32µ! 45µ! 63µ! BLAINE! PSD! (%)! (%)! (%)! cm2/gr! D10 (µm)! D50 (µm)! D90 (µm)! F1+ İdea 396 C! 6.000! 13,3! 6,8! 2,0! 3.780! 2.70! 15.69! 51.01! F1 + İdea 5668 S! 4.000! 14,3! 7,2! 2,1! 2.880! 2.59! 17.37! 53.72! F2 + İdea 396 C! 6.000! 17,8! 9,8! 4,2! 4550! 2.38! 14.87! 51.54! F2 + İdea 5668 S! 4.000! 19,5! 10,8! 4,2! 3.500! 2.55! 17.98! 63.44! F3 + İdea 396 C! 6.000! 16,5! 8,3! 3,5! 4.050! 2.28! 15.34! 54.68! F3 + İdea 5668 S! 4.000! 22,4! 13,7! 3,6! 3.230! 2.48! 19.56! 69.21! F4 + İdea 396 C! 6.000! 17,2! 9,3! 3,3! 4.000! 2.60! 16.53! 53.77! F4 + İdea 5668 S! 4.000! 18,4! 9,7! 3,4! 3.090! 2.91! 18.63! 60.24! F5 + İdea 396 C! 6.000! 17,7! 8,6! 3,6! 4.250! 2.20! 15.16! 50.44! F5 + İdea 5668 S! 4.000! 18,4! 8,8! 3,6! 3.150! 2.90! 18.00! 55.76! F6 + İdea 396 C! 6.000! 23,6! 11,8! 3,5! 4.140! 2.57! 17.25! 57.49! F6 + İdea 5668 S! 4.000! 28,2! 15,6! 5,3! 3.250! 2.68! 21.38! 71.03! F7 + İdea 396 C! 6.000! 20,7! 10,1! 3,3! 4.120! 2.60! 17.02! 55.86! F7 + İdea 5668 S! 4.000! 24,5! 12,9! 4,1! 3.210! 2.70! 20.32! 67.95! Sample! 20! Bazı klinkerler ile daha iyi PAAF Grubu Çimento Kimyasalları sonuçlara ulaşılmıştır.! LABORATORY WORKS IN TURKEY! Compressive Strengths, Water Demand, Setting Times, Pack-Set Indexs! Sample! Lab. Mill Revolution! Compressive Strengths (N/ mm2)! 2 d! 7 d! 28 d! Water Demand! Setting Times (Min.)! Initial Final Pack set index! F1+ İdea 396 C! 6.000! 28! 50! 60! 26! 110! 150! 6! F1 + İdea 5668 S! 4.000! 28! 49! 64! 26! 135! 175! 2! F2 + İdea 396 C! 6.000! 29! 46! 54! 27! 130! 170! 3! F2 + İdea 5668 S! 4.000! 28! 47! 57! 26! 155! 190! 1! F3 + İdea 396 C! 6.000! 19! 29! 38! 28! 215! 295! 3! F3 + İdea 5668 S! 4.000! 18! 30! 40! 28! 245! 310! 2! F4 + İdea 396 C! 6.000! 34! 44! 51! 27! 140! 175! 3! F4 + İdea 5668 S! 4.000! 32! 47! 52! 27! 135! 170! 2! F5 + İdea 396 C! 6.000! 33! 45! 50! 27! 90! 135! 4! F5 + İdea 5668 S! 4.000! 32! 47! 56! 27! 105! 160! 2! F6 + İdea 396 C! 6.000! 22! 35! 46! 26! 100! 155! 2! F6 + İdea 5668 S! 4.000! 20! 32! 47! 26! 135! 180! 1! F7 + İdea 396 C! 6.000! 25! 43! 51! 26! 130! 170! 4! F7 + İdea 5668 S! 4.000! 23! 40! 54! 26! 140! 185! 1! 21! The strengths of micro concretes that produced by treated Grubu Çimento cement with PAAF PAAF are higher than theKimyasalları others! LABARATORY WORKS IN TURKEY - Table 4! Micro Concrete Tests! Sample! Water ! Air! Weight! (Kg/m3)! Flow ! L0 ! Flow! L30 ! Difference! cm! cm! Comp. St.! 2 d! 7 d! 28 d! cm! MPa! MPa! MPa! F1 + İdea 396 C! 236! 0,6! 2215,0! 20,8! 20,7! 0,1! 14,0! 26,6! 34.5! F1 + İdea 5668 S! 228! 0,6! 2211,0! 21,4! 21,3! 0,1! 13,1! 28,9! 35,4! F2 + İdea 396 C! 228! 0,6! 2207,5! 20,5! 20,0! 0,5! 16,2! 26,1! 35,1! F2 + İdea 5668 S! 228! 0,8! 2206,5! 20,8! 20,4! 0,4! 15,4! 25,8! 34,4! F3 + İdea 396 C! 252! 0,4! 2187,0! 21,5! 21,0! 0,5! 13,4! 23,7! 32,7! F3 + İdea 5668 S! 231! 0,4! 2191,0! 21,5! 20,9! 0,6! 11,6! 24,8! 35,3! F4 + İdea 396 C! 225! 0,8! 2227,2! 21,9! 20,5! 1,4! 22,1! 30,0! 37,5! F4 + İdea 5668 S! 222! 0,8! 2225,5! 20,8! 20,3! 0,5! 23,0! 32,7! 39,4! F5 + İdea 396 C! 231! 0,6! 2214,2! 21,8! 20,3! 1,5! 20,6! 30,7! 39,7! F5 + İdea 5668 S! 228! 0,8! 2212,2! 21,5! 20,0! 1,5! 20,6! 31,8! 41,2! F6 + İdea 396 C! 225! 0,4! 2233,2! 20,5! 19,8! 0,8! 13,1! 22,3! 32,1! F6 + İdea 5668 S! 228! 1,0! 2219,0! 21,0! 20,0! 1,0! 11,0! 21,1! 34,3! F7 + İdea 396 C! 234! 0,8! 2217,5! 20,5! 20,0! 0,5! 13,1! 24,6! 31,5! 22! PAAF’lı çimento ile üretilen betonun dayanımları d PAAF Grubu Çimento PAAF ile çimento üretiminde elektrik Kimyasalları enerjisi daha LABORATORY WORKS IN TURKEY – Table 5! Concrete Tests! PAAF TRIALS! PAAF TRIALS! Mix no! 2013-92/1! Concrete Class! Cement Dosage! C25/30! kg/m3! W/C! Source! Natural Sand! 2013-92/2! Source! 2013-92/1! Concrete Class! 300! 300! 0,67! 0,67! F1+İdea 396 C! F1+ İdea 5668 S! %! Mix no! -! -! -! -! 2013-92/2! C25/30! Temperature! ºC! 22,0! 22,0! Temperature (Concrete)! ºC! 19,5! 19,6! Air! %! 0,5! 1,1! kg/m3! 201! 201! Additional Water! kg/m3! 8,0! Unit Weight (Calculated)! kg/m3! 2339! Unit Weight (Measured)! kg/m3! 2375! Dosage! kg/m3! 304! 69! 67! Water! Crashed Sand! %! 50! 50! Sand 1! %! 20! 20! Sand 2! %! 30! 30! Marmara B.! Marmara B.! %! -! -! W/C %! Slump! Cm! 18,0! 18,0! 2 days! N/mm2! 13,7! 12,9! Slump (30 Min.)! Cm! 17,0! 17,5! 7 days! N/mm2! 25,6! 27,3! Slump Loss! Cm! 1,0! 0,5! 28 days! N/mm2! 34,1! 38,4! Source! Concrete Admixtures! 23! PAAF Grubu Çimento Kimyasalları LABORATORY TRIALS IN TURKEY - Table 5! Concrete Results! 24 PAAF Grubu Çimento Kimyasalları ADVANCED LAB WORKS! Sample! Cement Additives! Lab Mill Revolution! F3 - 1! No additive! 6.000! F3 - 2! No additive! 4.000! F3 - 3! Idea 396 C! 6.000! F3 - 4! İdea 396 C! 4.000! F3 - 5! CSI 5668 S (PAAF)! 6.000! F3 - 6! CSI 5668 S (PAAF)! 4.000! Lab mill revolution is 33 % lower with PAFF! 25! PAAF Grubu Çimento Kimyasalları ADVANCED LAB WORKS – Table 8! Compressive Strengths! Sample! Lab Mill Revolution! Compressive Strengths (MPa)! 2 d! 7 d! 28 d! F3-1! 6.000! 25,3! 44,4! 54,9! F3-2! 4.000! 20,4! 38,8! 50,2! F3-3 (with traditional CA)! 6.000! 27,7! 46,9! 57,5! F3-4! 4.000! 23,2! 42,1! 52,3! F3-5! 6.000! 33,8! 49,8! 61,9! F3-6 (with PAAF)! 4.000! 28,6! 46,8! 57,8! 26! PAAF Grubu Çimento Kimyasalları ADVANCED LAB WORKS- Table 8! Compressive Strengths! 65! 60! 55! F3.1 (Without Cement Additive, 6000 Mill Revolution)! 50! 45! F3.3 (With Traditional Cemet Additive, 6000 Mill Revolution)! 40! 35! F3.6 (With PAAF/5668, 4000 Mill Revolution)! 30! 25! 20! 15! 2g! 7g! 28g! 27! PAAF Grubu Çimento Kimyasalları ADVANCED LAB WORKS - Table 8! PSD Results! Cement Additive! Lab Mill Revolution! D 10! D 30! D 50! D 70! D 100! F3 - 3! 396 C! 6.000! 2,19! 6,9! 14,5! 25,3! 124,0! F3 - 6! PAAF 5668 S! 4.000! 2,86! 7,9! 18,5! 32,0! 158,4! Sample! ! D 30 is lower with PAAF that may help strengt improvement! ! 28! PAAF Grubu Çimento Kimyasalları ADVANCED LAB WORKS – Table 9! XRD Analysis! F3 - 1! F3 - 2! F3 - 3! F3 - 4! F3 - 5! F3 - 6! C3S! 60,70! 59,70! 60,20! 59,90! 60,10! 59,60! C2S! 10,20! 10,00! 10,10! 10,40! 9,60! 11,30! C3Ac! 5,80! 7,00! 6,10! 6,20! 6,00! 6,50! C3Ao! 8,00! 7,80! 8,40! 7,30! 8,40! 7,00! C4AF! 6,50! 6,10! 6,90! 6,40! 6,50! 6,80! SiO2! 0,60! 0,40! 0,00! 0,00! 0,40! 0,00! CaSO4.2H2O! 3,80! 4,50! 4,50! 4,90! 4,50! 4,90! CaSO4.1/2H2O! 0,40! 0,30! 0,00! 0,00! 0,00! 0,00! CaCO3! 4,00! 4,20! 3,80! 4,90! 4,40! 3,90! 100! 100! 100! 100! 99,9! 100! Those analysis show that clinker qualities are closer each others.! 29! PAAF Grubu Çimento Kimyasalları ADVANCED LAB WORKS – Table 10! Spesific Surfaces ! Specific Surface Area! 0.95! 1.40! 0.90! 1.30! Bet Surface Area! 1.20! 0.85! 1.10! 0.80! 1.00! 0.75! 0.90! 0.70! 0.80! 0.65! 0.70! 0.60! 0.60! 0.50! 0.55! 0.40! F 3-1! F 3-5! F 3-3! F 3-2! F 3-6! F 3-4! 0.50! F 3-1! F 3-5! F 3-3! F 3-2! F 3-6! F 3-4! 30 PAAF Grubu Çimento Kimyasalları ADVANCED LAB WORKS- Table 11! Heat Evaluation (J/g)! Measurement of Heat of Hydration! The heat evaluation of cement trated by PAAF is better than the others.! Time (hours)! 31! PAAF Grubu Çimento Kimyasalları ADVANCED LAB WORKS - Table 12! Porosity Measurements! Porosity! Porosity Volume! 16 0,08 14 0,07 12 0,06 10 0,05 0,04 8 0,03 6 0,02 4 0,01 2 0 F 3-1 F 3-2 F 3-4 10 - 220 µm 0,002 - 0,03µm F 3-3 F 3-6 F 3-5 0,03 - 10µm Total Porosity is lower with PAAF! 0 F 3-1 F 3-2 F 3-4 0,002 - 0,03µm F 3-3 F 3-6 0,03 -10µm F 3-5 Total Porosity volume is lower with PAAF! 32! PAAF Grubu Çimento Kimyasalları ADVANCED LAB WORKS - Table 13! ESEM Photos, Without CA, 6000 Mill Revolution, 24 hours X 50 000! 33! PAAF Grubu Çimento Kimyasalları ADVANCED LAB WORKS - Table 13! ESEM Photos, With Convansiyonel CA, 6000 Mill Revolution, 24 hours, X 50 000! 34! PAAF Grubu Çimento Kimyasalları ADVANCED LAB WORKS - Table 13! ESEM Photos, PAAF, 4000 Mill Revolution, 24 hours, X 50 000! 35! PAAF Grubu Çimento Kimyasalları INDUSTRIAL TRIALS - Table 14! Output, Fineness and Blaine Values! Cement Sample! Output (%)! Dosage (g/ton)! 32 mic! 45 mic! Blaine! 396 C (Traditional CA)! 100! 450! 5,1! 2,2! 3830! PAAF (5668 S)! 130! 1.000! 6,7! 3,5! 3350! 36! PAAF Grubu Çimento Kimyasalları INDUSTRIAL TRIALS - Table 15! Strengths! Cement Sample! Output (%)! Blaine! 2 d (MPa)! 7 d (MPa)! 28 d (MPa)! 396 C (Traditional CA)! 100! 3.830! 24,8! 46,2! 56,1! PAAF (5668 S)! 130! 3.350! 23,7! 49,5! 63,0! 37! PAAF Grubu Çimento Kimyasalları INDUSTRIAL TRIALS! Strengths! 70! 60! 50! 40! 396 C (Traditional CA)! 5668 S (PAAF)! 30! 20! 10! 0! 2g! 7g! 28g! 38! PAAF Grubu Çimento Kimyasalları INDUSTRIAL TRIALS - Table 16! Water Demand, Workability and Pack Set Results! Cement! Outputj (%)! Blaine! Water Demand (%)! HIT! Pack Set! 396 C (Ordinary CA)! 100! 3.830! 30,0! 16,1! 3! PAAF (5668 S)! 130! 3.350! 28,5! 17,2! 1! Lower water demand and better workability with PAAF! 39! PAAF Grubu Çimento Kimyasalları RESULTS! The stregths are better with PAAF altough it is produced with low energy.! Water demand is lower with PAAF,! Pack Set Index is lower with PAAF that can make the transportation of cement easier.! 40! PAAF Grubu Çimento Kimyasalları RESULTS! Early strengths are equal but final strengths are better with PAAF than the cements produced with ordinary cement additives! 41! PAAF Grubu Çimento Kimyasalları RESULTS! According to BET results SSA results of cement treated with PAAF is lower! The photos taken by electron microscopy shows that the hydration level of cement with PAAF is better than the others.! According to porosity measurements, the porosty of the cement treated with PAAF is lower than the cement treated with traditional cement additives in spite of the fact that cement with PAAF is more coarser.! 42! PAAF Grubu Çimento Kimyasalları RESULTS! According to ESEM after hydration of cements:! ! C-S-H pases are not clear on the cement without cement additive.! ! C-S-H pahes are more clear with PAAF. ! ! Those works explaine the results getting with PAAF! 43! PAAF Grubu Çimento Kimyasalları RESULTS! The amount of etregyte pahes in the cement produced with ordinaray cement additives are higher than the cement with PAAF.! 44! PAAF Grubu Çimento Kimyasalları RESULTS! Using PAAF in grinding prosses provides: !! ! Output increase and energy saving in Cement production, ! Better workability and lower water demand in concrete.! ! 45! PAAF Grubu Çimento Kimyasalları RESULTS! Within these works performed by Idea Construction Chemicals and Siegen University , all steps of cement and concrete productions with PAAF have been analysed to understand all the effects which is very important to have the integration of cement and concrete.! 46! PAAF Grubu Çimento Kimyasalları THE PLANNED WORKS! ! Patent works, ! ! Changes in concrete that produced with the cement treated by PAAF,! ! Industrial trials in the cement plants that interested in PAAF.! 47! PAAF Grubu Çimento Kimyasalları SOURCES! ! Effects of cement particles size distrubition on performance properties of ! portland cement-based materials, Dale P. Bentz et al, 1999! ! Durability-Critical issuses for the future, P. K. Mehta, Concr International 19(7)! (1997) 27-33! ! An argument for using coarse cements in high performance concrete, C. J. ! Haecker et al, Cem Concr Res29(1999) 615-618! ! The Global Cement Report, Cemnet; ! Cement Production and Concrete in the Future, A. Yeğinobalı! ! Turkey Cement Industry, Cemnet! ! Cement in 21. Century, Jean Claude Rauman, Shandeep L. Sarkar;! ! Sustainability in Cement Production, Cembureau! ! Cements of Yesterday and today and concrete of tomorrow, Pierre-Claude Aitcin! 48! PAAF Grubu Çimento Kimyasalları Thank You! 49!
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