UTILIZATION OF IRONSILICATE FINES AS
REPLACEMENT OF FINE
AGGREGATES IN CEMENT
CONCRETE PAVEMENTS
eng. Emanuela Manolova, Ph.D
Iron-silicate Business Development Manager
eng. Vanya Stoyanova, Ph.D
R&D Manager
05.04.2017
AURUBIS BULGARIA
Content
1. Aurubis as a company
2. Iron-silicate fines (ISF) application in concrete
pavements
3. Influence of ISF on fresh
concrete mixture
4. Influence of ISF on hardened
concrete
5. Conclusions
Aurubis Group Globally
Production plants
Copper production
Commercial
Primary copper
»
»
»
»
Hamburg, Germany
Olen, Belgium
Pirdop, Bulgaria
Röthenbach, Germany
Commercial
Recycling /
Presious metals
»
»
»
»
Fehrbellin, Germany
Hamburg, Germany
Lünen, Germany
Olen, Belgium
Copper processing
Commercial
Copper products
»
»
»
»
»
»
»
»
»
»
»
Avellino, Италия
Buffalo, USA
Dolnẏ Kubin, Slovakia
Emmerich, Germany
Hamburg, Germany
Mortara, Italy
Olen, Belgium
Pori, Finland
Birmingham, UK
Stolberg, Germany
Zutpen, Netherland
International sales and distribution network of
Aurubis products – more than 20 countries
(Europe, Asia and North America)
3
Aurubis is the leading company in world
recycling market
Global scale recycling materials consumption
(in thousand tones)
Aurubis
Aurubis
Metallo Chimique (BE)
Boliden (SE)
MW Brixlegg (AT)
340
50
320
275
20
660
325
190
170
160
90
70
100
100
Copper scrab
KGHM (PL)
La Farga (ES)
60
Atlantic Copper (ES)
Chinese smelters
Japanese smelters
Electronic scrap
Copper scrap
55
Other recycling
materials
1500
240
Източник: Интернет страница на конкурент, изчисления на Аурубис
4
Aurubis is the second international producer of
cathodes
International producers of cathodes
(in thousand tones)
1 678
Codelco (CL)
1 147
Aurubis*
Aurubis
1 081
Freeport McMoran (US)
1 000
Jiangxi (CN)
Xstrata (CH)
660
Jinchuan (CN)
628
BHP Billiton (US)
619
Nippon (JP)
585
KGHM (PL)
580
Sumitomo (JP)
569
5
Production for 2016
Warehouse
Metallurgy
Sulphuric Acid Plant
Processed:
» Copper concentrates
» Copper scrap
Flotation Plant
Produced:
1 200 000 t
56 000 t
» Anodes
350 000 t
» Cathodes
230 000 t
» Sulphuric acid
» Iron-silicate fines
1 220 000 t
677 000t
Production process
Iron-silicate fines
1. Aurubis as a company
2. Iron-silicate fines (ISF) application in concrete
pavements
3. Influence of ISF on fresh
concrete mixture
4. Influence of ISF on hardened
concrete
5. Conclusions
Iron-silicate fines: definition & characteristics
Definition
» By-product, generated by a flotation of copper slag (both from furnaces
and convertors), during the metallurgic process in the copper plant.
Chemical composition
» Mostly ferrous and silicate oxides (Fe2O3 in the form of fayalite (Fe2SiO4)
and magnetite (Fe3O4)), together with smaller quantities of aluminium,
calcium and magnesium oxides.
Physical characteristics
» dark angular particles with rough texture and irregular
shape
» specific density is 3.8 g/cm³ (EN 1097-6)
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Iron-silicate fines: definition & characteristics
Grain size
» 50% of the grains are between 20 μm and 200 μm
» 50% of the grains are smaller than 20 μm
100
Particle Size Distribution of ISF
90
Passing amounts [%]
80
70
60
50
40
30
20
10
0
0.002
0.02
0.2
2
Sieve opening [mm]
Pozzolanic activity
» Presence of certain activity (EN 450-1 and ASTM-95)
10
Iron-silicate fines as a building material
Industrial wastes in concrete production
» counteracting the decrease of natural
resources;
» reducing the cost of construction materials;
» solving the problem of disposal of waste
materials, generated by different industries;
» improving the properties of composite
materials – both in fresh and hardened state.
Quarry for aggregates
Replacement material
» sand
» cement
Disposal of industrial wastes
11
1. Aurubis as a company
2. Iron-silicate fines (ISF) application in concrete
pavements
3. Influence of ISF on fresh
concrete mixture
4. Influence of ISF on hardened
concrete
5. Conclusions
Fresh concrete mixture with ISF
Concrete mix design
» application: vibro-compression cement pavements in industrial scale;
» ISF – 15%, 20%, 25% and 30% sand substitution;
» reduces quantities of natural sand 0.4mm.
Material
Reference mix
355
Mix 1
(15 % ISF)
kg/m³
355
Mix 2
(20 % ISF)
kg/m³
355
Mix 3
(25 % ISF)
kg/m³
355
Mix 4
(30 % ISF)
kg/m³
355
Cement 52.5 R
Coarse aggregate
4/12.5 mm
Natural sand 0.4 mm
Crushed sand 0/4 mm
Iron-silicate fines
Water
Chemical admixture
810
810
810
810
810
850
340
–
145
2.1
531
340
300
145
2.1
488
340
400
145
2.1
410
340
500
145
2.1
347
340
600
145
2.1
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Fresh concrete mixture with ISF
Behaviour of the fresh concrete with ISF
» improved workability;
» better filling up of the space between the
coarser grains;
» compacting the voids and pores;
» less energy for vibration;
» less bleeding;
outside storage of ISF as a building material
» reduce heat of hydration and water demand;
» affect setting characteristics.
Casting and Curing of concrete pavements
» in the bottom layer, 30 sec vibration;
» humidity chamber (20⁰C, 50%), 28 days
concrete mix with ISF
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1. Aurubis as a company
2. Iron-silicate fines (ISF) application in concrete
pavements
3. Influence of ISF on fresh
concrete mixture
4. Influence of ISF on hardened
concrete
5. Conclusions
Hardened concrete with ISF
Properties of hardened concrete
» Increases mechanical strength;
» Smooth polished surface;
» Reduces permeability;
» Improves durability.
№
Percent sand
substitution
1.
2.
3.
4.
15 %
20 %
25 %
30 %
15%
Flexural strength, MPa
Measured
Limit
value
3.7
≥3.6
3.7
≥3.6
4.9
≥3.6
4.5
≥3.6
20%
25%
30%
Water absorption, %
Measured
Limit
value
5.9
≤6.0
5.8
≤6.0
5.7
≤6.0
5.7
≤6.0
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Hardened concrete with ISF
Properties of hardened concrete
» 25% sand substitution gives the maximum strength;
» ISF could reduce the material needed;
» ISF reduces the water absorption of pavements, due
to compacted structure. The higher is the quantity of
ISF, the lower is the absorption.
» Reasons:
» Proven pozzolanic activity by EN 450-1 and
ASTM-95.
» SAI index of testing samples with ISF is 81%,
compared so reference samples with cement only
(75% in the standard).
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1. Aurubis as a company
2. Iron-silicate fines (ISF) application in concrete
pavements
3. Influence of ISF on fresh
concrete mixture
4. Influence of ISF on hardened
concrete
5. Conclusions
Conclusions
Ongoing investigations
» Successful utilization in concrete pavements in industrial scale;
» Making sustainable, high strength, durable and eco-friendly concrete
products;
» 25% sand substitution gives equilibrium in properties both in fresh and
hardened state;
Further investigations
» Application of ISF as a cement replacement;
» Production of ready-mix concrete in industrial scale;
» Production of ready-mix mortar in industrial scale;
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Thank you for your attention!
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