Composition and phase mineral variation of Portland cement ... · PDF fileAbstract--The raw...

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International Journal of Basic & Applied Sciences IJBAS-IJENS Vol:12 No:06 109 126206-8585- IJBAS-IJENS @ December 2012 IJENS I J E N S Abstract -- The raw materials, clinker, and cement from the Mass cement factory in Sulaimani City- Kurdistan Region NE- Iraq have been investigated using polarizing microscopy, X-ray diffraction (XRD), Scanning Electron Microscopy SEM and chemical analysis. This study will discuss about the composition and phases mineral variation from different sample type of the factory. Chemical composition analysis using X-ray fluorescence is one of the important quality analyses for examining of cement and widely used in cement industries for a long time as a tool to estimate phase composition. X-ray diffraction is one of the established techniques as a qualitative tool to identify phase existing in the sample. Microscopic invistigation and X-ray diffraction of clinkers from Mass factory indicating the presence of five principle constitutes alite,(C 3 S ), belite (C 2 S), aluminate (C 3 A) , ferrite (C 4 AF), as well as minor isotropic residue (Periclase, and free- lime). The obtained SEM micrographs show alite with well developed external shape and hexagonal outline and it is larger than the other existing phase while belite is semi rounded and irregular outline phase. The chemical analyses of raw materials used in Mass cement factory indicate that the local raw materials are suitable for cement industry after addition some additive such as iron oxide and sandstone. The chemical and mineralogical analyses for studied clinker samples show that the dominant phases composition are C 3 S and C 2 S while the C 3 A and C 4 AF are less abundant. Transformation of mineral phases is found affected by different temperature during cement production. The different types of mineral phases are observed during the production. Index Term-- Portland cement, Mass Factory, Raw material, Clinker, Phase composition I. INT RODUCT ION Portland cement is a hydraulic material composed primary of calcium silicates, aluminates, and ferrites. In a rotary kiln, at temperature reaching the 1450 C, clinker nodules are produced from a finely ground, homogenized blend of limestone, shale . and iron ore. The nodules are subsequently ground with gypsum, which serves to control setting, to a fine powder to produce finished Portland cement. The composition and texture (crystal size, abundance, and distribution) of clinker phases result from complex interactions of raw feed chemical and mineralogical composition, particle size distribution, feed homogenization, and the heating and cooling regime [1] and [2]. In order to simplify these phenomena, [3] proposed an approach for the development of the clinker phases. The ferric oxide (Fe 2 O 3 ) reacts with aluminum oxide (Al 2 O 3 ) and lime (CaO) to form the tetracalcium alumino ferrite (Ferrite C 4 AF or Ca 4 Al 2 Fe 2 O 10 ). The remaining aluminum oxide reacts with lime to form the tricalcium aluminates (C 3 A or Ca 3 Al 2 O 6 ). The lime reacts with the silicate oxide (SiO 2 ) to form two calcium silicates phases, the dicalcium silicate (Belite, C 2 S or Ca 2 SiO 4 ) and tricalcium silicate (Alite, C 3 S or Ca 3 SiO 5 ). One of the important quality parameters of Portland cement is its chemical and phase composition. It is necessary to determine a complete mineralogy of clinker cement to correctly understand, interpret and predict the outcome of any plant production process [4], and [5]. Every year a huge amount of Portland cement is produced and used for the construction of building, roads and highways and other local purposes in Kurdistan Region Northeast Iraq. Cement industry of Sulaimani City has been established and expanded very rapidly in the last six years, before that period, two cement companies have been established (Serchinar and Tasluja cement companies). Today, the industry comprises another two production sites (Bazian and Mass cement companies) beside the Tasluja cement company. The Serchinar cement company now stopped production of cement because it is located inside the population area. In order to understand phase transformation of mineral phases in clinker and powdered cement after mixing with gypsum for about 5 %, a feasibility study was carried out for seven samples of clinker and seven samples of powdered cement, from Mass Cement Company. Quantitative and qualitative analyses had done to understand correlation between phase estimation using Bogue calculation and mineral phase existing in the samples. Composition and phase mineral variation of Portland cement in Mass Factory Sulaimani Kurdistan Region NE- Iraq Tola Ahmed Mirza Mohammed Department of Geology, Faculty of Science and Science Education, School of Science, University of Sulaimnai Email: [email protected]

Transcript of Composition and phase mineral variation of Portland cement ... · PDF fileAbstract--The raw...

International Journal of Basic & Applied Sciences IJBAS-IJENS Vol:12 No:06 109

126206-8585- IJBAS-IJENS @ December 2012 IJENS I J E N S

Abstract-- The raw materials, clinker, and cement from the

Mass cement factory in Sulaimani City- Kurdistan Region NE-

Iraq have been investigated using polarizing microscopy, X-ray

diffraction (XRD), Scanning Electron Microscopy SEM and

chemical analysis. This study will discuss about the composition

and phases mineral variation from different sample type of the

factory. Chemical composition analysis using X-ray

fluorescence is one of the important quality analyses for

examining of cement and widely used in cement industries for a

long time as a tool to estimate phase composition. X-ray

diffraction is one of the established techniques as a qualitative

tool to identify phase existing in the sample. Microscopic

invistigation and X-ray diffraction of clinkers from Mass factory

indicating the presence of five principle constitutes alite,(C3S),

belite (C2S), aluminate (C3A) , ferrite (C4AF), as well as minor

isotropic residue (Periclase, and free- lime). The obtained SEM

– micrographs show alite with well developed external shape

and hexagonal outline and it is larger than the other existing

phase while belite is semi rounded and irregular outline phase.

The chemical analyses of raw materials used in Mass cement

factory indicate that the local raw materials are suitable for

cement industry after addition some additive such as iron oxide

and sandstone. The chemical and mineralogical analyses for

studied clinker samples show that the dominant phases

composition are C3S and C2S while the C3A and C4AF are less

abundant. Transformation of mineral phases is found affected

by different temperature during cement production. The

different types of mineral phases are observed during the

production.

Index Term-- Portland cement, Mass Factory, Raw material,

Clinker, Phase composition

I. INTRODUCTION

Portland cement is a hydraulic material composed primary of

calcium silicates, aluminates, and ferrites. In a rotary kiln, at

temperature reaching the 1450◦C, clinker nodules are produced

from a finely ground, homogenized blend of limestone, shale

.

and iron ore. The nodules are subsequently ground with

gypsum, which serves to control setting, to a fine powder to

produce finished Portland cement. The composition and

texture (crystal size, abundance, and distribution) of clinker

phases result from complex interactions of raw feed chemical

and mineralogical composition, particle size distribution, feed

homogenization, and the heating and cooling regime [1] and

[2]. In order to simplify these phenomena, [3] proposed an

approach for the development of the clinker phases. The ferric

oxide (Fe2O3) reacts with aluminum oxide (Al2O3) and lime

(CaO) to form the tetracalcium alumino ferrite (Ferrite C4AF or

Ca4Al2Fe2O10). The remaining aluminum oxide reacts with lime

to form the tricalcium aluminates (C3A or Ca3Al2O6). The lime

reacts with the silicate oxide (SiO2) to form two calcium silicates

phases, the dicalcium silicate (Belite, C2S or Ca2SiO4) and

tricalcium silicate (Alite, C3S or Ca3SiO5).

One of the important quality parameters of Portland cement is

its chemical and phase composition. It is necessary to

determine a complete mineralogy of clinker cement to correctly

understand, interpret and predict the outcome of any plant

production process [4], and [5]. Every year a huge amount of

Portland cement is produced and used for the construction of

building, roads and highways and other local purposes in

Kurdistan Region Northeast Iraq. Cement industry of

Sulaimani City has been established and expanded very rapidly

in the last six years, before that period, two cement companies

have been established (Serchinar and Tasluja cement

companies). Today, the industry comprises another two

production sites (Bazian and Mass cement companies) beside

the Tasluja cement company. The Serchinar cement company

now stopped production of cement because it is located inside

the population area.

In order to understand phase transformation of mineral phases

in clinker and powdered cement after mixing with gypsum for

about 5 %, a feasibility study was carried out for seven

samples of clinker and seven samples of powdered cement,

from Mass Cement Company. Quantitative and qualitative

analyses had done to understand correlation between phase

estimation using Bogue calculation and mineral phase existing

in the samples.

Composition and phase mineral variation of

Portland cement in Mass Factory Sulaimani –

Kurdistan Region NE- Iraq

Tola Ahmed Mirza Mohammed Department of Geology, Faculty of Science and Science Education, School of Science, University of Sulaimnai

Email: [email protected]

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II. THE SCOPE AND LIMITATION OF THE STUDY

To describe the transformation in cement chemistry and

mineral composition during manufacturing process as well as

review the standards which cements must comply in

applications of different cement types this study was

established in Mass cement factory Sulaimani city Northeast

Iraq. This research supports the industrial activity in Kurdistan

Region northeast of Iraq especially in Sulaimani city which

show enrichment in essential raw material used in cement

production.

Potential of raw materials in Mass Factory Sulaimani City

Kurdistan Region

Limestone deposits are widespread in substantial part of the

Kurdistan Region Northeast Iraq. Large tonnage is available

from Bazian area, notably from the Sinjar Formation (Fig. 1).

Limestone from this source is used as feedstock for large

cement works at Bazian area specially used by Bazian Cement

Factory, Tasluja Cement Factory and Mass Cement Factory.

The limestone deposit described by good quality and huge

amount in this area, gypsum and sandstone occurs in

recoverable quantity in Tertiary rocks of Fatha Formation in

Bazian area. Iron materials are found in small zone as magnetite

and siliceous magnetite within metamorphic unit in Penjween

area but unfortunately it cannot be used for manufacturing of

cement because of these occurrence have limited potential for

cement industry therefore the iron oxide is imported from

Hamadan – Iran Country. Clay materials from recent valley

deposits as well as from Fatha Formation in the same area

provide feedstock for cement factory.

Geology of the studied area

The clinker samples were supplied by Cement Industries of Mass factory which is located northwest of

Bazian village, 35 km far to Sulaimani city – NE Iraq and

extended next Sulaimani-Kirkuk highway the elevation above

sea level is 849 m and located in N 35 ° 37ʹ 55.8″ and E 45° 5ʹ

50″ (Fig. 1). The study area represents the north flank of

Khaladan syncline known as extremely folded zone. Generally,

Tertiary rocks are outcropped at the studied area. Dips are

towards NW-SE and changed between 20° to 30 °. Paleocene

aged Kolosh Formation [7] is a base rock. Eocene aged Sinjar

Formation (limestone, dolometic limestone-crystalline

limestone) is intercalated with this Formation. Gercus

Formation, consist of red mudstone, sandstone, shale, pebbly

sandstone with conglomerate lenses overlays these units. At

the top Pila Sipi Formation, consist of dolomitic limestone and

limestone at the lower parts and thin calcareous marl, chalky

limestone and chert at the upper parts overlays them all. At the

Bazian Mass cement factory s ite and quarry area Lower Eocene

aged Sinjar Limestone Formation and Quaternary aged talus

and alluvium which covered wide area at the plain, are

outcropped.

Fig. 1. Geological map of studied area by [6]

III. MATERIALS AND METHODS

The laboratory work was carried out on five rock samples

representing local and imported raw materials (Table I), as well

as another seven samples were taken from the raw mix, seven

samples from outlet of the kiln (Clinker) and seven samples

from powdered clinker (cement) after blending with gypsum

with about 5 % (Table II, III, and IV). The chemical

composition of the Raw mix, Clinkers, cement and raw materials

analyzed by using XRF type MDX1000 Cox ford Model EG50H

(RH) in Mass Cement Factory. Mineralogical studies include

X-ray diffraction analysis of powdered samples, Scanning

electron microscopy (SEM) and polarizing microscopy in

polished sections. A polished section of clinker was prepared

by mixing clinker mass with a small amount of epoxy resin.

Mineralogical analyses have been carried out using reflected

light microscope in Geology department – optic laboratory. X-

ray powder diffractometry using Shimadzu XRD 7000

instrument and following the Iraqi Geological Survey standard

work procedure, part 21 [8] were used. Scanning Electron

Microscope was carried out on one cement clinker sample in

University of Jordan Faculty of Science using SEM (EDS

Bruker Quantax EDS system) Model Inspect F50 Schottky FEG

with accelerating voltage 200 KV magnification of 1756 up to

80000X.

Chemical analysis

Raw materials

The analyzed local limestone from Sinjar Formation is

almost pure consist mainly of CaO 52. 35 % with small

impurities of SiO2, and MgO 4.46 %, 0.06 % respectively

Table I. The analyzed clay and silica sand samples from

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recent valley deposits and Fatha Formation respectively

show relatively high content of SiO2 47.29 wt %, 52.43

wt % moderate amount of Al2O3 and CaO 11.89 Wt %,

14. 56 wt %, 10.69, and 12.98 wt % respectively Table I.

The imported iron oxide from Hamadan area Iran

country contain high Fe2O3 (58.43 wt %) and the gypsum

from Fatha Formation contains SO3 and CaO up to 30 wt

% (Table I).

Clinker The analyses of homogeneous samples of raw mix, clinkers and

cement powdered from Mass cement factory are given in Table

II, III; IV the composition of raw mix and clinker are relatively

similar to standard clinker composition (Table II, and III).

However is slightly different from cement composition (Table

IV) due to addition of gypsum to the latter.

T ABLE I

CHEMICAL COMPOSITION OF THE RAW MATERIALS USED IN MASS CEMENT FACTORY.

Raw

materials

Oxide

Limestone Clay Sand Iron Ore Gypsum

SiO2 4.46 47.29 52.43 19.96 0.53

Al2O3 1.46 11.89 10.69 3.49 0.58

Fe2O3 0.83 5.42 5.28 58.43 0.29

CaO 52.35 14.56 12.98 2.70 32.41

MgO 0.06 2.68 2.93 1.84 0.15

SO3 - - - - 42.68

L.O.I 41.73 14.59 12.08 11.65 21.07

T ABLE II

CHEMICAL COMPOSITIONS OF STUDIED SAMPLES FROM KILN FEED MIXTURE POSITION OF MASS CEMENT FACTORY.

Average

Composition of

cement rock after

Glausen in [9]

Av. 7 6 5 4 3 2 1

S . No.

Oxide

14.2 14.33 13.91 14.29 14.52 13.89 15.22 14.22 14.29 SiO2

4.8 3.64 3.70 3.64 3.64 3.46 3.66 3.73 3.65 Al 2O3

1.6 2.22 2.28 2.28 2.16 2.17 2.20 2.17 2.30 Fe2O3

40.2 42.19 42.34 42.00 42.02 42.40 41.91 42.31 42.36 CaO

2.8 1.34 1.42 1.33 1.46 1.40 1.12 1.28 1.34 MgO

34.2 34.90 34.64 34.43 34.40 35.37 34.97 35.34 35.13 L.O.I

34.2 98.62 98.29 97.97 98.20 98.69 99.08 99.05 99.07 Total

71.79 75.34 75.61 75.0 75.04 75.71 74.84 75.55 75.64 CaCO3- c

content

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T ABLE III

COMPOSITION AND ESTIMATED MINERAL COMPOSITION OF CLINKER SAMPLES USING [3]

[10]'' BS 12-78: British standard

[11]'' ASTM-81 American standard

ASTM- 81 BS 12-78 7 6 5 4 3 2 1

S. No.

Oxide

22.2 21.19 21.9 21.8 21.95 21.84 21.22 21.24 21.67 SiO2

4.7 5.36 5.83 5.74 5.88 5.52 5.68 5.62 5.64 Al 2O3

2.1 3.27 3.34 3.4 3.36 3.35 3.37 3.29 3.37 Fe2O3

65.8 64.4 64.9 64.96 65.16 64.92 65.27 65.23 65.44 CaO

1.1 0.89 2 1.96 2.03 1.96 1.98 1.97 2 MgO

0.04 0.58 0.26 0.24 0.23 0.22 0.27 0.3 0.23 Na2O

0.19 0.36 0.09 0.07 0.09 0.09 0.08 0.12 0.08 K2O

0.23 < 2.0 0.35 0.31 0.32 0.31 0.35 0.42 0.31 Na2O + K2O

< 3.5 0.28 0.13 0.25 0.29 0.27 0.3 0.28 SO3

< 5.0 0.11 0.2 0.27 0.12 0.23 0.09 0.08 L.O.I

99.06 98.81 99.54 98.62 98.72 98.58 99.1 Total

1.5 – 4.0 2.41 2.38 2.34 2.46 2.38 2.39 2.39 SR

1.4 - 3.5 1.67 1.71 1.69 1.65 1.75 1.69 1.75 AR

1.7 - 2.3 2.09 2.10 2.09 2.11 2.16 2.16 2.13 HM

66 - 102 92.07 92.62 92.16 92.8 95.39 95.43 93.98 LSF

54 45 53.77 55.29 54.08 56.38 61.41 61.61 58.95 C3S

23 27 22.24 20.8 22.14 20.1 14.52 14.43 17.67 C2S

9 9 9.8 9.46 9.9 8.96 9.35 9.33 9.25 C3A

6 10 10.16 10.35 10.23 10.19 10.26 10.01 10.26 C4AF

< 2.0 2.0 0.74 0.45 0.62 0.43 0.69 0.7 0.75 CaO-Free

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T ABLE IV

CHEMICAL COMPOSITION OF STUDIED SAMPLES FROM POWDERED CEMENT OF MASS FACTORY

7 6 5 4 3 2 1

S. No.

Oxide

20.32 20.21 20.45 20.14 20.51 19.92 19.72 SiO2

5.12 5 5.05 5.08 5.08 4.97 4.8 Al 2O3

3.13 3.25 3.23 3.13 3.22 3.26 3.17 Fe2O3

63.14 63.18 63.24 63.16 63.3 62.94 63.18 CaO

1.58 1.64 1.57 1.7 1.63 1.56 1.72 MgO

2.65 2.11 2.4 2.61 2.31 3.19 3.2 L.O.I

95.94 95.39 95.94 95.82 96.05 95.84 95.79 Total

2.46 2.45 2.47 2.45 2.47 2.42 2.47 SR

1.64 1.54 1.56 1.62 1.58 1.52 1.51 AR

2.21 2.22 2.20 2.23 2.20 2.24 2.28 HM

97.03 97.65 96.67 97.89 96.47 98.56 100.2 LSF

63.69 65.32 63.43 65.41 63.03 66.74 70.5 C3S

10.22 8.68 10.79 8.41 11.26 6.78 3.36 C2S

8.27 7.75 7.92 8.17 8.02 7.66 7.36 C3A

9.53 9.89 9.83 9.53 9.8 9.92 9.65 C4AF

Mineralogical study

Microscopic and SEM investigation

Microscopic investigation indicate the presence of major

principles constitutes alite C3S, and belite C2S (Fig. 2 A, B &C)

the other constituents Ferrite C4AF and aluminates C3A are

often fine grained and they cannot be resolved with polarized

light microscopy. Most of these constitutes are nonmetallic,

very fine grain and show high refractive indices. Alite occurs

as brown phenocrysts and usually as hexagonal outline which

is makes up the major constituent in the studied sample. Belite

is the second major component occurs as rounded to semi

rounded blue grain and some time as irregular outline (Fig.2 C).

Ferrite occurs as lath-like while aluminate crystals may be

found between ferrite crystals (Fig. 3C).

The scanning electron microscope (SEM) appear to have

abettor potentials for the examination of cement clinker since

these are often fine grained that they cannot be resolved with

the polarized light microscope [12]. The obtained SEM –

micrographs show alite with well developed external shape and

hexagonal outline and it is larger than the other existing phase

(Fig.3A). Belite is semi rounded and irregular outline phase.

(Fig. 3B), as well as the minor isotropic residue of free lime are

also observed (Fig. 3 E)

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Fig. 2. ''A, B, & C'' Reflected light microscopic investigation for polished section of clinker sample

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Fig. 3. Scanning electron micrograph of clinker sample, A & B phynocryst well developed hexagonal crystal of alite; C &D

irregular and rounded crystal of belite; E free lime. X-Ray Diffraction (XRD)

XRD is a direct, bulk analysis technique where the patterns

provide phase, chemical and crystal structure information data

that may afford greater understanding of cement property

performance relationships [13].

The X-Ray diffraction analysis of clinker samples are given in

Figs 3 & 4. Both two clinkers samples contain alite and belite

as a major mineral phase, ferrite and aluminate represents as

minor constituents while the free lime and Periclase MgO

representative as trace phases (Figs 4 & 5).

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Fig. 4. Diffraction pattern for clinker Sample-1

Fig. 5. Diffraction pattern of clinker sample -2

IV. DISCUSSION

Ordinary Portland cement (OPC) is prepared by igniting a

mixture of raw materials, one of which is calcium carbonate and

the other is aluminum silicates. The most typical materials

which fit these compositions are limestone and clay or marl;

bauxite, iron oxide, silica sand may be used in adjusting

chemical compositions. Gypsum is commonly is used as

retarder.

Analysis of raw materials limestone and clay (Table I) indicate

their suitability for cement industry with addition of few

percentages of sand, and iron oxide. The clay from recent

valley deposits in studied area shows a suitable composition

and could be a good source for SiO2, Al2O3 (Table I). This clay

is poor in Fe2O3 and SiO2 therefore the imported iron oxide from

Iran Country and silica sand from Fatha Formation are added to

the mixtures as a source of Fe2O3 and SiO2.

Table II show that chemical composition of the kiln feed

mixture which are homogeneous as required in terms of the

amount of calcium carbonate content is range between (75-

75.61%), this ranges are close to optimum operating condition

of the chemical composition of kiln feed which must be ranged

(76-76.5%), this range give soft burning of kiln feed and

leading to clinker formation [14] also, amount of fuel used for

burning will be in economic range. The average CaO content of

kiln feed 42.19 % wt (Table II). These values of CaO content

within kiln feed produced are acceptable industrially due to

lesser than 42.85% wt [15], that produce hard burning through

kiln.

British standards [10] and American standard [11] specify

amounts of SiO2 in OPC within the range 21% to 22%. It has

been observed that Mass Cement within specified limit (Table

III, & IV).

Amount of CaO as specified by the [10] & [11] should be

within the range 64 % to 66 %. All samples of clinker cement

contain CaO within the specified limit that can be observed

from Table 3 and 4. [10] & [11] specify amounts of MgO in OPC

not more than 2.0%. It was found that all the cement samples

were within the specified limit Table III and IV. The magnesia

content is limited by the standard specifications not to exceed

2% because higher magnesia contents may be detrimental to

the soundness of the cement, especially at late ages [4].

Beyond that limit it appears in the clinker as free MgO

(Periclase). Periclase reacts with water to form Mg (OH) 2, and

this is the slowest reaction among all other hardening

reactions. Since Mg (OH) 2 occupies a larger volume than the

MgO and is formed on the same spot where the Periclase

particle is located, it can split apart the binding of the hardened

cement paste, resulting in expansion cracks commonly known

as magnesia expansion [1] and [15]

It was found that amount of Al2O3 and Fe2O3 in Mass cement

was within the specified limit (Table III & IV). If the lime

content is fixed, and the silica becomes too high, which may be

accompanied by a decrease in alumina and ferric oxide, the

temperature of burning will be raised and the special influence

of the high lime will be lost. If the lime content is too low,

which means an increase in the alumina and ferric oxide; the

cement may become quick-setting and contain a larger amount

of alumina compounds, which appear to be of little value for

their cementing qualities. Rapid setting is undesirable, and is

not permitted by the standard specifications, because the

cement sets up so rapidly that it cannot properly be worked in

the forms before stiffening occurs [16]

A high loss on ignition LOI indicates pre-hydration and

carbonation, which may be caused by improper and prolonged

storage or adulteration of OPC during transport or transfer. All

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the cement samples were found to be competent with regard to

maximum LOI limit of less than 5.0 % as specified by [10].

The silica ratio SR (SiO2 / Al2O3 + Fe2O3), Alumina ratio AR

(Al2O3 / Fe2O3) and the lime saturation factor LSF (CaO / 2.8

SiO2 + 1.2 Al2O3 + 0.65 Fe2O3) are important factors for chemical

control of cement [17], [18] and [4].

Increasing silica ratio impairs the burn ability of the clinker, by

reducing liquid phase content and tendency toward formation

of coating in the kiln. An increasing silica ratio causes a slow

setting and hardening of the cement. With decreasing silica

ratio the content of liquid phase increases, this improves the

burnability of the clinker and the formation of coating in the

kiln [15]. Generally and depending on [10] the silica ratio runs

between (1.5- 4.0), low values for silica ratios can be accepted

as low down to 1.5, for the all studied clinker and cement

powder samples the SR are more than 1.5 (Table III & IV) and

it is suited with standard specification for production of

Ordinary Portland cement.

Alumina Ratio (AR) it is characterizing the cement by the

proportion of alumina to iron oxide values of alumina ratio are

in the range from 1.4 to 3.5 [10]. The AR determines the

composition of liquid phase in the clinker, when it's lower than

1.4 both oxides are present in their molecular ratios and

therefore only tetracalcium aluminoferrite can be formed in the

clinker; consequently, the clinker cannot contain tricalcium

aluminate. This is the case called Ferrari-cement which is

characterized by low heat of hydration, slow setting and low

shrinking. A high alumina ratio together with a low silica ratio

results among other things, in a fast setting of the cement; this

requires the addition of a higher gypsum rate to control the

setting time. The studied clinker samples show that the AR are

range between (1.65 – 1.75) (Table III) and it fit to the market

requirements for cement.

The hydraulic modulus (HM) is generally limited by the values

(1.7-2.3), which has the following form; CaO / SiO2 +Al2O3 +

Fe2O3. It was found that with an increasing HM, more heat is

required for clinker burning; the strengths, especially the init ial

strengths set up and also the heat of hydration rises; and

simultaneously the resistance to chemical attack decreases [5].

Generally cements with HM lesser than 1.7 showed mostly

insufficient strength; cements with HM greater than 2.3 had

poor stability of volume hence the clinker of the Mass Factory

and powdered cement characterized by fitness of the HM it

ranges between (2.09 – 2.16) and ((2.20 – 2.28) respectively

(Table III & IV).

To attain complete lime saturation in the clinker the total silica

must be combined as C3S, all iron oxide must combine with the

equivalent amount of alumina to C4AF, and the remaining

alumina must combine to C3A. For technical purposes good

values of LSF ranged between (80-95), and the all studied

samples have a good value of LSF which are range between

(92.07 – 95.43) Table 3 and (96.47 – 100.2) Table IV. As a result

of market requirements for cements from different sources to

have similar properties and also to optimize clinker production

there has been a trend to converge on a ‘standard’ clinker

chemistry of LSF 95 – 97%, SR 2.4 – 2.6, AR 1.5 – 1.8. At most

plants the achievement of this ideal chemistry will require the

use of corrective materials such as sand and iron oxide.

Potential reaction and mineral phases formed in the clinker for

the studied samples were estimated by using Bogue

calculation (Table III). The estimation of alite mineral phases

(C3S) and belite (C2S) in clinker sample is range between (53.77

- 61.61) % and (14.42 – 22.24) % respectively ((Table III) that

values coincide with the mineral percentage content in

ordinary Portland cement specification described by [19],

(Table V).

The potential for C3S formation is given by the lime saturation

factor [20], [21], [22], [23] and [24]. Table III shows that the

Mass cement has high LSF and highest C3S. However, C2S is

decreased with increasing the LSF but it still an important

strength-giving compound (Fig. 6). It contributes to strength

development at 28 days and beyond C3A and C4AF do not

show a clear relation to LSF (Fig. 6).

The reactivity of the raw mixtures was evaluated on the basis

of the un reacted lime or free lime (CaO-Free) content after

sintering at various temperatures [25] and [26]. The CaO-Free

content in relation to the sintering temperature of the studied

clinkers from different clinker samples is given in Table III and

it is always below the 2. 0 %. T ABLE V

STANDARD SPECIFICATION OF THE MINERAL WEIGHT % CONTENT IN

ORDINARY PORTLAND CEMENT CALCULATED ACCORDING TO [3]

DESCRIBED BY [19].

Mineral content Wt %

C3S 40 - 80

C2S 0.0 - 30

C3A 07 - 15

C4Af 04 - 15

Fig. 6. Lime saturation factor (LSF) vs. mineral wt % calculated

according [3]

V. CONCLUSION

The overall conclusion of this study is that there is a range of

potential raw materials (limestone, clay, sand and Gypsum)

suitable in chemical composition for cement industry.

Microscopic and chemical study of clinkers and cement are

International Journal of Basic & Applied Sciences IJBAS-IJENS Vol:12 No:06 118

126206-8585- IJBAS-IJENS @ December 2012 IJENS I J E N S

essentials for control of cement quality. The XRD and chemical

investigation of clinkers show that the alite phase occurred as

major well-formed crystals, the belite crystals were few and

evenly distributed in relation while the ferrite and aluminate

phases represent minor mineral phases in cement of Mass

Factory. The Periclase phase and free- lime occurred as fine

very fine grain. Transformation of mineral phases is found

affected by different temperature during cement production.

Clinkering process affect the transformation of mineral phases

which have similar element but different phase in the clinker.

The clinker of Mass cement has high LSF and highest C3S

while C2S is decreased with increasing the LSF but it still an

important strength-giving compound. It contributes to

strength development at 28 days and beyond C3A and C4AF

do not show a clear relation to LSF.

Variations in chemical constituents affect the cement

properties like, hardening/hydration, setting time, corrosion

resistance, color. Therefore comparative study between cement

factories in Sulaimani city Kurdistan Region Northeast Iraq is

recommended to encourage quality production.

ACKNOWLEDGMENTS

I would like to acknowledge support for this work by the Mass

Cement Factory for permission of taking samples and doing the

XRF analysis namely Mr. Abdulqadir director of laboratory

work.

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