characterization of clinker produced by fluidized bed advanced cement kiln system

Cement Science and Concrete Technology, No.65, 2011

529

1,000t/

*1 *2 *2

*1274-8601 585*2 551-0021 7-1-55

FAKS

1.FAKS

200t/

FAKS

1

NEDO

1,000t/ FAKS

2

2.FAKS FAKS

-

Fig. 1Outline of NSP rotary kiln and FAKSWatanabe et al., 2007

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530

CO2NOx

NSP FAKS

3

FCK

Fig. 1

30

FBQ PBC 2

FAKS

Fig. 2

3. FAKS

3 ABC

A2

FAKS 13mm

Photo. 1

4.4. 1JIS R 5202

JCAS-01

12 4. 2 XRD

X XRD

X XPert PRO MPD

X CuKa

45kV 40mA

C3SM1M3 C2S

C3AC4AFPericlase

K2SO4K3NaSO42 f-CaO4. 312mm

0.1 -

Fig. 2 Schematic model of nucleation process in the FBK systemYuko et al., 2000

VHX-5004. 4

3,400

100cm2/g

SO3

2.0

Photo. 1Overview of clinker produced by FAKS

Cement Science and Concrete Technology, No.65, 2011

531

JIS R 5201

4. 5

3,400100cm2/g

SO3 2.0

V

A

Table 1

55 45 2 1

2

Table 1

AE

JIS A 1101

JIS A 1128

JIS A 1108

5.5. 1 Table 2

f-CaO 0.41.1 3

MgO

5. 2 XRD Table 3

A

C C3S M1/C3S

MgO C3S-M3

B C2S

2

5. 3

C Fig. 3 Fig. 6

Fig. 3

30m

Table 1Specified Mix Proportion

Sample NameW/C

S/A

Slumpcm

Air Content

Quantity of Material per Unit Volume of Concretekg/m3

Water Cement Sand 1 Sand 2 Gravel

B55 44.5 12 4.5

168 305 559 237 1,005C 168 305 559 237 1,007

B45 45.0 18 4.5

167 371 549 232 968C 167 371 549 235 968

Table 2Chemical Composition of FAKS Clinker

Sample NameChemical Composition

Ig.loss insol. SiO2 Al2O3 Fe2O3 CaO

A 0.07 0.24 22.53 5.00 3.26 64.38B 0.42 0.34 21.28 5.44 2.43 65.53C 0.23 0.28 23.26 4.71 2.73 64.77

Sample NameChemical Composition

MgO SO3 Na2O K2O TiO2 f-CaO

A 2.56 0.39 0.38 0.49 0.27 0.4B 2.81 0.62 0.18 0.52 0.23 1.1C 2.78 0.43 0.18 0.32 0.23 0.6

Sample NameModulus Mineral Composition Based on Bogue Formula

HM SM C3S C2S C3A C4AF

A 2.09 2.73 52.5 25.0 7.7 9.9B 2.25 2.70 64.9 12.1 10.3 7.4C 2.11 3.13 51.3 28.0 7.9 8.3

Cement Science and Concrete Technology, No.65, 2011

532

Fig. 4

10m

Fig. 5

FAKS1,325

1,450 100

Fig. 6

5. 4 Table 4 Fig. 7

Fig. 10 B

2

Table 3Mineral Composition of FAKS Clinker

Sample NameMineral Composition

C3S C2S C3A C4AF Periclase K2SO4 K3NaSO42 f-CaO

A 56.7 25.6 6.6 8.5 1.8 0.4 0.4 0.3B 62.0 18.1 9.6 7.0 2.1 0.3 0.7 0.1C 57.2 24.7 5.9 9.4 2.1 0.3 0.4 0.0

Sample NameRatio of Crystalline Phase in its Mineral Dierence between Rietveld Analysis and Bogue Formula

M1/C3S '/C2S ort/C3A C3S C2S C3A C4AF

A 0.21 0.07 0.38 4.2 0.7 -1.2 -1.4B 0.25 0.10 0.30 -2.8 5.7 -0.6 -0.4C 0.25 0.06 0.34 4.7 -2.3 -1.6 1.1

Fig. 6Interstitial PhaseSample C

Fig. 3Whole Texture of ClinkerSample C

Fig. 4Alite CrystalsSample C

Fig. 5Belite CrystalsSample C

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B

B 2 C3S HM

Table 2

3

MgO

A

C

5. 5 Table 5

Table 6Fig. 11 Fig. 12

Fig. 9Flow of FAKS Cement

Fig. 8Setting Time of FAKS Cement

Fig. 7 Density and Specific Surface Area of FAKS Cement

Table 4Results of Physical Tests for FAKS Cement

Sample NameDensityg/cm3

Specic Surface Areacm2/g

Setting Time TestFlowmmWater Content

Initial Setting Time Final Setting Time

A 3.15 3,640 29.2 2-45 3-48 212B 3.12 3,570 30.4 1-31 2-27 206C 3.15 3,630 30.0 2-02 3-08 206

Sample NameCompressive StrengthN/mm2 Bending StrengthN/mm2

3 days 7 days 28 days 91 days 3 days 7 days 28 days 91 days

A 32.2 39.8 53.3 61.7 6.7 7.6 8.6 9.1B 34.2 42.6 54.8 60.8 7.2 8.1 8.7 8.2C 28.4 38.7 53.9 65.7 5.9 7.4 8.8 9.7

Fig. 10Compressive Strength of FAKS Cement

Cement Science and Concrete Technology, No.65, 2011

534

6.0

2

B

6.FAKS

1 T. Yuko et al.New clinker formation process

by the fluidized bed kiln system, Cement and

Concrete Research, vol. 30, pp. 1113-11202000

2

165

pp. 6-92007

Table 6Compressive Strength of Concrete

Sample Name

W/C

3 days 7 days 28 days 91 days

Measured Value

Compensated Value

Measured Value

Compensated Value

Measured Value

Compensated Value

Measured Value

Compensated Value

B55-1

55

11.9 11.7 17.6 17.2 23.6 23.1 28.2 27.6B55-2 11.9 11.2 18.5 17.5 23.6 22.3 30.0 28.4C55-1 12.9 12.3 19.7 18.7 28.0 26.6 36.9 35.1C55-2 14.5 14.2 20.0 19.6 28.5 27.9 37.4 36.7

B45-1

45

20.8 22.7 26.9 29.3 34.0 37.1 39.8 43.4B45-2 20.3 20.9 25.8 26.6 33.2 34.2 39.8 41.0C45-1 21.3 21.3 29.6 29.6 37.2 37.2 49.2 49.2C45-2 21.5 22.7 29.6 31.2 37.3 39.4 49.5 52.2

UnitN/mm2

Table 5Property of Fresh Concrete

Sample NameW/C

Slumpcm Air Content

Temprature of ConcreteMeasured Value Compensated Value

B55-1

55

5.6 6.6 5.6 21.0B55-2 4.1 6.9 4.9 21.1C55-1 5.2 7.7 5.0 20.7C55-2 4.8 5.8 5.6 20.7

B45-1

45

8.3 3.8 7.8 21.5B45-2 7.2 5.7 6.6 21.7C45-1 8.4 8.4 6.0 21.2C45-2 9.2 6.5 7.1 21.2

Fig. 11 Compressive Strength of Concrete with W/C of 55

Fig. 12 Compressive Strength of Concrete with W/C of 45

Cement Science and Concrete Technology, No.65, 2011

535

Shigehiro ANDO*1, Hiroshi NOMURA*2 and Maki SEKIHIRO*2

*1 SUMITOMO OSAKA CEMENT Co., Ltd., Cement/Concrete Research Laboratory585, Toyotomi-cho, Funabashi-shi, Chiba 274-8601, Japan

*2 SUMITOMO OSAKA CEMENT Co., Ltd., Cement/Concrete Research Laboratory7-1-55, Minamiokajima, Taisyo-ku, Osaka-shi, Osaka 551-0021, Japan

ABSTRACTFluidized bed Advanced cement Kiln SystemFAKSis an innovative cement manufacturing technology with higher reaction efficiency than any other kiln system. A FAKS plant with the capacity of 1,000 tons/day was constructed by Kawasaki Plant Systems in the International Coal Utilization Project by New Energy and Industrial Technology Development OrganizationNEDOin Shandong Province, China. And its performance tests were conducted. In this study, clinker samples from a FAKS plant were examined by Chemical Analysis, Rietveld Analysis and Optical Microscopy. Moreover, physical tests for cement and tests for slump, air content and compressive strength of concrete were performed to confirm their qualities. As a result, it is clear that clinker produced by FAKS was burned as well as by conventional rotary kiln system, though there are differences in the process of clinker minerals formation, burning conditions such as temperature and retention time in the kiln, etc. Compared among the clinker samples from a FAKS plant, there was a significant difference in especially the increase of compressive strength in the long term. It is obvious that the physical property of cement could have been affected by the difference of mineral composition in our tests. In addition, it is possible that it might have been affected by the difference of a melting state of minor constituents such as MgO in clinker minerals.

KEY WORDSFluidized bed advanced cement kiln systemFAKS, Clinker

CHARACTERIZATION OF CLINKER PRODUCED BY FLUIDIZED BED ADVANCED CEMENT KILN SYSTEM