ADDITION OF FLY-ASH BEYOND BIS LIMIT

( AS MENTIONED IN IS 1489 : 1991 ),

IN PORTLAND POZZOLANA CEMENT A R&D WORK FOR CLEANER ENVIRONMENT

S.B.ROONGTA , T.S.DEWANGAN , DR. USHA SINGH Introduction : Fly ash is a artificial pozzolanic material, which is a inorganic residue obtained from the burning of pulverized coal. A finely divided Pozzolana form compounds which have cementitious properties, when mixed with hydrated lime and alkalies. As such, the generation/ consumption ratio of fly ash is very high in India, hence every year a huge stock of fly ash is increasing. As it comes under hazardous waste material, the disposal is also a major problem. But now a days in the many field the fly ash is used either as a ingredient of raw material or as a filler. The cement and concrete are the examples, where it is used as a pozzolanic material. The fly ash should conform the parameters laid down in IS 3812 : 2003 Part I and II for its different usage. Earlier , when IS 1489 :1969 for PPC was introduced in India , the addition of fly ash was limited from 10 25 % only. From 1980 onwards there is revolutionary change in cement technology and the production of high strength giving clinker started. Based on the production of high strength clinker , Bureau of Indian Standard revised its limit and was increased and now the limit of fly ash addition in PPC is 15 35 %. In India and other part of the world , the scientist are involved to increase the addition of fly ash in PPC manufacturing, to make the environment more cleaner. This is not only for Waste to best conversion but also for ash to cash, keeping environment friendly approaches for better to-morrow. Keeping the clean and green environment in mind, this research and development work was carried out in Quality Control Department of Cement Manufacturing Company Limited Meghalaya India in the laboratory scale, to know the impact of higher addition of fly ash beyond BIS limit, with respect to clinker quality, fineness and Indian Specification IS 1489 :1991 for Portland Pozzolana Cement. Presently OPC 43 Grade , OPC 53 Grade and PPC Part I ( Fly Ash based ) cements are being manufactured and marketed with STAR Brand, which become the most popular and leading brand of cement in North East States of India within a year of commencing production. The Company is also selling clinker to various small and mid sized customers for its premium quality as low alkali, low C3A and low Chloride are the requirement for mass construction , which are easily met by clinker / cement manufactured in CMCL.

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The cement grinding in Cement Manufacturing Company Limited, started in February 2005 . From June 2005 production of Portland Pozzolana Cement ( Fly ash based ) started. Initially the addition of fly ash was kept lower side and than gradually increased upto 33 % without compromising on any parameter During the process of more addition of fly ash we have conducted trial in laboratory for various parameters of cement and fly ash both. We are taking fly ash from Kahalgaon. The details of Quality Parameters of fly ash as per Indian Specification are as under :-

Table 3 : Specification of pulverized fuel ash (IS : 3812 2003) Requirement Test A. Chemical
1. SiO2 + Al2O3 + Fe2O3 2. SiO2 3. Reactive silica** 4. MgO 5. SO3 6. Alkalies as Na2O 7. Chloride 8. LOI % min % min % min % max % max % max % max % max min % max min % max 70 35 20 5 3 1.5 0.05 5.0 50 25 20 5 3 1.5 0.05 5.0 70 35 20 5 5 1.5 0.05 5.0 50 25 20 5 5 1.5 0.05 5.0
Fly ash used in CMCL for PPC production (Avg)

Characteristics

Part 1
Siliceous Calcareous

Part 2
Siliceous Calcareous

90.23 61.25 0.48 0.31 0.74 0.019 1.98 356 17.2 6.8 0.01 59.88*
=87.28% of OPC

B. Physical
1. Fineness, m2/kg 2. Wet 45micron sieve** 3. Lime reactivity, MPa 4. Autoclave % 5. Compressive strength at 28 days, MPa 320 320 200 200 34 34 50 50 4.5 4.5 4.5 4.5 0.8 0.8 0.8 0.8 Not less than 80% of the strength of corresponding plain cement mortar cube

* Compressive strength of fly ash-cement mortar cube 59.88 Mpa and corresponding test on plain cement-sand mortar cube 68.61 Mpa. Compressive strength of fly ash at 28 days 87.28 % strength observed against corresponding plain cement mortar cube. Testing carried out as per IS 1727 : 1967. ** Optional test

We have carried out the test in two parts. In first part we have taken trial up to 35 % addition of fly ash in laboratory scale and than commercial production also started up to 33 %

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addition of fly ash . Both the data are given below for taking out the co-relation in between them.

Portland Pozzolana Cement with higher additions of fly ash Quality product of PPC with higher addition of fly ash; depends on the quality of clinker and fly ash. Particle size and fineness is also important factor for strength development in cement. Trial conducted at laboratory scale replacement of OPC by consumption of fly ash at different quantities. Test results are as underTable 7 : Laboratory Ball Mill Physical Test Result (CMCL clinker with different percentage of fly ash)

Fly ash consumption

Physical Test
Normal consistency Fineness Le-Chatelier Expansion Autoclave Expansion Initial setting time Final setting time 1- Day c/strength 3 Days c/strength 7 Days c/strength 28 Days c/strength % M2/Kg mm % Minutes Minutes MPa MPa MPa MPa

0% 24.5 310 Nil Nil 95 130 28.0 43.0 54.0 68.0

20% 27.00 375 Nil Nil 110 145 18.0 36.5 49.0 62.0

25% 26.50 347 Nil Nil 140 175 16.0 28.5 38.5 60.5

30% 25.75 368 Nil Nil 135 170 18.0 28.5 40.0 58.0

35% 26.25 375 Nil Nil 140 175 16.0 26.0 38.0 56.0

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The Quality Parameters of Commercial Production are given below with fly ash addition from 20 - 33 %.

Physical Test Results of PPC (Commercial production with different percentage of fly ash)
Requirement as per IS : 1489-1991 (Part 1)

Fly Ash
20% 29.2 367 Nil Nil 110 160 16 27 37 61 25% 28.5 330 Nil Nil 120 160 15 25 35 58 30% 28.5 338 Nil Nil 140 170 13 22 32 59 33% 28.8 355 Nil Nil 135 175 13 21 36 60

Physical Test
Normal consistency Fineness Le-Chatelier Expansion Autoclave Expansion Initial setting time Final setting time 1- Day c/strength 3 Days c/strength 7 Days c/strength 28 Days c/strength % M2/Kg mm. % Minutes Minutes MPa MPa MPa MPa

300 (Min) 10 (Max.) 0.8 (Max.) 30 (Min) 600 (Max.) 16 (Min) 22 (Min) 33 (Min)

. In the second part of the trial we have conducted tests with 40 to 50 % of fly ash addition, the results are not only encouraging, but we would like to draw the attention of the concerned governing bodies, scientists of cement and environmental field to join their hands in the interest of the nation and the world to make more clean and green environment , the permissible range of addition of fly ash is to be reconsidered The Quality Parameters of cement with 40 50 % fly ash addition is given below to compare the data with different % of addition as per the requirement of Indian Standards IS 1489 :1991 (Part I )

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Chemical TEST LOI % IR% SO3% SiO2% Al2O3% Fe2O3% CaO% MgO%
Physical Test

40% Fly Ash

42% Fly Ash

45% Fly Ash

47%
Fly Ash

50% Fly Ash

0% Fly Ash

1.07 35.16 1.49 13.01 5.54 2.50 39.53 1.21

40% Fly Ash 26.25 350 Nil Nil 105 135

1.17 36.68 1.40 12.45 5.25 2.60 38.79 1.20

42% Fly Ash 26.50 360 1.0 Nil 110 140

1.32 40.31 1.38 10.81 5.14 2.70 36.31 1.21

45% Fly Ash 26.50 360 Nil Nil 110 140

1.40 41.89 1.30 10.61 5.09 2.75 34.52 1.15 47%

Fly sh 26.50 370 Nil Nil 105 135

1.55 43.68 1.20 11.36 5.05 2.85 32.70 1.01

50% Fly Ash 26.75 370 Nil Nil 100 130

0.46 0.07 2.46 20.61 6.31 3.80 64.49 1.21

0% Fly Ash 24.0 299 Nil Nil 90 125

N. C . % Blain M2/Kg Lechatelier Exp. mm. Autoclave Exp. % IST (Minutes) FST (Minutes) Compressive Strength ( MPa) 1- Day 3- Days 7-Days 28-Days

13 24 38 58

12 22 34 58

10 20 32 52

9 20 32 52

8 16 24 48

26 40 52 69

You may please observe from the above data that with 370M2/Kg fineness the cement with 50 %fly ash addition is also conforming the relevant specification. If the fineness is increased to more than 380 ,than it will cross boundary line for 3 days strength and on better side for 7 days also.

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Here it will be better to mention that the most important factor for higher addition of fly ash is the compatibility of clinker , which is used for the manufacture of PPC . We would like to inform you that in the process of Ordinary Portland Cement grinding and above mentioned PPC , the gypsum was not used as setting retarder. However with the use of 1.5 % Mineral Gypsum as setting retarder the chemical and physical parameters were observed as under in the next set of testing with another set of clinker. All the samples were prepared in laboratory ball mill. In this series of test Bhutan Gypsum was also used as setting retarder. : Chemical TEST Cement With 30% Flyash, 1.3% Gypsum 1.21 22.30 2.23 16.82 4.52 3.80 46.74 1.20 Cement With 35% Flyash, 1.3% Gypsum 1.35 26.13 1.93 15.39 4.42 3.40 45.42 1.20 Cement Cement With With 45% 40% Flyash, Flyash, 1.4% 1.4% Gypsum Gypsum 1.45 1.76 36.87 38.54 2.20 1.83 10.38 9.89 4.89 4.62 3.20 3.00 39.23 37.57 0.60 1.20 Cement 0% With Fly Ash 50% & O% Flyash Gypsum 1.5% Gypsum 1.92 0.36 45.29 0.17 1.86 2.36 9.79 20.55 4.36 5.80 2.80 4.20 32.27 64.56 1.01 1.41

LOI % IR% SO3% SiO2% Al2O3% Fe2O3% CaO% MgO%

Physical Test

Cement With 30% Flyash, 1.3% Gypsum 28.00 351 Nil 0.00 120 150

N. C . % Blain M2/Kg Lechatelier Exp. mm. Autoclave Exp. % IST (Minutes) FST (Minutes) Compressive Strength ( MPa) 1- Day 3- Days 7-Days 28-Days

Cement With 35% Flyash, 1.3% Gypsum 28.50 350 Nil 0.04 120 155

Cement Cement With With 45% 40% Flyash, Flyash, 1.4% 1.4% Gypsum Gypsum 28.75 29.00 350 360 Nil Nil 0.06 125 165 0.02 120 150

Cement 0% With Fly Ash 50% & O% Flyash Gypsum 1.5% Gypsum 29.50 26.00 370 300 Nil Nil 0.02 155 185 0.00 100 130

20 30 46 63

18 32 44 63

16 24 38 56

14 24 36 54

08 16 27 44

29 41 50 64

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The important characteristics of clinker quality are as under :THE HIGH-LIGHTS OF CMCL CLINKER 1. Above 52 % C3S content. 2. High SO3 content ( > 2 % ) in clinker. 3. Remarkably low Alkali content (< 0.6 % in terms of Na2O ). 4. Lower C3A content clinker ( < 6.5 % ). 5. Lower free lime content clinker. 6. Better strength with lower fineness. 7. Lower Heat of Hydration. 8. Lower alkali- aggregates reaction. 9. Darker clinker ( C4AF > 11 % ) 10. Most ideal to manufacture OPC, PPC, and PSC. 11. More resistant for aggressive environmental attack. 12. More sound cement. 13. Most ideal for Project-work, Mass construction, Bridge pier, Dam, Tunnels, Hydro-electric power stations, General purpose construction, and Specially high strength requirements. 14. Lower/No Gypsum requirements means higher contribution of clinker to produce cement ( more strength developing material ) 15. Low Chloride content clinker. 16. Scientifically designed composition, resulting more durable constructions.

Since the beginning , plant is using Meghalaya Coal , which is having 5 6 % sulphur content. The Plant is supplied by Walchand Ind. Ltd. Pune, which is equipped with 5 stage preheater with RSP pre-calciner. Presently plant is producing 1700 1800 MT clinker per day, without any jamming problem in pre-heater as it does not have any volatiles by-pass system. There is a lot of scope to work on the quality parameter of clinker, related to higher addition of fly ash and which is going on in Cement Manufacturing Company Limited. The

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plant performance can be quoted as an example in cement world, as no-body believes upon the plant operation parameters, for the volatiles Q factor, as it is far away from the acceptable limit for the cement plant operation , and that too, without by-pass system. For any more information /clarifications on above , concerned plant personnels and authorities can be contacted. References 1. Taylor H. F. W (1998) Cement Chemistry, Thomas Telford Publishing, London. 2. Perry Robert H & Green Don H. (1997) Perrys Chemical Engineers Handbook, Mc Graw-Hills New York. 3. Labahn Otto & Kohlhaas B. (1983) Cement Engineers Handbook, Bauverlag GmbH, Wiesbaden and Berlin. 4. Sarkar S. L. & Ghosh S. N. (1993) Progress in cement and concrete, Mineral admixtures in cement and concrete, Volume 4, ABI Books Pvt. Ltd. New Delhi 100 019 INDIA 5. IS 1760 (Part 3) : 1992 Chemical analysis of limestone, dolomite and allied materials (Part 3 determination of iron oxide, alumina, calcium oxide and magnesia, Bureau of Indian Standards New Delhi 110 002 6. IS 3812 (Part-1) : 2003 Pulverised fuel ash- Specification, Part- 1 for use as pozzolana in cement, cement mortar and concrete, Bureau of Indian Standards New Delhi 110 002 7. IS 3812 (Part - 2) : 2003 Pulverised fuel ash- Specification, Part- 2 for use as admixture in cement mortar and concrete, Bureau of Indian Standards New Delhi 110 002 8. IS 1489 (Part - 1) : 1991 Portland Pozzolana Cement - Specification, Part- 1 flyash based, Bureau of Indian Standards New Delhi 110 002 9. IS 4031 (Part 1 - 15) Methods of physical test for hydraulic cement, Bureau of Indian Standards New Delhi 110 002 10. IS 4032 : 1985 Methods of chemical analysis of hydraulic cement, Bureau of Indian Standards New Delhi 110 002 11. IS 1727 : 1967 Methods of test for pozzolanic materials, Bureau of Indian Standards New Delhi 110 002 12. Use of high sulphur content Meghalaya coal in Cement Manufacturing Company Limited by Mr. S.B. Roongta & T.S.Dewangan ( Paper published in 9th International seminar NCCBM 2005 ) 13. Blended Cement with higher addition of fly ash and fineness as a tool with respect to clinker quality by Mr. S. B. Roongta, T. S. Dewangan, Dr. Hemant Sahu ( A paper accepted for Indian Cement Industry Desk - Book.)

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Details of Authors 1. Mr. S.B. Roongta is having B.Sc. in Mechanical Engg. Degree from Birla Institute of Technology . Ranchi ( Bihar ) , having 47 years experience in cement industry. He joined Satna Cement Works as Trainee Mechanical Engineer and Retired as President of Birla Corps, presently working as a Managing Director in CMCL. 2. T.S.Dewangan is a merit scholar & M.Sc. in Inorganic Chemistry from Pt. Ravishankar University Raipur He started his carrier as Prof. in Deptt. Of Chemistry, Govt. Post Graduate College of Science Raipur.He was the top ranked student of this institution, among all the subjects of post graduation available therein. After two years in education,joined cement industry as trainee in Production & Q.C. in Century Cement. He has worked in Birla, Sanghi , Tata , and Lafarge Group. Presently working as Head of Department Quality Control in CMCL. 3. Dr. Usha Singh is having M.Sc. in Inorganic Chemistry from Saugar University M.P. She did Ph.D from Pt. Ravishankar University Raipur. Presently working as Prof. in Deptt. of Chemistry, Govt Post Graduate College Balaghat ( M.P. )

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