Professional Documents
Culture Documents
(Communicated by S. Diamond)
(Received September 15, 1977)
ABSTRACT
Alkalies in portland cement clinker occur as sulfates and,
depending on the amount of SO3 available, may also be present in
calcitun silicate and aluminate phases. Introduction of alkalies
into clinker minerals modifies their crystal structure which, in
turn, can change their hydraulic reactivity. Alkalies affect the
clinkering process by modifying the physicochemical properties
of the melt formed in the kiln, and may have an adverse effect on
the phase composition of clinker.
719
720 Vol. 7, No. 6
I. Jawed, J. Skalny
I. Introduction
Alkalies in clinker originate from the raw materials used for the
manufacture of portland cement -- i.e. clay, limestone, chalk, and shale --
all of which contain alkalies. Typical analyses are as follows (6):
Alkalies can also come from coal ash if coal is used as the primary fuel.
As will be described later, most of alkalies in clinker exist in some
combination with sulfur. Sulfur in clinker may come from oil or coal used
as fuel. Additionally, it may originate from raw materials such as clay or
shale where it occurs as pyrites, sulfates, or organic compounds.
About 50% of alkalies present in the raw feed are volatilized in the kiln
between 800°C to 1000°C. These alkalies are later partly condensed in
cooler parts of the kiln. Formation of rings and coatings on the kiln
lining has been attributed to the condensation of alkalies and their reaction
with the refractory material (7-10). The extent of volatilization varies with
raw materials, and is higher for clays than for feldspars. Usually
Vol. 7, No. 6 721
ALKALIES, CEMENTCLINKER, HYDRAULICITY
potassium compounds are more volatile than those of sodium but this is not
universally the case (ii). A direct linear relationship between the
density of the alkali-containing raw materials and the extent of volatilization
has been reported (12). The extent of volatilization is also affected by the
type of kiln. There is a general tendency for the retention of alkalies to
be higher as the energy efficiency of the kiln system increases (6). A
larger amount of alkalies is volatilized when gas or oil is used as fuel as
compared to coal (13).
Sulfur containing compounds from the raw materials and fuel are
oxidized in the kiln to SO 3 and a sulfur cycle forms. The first reaction
of SO5 is to form alkali sulfates, preferentially with potassium, and
later calcium sulfates. At higher temperatures, alkali sulfates are vapor-
ized and calcium sulfate is partly decomposed. More than half of the sulfur
originating from raw materials and fuel appears in the clinker; the rest is
lost in the flue gases and in the kiln dust. Besides reacting with alkalies,
SO3 can also combine with silicates and aluminates to form compounds such
as (2 CaO.SiO2)2.Caso4 or 4 CaO.3 Al203-SO3. These may build up in kiln
rings but decompose again at clinkering temperature.
Compounds containing alkalies and sulfur may be found in almost all parts
of the cement plant. These compounds occur in the clinker, on the kiln
linings and preheaters, in the kiln dust, in the flue gases, and in the
storage silos. Whereas the presence of fluorides and chlorides in the raw
feed enhances the volatility of alkalies (14-19), the presence of sulfur
leads to reduction of alkali volatility during clinker formation (20-22).
Alkali compounds in clinker can be divided into three main groups (25-26):
(a) Alkali sulfates; (b) Alkali aluminates and aluminoferrites; (c) Alkali
silicates. In some cases, alkali may also occur in the form of carbonates
(2S).
Alkalies as Sulfates
The characteristic sodi~n containing compound is NC8A3 and has been the
subject of extensive investigations (24,25,29-41). The exact stoichiometry
of NCsA 3 and its potassium containing analog is, however, very difficult to
confirm. Free alkali reacts with C3A to form NCsA 3 and free lime; this CaO
could theoretically react with C2S to form C3S but the reaction is sluggish
and often incomplete. Alkali contents may, therefore, influence the degree
of lime saturation and cause latent unsoundness.
The kiln dust contains alkali halides in addition to sulfates, the most
common being sylvite (KCl) (26,53). The most common sulfates in kiln dust
are arcanite [K2SO4) , aphthitalite [Na2SO4-3K2SO4) , and calcium langbeinite
(2CaSO4.K2SO4). Formation of lumps in cement during storage has been
attributed to another alkali calcium sulfate, syngenite (K2SO4.CaSO4.H2 O)
[54-56). Increased syngenite formation was noticed when cement contained
more than 12% by weight of C3A and had a total potassium content of about 1%
(57-59). Syngenite is also formed during grinding of clinker in the mill if
the temperature is lowered by water (60). Compounds of alkali and sulfur with
or without silicates are major contributors to the formation of rings and
coatings in the inner wall of kiln, suspension preheater, Lepol grate
chambers, etc. These coatings result from the molten matter and contain
alkali sulfates and chlorides,often together with spurrite (2C2S.CAC03) ,
sulfo-spurrite (2C2S.CASO4) , calcium sulfoaluminate (C3A.CaSO4) and calcium
langbeinite [2CaSO~.K2SO4) (61-67). The formation of spurrite is known to be
promoted by such fluxes as CaF 2 . Gutt and Smith (68) found that Na2SO 4 and
K2SO 4 acted similarly to CaF 2. Simultaneous presence of alumina and K2SO4,
however, discouraged spurrite formation.
Na2SO 4 melt (3.0 g/co) is very close to that of clinker liquid phase
(3702 g/cc) whereas that of K2SO 4 is lower (2.8 g/cc). Hence, Na2SO 4
droplets are dispersed into the parent melt whereas K2SO 4 droplets rise to
the surface and phase separation occurs. The high surface activity of K20
in comparison with Na20 is also important; it facilitates separation of
K2SO 4 as an independent liquid phase.
Ono et al. (81,82) found that with increasing alkali and decreasing
MgO contents the free CaO first increased and then decreased considerably
with increase in K20. ~-C2S increased with increasing Na20 + K20. The
decrease of specific gravity of clinkers is attributed to the occurrence of
~-C2S , which has low specific gravity. ~-C2S is stabilized by Na20 or K20
whereas ~'-C2S is stabilized by K20 or K20 + MgO. However, on increasing
K20 content, ~'-phase transforms into s-phase. Luginina et al. (83) have
discussed the microstructure of clinkers containing alkalies and MgO.
Presence of K2SO 4 imparted an equigranular texture to clinker with high
porosity and contributed to development of coarse crystals of belite.
Presence of MgO prevented the low temperature interaction of alkali with
CaCO 3 (i.e., spurrite etc., are not formed). Clinkers containing alkalies
Vo]. 7, No. 6 725
ALKALIES, CEMENTCLINKER, HYDRAULICITY
Pollitt and Brown (25) have shown that introduction of alkalies into
C3Amodifies its normal cubic fol~n to orthorhombic. This orthorhombic form
of CSA is formed with a minimum alkali content of 2.8% equivalent Na20 or
1.8% equivalent K20. Works of Moore (88,89), Day (90), and Fletcher et al.
(34) have also shown that small amounts of Na20 or K20 could replace CaO
in the cubic C3A and that greater replacement of CaO gave rise to orthorhombic
structures of NCsA 5. Boikova et al. (91) have also sho~n that presence of
Na20 results in four polymorphic modifications of C~. The hydraulic activity
of these modifications is a function of their Na20 content and is lower than
that of pure C3A. Maki (37,92), on the other hand, claims that orthorhombic
CsA exists in two forms, the low form containing 3.7% and the high form 5.9%
Na20. These forms also take small amounts of SiO 2 into solid solution. From
microscopic study of synthetic clinkers with varied contents of Na20 ,
Suzukawa (49) noted that NCsA 3 causes shirtings in the aluminoferr[te phase
composition towards the higher ferrite contents, i.e., from C4AF to C6AF 2.
Data of Butt et al. (95) show that the presence of alkalies in the raw
material decreases the rate of the clinkering reactions. Similar effects
of alkalies on clinker formation have also been reported by Benyei (94),
Volkonskii and Shteiert [95), and Lokot et al. (96).
Tsuboi et al. (98-100) found that the addition of SO X made burning and
sintering very difficult as a result of increased viscosity of the melt.
The alite crystals became larger and assumed "amoeba-like" shapes, whereas
belite crystals did not have lamellae. The C3A content of clinkers decreased
726 Vol. 7, No. 6
I. Jawed, J. Skalny
and the clinker pores became larger. Fukuda (i01) noted that an addition of
3.5% CaSO 4 to raw materials decreased sharply the C3A formation; at the
same time formation of C3A.C~was observed. Above a certain CaSO 4 level
(5.3%), the C3S formation decreased and a significant increase in free CaO
was noticed. Formation of C3A.Cg , when gTpsum is present in the raw meal,
has also been reported by Li (102).
VI. References
(i) T.E. Stanton, Proc. Am. Soc. Civ. Engr., 66, 1781 (1940).
(2) G.M. Idorn, Proc. Symp. Effect of Alkalies on the Properties of Concrete,
Sept. 1976 C & CA. London, p. 3 (1977).
(3) J.W. Figg, Alkali-Aggregate (Alkali-Silica and Alkali Silicate% Reactivity,
C ~ U R E A U , Paris (19/7).
(4) S. Diamond, Cem. Concr. Res., 5, 329 (1975).
(5) S. Diamond, ibid., 6, 549 (1976).
(6) F.M. Lea, The Chemistry of Cement and Concrete, Chem. Publ. Co.,
2nd Ed. N.Y. (1971).
(7) E. Vogel, Silikattech., 9, 361, 449, 502 (1958).
(8) H.E. Schwiete, Zement-Kalk-Gips, 9, 351 (1956).
(9) R. Al~gre and P. Terrier, Rev. N~teriaux Constr. et. tray. publ.
523, 89 (1959).
(I0) H.M. Garrett, Pit & Quarry, (3), 84 (1976).
(ii) M. Rustom, Schweizer. Arch. Angew. Wiss. Tech., 22, 197 (1956).
(12) I.P. Yanev et al., Trans. Mosk. Khim, Technol. Inst., 76, 125 (1973)
C. A. no. 82:14424IV.
Vol. 7, No. 6 727
ALKALIES, CEMENTCLINKER, HYDRAULICITY
(13) R.A. Loveland, quoted by W.J. ~ C o y and O.L. Eshenour, Proc. 5th
Intl. Syrup. Chemistry of Cement, Tokyo, I/ol. II, p. 437 C1968).
(14) H. Wood, Rock Prod., 45, 66 (1942).
(15) E.R. Holden, Ind. Engg. Chem., 42, 337 (1950).
(16) A.D. Azelitskaya, Silikattech) 5, 120 (1954).
(17) A.D. Azelitskaya, Tsement (3), 13 (1954).
(18) V.L. Pankratov and L.Y. Lopotnikova, Tsement, (S), 19 (1970).
(19) V.M. Blonakaya and V.M. Stepanov, Tsement, (4), 12 (1969).
(20) W.C. Taylor, J. Res. NBS, 29, 142 (1942).
(21) T.F. Newkirk, ibid, 46, (1950).
(22) J.P. Draper, quoted in The Chemistry of Portland Cement by R.H. Bogue,
p. 129, Reinhold Publ. Corp. N.Y. (1955).
(23) T.F. Newkirk, J. Res. NBS, 47, 349 (1951).
{24) T.F. Newkirk, Proc. 4th Int'l Symp. Chemistry of Cement, London,
p. 151 (1952).
(25) H.W. Pollitt and A. Brown, Proc. 5th Int'l. Symp. Chemistry of Cement
Tokyo, Vol. I, p. 322 (1968).
(26) L.D. Adams, Paper presented at 75th Annual Ceramic Society Meeting
at Cincinnati, April 1975.
(27) J.E. Mander, Proc. Symp. Effect of Alkalies on Properties of Concrete
Sept. 1976 C & CA. London, p. 27 (1977).
(28) J.E. Mander and J. Skalny, Ceram. Bull., 56, (1977) (to be published).
(29) L.T. Brownmiller and R.H. Bogue, Am, J. Sci., 23, 501 C1932).
(30) K.T. Greene and R.H. Bogue, J. Res. NBS, 36, 187 (1946).
(31) D.L. Heath, J. Amer. Ceram. Soc. 40, 50 (1957).
(32) J.A. Conwick and D.E. Day, J. Am. Ceram. Soc. 47, 654 (1964).
(33) Y. Suzukawa, Zement-Kalk-Gips, 9, 345 (1956).
(34) K.F. Fletcher et al., Mag. Concr. Res., 17, 171 (1965).
(35) A. Guinier and M. Regourd, Proc. 5th Int'l. Symp. Chemistry of Cement,
Tokyo, Vol. I, p. 1 C1968).
(36) S. Chromy and M. Gregor, Zement-Kalk-Gips, 21, 451 (1968).
(37) I. Maki, Rev. 24th Gen. Mtg. Cem. Asscn. Japan, Tokyo, p. 5 (1970).
(38) L.A. Dobronravova et al., Tr. ~bsk. Khim-Technol. Inst., 87, 44
(1975) C. A. no. 86:160080E.
(39) I.A. Kryzhanovskaya et a l . , Cem. and Lime Mfg. 65), 45 (1966).
(40) I. Maki, Cem. Concr. Res., 3, 295 (1973).
(41) M. Regourd et al., J. Appl. Cryst., 6, 355 (1973).
(42) E.S. Newman, J. Res. NBS, 61, 75 (1958).
(43) W.C. Taylor, ibid, 21, 315 (1938).
(44) W.C. Taylor, ibid, 27, 211 (1941).
728 Vol. 7, No. 6
I. Jawed, J. Skalny
(76) H. Kr~mer and H. zur Strassen, Proc. 4th Int'l. Symp. Chemistry of
Cement, Washington, p. 32 (1960).
(77) E. Woermann, ibid, p. 119 (1960).
•