Classifications

• • C—CHEMISTRY; METALLURGY
  • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
  • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
  • C04B28/00—Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements
  • C04B28/02—Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements containing hydraulic cements other than calcium sulfates
  • C04B28/04—Portland cements
• • C—CHEMISTRY; METALLURGY
  • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
  • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
  • C04B40/00—Processes, in general, for influencing or modifying the properties of mortars, concrete or artificial stone compositions, e.g. their setting or hardening ability
  • C04B40/0028—Aspects relating to the mixing step of the mortar preparation
  • C04B40/0032—Controlling the process of mixing, e.g. adding ingredients in a quantity depending on a measured or desired value
• • C—CHEMISTRY; METALLURGY
  • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
  • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
  • C04B7/00—Hydraulic cements
  • C04B7/36—Manufacture of hydraulic cements in general
  • C04B7/48—Clinker treatment
  • C04B7/52—Grinding ; After-treatment of ground cement

Definitions

• This invention is related to the production of High Performance Cement (HPC) where the clinker being the raw material for ordinary Portland cement (OPC) which is the major material in the construction sector, ground through a special grinding technology (regarding conformity to the designated principles during grinding, such as; regime temperature, humidity, grinding duration) by adding a modifier (Complex chemical composition) resulting improvement in mechanical- chemical properties of the cement particles produced.
• HPC High Performance Cement
• OPC ordinary Portland cement
• the invention is also related to the use of same technology to improve the performance and quality of all composite cement types other than pure Portland cement.
• the Invention also defines the production process and production units of the High Performance Cement, besides the use of modifier.
• Production of the cement used in the construction sector for over hundred years consists of two major stages. These are; production of clinker from the ground mixture of related raw materials after crushing and homogenization and grinding of clinker produced together with the gypsum and sometimes also by adding some other minerals.
• the main raw materials for cement production are, lime stone and clay, where the other constituents may be sand, bauxite, pyrite ash and iron ore.
• Clinker composition resulting from production process of clinker as main product, contains calcium oxide, silisium oxide, aluminum oxide and iron oxide.
• the cement (Portland cement) produced under known technologies are classified based on different raw material composition like, Turkish Standards TS ENV 197-2; and equivalent
• PC 32.5 relates to 32.5 N/mm 2
• PC 42.5 relates to 42.5
• TC is produced using trass (pozzolan)
• SC is produced using slag
• FAC is produced using fly ash where their strength classes are 32.5 N/mm 2 and 42.5 N/mm 2 (see Table 1 General Types of Cement).
• cements produced under known technologies do not directly provide required high strengths, workability and lower water cement ratio in concrete; production of high strength concrete becomes difficult, resulting strength restrictions leading to non economical concrete sections in high concrete structures.
• the required economic life of the concrete can not be long enough due to non achievement of the durability and/or strength quality of the concrete against various environmental conditions.
• it is aimed to develop a production technology aiming to produce high performance cement, by improving the properties of the cement produced with known technologies.
• the primary purpose of the invention is to produce High Performance Cement (HPC) as a result of developed production technology and using modifier, which provides reduction of water/cement ratio, increase compressive strengths for early (24 hours) and final (28 days) periods and improve basic properties like impermeability, non-shrinkage and non-cracking in concrete production.
• HPC High Performance Cement
• Other purpose of the invention is to prevent strength loses and increase the performance of cements resulting from replacement of limestone, trass (pozzolan) which are easy to extract in nature and/or industrial wastes like blast furnace slag, fly ash with clinker in order to reduce its content in cement production due to concerns related to cost and environmental pollution.
• the invention developed for the purpose defined here above is the production process of High Performance Cement to be used as a structural material in construction industry, and it consists of the following process steps:
• One preferred application of the invention is returning the cement particles, which are separated by the separator and not ground to the required fineness, back to the second ball mill through the air slides for re-grinding.
• Another preferred application of the Invention is feeding of the modifier from the modifier silo to the second ball mill by modifier feeding unit, in the ratio of the raw material passing through the raw material conveyor band of first mill.
• Another preferred application of the invention is fineness control of the end product by placing control valves and pressure gauges for adjustment of valve openings to increase or decrease the flow.
• HPC high performance cement
• High Performance Cement is developed through the process as detailed above, which contains modifier in variable ratios (0.5% - 2%) with respect to the raw material properties and especially the clinker content.
• Figure-1 Schematic diagram of the High Performance Cement production plant.
• This invention is related to the production of High Performance Cement (HPC) in order to improve dispersion and reaction capability of normal Portland clinker to be used as structural construction material; by adding the modifier and using the special grinding technology (regarding conformity to the designated principles while grinding, such as; regime temperature, humidity, grinding duration).
• HPC High Performance Cement
• the primary raw materials shall be Portland clinker, gypsum and the modifier with a certain ratio of the clinker content.
• any clinker could be used for HPC production the percentage of modifier shall change depending on chemical properties and quality of clinker used.
• the invention provides improvement of chemical and mechanical properties of the cement particles which provides reduction in water demand of the cement, resulting early as well as high strength for concrete besides high performance.
• High Performance Cement shall be classified similar to the other cement classes with respect to the strength class and raw material composition and named as in the range of
• the letter ⁇ " is used to represent high performance for the application of the Invention to the composite cements defined in the existing cement standards.
• HPC 62.5R is detailed as an example for description of the Invention.
• Diagram-1 Schematic diagram of the production plant for High Performance Cement is given in Diagram-1.
• the raw materials such as Portland clinker, gypsum for CEM-I type cements and trass
• the raw materials shall be dozed as per required flow using the weighing belt scales (2) placed under the feeding bunkers (1).
• the function of the weighing belt scales (2) is dosing of any raw material and re-adjustment as per the actual raw material flows automatically.
• Raw materials are transferred to the first ball mill from the weighing belts (2) through the feeding conveyor (3).
• Quantities of raw materials are measured by the speed controlled weighing belt scales (2).
• Quantities of raw materials on the weighing belts (2) are weighted continuously online and in consideration of the monitored speed of weighing belts, the actual material flow is calculated instantaneously.
• the actual material flow and the programmed flow are compared by PID Controller to calculate for adjustment of speeds of the weighing belt scales (2) for re adjustment of such speeds instantaneously.
• the quantities of raw materials are calculated using the weighing measurements on the load cells of the weighing belt scales (2).
• the speeds of the weighing belts are calculated by considering rotation speeds of wheel drums.
• All measurements and adjustments can be made on the control panel placed on the MCC Panel which can be controlled by programmable computer system. Furthermore, any instantaneous measurements can be observed continuously.
• the weightings are performed as per the recipes with automation system.
• the recipe contains; recipes name, lot number, percentage of programmed quantity and quantity in total, for modifier, clinker, gypsum, fly ash etc.
• the percentage inputs in recipes for each material like clinker, gypsum, limestone, slag, fly ash are multiplied by the quantity of end product to be produced and hourly feeding rate of each component to the first ball mill (6) are calculated by the system automatically.
• the quantity of modifier to be fed into the first ball mill (6) is adjusted with respect to the programmed percentage of clinker by weight. As the content of clinker in cement changes the percentage of modifier also changes accordingly.
• the modifier is fed to the second ball mill (12) in relation to actual recorded clinker quantity fed into the first ball mill (6) from the modifier silo (8) by the modifier feeding system (9). As a result, while fine grinding the modifier will be ground together with the other materials to enable the dispersion of the modifier to the whole mix.
• modifier is programmed to be %1 of the clinker
• modifier is programmed to be % 0.5 of the clinker
• Different recipes can be prepared with different ratios and quantities considering various raw materials for each product.
• the raw materials are being weighed with the specified ratios by the weighing belt scales(2) and transferred to the first ball mill (6) by the first mill feeding conveyor (3).
• the Dedusting is performed by the Filter (4) placed over the feeding conveyor (3).
• the balls located in the first ball mill (6) are 90 mm-60 mm that can perform coarse grinding approximately at the range of 0-
• the modifier is simultaneously fed to the second ball mill (12) from the modifier silo (8) by the modifier feeding system (9). Fine grinding of the mix for finished product shall be perform in the second ball mill having various size balls from 60 mm to 15 mm.
• the ground material passes through the separator (16) where the particles with the specified fineness defined at any range from 3500 to 9500 blaine are separated and transfers to the product silos (20-21), while any coarser particles are transferred back to the second ball mill
• the filters (5, 14) adjust the flow and speed of the material flowing through the first ball mill (6) and the second ball mill (12) while performing dedusting as well.
• the feeding system (9) and the conveyor belt (11) are replaced under the modifier silo (8) in order to control rate of feeding of the modifier to the mix.
• the cement particles separated to the required fineness (blaine) by the air swept and adjustable separator (16) is transferred to product silos (20, 21) by the transfer units (19) placed over the silos (20, 21).
• the coarse particles above the required fineness are conveyed back to the second ball mill (12) through air slides (13) for regrinding.
• the High Performance Cement stored in the silos (20, 21) is delivered to the customers either as bulk by cement trailers (29) or in packages by the trucks (28).
• the packing unit consists of an elevator (22), filter (23), screen (24), bunker (25), bag filling station (26) and screw (27).
• High Performance Cement can also be produced by feeding modifier while regrinding of the already produced cement.
• the dedusting during the production of High Performance Cement shall be achieved by using various filters (4, 5, 14, 18, 23). All production process is in closed cycle where dust and solid particles emission is below the allowable limits that can be verified by any air quality control testing.
• High Performance Cements are also compatible with other construction materials and can be used for similar applications as other cements.
• High Performance Cement can be utilized in high rise buildings, airport runways, bridges, marine and land works with special applications, sea structures and prefabricated concrete elements, where high strength and/or high performance is required.
• High Performance Cement has the property of non-shrinking for excellent use for joint fillers, grouting.
• the mortars produced by using HPC are resistant to permeability, high temperature differences and frost-defrost. Therefore, HPC can be used for such requirements, as well as precast concreting to avoid steam cure for early removal of the formwork, which provides advantages that can not be ignored.
• High Performance Cement provides workability, early and high strength, impermeability for concrete which results no need for other additives. Therefore, eliminating any other additive during concrete production will prevent possible dosing problems but anti freezing additive may be needed against frost during winter period.
• High Performance Cement should be utilized without using any other additives during concrete and mortar production, where water cement ratio should not exceed 45 %.
• water/cement ratio is kept at the range of 40-45 % in concrete mix designs, slump value shall be 80-120 mm and high strength shall be achieved.
• the water demand of the High Performance Cement is less, so while mortar testing consistency of mix should be considered instead of 0.5 w/c ratio as defined in related Cement Standards

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• Chemical & Material Sciences (AREA)
• Engineering & Computer Science (AREA)
• Ceramic Engineering (AREA)
• Materials Engineering (AREA)
• Structural Engineering (AREA)
• Organic Chemistry (AREA)
• Chemical Kinetics & Catalysis (AREA)
• Inorganic Chemistry (AREA)
• Curing Cements, Concrete, And Artificial Stone (AREA)
• Disintegrating Or Milling (AREA)
• Crushing And Grinding (AREA)

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Publications (1)

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• 2009
  • 2009-04-29 TR TR2009/03373A patent/TR200903373A2/xx unknown
• 2010
  • 2010-04-28 CN CN201080017253XA patent/CN102405197A/zh active Pending
  • 2010-04-28 RU RU2011148083/03A patent/RU2011148083A/ru not_active Application Discontinuation
  • 2010-04-28 EP EP10728930A patent/EP2424825A2/en not_active Withdrawn
  • 2010-04-28 WO PCT/TR2010/000088 patent/WO2010126457A2/en active Application Filing

Non-Patent Citations (1)

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