Cement composition and method for the preparation thereof

Abstract: The invention relates to a cement composition which can be hardened hydraulically and which consists of ground cement clinker material, granulated blast furnace slags and comminuted steel slags. The comminution of the steel slags is preferably carried out by grinding, in particular to a particle size of at most 0.2 mm and expediently to 0.09 mm. The ground steel slags have a Blaine value of at least 400 m²/kg, expediently 473 m²/kg, and a weight per unit volume of 2,800-4,000 kg/m³. The steel slags are chosen from air-cooled steel slags, foamed steel slags, granulated steel slags or a combination thereof. A method is also described for the preparation of a cement composition which can be hardened hydraulically, in which method cement clinker material and ground, granulated blast furnace slags are mixed with ground steel slags at normal or elevated temperature and pressure, the obtained mixture is cooled if desired, and comminuted to obtain a hydraulically hardenable cement composition. Use is made of a cement furnace if the present cement composition is prepared at an elevated temperature. Preferably a mixture of blast furnace slag cement and ground steel slags containing up to 30% of steel slags, or a mixture of Portland cement and ground steel slags containing up to 50% of steel slags is formed.

Description: The invention relates to a cement composition based on ground cement clinker material and ground, granulated blast furnace slags. Cement compositions have already been known for a long time and are subdivided into various quality grades, based on the strength achieved under standardised conditions. Various types of cement exist, such as Portland cement and blast furnace slag cement. Portland cement is formed from the composite raw materials in a rotary furnace at a temperature of about 1450°C with the formation of the cement clinker as semi-finished product. The cement clinker is, however, much too coarse to be able to react with water at a reasonable rate. However, the surface area and with that the reactivity become sufficiently high on fine grinding in ball mills. In order also to achieve a favourable course of hardening when water is added to the cement composition, up to 5% gypsum is often added to the clinker during fine grinding. Blast furnace slag cement consists of a mixture of ground, granulated blast furnace slags and ground Portland cement clinker and usually also contains up to 5% gypsum. It is pointed out that it is generally known to convert iron products obtained from a blast furnace into steel in a converter, for example by blowing through oxygen. During this operation a steel slag is formed which, however, has disadvantages for practical use since it is difficult to process after solidification since it first has to be broken down in order to obtain particles of suitable size. For this reason, steel slags were virtually only processed as filler in a road construction material. Further, it is pointed out that an inorganic hydraulically-setting binder consisting of cement clinker material and steel slags is known from S.E. Aleksandrov, Stroitel'nye Materialy, 1979, (9), 25. Such a binder appears to have a shorter setting time when the amount of steel slags is raised, compared with a binder consisting of cement clinker material and blast furnace slags. Surprisingly, a cement composition has now been found which just has a longer setting time and can also give after hardening a product having a better strength. The cement composition according to the invention is based on ground cement clinker material and ground, granulated blast furnace slags, and is characterized in that the composition further partly consists of comminuted steel slags. The use of steel slags is further known from Chem. Abstr. vol. 104, nr. 26, June 30, 1986, abstract nr. 229557a. According to this disclosure, the steel slags are nevertheless firstly fused together with granite, thereafter cooled with water and pulverized to obtain pellets. These pellets are nevertheless especially designed for the iron processing industry. Such a product cannot be used as an inorganic hydraulic setting binder, such as the present cement composition, due to its low strength. JP 61048460 A discloses the production cement compositions comprising blast furnace slags and cement clinker together with vitreous steel slags obtained by wind cooling the molten slag. NL-A-7111093 discloses a binder consisting of granulated blast furnace slags plus steel slags, in which the steel slags, due to their high content of combined CaO, can act as an initiator for the hydraulically acting blast furnace slag sand. In the cement composition according to the invention, on the contrary, the action of the granulated blast furnace slags is initiated by the (Portland) cement clinker material. A mixture of ground steel slags and blast furnace slags is also known from Chem. Abstr., vol. 112, nr. 2, January 8, 1990, abstract nr. 11226k, but here again the cement clinker fraction is missing in the produced material. At last, it is known from FR 2.102.685 to use steel slags as a catalyst-accelerator in a mixture known as "grave laitier". "Grave laitier" consists of a mixture of coarse ground stone and granulated blast furnace slags. Here also the cement clinker material as used according to the invention, is missing. Anyway, the invention is restricted to the use of air-cooled, comminuted steelslags. The steel slags are comminuted preferably by grinding, to a particle size of at most 0.2 mm, preferably at most 0.1 mm and expediently up to 0.09 mm. Such a particle size is advantageous since the commercially available cement powder usually has a particle size of up to ± 140 µ, as a result of which an intimate mixture can be formed on mixing the two constituents. The ground steel slags used according to the invention in a cement composition are expediently essentially freed from iron. Iron is usually present in the form of ferrites. The removal of iron is effected in a simple manner by applying a magnetic field and provides a fraction which has a high ferrite content and a fraction which has a low ferrite content. The fraction with the high ferrite content can be re-used as such in the blast furnace for the preparation of pig iron. Preferably, the ground steel slags have a Blaine value of at least 400 m 2 /kg, preferably at least 450 m 2 /kg. It is pointed out that the Blaine value for cement is about 400, depending on its quality. The weight per unit volume of the ground steel slags is expediently 2,800 to 4,000 kg/m 3 and in particular about 3,300 kg/m 3 . The invention also relates to a method for the preparation of a cement composition which can be hardened hydraulically and comprises at least cement clinker material and ground, granulated blast furnace slags, which is characterized in that cement clinker material and ground, granulated blast furnace slags are mixed with ground air-cooled steel slags at normal or elevated temperature and pressure, the obtained mixture is cooled, if desired, and comminuted to obtain a hydraulically hardenable cement composition. The present cement composition is thus based on a combination of cement clinker material and ground, granulated blast furnace slags. Therefore, blast furnace cement is preferably used as starting material. It has been found experimentally that optimum results can be obtained using a mixture of blast furnace slag cement and ground steel slags which contains up to about 30% steel slags. It is pointed out that the presence of the steel slags leads to a delay in the formation of cement setting. However, a delay in general leads to a higher strength and is therefore highly desirable. Since the ground steel slag itself already results in delayed hardening, no, or in any case less, gypsum has to be added to the cement composition. This constitutes an appreciable advantage in the long term. This is because the presence of gypsum (calcium sulphate) in cement can lead to the formation of ettringite. It is known that hardened concrete which contains ettringite can display crack formation if it comes into contact with sulphate-containing water. This crack formation occurs as a result of expansion of the ettringite. The absence of gypsum overcomes this problem. It is further pointed out that blast furnace cement consists of a mixture of (35-85%) granulated blast furnace slags and Portland cement clinker, a composition which is effective in practice for an end product of high strength, consisting of two parts of granulated blast furnace slags to one part of cement clinker. By now partially replacing the blast furnace slags and Portland clinker to be used for the production of the cement by finely ground steel slags, a cement is obtained which, it is true, hardens somewhat more slowly, but for which the strength obtained after hardening for 28 days is appreciably higher. Preferably, ground steel slags are used which have a weight per unit volume of 2,800 to 4,000 kg/m 3 , preferably about 3,300 kg/m 3 , and a Blaine value of at least 400 m 2 /kg and preferably 473 m 2 /kg. The particle size of the ground steel slags is at most 0.2 mm, preferably up to 0.1 mm and expediently up to 0.09 mm. It is pointed out that the invention is restricted to the use of ground steel slags cooled in the air. The invention is illustrated in more detail with the aid of the following illustrative embodiments. EXAMPLE I Steel slags from a steel converter were cooled in air, and ground, in a manner known per se. A powder having the following analysis results was thus obtained. ANALYSIS RESULTS FOR STEEL SLAG POWDER Property Result Composition (% m/m): CaO 43.7 SiO 2 18.3 Fe 2 O 3 18.9 Al 2 O 3 2.4 MgO 3.1 Na 2 O 0.15 K 2 O 0.05 Cl - 0.28 Loss on ignition (950°C) 3.9 Insoluble matter (HCl) 9.7 Mass per unit volume (kg/m 3 ) 3314 Blaine (m 2 /kg) 473 Although this steel slag powder contains a somewhat high amount of SiO 2 and a somewhat low amount of Na 2 O, this was found to be no drawback whatsoever when the powder was used in a cement composition, as can be seen from the results of a study on a mixture of blast furnace slag cement with the steel slag powder shown above: RESULTS OF STUDY ON MIXED CEMENTS Property Unit Blast furnace slag cement 90/10 Portland cement 80/20 60/40 40/60 Requirement in accordance with NEN 3550 WCF (water-cement factor) % m/m 27.8 26.6 24.7 22.3 21.2 20.1 - Standard consistency mm 7 7 5 7 4 5 - Start of setting min 240 280 175 245 238 240 > 60 End of setting min 285 330 200 275 265 280 - Dimensional stability mm 0.5 1 1.5 1 3.5 2.7 < 10 Tensile bending strength: 1 day MPa 0.90 0.83 2.00 1.59 1.16 0.36 - 3 days MPa 3.7 4.0 3.2 3.9 3.1 1.7 - 7 days MPa 4.5 6.4 4.5 4.9 4.2 2.7 - 28 days MPa 8.4 8.8 6.8 6.5 5.8 3.9 - Compression strength: 1 day MPa 3.0 2.6 7.6 5.6 3.8 1.3 - 3 days MPa 15.0 16.6 16.2 18.0 13.2 6.1 ≥ 11 7 days MPa 30.0 31.4 24.8 27.7 19.3 11.4 - 28 days MPa 44.8 48.2 39.8 34.2 28.4 17.3 ≥ 35 and ≤ 65 It can be seen from the above results that the addition of ground steel slags to blast furnace slag cement delays setting by about 40 min., and in the case of addition to Portland cement delays setting by about 65 min. As yet, the delay in setting in the case of addition to Portland cement does not appear to be dependent on the amount added. It can be seen from the values found for the tensile bending strength and the compression strength that the use of ground steel slags provide a cement composition of outstanding quality.

Claims: A cement composition comprising an intimate mixture of hydraulically hardenable components including ground cement clinker material, and ground, granulated blast furnace slags, characterised in that said mixture further consists of comminuted air-cooled steel slags having a particle size of at most 0.2 mm. A cement composition according to claims 1 characterised in that the steel slags are comminuted by grinding. Cement composition according to claims 1 or 2, characterised in that the steel slags have a particle size of at most 0.1 mm and preferably up to 0.09 mm. A cement composition according to claims 1-3, characterised in that the ground steel slags are essentially freed from iron. A cement composition according to claims 1-4, characterised in that the ground steel slags have a Blaine value of at least 400 m 2 /kg, preferably at least 450 m 2 /kg and expediently 473 m 2 /kg. A cement composition according to claims 1-5, characterised in that the ground steel slags have a weight per unit volume of 2,800-4,000 kg/m 3 , in particular about 3,300 kg/m 3 . A method for the preparation of a cement composition which can be hardened hydraulically and which comprises at least cement clinker material and ground granulated blast furnace slags, characterised in that cement clinker material and ground, granulated blast furnace slags are mixed with ground air-cooled steel slags having a particle size of at most 0.2 mm, at normal or elevated temperature and pressure, the obtained mixture is cooled if desired, and comminuted to obtain a hydraulically hardenable cement composition. A method according to claim 7, characterised in that a mixture of blast furnace slag cement and ground steel slags is formed which contains up to 30% of steel slags. A method according to claims 7 or 8, characterised in that a mixture of Portland cement and ground steel slags is formed which contains up to 50% of steel slags and preferably up to 40% of steel slags. A method according to claims 7-9, characterised in that ground steel slags which have a weight per unit volume of less than 4,000 kg/m 3 , preferably about 3,300 kg/m 3 , and a Blaine value of at least 400 m 2 /kg, preferably 473 m 2 /kg, are used.

Inventors: HOOYKAAS CAREL WILLEM JAN, HOOYKAAS, CAREL WILLEM JAN
Applicants: HOOP TERNEUZEN B V DE, DE HOOP TERNEUZEN B.V.
Application year: 1993
Main classification: C04B7
IPC codes: C04B7, C04B18, C04B28