Loesche-Separation Plant for Production of Ultrafine Granulated Blastfurnace Slag and Utilisation Concepts

Loesche-separation plant for production of ultrafine
granulated blastfurnace slag and utilisation concepts
Horst Michael Ludwig,
Bauhaus Universität Weimar, F. A. Finger-Institut für Baustoffkunde;
Holger Wulfert, Winfried Ruhkamp (speaker),
Loesche GmbH Duesseldorf | loesche.com

Loesche-separation plant for production of ultrafine
granulated blastfurnace slag and utilisationconcepts
Prof. Horst MichaelLudwig, Dr. Holger Wulfert, Presentedby Dr. WinfriedRuhkamp
global slag 2019, Aachen, Germany 27 March 2019

14th global slag conference, Aachen, Germany 27.03.2019
Agenda
Reduction of Clinker Factor
Grinding of Slag and/ or Cement
Properties of Slag containing Cement
Idea and Implementation of Ultrafine Grinding
Material Analysis – Cement Quality
01
05
04
03
02
Application of Ultra-Fine GGBFS06
Conclusion/Outlook07

World Business Council for Sustainable Development. GNR Project
European Cement Research Academy; Cement Sustainability Initiative;
CSI/ECRA-Technology Papers 2017, Duesseldorf, Geneva
Clinker factor: Global development
0
10
20
30
40
50
60
70
80
90
100
Clinkertocementratioin%
2000 2014
The framework
Other constituents besides clinker:
blast-furnace slag, fly ash, limestone,
puzzolans and calcined clay
Targets in clinker factor:
– 2030 : 65-70%
– 2050 : 60-65%
Future cement and concrete
standards are crucial for target
achievement
4

granulated blast furnace slag
250 million t/a – latent hydraulic reaction
fly ash
750 million t/a – pozzolanic reaction
limestone
factual unlimited – but almost inertother SCMs (silica fume, natural pozzolans etc.)
in minor quantity
Source: VDZ

Cement Norm

GGBFS
Clinker Limestone
Composite Cements

New cement class
composition proposals:
A clinker content of at least
50% * in case of CEM II/C for
slag, pozzolan or fly ash
Or at least 35% ** of clinker in
case of CEM VI (S-LL),
exclusively for ternary
constituent GBFS
acc. to Prof. Wolter
GGBFS
Clinker Limestone
Composite Cements
* **

LOESCHE
mills
factor ~1500
9

Usual fineness of slag and slag cement:
3.000 - 5.000 Blaine
High-quality blast furnace cements are producible,
particularly with separate grinding in a Loesche VRM
Advantages LOESCHE VRM
for slag grinding:
Lower energy consumption
Slightly steeper particle size
distribution (adjustable)
Faster change of product or
fineness
Drying of wet slags in same
process step possible

24
1
1
17
5
95
5
80
25
101
6
31
7
1
2
CS_Non Modular
LM 24.20 CCG
LM 30.30 CCG
LM 35.2+2
LM 41.2+2
LM 46.2+2
LM 48.2+2
LM 53.3+3
LM 56.2+2
LM 56.3+3
LM 59.3+3
LM 63.3+3
LM 65.4+4
LM 70.4+4
LM 72.4+4
11
Loesche Reference List (March 2018)
more than 1.400.000 tons cement capacity per day
24
377
CS Non Modular Mill
CS Modular Mill
35
5
14
1
14
1
Africa -
Subsahara
16
15
3
45
2
34
18
47
8 2
Asia (incl. China & CIS)
181
5
6
15
2
6
10
Europe
1 2 2
9
1
2
1
15
3
5
7
MENA
48
2
3
3
North America
8
33
1 2
13
10
1
18
3
4
South-East Asia /
Oceania
52
44
2
8
11
5
7
South America
more than
400
LOESCHE
cement & slag mills
worldwide!

Advantages
low heat development
high chemical resistance
high resistance against alkali-silica-reaction
high chloride resistance
high final strength
bright color

Consequence: for many applications, the blast furnace slag
content in cement and concrete is limited
Disadvantages
very slow strength development
long curing time
late demoulding
low freeze-thaw deicing salt resistance

Blast furnace slag grain with reaction seam of CSH phases
Properties of Slag containing Cement - Focus area early strength
14

slag partikel
clinker partikel
Hydration of
slag and clinker after 24 h
Source: BASF

Early strength of
different cements
with the same
clinker basic
0
5
10
15
20
25
30
35
CEM I 42.5 R CEM II/A-S 42.5 R CEM III/A 42.5 N CEM III/B 42.5 N
4
2
1 0,5
19
12
7
2
34
27
17
11
compressivestrength[N/mm²]
12 h 1 d 2 d

Early strength of
cements with
different
GBFS-content
(same clinker)
0
10
20
30
40
50
60
CEM I
42.5 R
CEM I
52.5 R
CEM II/A-S
42.5 R
CEM II/A-S
52.5 R
CEM III/B
42.5 N
9
20
6
15
0
15
28
10
23
5
32
44
28
40
13
51
58
50
58 57
compressivestrength[N/mm²]
18 h
1 d
2 d
7 d

< 3 µm
responsible for early
strength after 2 d
< 3 - 60 µm
responsible for 7, 28
and 90 d-strength
> 60 µm
no or less strength
contribution

19,6 20,1
36,538,2
42,5
77,8
61,7
65,0
86,9
0
10
20
30
40
50
60
70
80
90
BFS with 3.600 Bl. BFS with 5.000 Bl. BFS with 17.000 Bl.
pressurestrength[MPa]
2 d 7 d 28 d Blast Furnace Slag Cement
Mixtures 50%/50 % with CEM I 52.5 R
19
in the usual fineness (3000 – 5000 Blaine) range no improvement of the early strength possible

Blast Furnace
Slag
Loesche Mill
> 10.000 Blaine

Loesche Test Plant – results with GBFS
MV 8623-2 8625-1/8625-2
Blaine cm²/g 5457 15561 4313
P50-Cilas µm 7,122 2,091 8,376
P95-Cilas µm 22,761 7,039 23,343
share (mass) 100% 22,20% 77,80%

GBFS - Particle Size Distribution .
theory
product-0
psd 5:
x = 12
n = 1,1
ultra-fine-2
psd 4:
x = 5
n = 1,1
fine-1
psd 6:
x = 16
n = 1,1
0,1 1,0 10,0 100,0
%R[%]
particle diameter [µm]
CILAS-Lasersizer
4
5
6
90
95
50
10
1
0,1
99

Standard Range of Fineness up to 6.000 cm²/g (Blaine)
~7.000 achieved in VRM
Energy Consumption for High Fineness of Slags
20
40
60
80
100
120
140
160
3000 4000 5000 6000
kWh/t
cm²/g
GBFS grinding
BM system
LOESCHE VRM system

Standard Range of Fineness up to 6.000 cm²/g (Blaine)
Extended Range: Unknown absolute figures!
Energy Consumption for High Fineness of Slags
20
40
60
80
100
120
140
160
3000 4000 5000 6000
kWh/t
cm²/g
GBFS grinding
BM system
LOESCHE VRM system
0
500
1.000
1.500
2.000
2.500
3.000
3.500
4.000
4.500
5.000
3000 5000 7000 9000 11000 13000 15000
kWh/t
cm²/g
GBFS grinding
BM system
LOESCHE VRM system

Additional Installation
Cyclone group:
Additional cyclone group with housing and duct work
Additional product line with storage system
Enlarged demand for measurement and regulation
Small additional pressure drop for the fan
No additional grinding plant necessary
Hardly additional energy consumption (for standard product)
Increased flexibility for achieving product qualities

M
HGG
mill feed
M
additional
classifying
circuit

~ 4000 cm²/g > 10000 cm²/g
5000 cm²/g
P50: ~ 7-10 µm
Share: 85-90%
P50: ~ 2-2,5 µm
Share: 10-15%

Feed: 3,5 t/h
Coarse: 3,0 t/h
Fines: ~13%
Fines: 0,5 t/h
10.000 m³/h
fan: 16 kW
additional classifying circuit

test CEM I
test result no. 1 3 8 9 42,5 R
GGBFS LZ_6004- 5 17 39 24 * -
„without cement"
density g/cm³ 2,953 2,953 2,953 2,945 3,112
Blaine cm²/g 5048 3816 4385 14.530 3.370
P50 (Cilas) µm ~8,0 ~9,5 ~7,0 ~2,1
P95 (Cilas) µm ~23,5 ~25,5 ~23,5 ~8,2
water demand M.-% 31,5 32,0 32,0 - 29,0
setting-begin h:min 3:15 3:05 3:25 - 2:30
setting-end h:min 4:30 4:35 4:30 - 3:40
R_c (1 Tag) MPa 7,3 6,7 7,2 11,1 21,9
R_c (2 Tage) MPa 16,3 14,5 15,0 25,9 36,0
R_c (7 Tage) MPa 37,1 33,8 34,4 63,6 53,6
R_c (28 Tage) MPa 63,6 57,7 55,7 82,7 64,2
R_c (91 Tage) MPa 80,7 76,4 72,7 88,3 70,6
Compressive Strengths – Mixtures with 50% GBFS
29

Compressive Strengths – Mixtures with 50% GBFS
0
10
20
30
40
50
60
70
80
90
1 10 100
strength[MPa]
days
development of strength of selected test samples
5 17 39 24 * CEM I
CEM I: 3370 cm²/g
reference cement
24: 14.530 cm²/g
5: 5.048 cm²/g
17: 3.816 cm²/g
39: 4.385 cm²/g

36,0
24,9
33,2
15,1
30,5
6,5
25,0
43,1
39,0
59,7
32,4
63,6
20,2
58,9
53,1 52,2
69,2
55,8
78,8
45,1
73,5
0
10
20
30
40
50
60
70
80
90
CEM I 30% 30% 50% 50% 70% 70%
100% GGBS 4000 GGBS 12000 GGBS 4000 GGBS 12000 GGBS 4000 GGBS 12000
CompressivestrengthinN/mm²
2 d 7 d 28 d
GGBFS fineness influences the strength development

Application of Ultra-Fine GGBFS
Blast furnace slag cements
reduce CO2 emissions during
cement production.
Slag cements with high blast
furnace slag content are
currently used only in ready-
mixed concrete sector.
So far, the early strengths are
too low for use of such cements
in precast plants. This can be
changed by the new technology.
900
648
423
252
0
100
200
300
400
500
600
700
800
900
1000
CEM I 52.5 N CEM II/B-S 42.5 N CEM III/A 42.5 N CEM III/B 42.5 N
specificCO2-emissions[kgCO2/t]
Why are blast furnace slag-rich cements with high early strength needed?

Application of Ultra-Fine GGBFS
33
further possible applications
multi-component binder with minimal free gap
new cements with low hydration heat and high early strength
cements for shotcrete on basis of blast furnace cement
cements for paving stones without brown or white colorations
filling and ground binder
very fine cements for the consolidation of soils
finest additive for Ultra-High-Performance-Concrete
very bright cements as a substitute for expensive white cements

Application of Ultra-Fine GGBFS - 1. Example UHPC
34
silica fume ø app. 0,1 µm
Precondition for Ultra-High-Performance
Concrete (compressive strength ≥ 150 N/mm²)
is the filling of the void volume between the
coarse particles.
So far, the expensive material silica fume is
usually used. Ultra-Fine GGBFS would be an
equivalent, alternative with a lower price.
cement ø app. 10 µm

Ultra-High Performance Concrete UHPC
Dimensioning of beams with same carrying
capacity
35
steelUHPC
prestressed
concrete
reinforced
concrete
building
material
beam height
weight
Application of Ultra-Fine GGBFS - 1. Example UHPC
360 mm 360 mm 700 mm 700 mm
130 kg/m 110 kg/m 470 kg/m 510 kg/m

Application of Ultra-Fine GGBFS - 2. Example Shotcrete
36
In some cases, the shotcrete must be
sulphate resistant.
Here, the use of concrete with blast
furnace cements would make sense.
Due to the slow setting behavior, however,
the use of such cements is very difficult.
Ultra-Fine GGBFS could be very helpful.

white „blooming“
efflorescence
37
Application of Ultra-Fine GGBFS - 3. Example Paving Stone

Blast furnace cements can reduce
brown and white efflorescence in
paving stones.
However, the plants often have
difficult hardening conditions
(unheated curing chambers).
This often makes the use of slowly
hardening blastfurnace cement
impossible.
Ultra-Fine GGBFS could lead here
to a much higher hardening rate of
these cements.
38
CEM I 42,5 R CEM III/A 52,5 N
Application of Ultra-Fine GGBFS - 3. Example Paving Stone

0
10
20
30
40
50
60
70
80
90
1 10 100
compressivestrength[MPa]
days
39 24 * CEM I
Slag cement with
ultra-fine GGBFS CEM I
reference
cement
Slag cement
with standard
fineness of
GGBFS
Example CEM III/A 52.5N
39
Conclusion/Outlook
New process for ultra-fine slag has
been developed.
Plant size can be adapted to
market demand.
A variety of tests concerning the
use with cement were performed.
The specific power consumption
for ultra-fine slag is not neglectable
but still economical.
There exist a lot of possible
applications in the construction
industry.
Further tests especially in
combination with new cements will
enlarge the application diversity.

THANK YOU
for your attention
LOESCHE GmbH
Hansaallee 243
D-40549 Düsseldorf
Tel.: +49 211 5353 - 0
Email: loesche@loesche.de

Loesche-Separation Plant for Production of Ultrafine Granulated Blastfurnace Slag and Utilisation Concepts

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