Simultaneous solidification of two catalyst wastes and their effect on the early stages of cement hydration

Two catalyst wastes (RNi and RAI) from polyol production were considered as hazardous, due to their respective high concentration of nickel and aluminum contents. This article presents the study, done to avoid environmental impacts, of the simultaneous solidification/stabilization of both catalyst wastes with type II Portland cement (CP) by non-conventional differential thermal analysis (NCDTA). This technique allows one to monitor the initial stages of cement hydration to evaluate the accelerating and/or retarding effects on the process due to the presence of the wastes and to identify the steps where the changes occur. Pastes with water/cement ratio equal to 0.5 were prepared, into which different amounts of each waste were added. NCDTA has the same basic principle of Differential Thermal Analysis (DTA), but differs in the fact that there is no external heating or cooling system as in the case of DTA. The thermal effects of the cement paste hydration with and without waste presence were evaluated from the energy released during the process in real time by acquiring the temperature data of the sample and reference using thermistors with 0.03 °C resolution, coupled to an analog–digital interface. In the early stages of cement hydration retarding and accelerating effects occur, respectively due to RNi and RAl presence, with significant thermal effects. During the simultaneous use of the two waste catalysts for their stabilization process by solidification in cement, there is a synergic resulting effect, which allows better hydration operating conditions than when each waste is solidified separately. Thermogravimetric (TG) and derivative thermogravimetric analysis (DTG) of 4 and 24 h pastes allow a quantitative information about the main cement hydrated phases and confirm the same accelerating or retarding effects due to the presence of wastes indicated from respective NCDTA curves.     

CO2 sequestration by high initial strength Portland cement pastes

During the formation of pastes, mortar and concretes have been used to capture CO₂. This work presents a methodology to estimate the carbon dioxide (CO₂) sequestered by high strength and sulfate-resistant Portland cement pastes during their early stages of hydration, by Thermogravimetry and Derivative Thermogravimetry. Water to cement ratio equal to 0.50 and 0.70 were evaluated and the captured CO₂ amount was determined through TG/DTG curve data on initial cement mass basis, obtained during accelerated carbonation from the fluid state and accelerated carbonation after a first hydration process. The experiments were performed in a controlled chamber, maintaining the CO₂ content at 20 vol % and the temperature at 25 °C, at different relative humidity (RH) (60 and 80 %) ambient. The procedure allows one to estimate the amount of CO₂ sequestered by the initial cement mass of a given volume of paste, as well as to evaluate the RH and W/C ratio influence on the amount of hydrated formed products, mainly on the Ca(OH)₂, important for CO₂ fixation.     

Early stages hydration of high initial strength Portland cement

This work complements a quantitative thermogravimetric study of the first 24 h of hydration of a high initial strength and sulphate resistant Portland cement (HS SR PC) using non-conventional differential thermal analysis (NCDTA) and Vicat needle method. Different water/cement (W/C) ratios from 0.35 to 0.85 were used to evaluate the most indicated operating conditions to maximize calcium hydroxide production for further use in CO₂ capture. Thermogravimetric analysis data performed at 4 and 24 h of hydration were also compared to the NCDTA and Vicat data for each kind of paste, to analyze the influence of the W/C ratio on the simultaneous hydration and setting process. The increase of the W/C ratio increases the induction time retards the solidification and setting processes but increases the hydration degree as the W/C ratio is increased from 0.45. At 24 h, products prepared with 0.35 W/C ratio present a little higher hydration degree than those prepared with W/C = 0.45, because of the highest level of temperature in the reacting mixture in the former case, during the first 8 h. There is a practical limit of W/C = 0.66 to prepare the pastes, due to a limit of the miscibility between HS SR PC and water, above which, the excess of water forms a separated phase that does not interfere in the hydration process.     

Swelling effects in cross-linked polymers by thermogravimetry

A Brazilian coal power plant generates a waste composed by the fly and bottom ashes produced from coal combustion and by a spent sulfated lime generated after SO₂ capture from combustion gases. This work presents a study of the early stages of the hydration of composites formed by this waste and a type II Portland cement, which will be used for CO₂ capture. The cement substitution degrees in the evaluated composites were 10, 20, 30 and 40%, and the effect of the coal power unit waste on the hydration reaction was analyzed on real time by NCDTA, during the first 40 h of hydration. The results show that the higher is the substitution degree, the higher is the retarding effect on the cement hydration process. Actually, by respective thermogravimetric (TG) and derivative thermogravimetric (DTG) analysis on initial cement mass basis, this effect is caused by double exchange reactions among Ca and Mg components of the waste, during the first 4 h of hydration, which promote a much higher exothermic effect in the NCDTA curve, simultaneously to respective induction periods. The pozzolanic reactions, due to the presence of the waste silica and alumina containing amorphous phases, consume part of the original Ca(OH)₂ content existent in the waste in the case of 30 and 40% substituted pastes, and also from part of the Ca(OH)₂ produced in cement hydration reactions, in the case of the 10 and 20% substituted pastes.     

Effect of metakaolin pozzolanic activity in the early stages of cement type II paste and mortar hydration

The cement industry is one which most emits polluting gases to the environment, due to the calcium carbonate calcination, as well as to the burning of fossil fuels during the manufacturing process. Metakaolin (MK), in partial substitution to cement in its applications, is having a special worldwide growing role, for the technological increment due to its pozzolanic activity and mainly to the reduction of those emissions. In the present paper, the effect of pozzolanic activity of metakaolin was analyzed by thermal analysis in pastes and mortars of type II Portland cement in the first three days of the hydration, during which, relevant initial stages of the hydration process occur. By non-conventional differential thermal analysis (NCDTA), paste and mortar samples containing 0, 10, 20, 30 and 40% of metakaolin in cement mass substitution and using a 0.5 water/(total solids) mass ratio, were evaluated. The NCDTA curves, after normalization on cement mass basis and considering the heat capacity of each reactant, indicate that the pozzolanic activity behavior of metakaolin is different in pastes and mortars. Through the deconvolution of the normalized NCDTA curve peaks, it can be seen that ettringuite formation increases as cement substitution degree (CSD) increases, in both cases. Tobermorite formation is more enhanced in mortars than in pastes by MK, with a maximum formation at 30% of CSD. In the pastes, tobermorite formation increases as CSD increases but it is practically the same at 30 and 40% of CSD.     

Release characteristics of semi-volatile heavy metals during co-combustion of sewage sludge and coal under the O<Subscript>2</Subscript>/CO<Subscript>2</Subscript> atmosphere

Oil well cementing is a vital operation to assure casing stability and zonal isolation for oil and gas exploration. However, some scenarios demand the cemented region to withstand high thermal gradients and imposed deformations, as occurs in the case of oil wells subjected to cyclic steam injection at temperatures up to 250 °C, to reduce oil viscosity and to increase well pressure to facilitate heavy oil recovery. In this paper, the hydration of ductile special cement systems using styrene-butadiene latex (SBR) and carboxylated styrene-butadiene latex (XSBR) addition was studied by conduction calorimetry. The resulting heat flow curves, presented in log–log plots, were used to analyze the influence of those copolymers on the hydration stages of three families of cement pastes of different complexity. The simpler cement systems (SCCS) contained water, oil well Portland cement class G and SBR or XSBR in its composition. In medium complexity systems silica fume was added and in the higher complexity ones (HCCS), superplasticizer as well. The primary objective of adding those copolymers into the Portland cement paste is to obtain higher ductility properties after setting, silica fume to have good thermal stability up to 300 °C, while superplasticizer was added to guarantee good workability. Rheological tests were carried out to evaluate the effect of the copolymers on the composite viscosity. Thermogravimetric analysis of selected SCCS and HCCS samples was performed to quantify the main formed phases up to 24 h of cement hydration. From the obtained results, it was noticed that SBR and XSBR addition substantially affects hydration kinetics at all early age stages. Starting from pre-induction and induction periods, the main observed effect during these stages, was related to the increased viscosity of the pastes, which was higher in XSBR containing pastes, retarding the hydration reactions of respective following stages, when compared to pastes with the same cementitious matrix without copolymer addition.     

Evaluating cement hydration by non-conventional DTA; An Application to Waste Solidification

This paper presents a method to study cement hydration at ambient temperatures by using a micro processed non-conventional differential thermal analysis (DTA) system, which was used to evaluate the solidification/stabilization process of tannery wastes produced in the leather industry. The DTA curves of pastes composed by slag cement, Wyoming bentonite and waste are obtained in real time and used to analyze the heat effects of the reactions during the first 24 h of hydration. By applying a deconvolution method to separate the overlapped DTA peaks, the energy released in the several hydration stages may be estimated and consequently, the effects of each component on the solidification process. The highest separated DTA peak occurs during the several early stages of cement hydration and is due mainly to tricalcium silicate hydration. Very good correlation shows that the greater is the waste content in the paste composition, the higher is its effect on the rates of reactions occurring during the induction (dormant) period of cement hydration. The presence of bentonite used as a solidification additive in the stabilization process has a similar but less dramatic effect on the dormant period. This revised version was published online in July 2006 with corrections to the Cover Date.     

Importance of quantitative thermogravimetry on initial cement mass basis to evaluate the hydration of cement pastes and mortars

Thermogravimetric analysis (TG) curves of cement pastes and mortars are obtained by default on their respective initial sample mass basis. This fact does not allow a direct comparison of TG data of percentual mass losses due to the dehydration of a same hydrated component of differently aged pastes or mortars of same cement because the initial masses of the differently aged sample usually have different initial compositions. To solve this problem, one can transform the original thermal analysis curves from the initial sample mass basis to the initial cement mass basis, to have the same composition basis for any hydration time. This paper presents in detail how this can be done graphically and analytically and applies the method to study the evolution of cement hydration during the first 28 days of pastes and mortars prepared from the same type II cement. It also shows how to compare quantitatively the main cement hydrated phases formed during solidification and setting processes of pastes and mortars with different initial compositions as a function of hydration time.     

Early stages hydration of high initial strength Portland cement

Thermogravimetry (TG) and derivative thermogravimetry (DTG) were used to analyze the early stages of hydration of a high-initial strength and sulphate resistant Portland cement (HS SR PC) within the first 24 h of setting. The water/cement (W/C) mass ratios used to prepare the pastes were 0.35, 0.45, and 0.55. The hydration behavior of the pastes was analyzed through TG and DTG curves obtained after different hydration times on calcined cement mass basis to have a same composition basis to compare the data. The influence of the W/C ratio on the kinetics of the hydration process was done through the quantitative analysis of the combined water of the main hydration products formed in each case. TG and DTG curves data calculated on calcined mass basis of all the results were converted to initial cement mass basis to have an easier way to analyze the influence of the W/C ratio on the free and combined water of the different main hydrated phases. The gypsum content of the pastes was totally consumed in 8 h for all cases. A significant part of the hydration process occurs within the first 14 h of setting and at 24 h the highest hydration degree, indicated by the respective content of formed calcium hydroxide, occurs in the case of the highest initial water content of the paste.     

Lessons learned from fires of the wood caused by the spontaneous combustion of coal dust in underground mines

The capture of CO₂ and SO₂ from industrial gas effluents has been done usually by lime-containing products. For this purpose, cement pastes also can be used, due mainly to their calcium hydroxide content formed during hydration. To select the best cement for this purpose, TG and DTG curves of different Portland cement pastes (types I, II, III and G), prepared with a water-to-cement ratio (W/C) equal to 0.5, were analyzed at different ages, at same operating conditions. The curves were transformed into respective cement calcined and initial mass basis, to have a common and same composition reference basis, for a correct quantitative hydration data comparison. This procedure also shows that there is an unavoidable partial drying effect of the pastes before starting their analysis, which randomly decreases the W/C ratio at which were prepared, which indicates that, when results are compared on respective paste initial mass basis, assuming that the ratio W/C has not changed, possible calculation errors may be done. Type I, II and G analyzed cements have shown similar hydration characteristics as a function of time, while the analyzed type III cement has shown a different hydration behavior, mainly due to its highest Al₂O₃ and lowest SO₃ contents, promoting the formation of hydrated calcium aluminates, by the pozzolanic action of the excess of alumina, consuming Ca(OH)₂, which final content at 28 days was the lowest one, among the hydrated cements.     

Pozzolanic properties of a residual FCC catalyst during the early stages of cement hydration

The catalyst used in fluidized catalytic cracking (FCC) units of refineries after several recovery cycles in regeneration units, reduces its activity and it is partially substituted by new catalyst in the process. As it has a high silicon and aluminum oxides content, the pozzolanic properties of a Brazilian FCC spent residual catalyst, used in different substitution degrees to cement, were evaluated by three thermal analysis techniques during the early stages of hydration of a type II Portland cement. NCDTA curves show in real time that the residual catalyst, accelerates the stages of cement hydration. TG and DSC curves of respective pastes after 24 h of hydration evidence the pozzolanic activity of the waste, respectively, by the lower water mass loss during the dehydroxylation of the residual calcium hydroxide and by the lower dehydroxylation endothermal effect. Within the analyzed period, the higher is the cement substitution degree, the higher is the pozzolanic activity of the residual catalyst.     

Calcite,vaterite and aragonite forming on cement hydration from liquid and gaseous phase

Cement hydration products were studied as influenced by the hydration conditions (hydration time in liquid phase; relative humidity, RH, in gaseous phase). The formation of calcium hydroxide (portlandite, P) and its transformation to calcium carbonates is mainly discussed here. More hydration products, including P, were formed in liquid phase (paste) than in water vapor (powder), due to the higher availability of water molecules. Full hydration was observed only in the paste hydrated for 6 month, otherwise the P content, estimated from its water escape, DM(400-800°C), increased after storage in water vapor of the prehydrated paste. All the three polymorphs of CaCO₃ (calcite, vaterite and aragonite) were found on prolonged contact with air of the hydrated powder (XRD, HRTEM). Their content was dependent on sequence of RH conditions on hydration: higher after water retention, WR, on lowering RH=1.0→0.95→0.5, than after water sorption, WS, on increasing RH in the inverse order. It increased also on wetting and drying, both of hydrated powder and paste. Ca was found to accumulate on the micro-surfaces of WR samples (SEM, TEM), whereas more Al was observed on WS samples and the crystallinity of hydration products was here higher (ED). Dissolution-diffusion-recrystallization was possible: small Al-ions concentrated at one end and the bigger Ca ions - at the other end of some needles (TEM). At 400-500°C the P in cement transforms in air into CaCO₃, which decomposes at 600-700°C. Thus the sensitivity to carbonation was estimated from ΔM(600-800°C). This value was similar in pastes hydrated for 1 month and in powder (WR). It was lower in powder WS and much lower in the paste (6 months). It increased pronouncedly when the prehydrated paste was stored in water vapor in WS. The nanocrystals of portlandite, vaterite and aragonite, embedded in the amorphous matrix, were observed by HRTEM in the hydrated powder. They may contribute to the cement strength. This revised version was published online in July 2006 with corrections to the Cover Date.     

The effects of solvents on C–S–H as determined by thermal analysis

Un-hydrated Portland cement consists of several anhydrous and reactive phases, that when mixed with water react to form hydrates. The main hydration product of Portland cement is calcium silicate hydrate (C–S–H). It is the main binding phase in a concrete system, hence is important to construction chemists. The concrete engineer measures the compressive strength of concrete after prescribed hydration periods, typically 1, 3, 7, 28 days. It is often convenient to mimic these intervals by stopping the hydration reaction at the same times. Several techniques can be employed to stop this hydration reaction. One of which is solvent-based and involves mixing a polar solvent such as acetone or isopropyl alcohol, with the hydrated cement. This mixing should be vigorous enough to blend the free water, in the partially hydrated cement system, with the polar solvent without altering the cement system’s matrix. The solvent-water mixture has a much lower boiling point and the mixture quickly evaporates out of the system. This achieves two goals. It stops the hydration reaction at the moment of solvent mixing, and it removes free water to prevent further hydration from occurring. This procedure theoretically leaves behind a dry, chemically unaltered, partially hydrated cement paste. In this way, pastes can be analyzed after the prescribed 1, 3, 7 or 28 days of hydration. This paper uses thermogravimetric analysis (TG) results to investigate the assumption that solvents have no thermodynamic or chemical effect on the hydrated cement paste phases.     

Mineralogical evolution of cement pastes at early ages based on thermogravimetric analysis (TG)

Ordinary thermogravimetric analysis (TG) and high-resolution TG tests were carried out on three different Portland cement pastes to study the phases present during the first day of hydration. Tests were run at 1, 6, 12 and 24 h of hydration, in order to determine the phases at these ages. High-resolution TG tests were used to separate decompositions presented in the 100–200 °C interval. The non-evaporable water determined by TG was used to determine hydration degree for the different ages. The effect of particle size distribution (PSD) on mineralogical evolution was established, as well as the addition of calcite as mineralogical filler. Finer PSD and calcite addition accelerate the hydration process, increasing the hydration degree on the first day of reaction between water and cement. According to high-resolution TG results, it was demonstrated that ettringite was the only decomposed phase in the 100–200 °C interval during the first 6 h of hydration for all studied cements. C-S-H phase starts to appear in all cements after 12 h of hydration.     

Degree of hydration in cement paste and C<Subscript>3</Subscript>A-sodium carbonate-water systems

This research provides a fundamental understanding of the early stage hydration of Portland cement paste, tricalcium aluminate (C₃A) paste at water to cement ratio of 0.5 and C₃A suspension at water to cement ratio of 5.0 modified by 2 or 4 mass% of sodium carbonate. A high conversion of unreacted clinker minerals to gel-like hydration products in the cement-Na₂CO₃ pastes takes place rapidly between 1^st to 24^th h. Contrary the Ca(OH)₂ formation within the same time interval is retarded in the excess of CO₃²⁻ ions due to intensive rise and growth of CaCO₃ crystals in hydrated cement. Later, the conversion of clinker minerals to the hydrate phase is reduced and higher contents of calcite and vaterite relative to that of Ca(OH)₂ in comparison with those found in the Portland cement paste are observed. As a consequence a decrease in strength and an increase in porosity between hardened Portland cement paste without sodium carbonate and those modified by Na₂CO₃ are observed. C₃A hydrates very quickly with sodium carbonate between 1^st and 24^th h forming hydration products rich in bound water and characterized also by complex salts of (x)C₃A·(y)CO₂·(zH₂O type, whereas C₃A-H₂O system offers C₃AH₆ as the main hydration product. Higher content of the formed calcium aluminate hydrates in C₃A-Na₂CO₃-H₂O system also contributes to early strength increase of Portland cement paste.     

Comparing study on hydration properties of various cementitious systems

The hydration properties of slag sulfate cement (SSC), slag Portland cement (PSC), and ordinary Portland cement (POC) were compared in this study by determining the compressive strength of pastes, the hydration heat of binders within 72 h, the pore structure, the hydration products, and the hydration degree. The results indicated that main hydration products of PSC paste and POC paste are calcium hydroxide and C–S–H gel, while those of SSC paste are ettringite and C–S–H gel from the analyses of XRD, TG–DTA, and SEM. At the early curing age, the compressive strength depends on the clinker content in the cementitious system, while at the late curing age, which is related to the potential reactivity of slag. From hydration heat analysis, the cumulative hydration heat of PSC is lower than that of POC, but higher than that of SSC. Slag can limit chemical reaction and the delayed coagulation of gypsum, which also plays a role in the early hydration. So SSC shows the lowest heat release and slag can’t be simulated without a suitable alkaline solution. Based on MIP analysis, the porosity of POC paste is the smallest while the average pore size is the biggest. At the age of 90 days, the compressive strength of SSC can get higher development because of its relative smaller pore size than that of PSC and POC paste.     

Performance of G-Oil Well cement exposed to elevated hydrothermal curing conditions

G-Oil Well cement was modified by blending it with blast furnace slag and silica fume at various ratios. The hydration was carried out under the hydrothermal conditions (200 °C and 1.2 MPa) up to 7 days. TG and DTG were performed on cured pastes to identify the hydrated products, their quantity and their stability under given hydrothermal curing conditions. The microstructure of samples was observed by a scanning electron microscope. The mechanical compressive strength was determined and the pore structure was analyzed using mercury intrusion porosimeter. It was found out that the compressive strength values of blend G-Oil Well cements markedly increased with increasing blast furnace/silica ratio. The pore structure was consolidated, as demonstrated by the displacement of pore size distribution to the region of micro and nano pores.     

Study of dehydration and rehydration processes of portlandite in mature and young cement pastes

The hydration process of the cements induces the formation of different kinds of hydration products. The main products of hydration are C?CS?CH gel and portlandite [Ca(OH)₂]. The C?CS?CH gel is an amorphous compound that is discomposed progressivity with the temperature until approximately 1,000?°C, while the portlandite is discomposed between 450 and 550?°C. Also, calcium carbonate can be formed as a consequence of the portlandite carbonation. All of these processes can be analysed and quantified by simultaneous differential thermal analysis and thermogravimetric analysis. And by X-ray diffraction it is possible to identify the crystalline phases. Some authors have corroborated that the portlandite can be rehydrated, after dehydration processes due to thermal exposition of the cement paste. But all of these experiments have been made with young cement pastes or at temperatures lower than 650?°C. In this work the behaviour of young and mature cement pastes have been studied in relation with the portlandite decomposition and the possibility of the rehydration of it in water presence. We found that young pastes and old pastes, stored at laboratory conditions, and later burned, show a certain grade of rehydration, specially the pastes burned at 650?°C (with ??80% of reformation of portlandite) with respect to the pastes burned at 1,000?°C (between 20 and 40%). It is corroborate that the rehydration process is directly related to the formation of CaO during the burning. Also, a formation of unstable portlandite is detected in young pastes burned at 650?°C, which can be rehydrated easily. Although, the mature pastes that have been burned initially and stored under laboratory conditions cannot be rehydrated, due to the formation of stable products during the storage.     

Simultaneous IR/TG study of calcium carbonate in two aged cement pastes

Two aged cement pastes (7 years) were studied for H₂O and CO₂ evolution, the combined amounts of which were measured by TG and identified by thermo-IR analysis. This indicated the presence of three forms of carbonates, which decomposed at different temperatures. The displacement with time of the evaporation of sorbed water to higher temperatures (500–700°C, TG, MS) shows the possibility of its incorporation into carbonate hydrates and/or hydroxy hydrates, postulated previously. The decomposition of all the hydration products needed a thermal energy increasing with ageing (increased temperature measured by TG). The carbonation process proceeded for 7 years in the weaker paste, whereas it terminated before 5 years in the stronger one. The CSH water content did not change with ageing, whereas that of portlandite was lowered, which though did not account for the increase in carbonate content (TG). Possibly some Ca²⁺ from the CSH gel was involved in this process. In the stronger paste the growth with time of organic matter was found (IR, TG/DTG).     

A study of the carbonation profile of cement pastes by thermogravimetry and its effect on the compressive strength

In a previous work, the authors have carbonated totally high initial strength and sulfate-resistant Portland cement pastes. In order to solve the mechanical problems caused by the intense carbonation that occurred during those experiments, new carbonation conditions were applied in this study. The obtained products were analyzed with respect to the carbonation reactions by thermogravimetry and compressive mechanical strength. Comparative analysis with reference pastes obtained without carbonation at the same age shows that CO₂ capture increases with carbonation time. However, there is an optimum time, up to which the carbonation treatment does not affect the mechanical properties of the paste. Below this time, the lower is the carbonation time the higher is the increase of compressive strength, when compared to that of the reference pastes processed at same operating conditions without carbonation.