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State Key Laboratory of Materials-Oriented Chemical Engineering, College of Materials Science and Engineering, Nanjing University of Technology, Nanjing 210009, China
Lafarge A & C Technical Service (Beijing) Co. Ltd., Beijing 100027, China
h i g h l i g h t s
" Design of experiments (DoE) was adjusted in the cement clinker chemistry.
" Combination effects come from the interactions of SO3 with MgO and temperature, which can demonstrate in the contour plot.
" MgO favors the formation of M3 type alite while SO3 stabilizes M1.
" Temperature and sintering time have little effect on the crystal modications of alite.
" The amount of C4AF is increased with likewise increasing SO3 content.
a r t i c l e
i n f o
Article history:
Received 19 April 2012
Received in revised form 22 June 2012
Accepted 22 July 2012
Available online 7 September 2012
Keywords:
Design of experiments
Formation of alite
Interaction
Alite polymorphism
Cement clinker
a b s t r a c t
The design of experiments (DoE) was adjusted in cement clinker chemistry, with alite polymorphisms in
the clinker taken into account. The additions of SO3, MgO, as well as two other factors, sintering temperature and time, were included to study clinker formation and alite polymorphisms. XRD quantitative
analyses and thermal analysis (DSCTG) were used to collect quantitative data from the samples and
to investigate the clinkerization of the raw meal. The central composition design was used to design
the experiments and the response surface methodology was used to evaluate the results. The addition
of SO3 inhibited the formation of alite in the clinker, while MgO compensated for any negative effects
caused by the SO3. A contour plot interpreted the combination effects of these four factors. The amount
of C4AF was then increased with a likewise increasing SO3 content. MgO favored the formation of M3 type
alites, while SO3 stabilized the M1. Alite modication, which is related to hydration properties, could be
helpful for efcient use of high MgO content calcite in cement production.
2012 Elsevier Ltd. All rights reserved.
1. Introduction
MgO and SO3 are the most frequently existing minor components in industrial clinkers [13]. MgO can lower the melting temperature and increase the quantity of the liquid phase during the
clinkers sintering process [1,4], while the addition of SO3 leads
to the stabilization of belite and lime at clinkering temperatures,
thus decreasing the C3S content [1]. The added combination of
MgO and SO3 can be helpful in the production of high SO3 content
clinkers [1]; additionally, the MgO to SO3 weight ratio can also
modify alite polymorphs in the clinker. Maki [3,5] investigated several industrial clinkers with varied MgO to SO3 weight ratios and
found that high ratios promoted M3 formation while low weight
ratios favored M1 formation. Emanuelsons [6,7] work concluded
that, according to the XRD pattern, a high SO3 content in Portland
Corresponding author. Tel.: +86 25 83587234.
E-mail address: xdshen@njut.edu.cn (X. Shen).
0950-0618/$ - see front matter 2012 Elsevier Ltd. All rights reserved.
http://dx.doi.org/10.1016/j.conbuildmat.2012.07.099
cement clinker with MgO (34 wt.%) yielded more M1 type alites
while a low content resulted in M3 type alites.
Studies [4,8] have shown that the highest limit of the incorporated amounts of MgO in the clinker minerals is about
2 wt.%. The clinkers with relatively high amounts of MgO sintered under a higher temperatures could cause MgO to enter
into the liquid; during the consequent cooling process, much
of the MgO remains in the aluminate and ferrite phases, but
small amounts of MgO can separate as small periclase crystals
[9]. Lorke [10] has tried to decrease the periclase content in
clinkers by increasing the coarse raw mixed content, which
can yield alite enriched with MgO.
The SO3 dosage in a clinker has a strong preference for belite,
which can decrease the liquids viscosity and surface tension. The
polymorphic forms of C3S and M1 are predominant in the constituent phase. It was recorded [11] that the threshold of SO3 for the
formation of C3S is 2.5 wt.%. The SO3 dosage can also impact the
C3A and C4AF contents [5,11].
549
Al2O3
Fe2O3
CaO
KHa
SM
IM
C3S
C2S
C3A
C4AF
23.4
5.57
3.1
67.93
0.88
2.2
1.4
53.6
21.8
8.21
12.41
2. Experiment
2.1. Sample preparations
The cement clinker was synthesized with analytical reagent grades of CaCO3,
SiO2, Al2O3, Fe2O3 MgO and CaSO42H2O. The MgO was added directly to the samples, while the additional CaO taken from gypsum was considered in the total
CaO content. For a blank sample, the parameters are shown in Table 1.
The prepared raw meals were homogenized in a ball meal bottle with water and
agate balls for 12 h. Then the liquid meal was dried and pressed into discs for the
sintering process.
Clinkers were sintered in a resistance furnace, the temperature of which was
calibrated with Ferro PTCR-MTH testing rings (Ferro Electronic material systems,
5 C). Samples were placed in Pt crucibles, heated at a rate of 10 C/min, calcinations at 1000 C for 30 min, then up to sintering temperatures (1450 C, 1500 C,
and 1550 C respectively) and held for a required time (30 min, 75 min and
120 min). The sintered clinkers were then cooled with forced air.
Table 3
Design matrix of factors and the phase composition of clinkers.
Run No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
Factors
C3S
C2S
C4AF
C3A
f-CaO
0
1
1
1
0
0
1
1
1
0
0
0
0
1
0
1
0
0
1
1
1
1
1
1
1
0
1
0
1
0
1
0
1
1
0
1
1
1
1
1
0
0
0
0
1
0
1
0
0
1
1
1
1
0
1
1
0
1
0
1
0
1
0
1
1
0
0
0
1
1
1
0
0
1
0
1
0
1
0
1
1
1
1
1
0
1
1
0
1
0
1
0
1
0
1
1
0
0
0
1
1
1
1
0
0
0
1
0
1
0
0
1
1
1
1
0
1
1
1
1
0
1
0
1
51.5
49.8
32.4
53.6
56.9
50.2
49.3
16.9
57.7
47.6
51.1
56.8
50.8
46.4
57.6
54.6
54.6
47.3
55.5
40
48.8
54.9
36.4
54.7
56.9
54.6
44.9
55.9
3.2
55.8
56.9
28.3
27.1
41.1
25.5
23.9
29.7
28
52.4
23.5
31.4
29.7
23.7
29.9
31.7
24.2
23
25.6
32.4
22.6
34.8
28.7
22.8
35.3
22.6
22.8
27.2
32.1
26
61.6
27.1
23.5
14.1
11.3
11.1
12.4
13.7
14.1
11
12.2
11.8
14.1
13.3
14.7
13.6
13.1
13.7
10.2
14.6
13.5
9.9
13.4
13.3
9.8
10.5
8.4
12.6
13.7
13.5
13.6
10.5
13.1
12.2
2.9
7
10.4
4.5
3.4
3.1
10.5
11.2
3.5
3.5
2.9
2.9
2.8
4.9
2.4
11.7
2.8
3.1
11.4
6.4
4.9
11.7
13.7
12.2
5.1
2.2
5.6
2.6
13
2.2
4.3
2.4
2.5
5
1.9
0.7
1.7
1.1
7.3
0.5
3.3
2
1.2
2.1
1.4
1.4
0.5
1.5
2.6
0.5
2.4
0.8
0.6
4
1.2
0.8
1.3
1.6
1.1
10.1
1.1
0.7
2.2. Characterization
2.2.1. X-ray diffraction (XRD)
All samples were nely grounded in order to perform the powder diffraction
measurements. XRD data was collected on a Thermosher ARL 9900 series X-ray
workstation using Co Ka radiation (k = 0.1788996 nm) running in reection geometry (h/2h) at room temperature. The data was collected from 8 to 80 (2h) during
15 min with a step size of 0.02; more detailed XRD patterns were performed for a
range of 3541 and 6062 at a rate of 0.5/min. The X-ray tube worked at 40 kV
and 40 mA. The quantitative analysis was performed with the Reference Intensity
Ratio (RIR) method using Visual Crystal software supplied by Thermosher.
2.2.2. Differential thermal analysis
The Netzsch STA 449c thermal analyzer obtained differential thermal measurements. The DSC curves were obtained at a heating rate of 20 C/min in simulated air.
Table 2
Factors and factor levels adopted.
Notation
M
S
T
t
Factor
Low level
Intermediate level
High level
Coded
Actual
Coded
Actual
Coded
Actual
1
1
1
1
0
0
1450
30
0
0
0
0
2
1.5
1500
75
1
1
1
1
4
3
1550
120
550
Table 4
Analysis of variance (ANOVA) of the CCD models for phase composition of clinkers.
Terms
C3S
MgO
SO3
Temperature
Time
MgO SO3
MgO temperature
MgO time
SO3 temperature
SO3 time
Temperature time
Regression
Linear
Interaction
C2S
C4AF
C3A
f-CaO
3.337
5.69
2.968
1.895
2.788
1.707
0.43
2.203
1.219
0.243
0.003
0
0.008
0.073
0.011
0.103
0.672
0.039
0.237
0.81
0
0
0.035
3.483
7.483
3.71
2.059
3.814
2.153
0.764
2.88
1.643
0.016
0.002
0
0.001
0.053
0.001
0.044
0.454
0.009
0.116
0.987
0
0
0.002
3.16
1.963
0.598
0.393
0.179
0.007
0.645
0.486
0.138
0.75
0.005
0.064
0.556
0.698
0.86
0.995
0.526
0.632
0.891
0.462
0.19
0.023
0.969
4.011
0.015
0.52
0.649
0.269
0.04
0.338
0.041
0.031
0.327
0.001
0.988
0.609
0.524
0.79
0.969
0.739
0.967
0.975
0.747
0.148
0.013
0.999
4.206
5.519
3.909
3.166
4.751
2.195
0.875
2.461
1.43
0.295
0
0
0.001
0.005
0
0.04
0.392
0.023
0.168
0.771
0
0
0.001
Table 5
The optimized analysis of variance (ANOVA) of the CCD models for phases in clinker.
Terms
MgO
SO3
Temperature
MgO SO3
SO3 temperature
R2 (%)
C3S
C2S
C4AF
C3A
3.14
5.354
2.793
2.624
2.073
0.004
0
0.01
0.015
0.049
69.70
63.60
3.071
6.598
3.271
3.363
2.54
0.005
0
0.003
0.002
0.018
76.50
71.80
3.583
2.225
0.001
0.034
4.715
R2adj (%)
Linear
Interaction
0
0.01
0
0.001
on cement additives, and Senff et al. [25] used DoE in their investigation of belite sulfoaluminate cement. Basma [26] used a mixture design based on DoE on the mechanical properties of
cement blended with slag. Moseson [27] used a mixture design
to investigate alkali-activated cement. A great deal of work [28
31] has been done in concrete research based on the DoE. All these
works certify the feasibility of such a statistical method in cement
and concrete research.
In this paper, a statistical method of DoE based on response surface methodology (RSM) has been adopted to study cement clinker
mineral compositions. By using such a method, it is possible to
study the effects of main and mixed (interaction) independent
variables on the formation of the clinker phases. The empirical
model of each phase can be tted with a group of well-designed
experiments.
3.1. Central composite design (CCD) of DoE
The central composite design (CCD) is used for the RSM; more
details are available in Refs. [20,21,24]. Two kinds of factors are
considered: (a) additives, and (b) sintering controls; all factors, factor levels and codes are shown in Table 2. The design matrix of the
CCD model and the corresponding clinker phase composition statistical data are given in Table 3.
4. Results and discussions
An analysis of variance (ANOVA) is performed to determine the
signicant and insignicant parameters as well as the validity of
the full models [32], as shown in Table 4. Statistical signicance
is determined by the p-value of ANOVA. Terms with a p-value less
than 0.05 are considered signicant. The effectiveness of a term is
38.85
34.48
0.001
fCaO
p
0
43.39
41.44
0
3.241
4.252
3.012
3.661
0.003
0
0.006
0.001
66.26
61.07
0
0.001
551
Fig. 3. C3S content contour plot of the addition of SO3 and MgO.
Table 6
Phase composition (%) of samples sintered at 1450 C, for 30 min.
Doping
Mineral composition
MgO
SO3
C3S
C2S
C4AF
C3A
f-CaO
0
0
4
4
0
3
0
3
54.65
3.21
49.84
40.03
22.64
61.57
27.09
34.83
8.42
10.51
11.29
13.39
12.15
12.98
6.96
6.44
1.19
10.1
2.53
2.35
3.0% SO3 (far more than the threshold of 2.5% [11]) and without
MgO, yields a 10.1% f-CaO content when sintered at 1450 C for
30 min. This is primarily because SO3 can stabilize C2S, thus retarding the formation of C3S [1,11].
MgO contributes to the formation of C3S in the clinker [2,3,11],
since the t value of MgO is 3.14, which is ranged as second in all
signicant terms. The level of SO3 determines the effects of MgO,
which explains the interaction between SO3 and MgO. When the
SO3 addition is set at a low level, such as 0%, the variation of the
C3S content is not sensitive to the increasing dosage of MgO. On
the contrary, MgO signicantly improves the C3S content, compensating the negative effects of SO3 (Fig. 3). This is because the role of
MgO in the sintering process is to lower the viscosity of the liquid,
and then promote the formation of the clinker phases [1].
Temperature is also a positive factor for C3S formation, because
the elevated temperature can yield a greater amount of C3S. However, for samples with SO3, the temperature modies the C3S content. The interaction between temperature and SO3 content can
also be explained as an SO3MgO interaction wherein the enhanced temperature compensates the negative effects of SO3 at
high dosage levels (Fig. 4).
552
Fig. 4. C3S content contour plot of the addition of SO3 and temperature.
Fig. 6. The contour plot of C4AF content versus addition of SO3 and MgO.
Fig. 5. f-CaO content contour plot of the addition of SO3 and MgO.
For the f-CaO phase, the interaction between SO3 and MgO is
signicant (Table 5); the less f-CaO is presented, the more silicates
are formed. Such an interaction is in agreement with the combination effects of SO3 and MgO on C3S content (see Fig. 5).
According to ANOVA, the empirical models of phase compositions can be derived as shown:
Fig. 8. DSC curves for samples with various MgO and SO3 content.
Temperature;
4.2. Intermediate phases
553
0
0
4
2
SO3 content
0
3
0
1.5
Peak No.
Dehydration of anhydrite
Decarbonation
Clinkering
130
124
820
820
820
813
1255
1309
1367
1379
1346
1352
1395
1419
1437
Fig. 10. Characteristic windows of MgO and SO3 doped samples sintered at
different temperature and holding time.
(Table 5), which agrees with previous ndings [5,11]. The tted
equations are as follows:
554
Fig. 12. Characteristic windows of clinker with different doping amounts, all the
samples were sintered at 1500 C for 75 min.
Ka) and 5152 (Cu Ka) window documented in Taylors book [1],
as well as another characteristic window (about 37, Cu Ka) mentioned by Courtial [34].
4.4.1. Sintering
The sintering process does not affect the crystal modications of
alite in the clinkers. All samples presented similar characteristic
patterns (Fig. 9). The alite in the blank samples obtained during different sintering processes is an M type (the XRD patterns are not
typical M1 or M3 type). For samples doped with MgO and SO3,
the sintering process alters the alite modications (Fig. 10). For
samples doped only with MgO, the higher sintering temperature
could vary the crystal structures to some extent; at high sintering
temperatures, the sintering time could also provide an obvious impact on the crystal structure (Fig. 11). Samples doped only with SO3
hinder C3S formation, so the alite crystal modications are not discussed here.
4.4.2. MgO and SO3 doping
The addition of MgO and SO3 can cause changes in alite modications. MgO alone typically yields M3 type alites in the clinker
[1,3,11,33]; the characteristic patterns [33,34] of M3 at 61 and
38 (Co Ka) appear markedly (see Fig. 12).
There are no signicant differences among various dosages of
SO3. It can be seen that the addition of SO3 in the samples with
MgO results in the transformation of M3 to M1. A typical M1 type
alite could be certied by the disappearance of the shoulder peak
at about 38 and the modication of the double peak at about
61, according to Maki [1,33] and Courtial [34], shown in Fig. 12.
This evidence reveals the transformation of M3 to M1 type of alite.
There are no differences among the SO3 amounts or the alite
modications in the MgO absent clinkers. Only the M1 alite was
obtained when SO3 was added.
5. Conclusion
Results show that additions of SO3 hinder the formation of alite
in clinkers; such an effect is lessened by the addition of MgO. MgO
itself contributes to the formation of C3S by decreasing the clinkers
formation temperature. The combination effects come from interactions of SO3 with MgO and varying temperatures, which can be
demonstrated in the contour plot. The empirical models derived
from DoE are obtained. SO3 and MgO impact the interstitial phase
content, and C4AF increased as increasing SO3 content was added.
MgO can stabilize M3 type alites, while the addition of SO3 stabilizes M1 type alites. The sintering protocols have little impact on
555