Concentration effect of sodium carbonate and sodium aluminate as accelerator and

H2O mixing against physical properties: Flow ability, setting time, and strength in low
cement castable refractory product (Case study: PT. Indoporlen)
Mei Krismahariyanto, Bungaran Saing, and Hernowo Widodo

Citation: AIP Conference Proceedings 1877, 090002 (2017); doi: 10.1063/1.4999897

View online: http://dx.doi.org/10.1063/1.4999897
View Table of Contents: http://aip.scitation.org/toc/apc/1877/1
Published by the American Institute of Physics
 Concentration Effect of Sodium Carbonate and Sodium
Aluminate as Accelerator and H2O Mixing against Physical
Properties: Flow ability, Setting Time, and Strength in Low
Cement Castable Refractory Product
(Case Study: PT.Indoporlen)
Mei Krismahariyanto1, a) Bungaran saing1, b) Hernowo Widodo1, c)
1
Faculty of Engineering, Universitas of Bhayangkara Jakarta Raya, Jakarta 12140, Indonesia
a)
Author: meikrismahariyanto@gmail.com
b)
bungaran.saing@yahoo.com
c)
hernowo.widodo@yahoo.com

Abstract. The research was intended to analyze effect of comparison concentration between accelerator and H 2O mixing
against characterization of flow ability, setting time and strength at low cement castable refractory product (case study at
PT. Indoporlen Refractory), Shown the kinds of accelerator sodium aluminate and sodium carbonate have good
characterization result against flow ability and setting time while additional H2O mixing conclude to good strength with
different kinds of temperature at 110 oC, 900 oC and 1450 oC which revealed the measurement are above to allowed
specification and as well the strength test coming from accelerator of sodium aluminate and sodium carbonate in various
concentration 0.01% until 0.04% and with various of H2O mixing 5.0 until 6.5% achieves the strength above in allowed
specification of PT.Indoporlen.

Key Words :Accelerator, Sodium Aluminate, Sodium Carbonate, Refractory

INTRODUCTION
PT.INDOPORLEN or Indoporlen Ltd.Co (IP in abbreviation) was established in 1975 to respond to rapid
economic and industrial growth in Indonesia during decades. The company determined commitment is to provide
specific, reliable and economical solutions to numerous industrial sectors using high temperatures as a process
feature for industries such as iron, steel, alumunium, cement, fertilizer, and other industries. Located on the strategic
area of Bekasi-Jakarta, supported by 300 numbers of employees and having high production capacity fire clay
bricks, high alumina bricks, and monolithic refractories. Some products are designed to meet very special service
conditions.
As shown in the curve trend 2013-2015 40% production rate are low cement castable, which have as a best seller
product in his total production, and 40% market share mostly dedicate to Iron and steel industries as well. In their
service sometimes found complaint from their costumer that LC castable production facing longer setting time in
site installation compared to IPs specification. Currently to accommodate the issue IP use imported chemical
sodium aluminate (SA) as accelerator, due to effectiveness lead to an early stiffening of the mix [21] which
typically required for LC castable to get an initial set of cement in his hydration process. SA can alter the hydration
kinetics and microstructure development of cement paste, thus resulting in changes in macro properties of the
castable such as setting behavior, strength development and transport properties [13,14].

4th International Conference on the Advancement of Materials and Nanotechnology (ICAMN IV 2016)
AIP Conf. Proc. 1877, 090002-1090002-14; doi: 10.1063/1.4999897
Published by AIP Publishing. 978-0-7354-1557-7/$30.00

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 The quality of the water also plays an important role in the preparation of LC castable, impurities in water may
interface with the setting of the cement and may adversely affect the strength of the concrete, the chemical
constituents present in water may participate in the chemical reactions and thus effect the setting, hardening and
strength development of castable. A popular measurement to the suitability of water for making castable is that if it
is fit for drinking it is also fit making castable. IPs Recommendation for Impurity in water that alkali carbonate
should not exceed 1000 ppm, chlorides salt dont exceed 500 ppm, sulphates salt dont exceed 1000 rpm, water pH
not allowed to below 6 or higher than 8, not allowed containing sugar, suspended particle (excrements, humus, etc)
or any other particles.
Hence investigation is carried out in order to evaluate the effect of alkali carbonate substance but not exceed
1000 ppm on setting time and strength of low cement castable under laboratory conditions. We use sodium
carbonate as our investigation as accelerator due to the chemicals easier found in chemical store in Indonesia if
compared to sodium aluminate are existing materials used in Indoporlen previously

FIGURE 1. PT. Indoporlens product data trend 2013-2015

EXPERIMENTAL PROCEDURES

Raw materials
In this experimental work, alumina bauxite as a aggregate and CB rotary as fine powder were supplied from
green minerals, Andalusite purusite and Kerphalite were supplied from Damrec SAS, calcined alumina grade NSR-
03 were supplied from Hindalco, CAC 70 were supplied from Calderys, Silica fume were from Nara Techno, and
dispersant were from Possehl.
TABLE 1. The chemical composition materials and dispersant used in experiment.
No Raw mat. Chemical comp.
Al2O3 SiO2 Fe2O3 CaO Na2O+K2O
1 Alumina bauxite 80 80 - d2 - -
2 CB Rotary 85 d8 d2 - -
3 AND purusite 59 d40 d0.8 d0.2 d0.5
4 AND KA 59 d40 d1.2 d0.1 d0.5
5 Calcin Alumina 99 d0.03 d0.03 - d0.5
6 CAC 70 cement 70 d d0.25 d30 -
7 Silica Fume - 95 d0.05 d1 d2
8 dispersant Total P2O5 70% d0.04 - -
9 Sodium Aluminate 55 - Total Na2CO3 7% d40
10 Sodium carbonate Total Na2CO3 99% min

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 Q value and percentage of accelerator
Prior to making experiments, the weight percentages of the consumed material were listed in Table 2. The
percentages of the accelerator were varied as 0.01, 0.02, 0.03, and 0.04. The Andreasson model equation was used to
determine the ratio of the range particle size of the alumina according to the particle size distribution parameter (q
value), in this study q value is 0.2 as a fixed variable.
TABLE 2. Percentage of material used in experiment

No Raw mat. Size (mm) percentage

1 Alumina bauxite 80 3-5 9
2 Alumina bauxite 80 1-3 31
3 Alumina bauxite 80 0-1 8
4 Cb Rotary 200 mesh 13
5 AND Premium 0-4 7
6 AND Kerphalite 0.3-1.6 10
7 AND Purusite 200 mesh 5
8 Calc.Alimina NSR 03 5 mic 4
9 CAC Calal 70 5 mic 8
10 Silica Fume GW 5 mic 5
11 Dipersant 100 mesh 0.1

Preparation for specimen LC castables

Weigh amount of the material according to the defined formula with variation of accelerator inside and amount
of H2O mixing as defined sequences of experiment as below listed in Table 3

TABLE 3. Weigh amount material and H2O

Tahap (%) (%) (%) Kons.H2O (%)

NaAlO2 Na2CO3 CaCl2
1 0.01 - - 5 5.5 6 6,5
2 0.02 - - 5 5.5 6 6,5
3 0.03 - - 5 5.5 6 6,5
4 0.04 - - 5 5.5 6 6,5
5 - 0.01 - 5 5.5 6 6,5
6 - 0.02 - 5 5.5 6 6,5
7 - 0.03 - 5 5.5 6 6,5
8 - 0.04 - 5 5.5 6 6,5
9 - - 0.01 5 5.5 6 6,5
10 - - 0.02 5 5.5 6 6,5
11 - - 0.03 5 5.5 6 6,5
12 - - 0.04 5 5.5 6 6,5

Poured the weighed material into Hobart mixer VRI, do the dry mixed for 5 minutes then add the water for 30-40
second to reach stiffening time with various concentration of H2O mixing, finally do the wet mixed after consistency
has been achieved.
Continue further step, to check Flow ability the dough after got consistency, to comply standard CEN XP ENV
1402-4 alumina based non self flow dense castable determination of consistency , the dough pour to the cone mold
(inner diameter on top lid are 70 mm and inner at the bottom 100 mm) should takes time 30 second to fill up the
cone, then lift up the cone immediately and let the dough to spread out assisted by vibration with measurement 0.5-

090002-3
0.55 amplitude for 30 second, measure the reach of spread out with tap rule or caliper afterwards, makes average if
any difference distance of length spread out. While prepare for checking setting time / hardening the material with
sequences are putting the dough into plastic cup 200 grams then get inside to curing chamber equipped higro-thermo
apparatus to maintains the material keep in 20 oC and 95% of humidity at 1 atm. Checked time of hardening of
material on every 30 minutes. For checking the strength encompasses cold crushing strength (CCS) and Modulus of
rupture (MOR) the material casted into block mold dimension are 230x65x54 mm according to PRE / shape B as
IPs requirement standard and refer to ASTM C-133, the specimen for this purpose cured at 24 hours at curing
chamber 20 oC/95% RH, dried at oven for 24 hours finally fired at 110 oC, 900 oC and 1450 oC, the destructive test
carried out at room temperature and the machine related to this purpose flexural & Compression test Hualong type
KN 1000

RESULT AND DISCUSSION

Setting Time Measurement

Based on terminology ASTM C71-08 that definition of setting time of castable is elapsed time of refractory
product of castable to hardened after casted at ambient temperature till reach consistency quiet enough so the shape
has already constant without any deformation or slumping process. IPs requirement for this measurement around
60-120 minutes.

Setting time of Sod.Aluminate (NaAlO2)

FIGURE 2. Effect of NaAlO2 concentration for setting time

Based on above test shown increasing of concentration of NaAlO2 added into mixture impact to more quick of
setting time. For this case found ideal time has happen on adding accelerator in concentration 0.02% with H2O
mixing 6.5%, (13)(14) in their journal expressed that sodium aluminate in those characterization might change
hydration process in kinetic and improve the microstructure of cement, therefore generate physical change like
setting time behavior, increasing the strength, and heat transfer properties, Anderson (13) defines that on his journal
that sodium aluminate involve to increasing speed of alite hydration or tricalsium silicate (C3S, Ca3SiO5) and belite
or DiCalcium Silicate (C2S, Ca2SiO4) from cement phase with his exothermal reaction. Reaction follows are :

Cement Hydration :

3CaOAl2O3/4CaOAl2O3Fe2O3 + CaSO4 + H2OCa6Al2(SO4)3(OH)12.26H2O(whenSO42-/Al2O33.0)..(1)

3CaOSO42-/2CaOSO42- + H2O CaSO4H2O + CaOH2 ....(2)
Ca6Al2(SO4)3(OH)12.26H2O + CaO3Al2O3Ca2Al(OH)6.X.xH2O(when1.0<SO42-/Al2O3<3.0).(3)

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After adding Sodium aluminate :

4NaAlO2 + 2H2O NaOH + Al(OH)3. ...(4)

Ca(OH)2 + Al(OH)3 + CaSO4 + H2O Ca6Al2(SO4)3(OH)12.26H2O or Ca2Al(OH)6.X.xH2O (depend on ratio SO42- /
Al2O3) .(5)

After realizing of Gypsum :

3CaOAl2O3 + Al(OH)3 + H2O 2CaO.8Al(OH)3 ...(6)

3CaO + H2O 4CaO.10Al(OH)3 + 2CaO.8Al(OH)3 ..(7)

The above reaction shown sodium aluminate hydrolyzed by water releases sodium hydroxide (NaOH) and
aluminum hydroxide (Al(OH)3) as equation no.4, sodium hydroxide increasing alkalinity solution in paste cement
therefore speed up solubility of calcium aluminate phase and phase of calcium silicate ion cement phase, in being
hydration process cement cation of Na might absorb into structure Ca2Al(OH)6.X.xH2O and CaSO4H2O gel,
Aluminum hydroxide might react to calcium hydroxide plus gypsum to createCa6Al2(SO4)3(OH)12.26H2O or
Ca2Al(OH)6.X.xH2O phase like equation no.5 depend on ratio sulphate to aluminate as experiment result of
Christensens Ca6Al2(SO4)3(OH)12.26H2O or Ca2Al(OH)6.X.xH2O phase can be produced directly on hydration
process after adding of sodium aluminate into cement, decreasing ratio sulfate aluminate drastically and
Ca2Al(OH)6.X.xH2O create faster, Calcium hydroxide in 5th equation come from dissolving process phase calcium
aluminate or calcium silicate phase in cement phase, and aluminum hydroxide come from dissolving process
Calcium aluminate phase or hydrolization phase from sodium aluminate. After releasing gypsum, phase of calcium
aluminate will start to react to aluminum hydroxide or water as shown in 6th and 7th equation, Ca2Al(OH)6.X.xH2O
phase is cationic layer from Ca2Al(OH)6 which was separated through anion interface which surrounding by water
molecular, different kinds of anion could be anion X like OH-, SO42-, and CO32-, generated product from hydration
process like 4CaO.Al2O319H2O and 2CaOAl2O38H2O will creating Ca2Al(OH)6OH-.27H2O.

Setting time of Accelerator Natrium Carbonate (Na2CO3)

FIGURE 3. Effect of Na2CO3 concentration for setting time

Based on above data shown that any trend of increasing concentration of Na 2CO3 thus faster setting time, It
happens on the concentration 0.03% and 0.04% with H2O mixing 5-6%, this case caused by hydraulic bonding
reaction cement collaborate with accelerator results the mechanism become reactive. Cited from the journal (15),
that reaction on cement hydration with water as follows reaction :

Na2CO3 + 5CaO + 7SiO2 + H2O Ca4Si6O15(OH)23H2O + Na2SiO3 + CaCO3 . (8)

and resulted last compound e.g CaCO3 would react back to create gyrolite (hydrated Calcium aluminate cement)
reaction are

4CaO + 6 SiO2 + CaCO3 Ca5(Si6O18H2)4H2O + H2CO3 .(9)

followed heat releasing / exothermally.

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 Flow ability of Accelerator
Based on the ASTM C-1445-07 terminology of Flow ability of castable is ability to deterioration of castable to
spread out to reach certain square with certain timing and vibration assisted, this experiment ideal flow ability has
defined between 210-260 mm

Flow ability of Sodium aluminate (NaAlO2)

FIGURE 4. Effect of NaAlO2 concentration to Flow ability

Based on data above shown that additional of concentration of sodium aluminate results flow ability ideal
happens on concentration 0.01% , 0.02% and 0.03% with H2O mixing concentration between 5 5,5%, this cases
caused by plentiful amount of water lead to more dissolution of fine powder till have segregation (separately
between aggregate and fine powder) thats way the flow ability become larger. Shown as well more additive of
accelerator trend to have smaller distance of ability caused exothermal reaction effect to faster hydration of cement

Flow ability of Sodium carbonate (Na2CO3)

FIGURE 5. Effect of Na2CO3 concentration to flow ability

Above data shown that flow ability occur on concentration of sodium carbonate 0.01, 0.02, and 0.03% with H2O
mixing 5%. In this case are similar to NaAlO2, additional of water contributes to flow ability properties of material,
if water added to mixing trend to distance of flow ability become more, more of sodium carbonate concentration
trend to smaller deterioration caused effect of cation Na+ is stronger therefore the releasing of caloric effect to rate
of slumping

090002-6
Effect of additional Sodium Aluminate (NaAlO2) and H2O mixing against MOR conducted
to various specimen after dried 110 oC and fired at 900 oC and 1450 oC
Cited from terminology ASTM C-133 the modulus of rupture is the maximum transverse breaking stress applied
that a material can withstand before fracture. The property gives an indication of the bond strength of the refractory
that results from its chemistry and mineralogy after production.

The MOR Properties of Sodium aluminate (NaAlO2) at 110 oC

FIGURE 6. Effect of NaAlO2 concentration for MOR at 110 oC

Based on above data indicates additional concentration of sodium aluminate and H2O mixing with various kind
of concentration shown strength of MOR value are on over allowance (minimum 100 kgf/cm2) prove that dried
specimen of castable at 110 oC can withstand perpendicular force till 2 times of allowance load. Cited from the
journal [16] that more additional of sodium aluminate have trend to more strength caused by increasing of hydration
cement.

The MOR Properties of Sodium aluminate (NaAlO2) at 900 oC

FIGURE 7. Effect NaAlO2 concentration for MOR at 900 oC

Other side, conducted test on specimen of castabel fired at 900 oC shown the strength are more than allowance of
IPs requirement (min. 110 Kgf/cm2) means at condition 900 oC castable can withstand the strength till 2 times
allowance load. Cited from the journal [17] in this phase occur decomposition of Ca(OH)2 , CaCO3, Ca2Al(OH)6OH-
.12H2O, impact to smaller porosity.

090002-7
 The MOR Properties of Sodium aluminate (NaAlO2) at 1450 oC

FIGURE 8. Effect NaAlO2 concentration for MOR at 1450 oC

The data for the specimen after fired at 1450 oC shown more additional of concentration of sodium aluminate
impact to more the strength compared to allowance of IPs requirement (min. 150 Kgf/cm2), it means the resistance
of fracture can stand till concentration of sodium aluminate 0.04% but H 2O mixing till 5.5% will occur segregation
hence the strength become decreased.

Effect of additional Sodium Carbonate (Na2CO3) and H2O mixing against MOR conducted
to various specimen after dried 110 oC and fired at 900 oC and 1450 oC

The MOR Properties Sodium Carbonate (Na2CO3) at 110 oC

FIGURE 9. Effect of Na2CO3 concentration for MOR at 110 oC

As above data shown that specimen after dried at 110 oC can withstand till over allowance of IPs requirement
(min. 100 Kgf/cm2), indicates that additional various of concentration sodium carbonate and water will go up the
strength, but any anomaly if have more water trend to decreasing of strength caused [17] creates more porosity and
segregation will occur on.

090002-8
 The MOR Properties Sodium Carbonate (Na2CO3) at 900 oC

FIGURE 10. Effect of Na2CO3 for MOR at 900 oC

The data shown that additional of concentration sodium carbonate till have 0.04% and additional of H2O mixing
till 6,5% indicates the strength are more than IPs requirement (min. 110 kgf/cm2) but trend found if more water
effect to the strength become down caused segregation process is ongoing.

The MOR Properties Sodium Carbonate (Na2CO3) at 1450 oC

FIGURE 11. Effect of Na2CO3 concentration for MOR at 1450 oC

For the data on specimen after fired 1450 oC shown increasing concentration of sodium carbonate will go down
collaborates with increasing H2O mixing, ideal performance would be achieved (min. 150 kgf/cm2) on concentration
H2O mixing 5% and sodium carbonate between 0.01 till 0.04%, according to cited journal [17] creating of porous
have more caused additional H2O mixing went up and increasing additional concentration Na2CO3 will effect to
speed up hydration process of calcium aluminate cement.

090002-9
 Effect of additional Sodium Aluminate (NaAlO2) and H2O mixing against CCS conducted
to various specimen after dried 110 oC and fired at 900 oC and 1450 oC
According to terminology ASTM C-133 definition of Cold crushing strength or compression strength is
maximum load per square of specimen will be received into material refractory, this properties are important since
the strength is corresponded to impact resistance. Good refractories on CCS will have good against load of impact
from the environment.

The CCS Properties of Sodium Aluminate (NaAlO2) after dried 110 oC

FIGURE 12. Effect of NaAlO2 concentration for CCS at 110 oC

Above data says that the strength on specimen after dried 110 oC shown increasing of additional NaAlO2 with
various additional H2O mixing comply to IPs allowance requirement (minimum 350 kgf/cm2), in this case
increasing additional concentration of sodium aluminate have trend to high strength otherwise increasing H2O
mixing have trend to go down caused any creating porosity will effect to weakness of strength.

The CCS Properties of Sodium Aluminate (NaAlO2) after fired 900 oC

FIGURE 13. Effect of NaAlO2 concentration for CCS at 900 oC

As shown the strength of specimen after fired at 900 oC, increasing additional of NaAlO2 with various H2O mixing
the results are in IPs requirement (minimum 350 kgf/cm2), this case indicates that increasing additional
concentration of NaAlO2 have trend to higher strength otherwise increasing concentration of H 2O mixing have
trends to low strength due to higher creating porosity would effect to weak of strength .

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 The CCS Properties of Sodium Aluminate (NaAlO2) after fired 1450 oC

FIGURE 14. Effect of NaAlO2 concentration for CCS at 1450 oC

As above shown the data indicates behavior of specimen after fired at 1450 oC, increasing concentration of
NaAlO2 with various H2O mixing revealed that strength are in IPs requirement (minimum 700 kgf/cm2), this result
conclude that increasing concentration of H2O mixing have trend to lower the strength due to creating porosity
would effect to lower the strength.

The CCS Properties of Sodium Carbonate (Na2CO3) after dried at 110 oC

FIGURE 15. Effect of Na2CO3 concentration for CCS at 110 oC

Based on above data indicates that specimen after dried at 110 oC with the increasing additional of Na2CO3
collaborate to various additional H2O mixing results the strength are in IPs requirement (minimum 350 kgf/cm2),
this result reveal that additional concentration of Na2CO3 would be higher otherwise increasing H2O mixing have
trend become lower. This matter caused any creating of porosity impact to lower of the strength.

090002-11
 The CCS Properties of Sodium Carbonate (Na2CO3) after fired at 900 oC

FIGURE 16. Effect of Na2CO3 for CCS at 900 oC

Based on above data shown that specimen after fired at 900 oC, increasing additional concentration of Na2CO3
with various H2O mixing are in IPs requirement (minimum 350 kgf/cm2), it conclude that increasing concentration
of Na2CO3 will lead to higher strength otherwise increasing additional of H2O mixing have trend to lower strength
due to porosity has been created thus the strength become lower.

The CCS Properties of Sodium Carbonate (Na2CO3) after fired at 1450 oC

FIGURE 17. Effect of Na2CO3 for CCS at 1450 oC

Based on above data shown increasing additional concentration of Na2CO3 with various additional of H2O are in
IPs requirement (minimum 700 kgf/cm2), it conclude that increasing additional of Na2CO3 would lead to higher
strength otherwise increasing additional of H2O mixing have trend to lower the strength caused creating porosity
would effect to decreasing the strength.

090002-12
 CONCLUSION AND SUGGESTION

Conclusion
1. Setting time measurement : Na2CO3 have value on concentration 0.03% and 0.04% with H 2O mixing 5-6%
comply to IPs requirement (60 120 minutes)
2. Flow ability measurement : got trend to sodium carbonate with concentration 0.01, 0.02, and 0.03% with
H2O mixing 5% comply to IPs requirement (210-260 mm)
3. MOR at 110 oC measurement : additional various of concentration sodium carbonate and various of water
have behavior close to existing IPs material accelerator thus comply to IPs requirement (min.100 Kg/cm2)
4. MOR at 900 oC measurement : various additional of concentration sodium carbonate between 0.01 till
0.04% and additional of H2O mixing till 6,5% have comply to IPs requirement (min. 110 kgf/cm 2)
5. MOR at 1450 oC measurement : The performance of various sodium carbonate between 0.01% - 0.04%
have comply to IPs requirement (min. 150 kgf/cm2)
6. CCS at 100 oC measurement : increasing additional of Na2CO3 collaborate to various additional H2O mixing
results the strength are in IPs requirement (minimum 350 kgf/cm2),
7. CCS at 900 oC measurement : increasing additional concentration of Na 2CO3 with various H2O mixing are
in IPs requirement (minimum 350 kgf/cm2),
8. CCS at 1450 oC measurement : Based on above data shown increasing additional concentration of Na2CO3
with various additional of H2O are in IPs requirement (minimum 700 kgf/cm2),
9. Accelerator can be a candidate as accelerator to substitute Existing accelerator sodium aluminate.

Suggestion
Based on the result would be as our recommendation to make step further to improve characterization product
of refractory as follows :
a. It might be interested if any research involve to effect accelerator in other kinds class of refractory such as
conventional, ultra low cement , and non cement castable.
b.Beside accelerator, It would have any advantage if retarder also as a chosen for further subject apply in all
kind of castable

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