METHOD AND APPARATUS FOR HIGH-THROUGHPUT PREPARATION OF A CEMENT-BASED MATERIAL
20250010515 ยท 2025-01-09
Inventors
- Xuehong REN (Beijing, CN)
- Jiayuan YE (Beijing, CN)
- Xiao ZHI (Beijing, CN)
- Hongtao Zhang (Beijing, CN)
- Di SHI (Beijing, CN)
- Wensheng ZHANG (Beijing, CN)
- Zhaijun WEN (Beijing, CN)
Cpc classification
B28C7/0007
PERFORMING OPERATIONS; TRANSPORTING
B28C9/002
PERFORMING OPERATIONS; TRANSPORTING
International classification
B28C7/00
PERFORMING OPERATIONS; TRANSPORTING
B28C9/00
PERFORMING OPERATIONS; TRANSPORTING
Abstract
A method and an apparatus for high-throughput preparation of a cement-based material are released and belong to the technical field of cement production. According to the technical solution of the present application, a single-mine, a single-phase or a unit components maintaining specific hydration hardening characteristics are used as structural units, and the method comprises the following steps that (1) the structural units are placed in storage tubes X1, X2, X3 . . . Xn respectively; (2) the materials in the storage pipes are put according to the composition design proportion of the cement-based material, and Y1, Y2, Y3 . . . Ym of mixed materials are prepared; (3) fully and uniformly mixing the Y1, Y2, Y3 . . . Ym of mixed materials through a uniform mixing device; and 4) respectively filling the Y1, Y2, Y3 . . . Ym of uniformly mixed materials into storage tanks Z1, Z2, Z3 . . . Zm to prepare m groups of cement-based material samples. The method and device are easy to operate and high in applicability, and the material research and development manpower and resource cost can be greatly reduced.
Claims
1. A method for high-throughput preparation of a cement-based material, wherein single-mine, single-phase, or a unit component maintaining specific hydration and hardening characteristics are used as a structural unit, the method comprises following steps: 1) placing the structural units in storage tubes X1, X2, X3 . . . Xn respectively; 2) putting the materials in each of the storage tubes according to the design proportion of the cement-based materials, and then preparing Y1, Y2, Y3 . . . Ym of mixed materials respectively; 3) fully and uniformly mixing the Y1, Y2, Y3 . . . Ym of the mixed materials through a uniform mixing device respectively; and 4) filling the Y1, Y2, Y3 . . . Ym of the uniformly mixed materials into storage tanks Z1, Z2, Z3 . . . Zm respectively to prepare m groups of cement-based material samples.
2. The method for high-throughput preparation of a cement-based material according to claim 1, characterized in that the structural unit is a single-mine of cement clinker which comprises alite (a solid solution of tricalcium silicate C.sub.3S), belite (a solid solution of dicalcium silicate C.sub.2S), tricalcium aluminate (C.sub.3A), calcium aluminate (CA), calcium dialuminate (CA.sub.2), mayenite (C.sub.12A.sub.7), dicalcium ferrite (C.sub.2F), tetracalcium aluminoferrite (C.sub.4AF), hexacalcium aluminodiferrite (C.sub.6AF.sub.2), hexacalcium dialuminoferrite (C.sub.6A.sub.2F), ye'elimite (C.sub.4A.sub.3$), calcium fluoaluminate (C.sub.11A.sub.7.Math.CaF.sub.2), calcium chloroaluminate (C.sub.11A.sub.7.Math.CaCl.sub.2), barium calcium sulphoaluminate (C.sub.3A.sub.3$.Math.BaO), strontium calcium aluminate (C.sub.3A.sub.3$.Math.SrO), ternesite (C.sub.5S.sub.2$), tricalcium phosphate (C.sub.3P), tetracalcium phosphate (C.sub.4P), calcium phosphoaluminate (C.sub.8A.sub.4P), gehlenite (C.sub.2AS), periclase (MgO), free gypsum (f-CaSO.sub.4), and free calcium oxide (f-CaO).
3. The method for high-throughput preparation of a cement-based material according to claim 2, wherein the structural unit further comprises a cement component unit including gypsum, slag, volcanic ash, fly ash, silica fume, and limestone.
4. The method for high-throughput preparation of a cement-based material according to claim 2, wherein the structural unit further comprises a concrete structural unit including sand, stone, and concrete admixtures, as well as supplementary cementitious materials such as phosphorus slag, steel slag and so on.
5. The method for high-throughput preparation of a cement-based material according to claim 2, wherein the structural unit further comprises a single-mine of cement clinker, cement components, supplementary cementitious materials, and sand/gravel materials with different fineness and particle gradation.
6. The method for high-throughput preparation of a cement-based material according to claim 1, wherein performing composition structure and performance tests on the m groups of cement-based material samples respectively for screening specific or excellent performance cement-based materials and producing data, the composition structure and performance tests, including chemical composition, mineral composition, density, fineness, hydration heat evolution, setting time, strength, composition and structure of hydration products, volume soundness, impermeability, freeze-thaw resistance, workability, sulfate resistant, chloride resistant, and wear resistance.
7. An apparatus for realizing the method for high-throughput preparation of a cement-based material according to claim 1, comprising: n of primary storage silos for accommodating raw materials of cement-based material composition unit, wherein flow valves are provided at bottom ends of each of the primary storage silos, and m of secondary pre-loaded tanks for receiving materials from any two or more of n of the primary storage silos and mixing the materials uniformly; wherein n of the primary storage silos are arranged on a primary storage silo delivery device in a rotating or linear sliding manner, and m of the secondary pre-loaded tanks are arranged on a secondary pre-loaded tank delivery device in a rotating or linear sliding manner; a feeding control device is provided between the primary storage silo delivery device and the secondary pre-loaded tank delivery device.
8. The apparatus for realizing the method for high-throughput preparation of a cement-based material according to claim 7, further comprising m of terminal storage tanks for receiving target material discharged from the secondary pre-loaded tanks.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
[0026]
[0027]
[0028]
[0029]
[0030]
[0031]
DETAILED DESCRIPTION
[0032] The present application uses single-mine, single-phase, or unit components maintaining specific hydration and hardening characteristics as structural units, achieving rapid batch production of cement-based materials through high-throughput testing apparatus. This method is fast, efficient, low-carbon, environmentally friendly, and economical.
[0033] The present application comprises a method for high-throughput preparation of a cement-based material, which uses a single-ore, a single-phase, or unit components maintaining specific hydration and hardening characteristics as structural units.
[0034] The method is carried out as following steps: [0035] 1) placing the structural units in storage tubes X1, X2, X3 . . . Xn respectively; [0036] 2) putting the materials in each of the storage tubes according to the design proportion of the cement-based materials, and then preparing Y1, Y2, Y3 . . . Ym of mixed materials respectively; [0037] 3) fully and uniformly mixing the Y1, Y2, Y3 . . . Ym of the mixed materials through a uniform mixing device respectively; [0038] 4) filling the Y1, Y2, Y3 . . . Ym of the uniformly mixed materials into storage tanks Z1, Z2, Z3 . . . Zm respectively to prepare m groups of cement-based material samples.
[0039] Further, the structural unit is a single-mine of cement clinker which comprises alite (a solid solution of tricalcium silicate C.sub.3S), belite (a solid solution of dicalcium silicate C.sub.2S), tricalcium aluminate (C.sub.3A), calcium aluminate (CA), calcium dialuminate (CA.sub.2), mayenite (C.sub.12A.sub.7), dicalcium ferrite (C.sub.2F), tetracalcium aluminoferrite (C.sub.4AF), hexacalcium aluminodiferrite (C.sub.6AF.sub.2), hexacalcium dialuminoferrite (C.sub.6A.sub.2F), ye'elimite (C.sub.4A.sub.3$), calcium fluoaluminate (C.sub.11A.sub.7.Math.CaF.sub.2), calcium chloroaluminate (C.sub.11A.sub.7.Math.CaCl.sub.2)), barium calcium sulphoaluminate (C.sub.3A.sub.3$.Math.BaO), strontium calcium aluminate (C.sub.3A.sub.3$.Math.SrO), ternesite (C.sub.5S.sub.2$), tricalcium phosphate (C.sub.3P), tetracalcium phosphate (C.sub.4P), calcium phosphoaluminate (C.sub.8A.sub.4P), gehlenite (C.sub.2AS), periclase (MgO), free gypsum (f-CaSO.sub.4), and free calcium oxide (f-CaO).
[0040] Under the concept of the present application, a person skilled in this field can use the characteristic of various mineralogical phases, listed in the following table as the structural units of the present application. Of course, it cannot be ruled out that in the future, a person skilled in this field can make corresponding selections or discards when new discoveries are discovered regarding the properties of various mineral types in the table with technological progress in this field.
TABLE-US-00001 Cement clinker minerals and their properties Mineral types Properties Tricalcium silicate (C.sub.3S) Hydration reaction fast in the early stage, the large amount of hydration heat release and the main contributor to Portland cement's strength in the early and middle stages. Dicalcium silicate (C.sub.2S) Hydration reaction slow, low strength in the early stages, sustainable growth of strength in the later stage and the main contributors to Portland cement's strength in the later stage Tricalcium aluminate(C.sub.3A) Hydration and hardening fastly, fully hydratable in 3 days, but low strength and losing strength in the later stage, the large amount of dry shrinkage Calcium aluminate (CA) Normal coagulation, hydration and hardening rapid, the large amount hydration heat release, and the main contributors to the strength of aluminate cement Calcium dialuminate (CA.sub.2) Hydration reaction slow, low strength in the early stage, and s sustainable growth of strength in the later stage Monocalcium Chemically inert mineral, no hydration activity, but high hexaaluminate (CA.sub.6) heat resistance Mayenite (C.sub.12A.sub.7) Fast coagulation, hydration and hardening extremely fast, but the strength not as high as that of CA Dicalcium ferrite (C.sub.2F) Weak hydration activity Tetracalcium aluminoferrite Hydration reaction fast, the hydration heat release only lower (C.sub.4AF) than that of C.sub.3A, and high strength in both early and later stages Hexacalcium Hydration heat release rate lower than that of C.sub.4AF, low aluminodiferrite (C.sub.6AF.sub.2) strength in the early stage but high strength in the later stage Hexacalcium higher strength in the early stage but lower strength in the dialuminoferrite (C.sub.6A.sub.2F) later stage than that of C.sub.4AF Ye'elimite (C.sub.4A.sub.3$) High hydration activity, early strength and expansion, the main contributor to the strength of sulphoaluminate cement in the early stage Calcium fluoaluminate Hydration and hardening fast, and fast growth of strength in (C.sub.11A.sub.7CaF.sub.2) the early stage, but low strength overall Calcium chloroaluminate Hydration performance similar to that of calcium (C.sub.11A.sub.7CaCl.sub.2) fluoaluminate, hydration and hardening fast Barium calcium Hydration and hardening fast, the strength being significantly sulphoaluminate higher than that of Ye'elimite (C.sub.3A.sub.3$BaO) Strontium calcium Fast hydration and hardening, the strength being also higher aluminate (C.sub.3A.sub.3$SrO) than that of Ye'elimite Ternesite (C.sub.5S.sub.2$) Good potential hydration activity higher than that of dicalcium silicate and hydration fully in the presence of aluminum sources existing Tricalcium phosphate (C.sub.3P) Hydration Slow at room temperature Tetracalcium phosphate Mainly used as bone cement (C.sub.4P) Calcium phosphoaluminate Mainly providing strength in the middle and late stages (C.sub.8A.sub.4P) Perovskite (CT) Unique electromagnetic properties such as isomerization and electrocatalysis Gehlenite (C.sub.2AS) Very low hydration activity Periclase (MgO) Not conducive to the soundness of Portland cement Free gypsum (f-CaSO.sub.4) Guaranteeing the formation of ettringite in sulphoaluminate cement Free calcium oxide (f-CaO) Affecting the soundness of cement
[0041] Further, the structural unit further comprises the cement component unit, which is gypsum, slag, volcanic ash, fly ash, silica fume, and limestone.
[0042] Further, the structural unit further comprises the concrete structural unit that includes sand, stone, and concrete admixtures, as well as supplementary cementitious material such as steel slag and so on.
[0043] The composition, structural and performance tests on the m groups of cement-based material samples are performed respectively for screening specific or excellent performance cement-based materials including chemical composition, mineral composition, density, fineness, hydration heat evolution, setting time, strength, composition and structure of hydration products, volume soundness, impermeability, freeze-thaw resistance, workability, sulfate resistant, chloride resistant, and wear resistance.
[0044] As shown in
[0047] A feeding control device is provided between the primary storage silo delivery device and the secondary pre-loaded tank delivery device.
[0048] The apparatus further comprises m of terminal storage tanks for receiving target material discharged from the secondary pre-loaded tanks.
[0049] The apparatus for realizing the method for high-throughput preparation of a cement-based material in the present application uses single-mine, single-phase, or unit components maintaining specific hydration and hardening characteristics as structural units, and the intrinsic properties of the materials can be effectively controlled. After storing them on a disk-shaped or linear movable device, the unit materials can be flexibly configured and mixed according to design requirements. Further, it can solve the problem of high-throughput experimental preparation of complex multielement cement-based materials, realize screening and optimization of material composition and performance rapidly, and greatly shorten the R&D cycle and save research and development costs.
[0050] In order to explain the present application in detail and better understand the technical solution and advantages of the present application, the following will provide a detailed description of the present application in combination with embodiments and drawings, but the present application is not limited to the following embodiments.
Embodiment 1
[0051] The target of embodiment 1 is to prepare a Portland cement clinker with the 30020 m.sup.2/kg surface area. The design proportion of the cement clinker to be prepared is shown in Table 1. Four cement clinker single-mine, i.e., Alite (solid solution of tricalcium silicate), Belite (solid solution of dicalcium silicate), tricalcium aluminate, and tetracalcium aluminoferrite, are calcined and prepared respectively according to the design of the target cement clinker. Four types of clinker are finely ground into powder with the 30020m/kg surface area. The above-mentioned single-mine raw materials are placed in the corresponding unit material storage tubes X1, X2, X3, and X4 of the high-throughput test apparatus (see
TABLE-US-00002 TABLE 1 Composition of designed clinker (wt %) Tricalcium Tetracalcium No. Alite Belite aluminate aluminoferrite M1 65 20 3 12 M2 58 25 10 7 M3 65 18 5 12
[0052] The mineral composition of the M1, M2, and M3 clinkers prepared above is measured by XRD (X-ray diffraction), and the XRD results are quantitatively analyzed by the Rietveld method. The results show that the refined fitting Rwp factor for different samples is far below 15, with an average of between 7 and 8. The refined fitting effect is shown in
TABLE-US-00003 TABLE 2 Composition of determined clinker (wt %) Tricalcium Tetracalcium No. Alite Belite aluminate aluminoferrite M1 65.74 18.62 3.68 11.05 M2 58.43 24.79 9.88 6.36 M3 65.54 20.54 4.67 11.67
[0053] The hydration heat release test was conducted on three groups of cement clinker samples prepared, and the results are shown in
Embodiment 2
[0054] The target of embodiment 2 is to prepare a new type of low-carbon cement clinker. The system of the cement clinker to be prepared is a ye'elimite-ternesite cement clinker system, and the design proportion is shown in Table 3. Three types of cement clinker single-mines, namely ye'elimite, ternesite and dicalcium silicate, are prepared by calcination respectively according to the composition of cement clinker. Wherein, ternesite is a newly discovered low-carbon clinker mineral with hydration activity. Three types of clinker phases are ground into powder with a specific surface area of about 30020 m.sup.2/kg. The above-mentioned single-mine raw materials are placed in the corresponding unit material storage tubes X1, X2, and X3 of the high-throughput test apparatus (see
TABLE-US-00004 TABLE 3 Composition of designed clinker (mass percentage/%) Dicalcium No. Ye'elimitee Ternesite silicate S1 30 50 20 S2 30 30 40 S3 30 10 60
[0055] Three groups of cement clinker S1, S2, and S3 are mixed at the 0.4 w/c (a ratio of water and cement). The mixed slurry is poured into a mold with 30 mm30 mm30 mm, placed under standard constant temperature (201 C.) and humidity (951%) for 7 days. After hardening, the samples are demoulded and cured in water for 28, 56, and 90 days, respectively. The compressive strengths of them are measured, and the hydration synergism of three clinker minerals in a new system is analyzed.
Embodiment 3
[0056] The target of embodiment 3 is to prepare cement, and the composition design of the target cement to be prepared is shown in Table 4. According to the clinker components involved in cement, four single-mines raw materials of clinker, namely alite (solid solution of tricalcium silicate), belite (solid solution of dicalcium silicate), tricalcium aluminate, and tetracalcium aluminoferrite, are prepared by calcination respectively. Raw materials for the structural unit of three types of cement from industrial sources, namely gypsum, slag, fly ash and limestone, are collected and prepared. The eight raw materials shall be processed and controlled to a certain particle size or fineness according to the fineness requirements of the target material, wherein the mineral surface area of the cement clinker is 30020 m.sup.2/kg. Slag is processed into two particle size gradations respectively: slag 1 # has a specific surface area of 45020 m.sup.2/kg, and slag 2 # has a specific surface area of 50020 m.sup.2/kg. The specific surface area of fly ash is 45020 m.sup.2/kg, and the specific surface area of limestone powder is 30020 m.sup.2/kg. The above-mentioned unit raw materials are placed in the corresponding unit material storage tanks X1, X2, X3, X4, X5, X6, X7, X8, and X9 of the high-throughput test device (see
TABLE-US-00005 TABLE 4 Composition of cement designed in embodiment 3 (mass percentage/%) Tricalcium Tetracalcium Slag Slag fly No. Alite Belite aluminate aluminoferrite Gypsum 1# 2# ash Limestone W1 60 19 3 11 2 5 0 0 W2 50 21 6 6 2 10 5 0 0 W3 60 19 3 11 2 0 5 0 W4 50 21 6 6 2 0 15 0 W5 50 21 8 6 5 5 5 0 W6 50 21 6 6 2 5 5 5 W7 50 21 8 6 5 0 0 10 W8 30 21 8 6 2 5 5 3
TABLE-US-00006 TABLE 5 Designed Composition of cement of control samples (mass percentage/%) Tricalcium Tetracalcium fly No. Alite Belite aluminate aluminoferrite Gypsum Slag ash Limestone Control 60 19 3 11 2 5 0 0 sample W1x Control 50 21 6 6 2 15 0 0 sample W2x
[0057] According to GB/T12960 Quantitative Determination of Constituents of Cement, the contents of slag and fly ash in the above ten groups of cement prepared are measured and analyzed respectively. In this method, the selected dissolution method is used for samples containing fly ash, and the cement sample is selectively dissolved with the nitric acid solution, in which the component of the fly ash is insoluble while the other components are dissolved. The selective dissolution method is adopted for samples containing slag. After the cement sample is selectively dissolved by a solution containing EDTA at pH=11.60, the clinker minerals, gypsum, and carbonates are dissolved, while the other components are essentially insoluble. The content of limestone depends on the content of carbon dioxide. The carbon dioxide is determined by the alkali asbestos absorption weighing method. The content of each component in the cement is calculated from the results of selective dissolution, the content of carbon dioxide and sulphate sulfur trioxide in the cement. The determination results of gypsum, slag, fly ash, and limestone content in 10 groups of cement samples are shown in Table 6. It can be seen from the table that the determination results of gypsum, slag, fly ash and limestone content in 8 groups of cement samples prepared according to the method of the present application are tallying with the designed composition of cement. This indicates that 8 groups of cement samples with set composition have been successfully prepared according to the method of the present application. However, the comparison of W1x and W2x prepared by traditional test methods has a relatively large error in slag content compared to the actual mixing amount. This is mainly due to the traditional process, in which clinker is prepared by calcining first and then adding admixtures to prepare cement adopted by the control sample. This complex sample preparation process o leads to certain sample composition design errors. When compared to the method of the present application, the clinker prepared by calcination not only has the component solid solution and vitreous phase but also has problems of insufficient reaction kinetics and non-ideal chemical equilibrium state, resulting in the presence of unreacted phases or components such as free calcium oxide. Among them, the dissolution characteristics of the vitreous phase are similar to those of slag. The presence of the vitreous phase cannot be effectively distinguished when using selectively dissolved method. It can be seen that the sample prepared by the present application is closer to the actual theoretical composition of the sample, which is conducive to in-depth revealing the changes in the composition and structure of the sample.
TABLE-US-00007 TABLE 6 Composition of determined cement (mass percentage/%) fly No. Gypsum Error Slag Error ash Error Limestone Error W1 2.1 0.1 5.2 0.2 0.0 0.0 0.00 0.0 W2 2.0 0.0 14.9 0.1 0.0 0.0 0.00 0.0 W3 1.9 0.1 0.0 0.0 4.7 0.3 0.00 0.0 W4 2.1 0.1 0.0 0.0 14.5 0.5 0.00 0.0 W5 4.9 0.1 4.7 0.3 4.8 0.2 0.00 0.0 W6 1.9 0.1 4.6 0.4 5.1 0.1 5.02 0.02 W7 5.1 0.1 0.0 0.0 0.0 0.0 10.01 0.01 W8 2.2 0.2 4.9 0.1 4.8 0.2 3.05 0.05 Control sample 0.0 0.0 5.7 0.7 0.0 0.0 0.00 0.0 W1x Control 0.0 0.0 15.8 0.8 0.0 0.0 0.0 0.0 sample W2x
[0058] Ten groups of cement samples are moulded and prepared in accordance with GB/T17671 Test method for strength of hydraulic cement mortar, and their strength properties at 3 and 28 days are measured. The results are shown in Table 7. It can be seen from the table that different cement samples prepared by the present application method exhibit significant differences in strength properties due to differences in composition and fineness, wherein cement with relatively high alite content or a certain amount of gypsum and slag, especially samples with finer slag fineness, exhibit relatively excellent properties. The W-5 sample has excellent flexural and compressive strength simultaneously. It can be seen that this present application method can be used to quickly prefer and optimize the composition and fineness or gradation of the designed cement. In addition, it is not difficult to see from the comparison that W1x and W2x prepared by the traditional process and the theoretical design possess certain differences in their performance due to the relatively large deviation between the composition of the control samples when compared to the W1 and W2 samples prepared by the method of the present application. As mentioned earlier, this is mainly due to the large difference between the actual composition and theoretical actual composition of the samples prepared by using traditional methods. In traditional sample preparation methods, although the corresponding composition is designed according to the idealization during the calcination process, it is often inevitable to form a vitreous phase, solid solutions of components, unreacted phase components and so on during the actual firing process.
[0059] Obviously, the performance of W1 and W2 samples prepared by the method of the present application is closer to the performance of the theoretically designed sample composition. This indicates that this method can reduce sample preparation errors in complex processes, and using structural unit materials such as single-mine or single-phase as basic elements can directly match and design the mineral phase composition of cement. That is more consistent with the original design intent, conducive to mastering more objective and realistic the changing law in material composition and structure. That is also beneficial to essentially reveal key factors, conditions, and laws that affect material performance, and promote scientific and effective screening of material components and properties with excellent performance. At the same time, the development of various new cement-based materials can be accelerated based on more objective and scientific change laws in material composition and structure.
TABLE-US-00008 TABLE 7 Strength properties of prepared cement samples Flexural Compressive Flexural Compressive strength strength strength strength at 3 days at 3 days at 28 at 28 No. (Mpa) (Mpa) days (Mpa) days (Mpa) W1 6.2 29.8 7.3 51.9 W2 5.3 28.2 6.8 48.7 W3 5.9 28.7 8.3 49.9 W4 5.2 28.2 6.5 49.5 W5 5.8 29.5 8.3 51.4 W6 4.9 26.2 6.3 45.2 W7 5.1 27.1 6.7 47.7 W8 6.1 30.2 8.5 51.5 Control 6.5 30.1 7.8 53.2 sample W1x Control 5.7 28.8 7.1 49.5 sample W2x
[0060] In addition, fineness and gradation have a significant impact on the performance of cement materials and concrete. In the preceding embodiments, the fineness parameters of the corresponding clinker single-mine are recorded, and there are two types of records for slag with different fineness. However, in practical applications, it is necessary to control the fineness of the clinker and slag according to the design requirements, such as grinding the clinker single-mine into a powder with a specific surface area of about 30020 m.sup.2/kg; slag can be designed in different fineness or gradation such as 300 m.sup.2/kg, 500 m.sup.2/kg, 700 m.sup.2/kg, etc. When preparing concrete, a person skilled in this field reasonably configures various gradation fineness settings such as sand and clinker based on the technical content disclosed in the present application.
[0061] The present application is not limited to the above-mentioned embodiments. Based on the technical solution disclosed in the present application, a person skilled in this field can make some substitutions and modifications to some of the technical features without creative labor based on the disclosed technical content. These substitutions and modifications are within the protection scope of the present application.