N.S.Bazhirov, M.S.Dauletyarov, А.S.Kolesnikov, К.N.Bazhirova, Zh..Kupyasharov N.Nurzhigituli, S.Мamitbaeva, М.Кalibaeva, G.Еsenbaeva

M.Auezov South Kazakhstan State University, Shymkent city

INTEGRATED USE OF NATURAL AND ARTIFICIAL MINERAL RAW MATERIALS IN THE PRODUCTION OF COMPOSITE BINDING MATERIALS

One of the most important tasks of the modern sector of the building industry is the development and introduction of resource-saving technologies, providing comprehensive utilization of industrial waste and natural materials that allow efficient use of raw materials and energy resources.

Portland cement and its variants are the final product of the cement industry, at the same time there are the main starting components in the production of concrete defense and reinforced concrete, determining feasibility and performance of the products largely. Among the most promising ways of improvement cement production’s efficiency significantly changing without its technology is the allotment to its composition with various mineral supplements, which influences actively in the process of cement hydration on the formation of structure and properties of cement stone. In the capacity of these supplements are economically feasible to use large-tonnage wastes which includes granulated metals and phosphate slag, fly ash thermal power plants and natural aluminum silicate materials

Despite the large number of scientific studies on the use of active mineral additives for cements, their practical input in Portland cement is 30-35% of the weight from the clinker but fly ash thermal power plants practically are not used as a mineral additive in cement production. Item identification of the additives is limited. Therefore, the range of supplement’s extension, unused types of aluminum silicate raw materials represents great practical interest.

The cement industry is one sector of the construction, where natural and man-made aluminum silicates (diatomite, tripoli powder, tuffs, glinite, burnt clay, metallurgic and phosphorus slag, fly ash TPP) can be used on a large scale and with high efficiency. Nowadays, the resources of these minerals are significantly exceed their usage. Therefore, the integrated use of natural and artificial aluminum silicate is one of the most affordable ways of improvement of cement production’s efficiency. The importance of the usage TPP is in terms of environmental enhancement as well as waste disposal costs, land restoration and maintenance of stockpiles account for about 10% from the cost of production.

The natural zeolite rock (DSP)takes a specific place among known active mineral additives for cements, which is characterized by a very wide range of chemical and mineralogical composition and with different properties. The widespread usage of zeolite-containing rocks, and the organization composite (mixed) cements production will provide significant savings of expensive cement clinker.

In connection with the discovery of large deposits of zeolite-containing rocks in the Republic of Kazakhstan there was a need for systematic research to study their impact on the basic technological, construction and performance properties of composite cements and concretes on their basis in relation to the conditions of the construction industry.

The aim of this work is development of the effective formulations of composite cements which based on Portland cement clinker, artificial and natural origin of aluminum silicates, the study of the characteristics of their interaction with the hydration products of Portland cement clinker.

The solution of resource economy problem will allow involving cement tonnage artificial wastes - TPP ash (hardly used at the moment) and natural aluminum silicate materials - zeolite-containing rocks (DSPs) in the production, adue to the combined usage which expands the base of raw material on construction industry, and improves the environmental situation as well as reduced costs of the construction.

 To achieve this goal the following objectives:

- To learn the basic characteristics, properties and nature of the mechanism of the pozzolatic activity of fly ash and zeolite rocks which depends on the activation;

- To optimize formulations of composite cements, to identify the main technological parameters of a composite cement;

Applying analytical review showed a significant number of publications devoted to the sharing of granulated slag and other mineral supplements in the production of blended cements. Recently, it is given considerable attention that component of blended cements are used as a new kind of active mineral supplements- natural zeolite rocks [2].

Zeolites have similar composition and properties of minerals, which includes aqueous aluminum silicates of calcium and sodium from the skeleton subclass of silicates. The crystalline structure of zeolites is formed by tetrahedral groups of SiO2 and ALO4,which united by common vertices in three-dimensional framework, permeated cavities and channels. The water molecules and metal cations are existed in the end. Grate of (Si, Al) O4 tetrahedrons has very large volumes of cavities and channels, H2O molecule bound weakly, so zeolites easily give their crystallization water and there are capable to the reversible cation exchange - without destruction of the crystal lattice.

Minerals are distinguished according to the composition:

   - Zeolite contains more than 50% of zeolite minerals;

   - Zeolite - from 15 to 50% of zeolite minerals;

   - Zeolitic- about 15% of zeolite minerals.

 In this article is used zeolite-containing rocks in Shanhay field (Sarah-Ozeksky district of Almaty region), fly ash thermal power plants, clinker "ShymkentCement". The chemical composition of the starting materials is shown in Table 1. As a result of X-ray diffraction it can be seen that the basic mineral is zeolite (d = 3.97; 3.22, 2.79 A), moreover, they includes foreign substance of clay minerals.

It was carried out complex mechanical and physico-chemical studies in order To study the properties of composite cements . The findings of Cement by co-grinding the components to subtlety, which characterized by 10% residue on the sieve number 008.

Table 1 – Chemical composition of raw materials

Name of the material	Chemical composition, %
	SiO2	Al2O3	Fe2O3	CaO	MgO	SO3	R2O	P.p.p.
Portland cement clinker	21,31	4,86	4,52	65,29	1,99	0,41	0,41	-
Zeolite-containing rocks	67,78	12,82	1,43	2,32	0,64	-	5,87	8,62
Fly ash TPP	45,71	20,83	12,32	10,78	5,46	2,36	-	8,23

The results of the standard physic- mechanical tests have shown that the combined usage of complex mineral ash additives (20%) and zeolite rocks (10) vintage strength of composite cements 5-7 MPa increases the strength of cements with a separate mineral supplement. The growth of zeolite rock dosage leads to rise and degradation of cement strength due to the ability of zeolites in order to adsorb water by means a separate additive or as part of the mixed additives

The effectiveness of active mineral additives in composite cements production determine according to their chemical and mineralogical composition, nature and size of the specific surface area, the ability to enter into chemical interaction with the active Portland cement clinker and with calcium hydroxide. The active mineral additives test is concluded the definition of their activity, which is defined as the ability to react with calcium hydroxide. This activity is characterized by the number of binding calcium hydroxide and the speed which this process proceeds.

The test results set (Table 2) that the ash on the parameters of activity can not be attributed as an active mineral additives for cements. The studies have also shown that zeolite containing breed is highly active mineral additive, as well as the number of absorbed calcium hydroxide from the solution of the lime increases more than 3 times the standard requirements.

These findings are in agreement with the physico-chemical studies results of the reaction products of pozzolanic additives with Ca (OH) 2 in the lime mortar. In comparison of diffraction patterns can be judged a weak chemical interaction of ash with Ca (OH)2, that evidenced by a slight change in the diffraction reflections of ash.

Table 2 – Results of pozzolic additives activity’s tests

№ p.p	Name of the figure	Units of measurement	Requirements of the standards	The types of pozzolatic supplements
				Zeolite-containing rocks	Fly ash TPP-2
1	The end of the normal setting density test on the base of pozzolatic supplements, hydrated lime and gypsum	24 hours	Not less 7	1	1
2	Water resistance of model	24 hours	Not less 3	10*	10*
3	The quantity of Cao, which is absorbed pozzolic additive by saturated lime solution	Mg/g	50	169,9	37,8
* test discontinued

There has a significant decrease of the diffraction intensity of the peaks which associated with the occurrence of chemical interaction due to the diffraction pattern of products reaction of the zeolite rock with Ca (OH) 2 in a mortar that confirms the results of the research activity of lime by absorption method (Table 2) and physical and mechanical tests. Reaction products pozzolic additives with lime are highly disperse gel state and this explains the absence of reflection diffraction Hydro silicates except peak with d = 3,04 A.

Thus,results of the research shows the feasibility and effectiveness of the integrated usage of TPP ash and zeolite rocks in the production of composite binding.

Bibliography

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