3rd International Conference on Alternate Fuels and Raw ... Mr Akhilesh...S.No. Properties...

Best Practices in Utilization of Alternate Raw Materials : Utilization of wastes Jarosite and Lead Zinc Slag

3rd International Conference on

Alternate Fuels and Raw Materials in Cement Industry on

March 23-24, 2017

Presented byAkhilesh ShuklaHead – R&DHindustan Zinc Limited1

Hindustan Zinc – Snapshot

2

Hin

du

stan

Zin

c

Hindustan Zinc – A Sustainable Enterprises

3

Defining the Benchmark

4

Safety & Sustainability

5

Portfolio of Tier 1 Assets

6

Strong Track Record of Growth

7

Community Engagement

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Hindustan Zinc – Major Waste Profile

Particular Approx Generation(MT/year)

Locations Current Status

Jarosite 45,000 – 60,000 Debari SLF

Jarofix 4.5 – 5.5 Lac Dariba, Chanderiya SLF

ISF Slag 70,000 – 80,000 Chanderiya Sold

Fuming Slag 0.8 – 1.0 Lac Dariba Partly sold

MCTP Slag 40,000 – 50,000 Debari Yard

Flyash 3.0 Lac Chanderiya, Dariba, Zawar

Sold

Gypsum cake 8,000 – 10,000 Dariba, Chanderiya, Debari

SLF

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* Already being used in PPC.10

Constituents ISF Slag FF Slag Flyash*

SiO2 18-22% 30 - 35% 50 – 60%

Fe2O3 29-36% 30 – 35% 4 – 6%

Al2O3 7-9% 8 – 10% 25 – 30%

CaO 15-19% 16 – 19% <1%

MgO 1.5-2.0% 4 – 7% <1%

ZnO 4-10% 2–2.5% -

PbO 0.5-1.5% - -

SO3 1.3-1.5% <0.1% <0.5%

Carbon 0.5-1% - <1%

Alkali <1% 2 – 3% <2%

LOI - 2.5% 8.8%

IR - ~ 1.34% 85-90%

Constituents Jarosite Jarofix Gypsum

SiO2 4.7 – 5.5% 11.16% 20.74% (silica + IR)

Fe2O3 25 – 34% 25.18% 0.59%

Al2O3 4.0 – 5.5% 6.72% 0.37&

CaO 4.2 – 4.8% 12.78% 26.5%

MgO 0.1 – 0.2% 0.45% 0.33%

ZnO 2 – 2.5% - -

PbO 1.5 – 2.5% - -

SO3 31 – 35% 20.80% 33.26%

Carbon - - -

Alkalki <1% <3% <0.2%

LOI 8 – 10% 27.15% -

IR 5.0 – 11.0% 16.10% -


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Characterization of Major Wastes

ISF Slag– Glass Content : 42%

– Glass Content of Devitrified Slag : 72%

(1350oC, water quenched)

– Bond Grindability Index : 16.79 kwh/short-ton

Blast Furnace Slag– Glass Content : 97%

– Bond Grindability Index : 15.8 kwh/short-ton

Flyash– Lime Reactivity : 6.4 Mpa

– Blaine’s fineness : 406 m2/kg

FF Slag

– Glass Content : 88%

Jarosite– Blaine fineness : >600 m2/kg

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• Cement & Construction Industries by NCBM, Ballabhgarh

Initiatives for ISF Slag Utilization

Properties of concrete prepared from ISF slag

S.No. Properties PSC-Control PSC – Slag OPC-Control OPC – Slag

1Compressive Strength (N/mm2) 25.55 27.20 26.22 27.52

2Flexural Strength (N/mm2)

4.24 4.31 4.35 4.52

3 Carbonation Nil Nil Nil Nil

4Modulus of Elasticity(N/mm2) 2.36x104 2.56 x104 2.42x 104 2.54 x104

5 Drying Shrinkage(%) 0.02 0.019 0.024 0.022

6

Chloride Ion Permeability(Coulombs) 1004 809 2791 1791

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• Cement & Construction Industries by NCBM, Ballabhgarh

Weight Loss of cement mortar cured in different environment

S.No. SampleCuring

EnvironmentLoss on ignition at different ages (%)

14 days 28 days

1. Control – OPC

Normal 5.41 5.71Sulphate 4.27 4.79Chloride 4.59 5.10Alkali 4.08 4.75

2. OPC – Slag


3. Control - PSC


4. PSC – Slag



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• Raw material that can be substituted with ISF slag in cement plant

(Tentative Calculation)

Source100 MT slag can

substitute

Fe2O3 34 MT

CaO 18 MT

SiO2 12.5 MT

Al2O3 7.68 MT

Bauxite Makeup for Al2O3

-32.0 MT

(to be added)

Coal Saved 2.67 MT


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• Current Status

– BIS approval received for using Lead – Zinc slag as performance

improver in OPC (IS 269).

– RSPCB consent available with HZL for its sale for cement

manufacturing, road construction, bricks & tiles manufacturing.

– More than 4 Lac MT slag sold to nearby cement manufacturers in last

5 years, mainly to Shree Cement, Lafarge, JK cement, Aditya Cement,

Birla Cement etc.


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• Road Construction Studies by CRRI, New Delhi– Feasibility study were done for using ISF slag as fine aggregate for construction of

embankments, GSB, cement concrete and bituminous layers

Geotechnical properties of ISF slag and local soil

Property ISF Slag Local SoilMoRTH Specifications

EmbankmentMoRTH Specifications

Subgrade

classificationPoorly Graded

SandSandy Clay - -

Sp. Gravity 3.60 2.68 - -

Liquid Limit,% - 37.5 Less Than 70 Less Than 70

Plasticity Index, % Non plastic 21 Less than 45 Less than 45

Density, kN/cu.m 23.5 20.0 Min. 15.2, h < 3mMin. 16, h > 3m

Min. 17.5

Angle of internal Friction, φ

37 deg. 25 deg. - -

Cohesion, c, kN/sq.m zero 8 - -

CBR, % 26 22 - -

Permeability, m/sec 1.4 x 10-4 - - - 17

Geotechnical properties of ISF slag and local soil mixes

Property 75% Slag25 % Soil

50 % Slag50 % soil

25 % Slag75 % Soil

MoRTH SpecificationsEmbankment/Subgrade

Liquid Limit,% 20.5 24.0 28.5 Less Than 70

Plasticity Index, %

Non plastic

Non plastic

13.5 Less than 45

Density, kN/cu.m

24 23.5 22.5 Min. 15.2, h < 3mMin. 16, h > 3mMin. 17.5(subgrade)

Angle of internal Friction, φ

34 deg. 32 deg. 32 -

Cohesion, c, kN/sq.m

zero 3 5 -

CBR, % 45 55 36 -

Permeability, m/sec

6.7 x 10-6

1.5 x 10-6

2.5 x 10-8

-


Geotechnical properties of cement stabilized mixes

MixCement

Content, %Avg. UCS

kN/m2

25 % ISF, 75 % Soil

3 1534.8

6 2572.4

9 3400.2

50 % ISF, 50 % Soil

3 1213.1

6 2306.6

9 3198.1

75 % ISF, 25 % Soil

3 1116.1

6 1696.3

9 2763.6

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• ISF Slag is a sand size material with good density, high angle of friction and good drainage property.• ISF Slag and slag-soil mixes satisfies the specified density and plasticity requirements for

embankment and subgrade applications.• 50% Slag and 50% soil mix has better CBR and permeability and may be used in sub-base layer.• ISF Slag may be used in cement stabilized sub-bases.• 15% Slag may be used in WMM layer.• 10% Slag may be used in BM Grade I & II.• 25% Slag may be used in DBM Grade I & II.• 15 - 20% Slag may be used in SDBC and BC Mixes.• 20 to 40% slag may be used in PQC mixes.• Up to 20% slag may be used in DLC mixes.

• Meets all required specs of MORTH in embankment, GSB, BM, etc.

• Proven material for road construction in many layers.

• Contractors are very much willing to lift the material, but constrained by the lack of mention of slag in BOM / TOR with NHAI and statutory permits to utilize the same.

• Easily available in huge quantities vis-à-vis soil and stones in the vicinity.

• Natural soil is sparely available.

• Cheaper material

• Lead distance almost same as for soil and stones.

• Road construction is much economical as compared to that of road constructed with soil & stone aggregates.

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Initiatives for Jarosite Utilization

⁻ Control sample - OPC clinker was inter ground with 5% mineral gypsum.

⁻ Further study was taken up on roll of Jarosite as set retarder of OPC by total/part replacement of gypsum.

⁻ Different cement samples were prepared by inter grinding of clinker of different doses of Jarosite in ball mill (1-5% replacement).

⁻ Blain fineness is 3360/3220 at 5% replacement against 3110 in control.

⁻ At 3% replacement LOI/SO3/IR is 1.86-2.2%/2.43-2.47%/0.5-0.54%.

⁻ This comply IS:8112-1989.

⁻ Blain fineness increased with increased dose of Jarosite

⁻ Heat of hydration decreased with 3% Jarosite load

⁻ Differential leaching of toxicants is not remarkable as compared to Control OPC

⁻ Compressive strength in different curing media increased with Jarosite cement as compared to control cement , remarkably in alkali soln by 6-7 Mpa.

⁻ 3% replacement was observed to be optimum and ideal.

• Jarosite as Set Controller in Cement Industry by NCBM, Ballabhgarh

BIS recommended that Jarosite can be used within the 1% of additions along with set retarder, which is not harmful.

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⁻ 0.5-2.0% of typical Jarosite in cement raw mixes with different limestone grades & other conventional materials were studied

⁻ The clinker parameters such as LSF, SM and AM were maintained in the range of 0.92, 2.07-2.18 and 1.01-1.14 respectively.

⁻ The mineral phase developments and micro-structures of laboratory clinkers fired at 1400±5oC were found to be adequate in presence of optimum dose of 1.5% Jarosite and were comparable to control clinker (without Jarosite addition) prepared at 1450±5oC.

⁻ The presence of Fe2O3, SO3 and ZnO in Jarosite has led to fluxing and mineralizing effect on clinkerization reaction.

⁻ Burnability studies of cement raw mixes utilizing 1.5% optimised dose of Jarosite @ 1300 – 1450oC showed:

– Lowering in clinkerization temperature by ~50oC,

– Increase in the rate of lime assimilation,

– Increase in the formation of C3S

– Physical performance of ordinary Portland cement prepared using Jarosite at ~50oC lower temperature was found to be comparable to control cement.

– The leaching of heavy elements including zinc and lead was found to be negligible indicating its fixation in hydrated phases.

• Jarosite as Mineralizer in Cement Industry by NCBM, Ballabhgarh

Initiatives for Jarosite Utilization

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Other Initiatives

• Hindustan Zinc is exploring different avenues for consumption of its wastes.

• One of the opportunity lies in Paste Fill plant of underground mines.

• FF slag, Jarosite and Flyash consumption is being explored with partial replacement of cement in paste fill plants.

• The results are positive.

• Studies are also being done for usages of Jarosite in Concrete and Mortar.

Proportion of solid powders

Compressive Strength, (MPa)

Tailing, % OPC, % 7 Days 28 Days92 8 1.01 1.6893 7 0.78 1.1194 6 0.83 1.0395 5 0.54 1.0596 4 0.42 0.73

Proportion of solid powdersCompressive

Strength (MPa)

Tailings % OPC, % Flyash, % 7 Days 28 Days

92 7 1 0.98 2.1492 6 2 0.65 1.9692 5 3 0.50 1.3592 4 4 0.54 1.09


Strength (MPa)

Tailings% OPC, % FF Slag, %7 Days 28 Days

92 7 1 1.35 2.7492 6 2 1.18 2.2192 5 3 0.79 1.8592 4 4 0.69 -


Strength (MPa)Tailing% OPC, % Jarosite, % 7 Days 28 Days

92 7 1 1.25 2.2692 6 2 1.24 2.3492 5 3 1.25 1.7792 4 4 0.86 0.94

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Thanks . . .

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3rd International Conference on Alternate Fuels and Raw ... Mr Akhilesh...S.No. Properties...

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