Investigation on grinding impact of fly ash particles and its characterization analysis in cement mortar composites

Ain Shams Engineering Journal 10 (2019) 267–274

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Civil Engineering

Investigation on grinding impact of fly ash particles and its characterization analysis in cement mortar composites L. Krishnaraj ⇑, P.T. Ravichandran Department of Civil Engineering, Faculty of Engineering and Technology, SRM Institute of Science and Technology, Kattankulathur 603203, Tamil Nadu, India

a r t i c l e

i n f o

Article history: Received 10 March 2017 Revised 30 January 2019 Accepted 1 February 2019 Available online 14 February 2019 Keywords: Secondary cementitious materials Fly ash Grinding process Ultrafine fly ash Compressive strength Microstructure study

a b s t r a c t The extensive usage of cement in almost all infrastructure projects will affect the health of construction industry around the world. At present, the entire globe is marching towards sustainable, eco-friendly and energy efficient infrastructure development with economic viabilities. The research elucidates the effect of grinding of Fly Ash (FA) and Ground Fly Ash (GFA) was studied. The fly ash particles are ground from 727 cm2/g to 3526 cm2/g specific surface area Ground fly ash were analyzed from the Blaine’s fineness test and particle size and optimized with 120 min of grinding to achieve the ultra-fine particle size. The Cement replacement by 15% FA and 30% GFA were determined from the mechanical strength of blended mortar specimens. The investigation is aimed to increase the consumption of fly ash and enable to reduce the usage of natural resources for the cement production with ultrafine fly ash as an efficient replacement material. Ó 2019 The Authors. Published by Elsevier B.V. on behalf of Faculty of Engineering, Ain Shams University. This is an open access article under the CC BY-NC-ND license (http://creativecommons.org/licenses/by-ncnd/4.0/).

1. Introduction The consumption of cement in construction industry increases the production of cement rapidly; it deploys the natural resources and increases the cement production cost, which ultimately increases the construction cost. Hence, the researchers and engineers are concentrated to identify an alternate material for replacement of cementitious materials, which also reduces the emission of CO2. Among the various industrial wastes, a large volume of available fly ash is used as a replacement material for cement as it has cementitious properties and also solve the challenging issue of fly ash disposal problems [1]. Various studies have been done to use the fly ash as cementitious material from the beginning of the 19th century. Though efforts have been made to utilize the fly ash, yet it is less in the utilization. Hence, there is a pressing need for finding higher utilization percentage of an improved version of fly ash to address the reduction of natural resource usage in cement production [2,3]. ⇑ Corresponding author. E-mail addresses: [email protected] (L. Krishnaraj), [email protected] (P.T. Ravichandran). Peer review under responsibility of Ain Shams University.

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The future challenge for the construction material industry is obviously to develop a conducive environment by reducing cement content to an extent possible. In this concern, a detailed investigation is required in the construction field and its materials are unavoidable. To develop innovative and smart construction material, the implementation of nanoparticle in cement and construction industry is the promising technique. Currently there is an extraordinary interest in nano materials and nanotechnology due to their advantages [4,5]. Recently the nano science and nanotechnology become a popular word. The nanomaterial defines that the materials have minimum one measurement in nanometer range at the microstructure level [6–8]. The researchers are effectively used the Nano materials due to the primary characteristics such as particle size smaller, narrow size particle distribution, no agglomeration, and dispersibility. The nanoparticle produced from the top down process of synthesis techniques by using mechanical attrition called ball milling process [9,10]. The researchers are focused on ball mill grinding process which is commonly used in cement industry. The macro crystalline particles are broken down in microcrystalline or Nano crystalline particle during grinding process. The researchers concluded the particle size reduction through the ball milling has the added advantages and also being a simple technique, comparatively inexpensive and applicable to any material which can be easily scaled down of large quantities of materials [11]. To understand the Nano Materials behaviour in a mortar, the researchers was conducted to comprehend the water demand,

https://doi.org/10.1016/j.asej.2019.02.001 2090-4479/Ó 2019 The Authors. Published by Elsevier B.V. on behalf of Faculty of Engineering, Ain Shams University. This is an open access article under the CC BY-NC-ND license (http://creativecommons.org/licenses/by-nc-nd/4.0/).

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setting time and cement mortar strength due to the inclusion of nano materials. The cement mortar is prepared using the combination of nano fly ash and nano silica. The presence of nano materials did not have much impact on the consistency. To a larger extent the changes are seen in the setting time and cement mortar compressive strength. Results indicated that inclusion of nano-cement had reduced the time taken for setting of cement paste. However, the inclusion of nano-fly ash material and nano-silica fume had a reverse effect. It was observed that both initial and final setting was longer compared to the nano-cement based cement paste [12]. The Top-Down Nanotechnology is best practice for production of ultrafine cement particles, which is attain more popularity. The previous researchers explain about the combination of the cement particle to the ultrafine level through bead milling process. During this process, cement particles are to ground for 1–6 h along with grinding agents methanol and ethanol. It was evaluated that the size of the cement particle declines with the rise in grinding time and also bead milling process can yield 90% of the cement particles less than 350 nm after 6 h milling without affecting the chemical phases. Bead milling process was able to produce ultrafine nanoscale cement particles ranging 200–300 nm from a micro-scale particle of 12.57 nm size. From the particle size analysis, it is concluded that the performance of ethanol as a grinding agent is more efficient as compared to that of the methanol. Scanning Electron Microscope (SEM) micrographs of the particles before and after milling clearly proved the combination of the cement particle by the wet grinding of the cement [13–15]. However, the ball milling process is understood to be energy demanding process, because the energy consumption of raw materials grinding is about 110–150 KW h per ton of cement production. The cement grinding mill circuit loaded approximately 95% through clinker raw materials and rest of the feeding material is performing properties enhancer [16,17]. In grinding process, the quality of cement in terms of fineness was measured by using Blaine’s surface area and particle size distribution analysis [18]. The ball milled powder particles having the non-spherical shape, changes in physical characteristics only and no alteration in chemical composition of a particle [19,20]. The researchers found that the use the mechanical grinding technique is good choice for fly ash particle grinding to get better performance, effectiveness and strength aspect. The effect of ball mill grinding has been explained mainly two types of mechanisms. The first mechanism principles based upon mechanical behavior of particles and particles surface alteration. The second mechanism based upon changes in particles arrangement. In ball mill grinding method, the particles shape and size changes prevent the sticking of finely dispersed particles and also agglomerations. Which is evident to that, the increase in mechanical performance of ball milled materials [10,21]. The present research work focus to study consequence of fly ash particle with and without ball milling of samples. The OPC and fly ash samples are taken as control sample and compared with ball milled ground fly ash, to examine the effect of grinding process on fly ash particles fineness. The fly ash particles characterization analysis was studied by using Particle Size Analyzer (PSA), X ray Diffraction (XRD) pattern, SEM analysis, Fourier Transmission Infra Red (FT-IR) spectroscopy. Also the physical test and chemical composition, mechanical strength of blended mortar have been investigated.

The OPC is replaced with 0, 15, 30, 45 and 60% by weight of high calcium class C fly ash. The class C fly ash were obtained from the Neyveli thermal power plant, from Neyveli, Tamil Nadu, which is taken as a Fly Ash (FA). The fineness and specific gravity of class C fly ash is 727 cm2/g and 2.67 respectively. The FA samples are ball milled with different duration to produce the finer particles of Ground Fly Ash (GFA), having the specific gravity was 2.43. The GFA finer particles are having the range 90% of particles less than 10 mm. The sand to binder ratio was 2.75:1 adopted to prepare mortar specimens. The fine aggregate is taken as standard Ennore sand were grade-I, II, III equally mixed in this research, according to IS 2116:1980 [22]. The distilled water is used in this research for preparation blended mortar cubes. The water to binder ratio was taken based on flow spread value of mix combinations IS 1727:1967 [23]. 2.2. Test methods 2.2.1. Test on powder sample The fineness of fly ash powder is analyzed by the sieve residue method and Blaine’s fineness surface area test. The residue of the fly ash is found with 45-mm sieve analysis. The Blaine’s surface area of grinded fly ash particles is determined with automatic Blaine’s air permeability method according to the Indian standard IS1727-1967. To determine the distribution of particle size with and without ball milled fly ash powder samples were studied by using a Lasers diffraction of Compagnie industrielle des particle size analyzer test was employed in cilas ecosizer dry mode [24]. The test results was obtained as a tabular form and bar chart histogram were interpreted and compared like semi log graph and table values. 2.2.2. Materials characterization study The microstructural behavior characteristics of OPC, FA and GFA produced using the laboratory ball mill grinding were analyzed using an X-ray diffraction characterization technique to find the crystalline size of the quartz phases. The ball milled fly ashes have studied by using an accelerating voltage of 30 kV and a current of 20 mA. The fly ash particles are scanned at a speed level of 2 deg
min 1 in the 2h range from 10 to 70° [25]. The PANalytical X’pert Pro was used for the XRD characterization. Goniometer is the part where test samples have been placed and detector which collects the reflected signal from the sample. The measurement were taken at every 0.0170° step from 5° to 100° with a potential of 40 kV, 30 mA in this work. The microstructures of ball milled and virgin fly ash powder samples used in this study are analyzed using a scanning electron microscope (SEM) in addition to the energy dispersive X-ray spectroscopy (EDX) to ascertain the elemental composition, morphology characters and texture. The magnifying instrument amplification going from 20 to around 60,000 and 3-D determination of up to 15 nm in an examining strategy by utilizing ordinary SEM methods. To determine the functional groups contains with and without ball milled samples, a Fourier Transform Infrared (FT-IR) spectroscopy analysis is performed in the wave region from 400 to 4000 cm 1 wavelength [26–28]. Sample preparation and analysis techniques for FTIR for powder sample by using KBr Discs analysis techniques. 2.3. Test on blended cement paste and mortar specimens

2. Experimental program 2.1. Material details The Ordinary Portland Cement (OPC) 43 grade, which has 3.15 specific gravity used as a principle materials in this investigation.

The normal consistency and setting times of the samples measured according to the IS 4031-1999 [29]. The water to binder ratio was used in this investigation based on the workability value which satisfies the flow range in 100 ± 5 mm as per the IS17271967. To study the compressive strength, the mortar specimen

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were cast in 50 mm cube steel mold and demoulded after 24 h then kept for normal curing up to testing of the specimen at the duration of 3, 7, 14, 28 days according to ASTM C 109 [30]. The OPC replacement by different mix ratios of FA and GFA sample specimen are casted 108 cubes to study the compressive strength mortar samples. To determine split tensile strength of the effect of ball milled fly ash on blended cement mortar, the specimens in 50 mm diameter and 100 mm height of cylinder were prepared in steel mould. All the cubes and cylinders of different mix combinations specimens are cured in saturated lime water for various curing ages according to the IS 1727:1967. 2.4. Grinding mill parameters The ball mill grinding test is carried out in a horizontal attrition ball mill of 2 L capacity with dual cylinder model manufactured by 440C stainless steel. The cylinder rotational speed is maintained as 120 rpm. The cylinder is feed with a fly ash particle to ball ratio is 1:10 according to the previous researchers findings. The grinding media is having the 20 kg stainless steel ball with 12 mm and 25 mm diameter. The duration of balling done at 15, 30, 45, 60, 120 and 180 min were grinded to produce finer fly ash particles of the Ground fly ash (GFA). In grinding process the stainless steel balls and cylinders are considered as an effectual grinding media to reduce wear loss, increases the ball milling effectiveness and durability by comparing to the glass and alumina based grinding media [10,31]. 2.5. Impact of particle size reduction The previous researchers were concluded that the fly ash has more spherical particles which is having the less binding properties, its leads to increases the strength gain in early ages [32,33]. And also porosity is more which leads to major problems in strength and durability aspects. To overcome these issues, the fly ash is ball milled from coarser particles to ultrafine particles which is having more surface area to gain more binding properties [34,35]. In this connection, Fly ash is ground with different ingredients in the cement manufacturing process is called combined grinding. The concept of particle size reduction to increases the specific surface area of the particle. Inborn properties of the fly ash not entirely used in cement manufacturing because of typical physical properties of fly ash which make it hard to grind. The poor grinding of fly ash is consequences in low lime reactivity. Fly ash molecule size of 5 to 15 mm is perfect to accomplish great filler impact, and speedier disintegration in alkalis whiles the procedure of cement hydration. Fly ash Grinding Ball Mill is practical for its run of the ball mill grinding process in which extreme shearing strengths take a shot at particles at fast. For fast of crushing ball mill and extraordinary shearing strengths following up on fly ash particles, required particle size reduction accomplished in brief time. Pulverized fly ash particles are amorphous, and structure is non-crystalline.

Fig. 1. Specific Surface Area and Sieve Residue Analysis.

the saturation point reached. After 120 min percentage of grinding effect is less. The percentage of sieve residue progressively decreases with increase in grinding period up to 120 min of grinding which identified the inflection point. After inflection point, the sieve residue starts to increases due to agglomeration of particles [36]. The optimum grinding time was taken as 120 min to produce the Ground fly ash. The impact of ball mill grinding on the distribution of particle size curves has been shown Fig. 2. The increase in ball milling duration, the particle size distribution curves moved towards left side, which is evident, that presence of ultrafine particles. The optimized grinding time based on the particle size distribution results of 120 min is showing the best values. The particle size contents in the range of 0–5 mm, 6–12 mm, 15–25 mm, 32–45 mm improved by 23%, 24%, 28%, 22% respectively compare to the fly ash sample. The distribution of particle size analysis shows that the fly ash as well as ground fly ash manufactured by the laboratory ball mill grinding process shows an extensive role in envisaging the preferred characteristics and the performance of the grounded fly ash sample. The particle mean diameter at 10, 50, 90% of fly ash (FA) are 1.6, 18.57, 62.7 mm respectively. Similarly, the particle mean diameter at 10, 50, 90% of ground fly ash (GFA) are 2.2, 27.35, 92.09 mm respectively. Therefore, it is evaluated that

3. Results and discussion 3.1. Test on material synthesis To find the ultrafine particles of fly ash, Blaine’s fineness test was performed with 15, 30, 45, 60, 120 and 180 min of ball milling to produce the ground fly ash. The specific surface area of fly ash particle and sieve residue Vs Grinding time is shown in Fig. 1. From this figure, it can be observed that the surface area of particle is gradually increasing with increase in ball mill grinding time. The specific surface area increases gradually up to 120 min after that

Fig. 2. Particle Size Analysis of Samples.

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the ball milled process used in this work is the proper line through which ultrafine particles can be produced compare to the previous research [37]. In the production of ultrafine particles by ball mill grinding of fly ash can further be clarified in SEM analysis.

3.2. Material characterization Fig. 3. Compares the XRD patterns of fly ash and ball milled ground fly ash with 15, 30, 45, 60 and 120 min of grinding time. It is observed that the highest peak at 26.5° which shown quartz phase. It envisaged that the peaks corresponding to the Calcium Hydrate (CaH) appeared at 2 theta values 31.5 and 60 for the FA and GFA samples. The XRD peaks corresponding to the Calcium silicate (CaS) appeared at 2theta values 20.5, 36.5 and 55.5 for the FA and GFA samples. The XRD peaks corresponding to the Quartz appeared at 2 theta values 26.6, 36.5 and 68.5 for the FA and GFA samples. It is witnessed from the characterization analysis, that the peak point communicates to a particular phase which seems at the angle of pose (2 theta) value similar for FA samples and GFA samples with different grinding period of intervals [16,20,38]. Therefore it is observed that the GFA sample shows there is no change in chemical composition due to the grinding of FA samples. The spectra of FA and various grinding time intervals GFA is shown in Fig. 4. The peak intensity at 3450–3400 cm 1 was shown in all the spectrum is OAH stretching of Si-OH group. The peak intensity of 15, 30, 45, 60, 120 and 180 min of GFA samples are compared to FA peaks, it is observed that the enhancing with increasing grinding time is an indication for the particles quartz structure breaking and formation of SiAOH group [19,39]. FT-IR spectroscopy is evident that the characteristic AOH stretching vibration high-intensity increase by reduction of particle size FA into GFA.

3.3. Interpretations of microstructure of the materials The FA samples, GFA samples with a grinding time of 30, 60 and 120 min of grinding morphology is shown in Figs. 5–8 respectively. It is observed that FA particles are the spherical shape and their surface are smooth and dense, in FA samples having less part of irregular shape of particles that can be seen. The ground fly ash particles are irregular in shape, no spherical particles and almost most of the particles are loose and porous surface structure. As envisaged from the figure, the FA particle size was in micro level. However, the particle size of FA samples are a larger size and with an increase in ball mill grinding time decreased ultrafine particle size, which is evident from the SEM images [20,40].

Fig. 4. FT-IR band results of FA and GFA with Different Grinding Time.

Fig. 5. SEM Analysis of FA samples.

3.4. Physico-chemical activation by grinding The water demand is identified through the normal consistency, setting time and flow spread value of OPC partially replaced by FA and GFA with 0, 15, 30, 45 and 60% by weight is shown in Figs. 9, 10 and 11 respectively. The figure indicates that the standard consistency of blended OPC containing FA and GFA is initially diminished and increased with increase of FA and GFA content in OPC samples. The water demand of the FA is 31.66% to 36.33% and similarly, the water demand of the GFA is 32.5% to 46%, while compared with

Fig. 3. XRD pattern for FA and GFA samples with different grinding time.

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Fig. 6. SEM Analysis of GFA at 30 min grinding samples.

Fig. 9. Normal consistency values of samples.

Fig. 7. SEM Analysis of GFA at 60 min grinding samples.

Fig. 10. Setting Time of samples.

Fig. 8. SEM Analysis of GFA at 120 min grinding samples.

reference OPC samples. Compare to the FA and GFA Samples. The GFA replacement takes more water demand due to the higher fineness compare to the FA samples. The Initial and final setting time decreased with increasing of FA and GFA content replacement in OPC samples. The replacement of OPC by FA and GFA sample acts

as a retarder of hydration process which is conferred from the previous researcher [19,28,40]. The GFA sample gives less setting time compare with FA samples. The GFA samples can play a vital role in reducing the water requirement of normal consistency and decrease in setting time, due to the fineness of particles reducing the porosity in GFA sample. The flow table test was done to examine the workability of blended fly ash cement mortar and to identify the water to binder ratio required from the flow value of 100 ± 5 according to IS: 1727:1967. Fig. 11 shows flow table spread values of OPC partially replaced with FA and GFA of 0, 15, 30, 45, 60% by weight with different water binder ratio. From the results, the OPC replacement 0, 15 and 30% of FA and GFA sample mix proportions gives 0.5 w/b ratio. The OPC replacement by 45 and 60% of FA and GFA sample mix proportions gives 0.55 w/b ratio, which satisfies the flow values. The flow value decreased with increasing of FA and GFA content replacement. The flow table spread value shows the similar indication of standard consistency values and setting time values. The blended mortar flow ability was increased based on cement

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Fig. 11. Flow Table Spread Value of Samples.

with fly ash particles bonding characteristics [41,42]. Its shows flow decreases with increase in fly ash contents. Due to the water is entrapped through porosity such as agglomerates and not improving the flow ability of mortar. The chemical composition of fly ash and grounded fly ash analyzed by using energy dispersed X- ray analysis (EDX) is shown in Figs. 12 and 13. From the results, it observed that the presence of Al, Si, and O elements peaks correspond to the mullets and silica which is present in the fly ash and ball milled with different duration of ground fly ash. The chemical composition of the fly ash and grounded fly ash sample of different duration analyzed using X-ray fluorescence (XRF) analyzer are also shows the identical results. Form the observed results its evident that grinding process may

Fig. 12. EDX results Fly Ash Samples.

Fig. 13. EDX results of GFA at 120 minutes grinding samples.

reduce the particle size into a ultrafine level without altering the chemical composition [20,27]. 3.5. Compressive strength of ball milled ground fly ash mortar The mortar specimens were used to prepared by OPC without and with the replacement of 15, 30, 45, 60% by weight of FA and GFA samples at the testing age of 3, 7, 14, and 28 days test results shown in Fig. 14. From the test results, at the early age 3rd-day, the compressive strength of blended OPC of 15, 30, 45 and 60% of GFA mortar specimen gives 18, 21, 35 and 32% higher strength compared to the OPC with FA mortar specimens. Similarly, at 28th

Fig. 14. Compressive Strength of Mortar Specimens.

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Fig. 15. Split Tensile Strength of Mortar Specimens.

day compressive strength of blended OPC of 15, 30, 45 and 60% of GFA mortar specimen gives 7, 26, 24 and 31% higher strength compare to the OPC with FA mortar specimens [17,43]. The optimum replacement of OPC mortar by FA samples was 15% and by GFA samples was 30%, which is evident that the FA and GFA mortar samples give 5 and 8% higher compressive strength of OPC control mortar specimens at 28 days strength. 3.6. Split tensile strength of ball milled ground fly ash mortar The ball milled fine fly ash particles shows better performance at compressive strength of blended samples. To analyzes the effect on tensile properties, the cylinder specimens are prepared to study at the ages of 3, 7, 14 and 28 days of OPC replaced by using 0, 15, 30, 45 and 60% of FA and GFA sample results are shown in Fig. 15. From the test results, it is noticed that the OPC replacement by 30% of FA and GFA sample gives 11 and 43% of higher split tensile strength compared to the OPC specimens. The OPC partially replaced by using GFA sample at all replacement shows higher strength compared with control specimens. The grinded fly ash particle shows better results compared to the fly ash particles. Due to the very finer particle presence in the GFA mortar specimen gives better binding properties [33,44]. This is proved in micro structural results. 4. Conclusion This investigation gives an innovative technique to produce ultrafine fly ash utilizing high energy ball milling process. Based on the test results, ball mill grinding process is a unique idea to produce ultrafine nanoscale fly ash particles from micro-scale particles. There are noteworthy differences in particle size distribution, physical properties, particle morphology and compressive strength of fly ash samples over the ground fly ash samples. From the particles size distribution analysis the optimum grinding time of ground fly ash was identified as 120 min. The ground fly ash particle size contents in the range of 0–5 mm, 6–12 mm, 15– 25 mm, 32–45 mm are improved by 23%, 24%, 28%, 22% respectively compare to the fly ash. The ball milled GFA sample shows less setting time compared with OPC and FA samples with different replacement. The GFA samples plays a vital role in dropping the water demand of normal

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consistency and decrease in setting time, due to the fineness of particles reducing the porosity in GFA sample. Since, the replacement of OPC by FA and GFA sample is acts as a retarder in hydration process. From the compressive strength test results, the optimum replacement of OPC mortar by FA samples was 15% and by GFA samples was 30%, Which shows the FA and GFA mortar samples gives 5 and 8% higher compressive strength with compare OPC control mortar specimens at 28 days strength. From the Split tensile strength test, the GFA blended cement mortar specimens gives more strength compared to the FA blended mortar specimens. The ball milled fly ash particles replacement of OPC sample shows better performance in split tensile behavior. So the replacement of GFA is very effective than the FA samples. This is due to the finer particles present in the GFA sample, which is having more surface area to gain more binding properties. In other hands, the pores will be reduced in GFA blended mortar specimens is the reason to increases the strength properties. The investigation paves the path to use the ultrafine fly ash for replacement of cement in the construction industry. Since, the ultrafine fly ash is behaving an energy efficient, economic and sustainable green material along with the other materials. Also, it enables to reduce the usage of natural resources, minimize the carbon footprints and greatly help to solve the environmental threat as a disposal in land and contamination. Acknowledgment The authors wish to thank Nano Technology Research Centre and Department of Physics and Nano Technology, SRM Institute of Science and Technology, Kattankulathur for their help to conduct Microstructural analysis.

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L. Krishnaraj is Assistant Professor in Civil Engineering Department, SRM University, Kattankulathur. He obtained his B.E. degree in Civil Engineering from Adhiyamaan Engineering College, Anna University. He received his Post Graduate from SRM University. He has published over 20 research paper in national and international journals and conferences. He is life time member of Indian Concrete institute and Life member of Indian Society for Technical Education.

Dr. P.T. Ravichandran is Professor in Civil Engineering Department, SRM University, Kattankulathur. He obtained his B.E. degree in Civil Engineering from Madurai Kamaraj University. He received his Post graduation and Ph.D. from College of Engineering Guindy, Anna University. He has published over 70 research papers in National and International Journals and Conferences. He is a Life Fellow of Indian Geotechnical Society and Institution of Engineers (I) and Life member of Indian Society for Technical Education and Indian Road Congress.