s10163-020-00983-x (1)
s10163-020-00983-x (1)
s10163-020-00983-x (1)
https://doi.org/10.1007/s10163-020-00983-x
ORIGINAL ARTICLE
Dregs and grits from kraft pulp mills incorporated to Portland cement
clinker
Caio Moreira Miquelino Eleto Torres1 · Claudio Mudadu Silva1 · Leonardo Gonçalves Pedroti2 ·
Wellington Emilio Hilarino Fernandes2 · Fabiane Carvalho Ballotin3 · Antonio José Vinha Zanuncio4
Received: 30 August 2019 / Accepted: 7 January 2020 / Published online: 29 January 2020
© Springer Japan KK, part of Springer Nature 2020
Abstract
The expansion of the kraft pulp industry in Brazil increases the generation of solid waste, which needs to be adequately dis-
posed of. The objective of the present study was to investigate the technical viability for cement production by mixing with
clinker 0, 2.5, 5, 7.5, 10, and 15 wt% of alkaline dregs and grits, normally disposed of in landfills. The materials (residues
and clinker) were characterized for mass, specific area fineness, X-ray diffraction, scanning electron microscopy with disper-
sive energy spectroscopy, pozzolanicity, and thermogravimetric analyses. Laboratory assays were carried out. The material
physical–chemical properties were satisfactory for clinker addition and the laboratory assays with less than 15 wt% of dregs
and grits in the mixture were efficient. Dregs and grits may be added to up to 10 wt% to clinker for cement production under
the same preparation conditions and degree of grinding. The results pointed out to important environmental achievements
to both pulp and cement industry.
Keywords Cement clinker · Dregs · Grits · Kraft pulp mill · Waste management
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852 Journal of Material Cycles and Waste Management (2020) 22:851–861
concrete formulation [17, 18], composting [19], and for use The dregs and grits in natura were dried in an oven at
in ceramics [20]. 100 °C for 24 h and ground in a Pavitest ball mill. Follow-
Globally, cement is the most widely produced bonding ing this, they were disaggregated in a Pulverisett 14 Fritch
material, and is a fundamental material for infrastructure grinder and crushed until they could pass through a 75 μm
construction. By the end of 2018, there was a 1.23 wt% sieve (200 mesh). The clinker was ground and crushed until
growth in relation to the previous year, reaching an annual it passed through a 75 μm sieve (200 mesh) (Fig. 1).
production of 4.1 billion tons of cement [21, 22].
The Portland cement manufacturing industry contributes Material characterization methods
to greenhouse gas emissions due to the large carbon diox-
ide volumes (CO2) emitted during production, representing The physical, mineralogical, microstructural, and chemical
between 5 and 7% of the global CO2 emissions produced by characterization of dregs, grits, and clinker were determined
mankind, subject to a rigorous investigation of institutions in assays for mass, specific area fineness, X-ray diffrac-
worldwide [14, 22–25]. tion (XRD), scanning electron microscopy with dispersive
Cement production demands significant quantities of raw energy spectroscopy (SEM/EDS) and EDX, pozzolanicity,
materials such as limestone, clay, and gypsum. The Port- and thermogravimetric analyses (TG/DTG) [39–44].
land process, the most common, consists in grinding the raw The material in natura (grits, dregs and clinker) and
materials, mixing them in adequate proportions and burning those with the most relevant substitution were submitted to
this mixture in rotating furnaces at a temperature around SEM/EDS assays, X-ray spectroscopy by energy dispersion
1450 °C for cement manufacture. These materials are cre- (EDX), XRD, pozzolanicity, TG/DTG, specific area, and
ated forming balls of a synthesized material with 5–25 mm fineness analysis. The assays were performed according to
diameter, named clinker [26, 27]. Brazilian norms.
It is important to be aware of how to use these rocks in The samples were metalized at the Center for Microscopy
cement production, because there are particularities in their and Microanalysis of the UFV, on Metalizer Quorum Q150R
chemical composition and in the transportation logistics S equipment. The scanning electron microscopy analyses
between the deposits and the consumer market. Given this, (SEM) were performed with an FIB microscope (to analyze
most of the world cement is used in the country where it is the scan), regarding FEG 3D FEI with the energy and X-ray
produced [21, 22]. scatter detection system (EDS). These analyses were per-
Replacing the clinker by other viable materials helps to formed at UFMG Microscopy Center.
reduce excessive extraction of non-renewable and virgin raw The EDX analyses were performed on the X-ray fluores-
materials, to produce sustainable cements and meeting the cence spectrometer by Dispersive Energy (micro EDX 1300
Kyoto Protocol for CO2 emission reduction objectives [22, Shimadzu).
28–35]. The X-ray diffraction (XRD) patterns were analyzed with
Current trends in "Industrial Ecology" seek to find inte- a DaVinci diffractometer model Bruker D8-Discover with
grated solutions across multiple industrial typologies to use CuKα (1.5406 Å) at 20°, 40°, 60°, 80°, and 100° with a
the materials considered waste in a generator type, but in scanning velocity of 4° min−1.
another type can become a useful raw material [36–38]. The pozzolanic (pozzolanicity) activity assay [39] con-
The objective of this study was to investigate the use of sisted of measuring conductivity variations of a calcium
dregs and grits, generated in kraft pulp mill recovery sectors, hydroxide Ca(OH)2 saturated solution with and without the
as a raw material for partial clinker substitution in Portland addition of the material to be analyzed.
cement production. Therefore, an environmental liability The thermogravimetric analyses (TG/DTG) were car-
is given a positive outcome leading to reduced landfilling, ried out on a Shimadzu DTG 60H equipment with synthetic
recycling materials, and reducing the extraction and use of nitrogen flow (50 mL min−1) in a temperature bracket of
non-renewable virgin raw materials with potential for reus- 10–900 °C and a heating ratio of 10 °C min−1 with sample
ing raw materials in cement production. masses of approximately 6 mg.
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Fig. 1 Experimental plan to test the dregs and grits mixed with clinker for cement production
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The elastic modulus assay for the specimens was started Results and discussion
after the evaluation of a proof body of the same age and
trace, to estimate compression resistance. Three speci- Material characterization
mens were assayed for the elastic modulus for compression
resistance by age (3, 7, and 28 days) and traces, previously The scanning electronic microscopy (SEM) images (Fig. 2a,
established. b) suggested that clinker is a homogenous material with reg-
The production and reading of the data assayed applying ular surfaces, rounded grains ( C3S), and plates similar to a
a load of 0.5 MPa/s with an EMIC brand, DL600KN model hexagon (C2S) [27, 62].
universal machine, was realized with a cell of charge Trd 30 The rounded grains in the sample were determined at a
with tesc software. The specimens were submitted to three magnification of 1.000× (Fig. 2a). A grain with rectilinear
cycles of charge and discharge with the tension of a level plates and similar to a hexagon was observed at magnifi-
below or equal to 0.5 MPa and above or equal to 30 wt% cation of 2.000× (Fig. 2b). Scanning electron microscopy
of the tension of the expected rupture. The deformations images showed particles in the dregs and grits with smaller
were measured with readings with a Trd11 model clip gage. dimensions than those of clinker, which presented rounded
The program calculated the compression resistance and the grains rich in Ca, shown in the EDS analyses.
elastic modulus of the specimens based on the data provided The three EDS samples analyzed (Fig. 3) showed the
(average diameter and expected rupture). presence of Na, Mg, Ca, Si, C, and O with higher C and Na
levels in the dregs. This may be due to the burning of black
Statistical analysis liquor in the boiler and the addition of oxidizing Na reagents
(NaOH and Na2S) in the process of carbohydrate separation
The data for compression resistance and for the elastic mod- (kraft pulping), respectively. The calcium level in the grits
ulus with the addition of 2.5, 5, 7.5, 10, and 15 wt% of dregs is higher than in the other two materials, due to the CaO
and grits to clinker and the control (100 wt% clinker) were addition, during the calcination process stage, generating
submitted to variance analysis (ANOVA). Significant differ- residues [6, 7, 9, 63]. The high Au concentrations are due to
ences between treatments were compared using the Tukey sample metallization, which consists of filling the samples
test at 5 wt% significance. with a thin gold layer to improve the electrical conductivity
of the material.
The clinker, dregs, and grits’ chemical composition,
expressed in oxides, using EDX analysis (Table 2) showed
materials with elevated calcium oxide levels (CaO), which
influenced its mechanical properties. On the other hand, its
Fig. 2 Scanning electron microscopy images of powdered clinker: magnified × 1.000 (a); 2.000 (b); powdered dregs × 1.000 (c); × 2.000 (d);
powdered grits × 1.000 (e); × 2.000 (f)
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Fig. 3 Dispersive energy spectroscopy (EDS) of clinker, dregs, and grits together on the same graph (a) and individually for clinker (b), dregs
(c), and grits (d)
Table 2 X-ray spectroscopy by CaO SiO2 Al2O3 Fe2O3 SO3 MgO K2O Na2O TiO2 Cl Others
energy dispersion (EDX) for
clinker (Cl.), dregs (Dr.) and Cl. (wt%) 64.55 20.65 3.02 3.23 1.00 0.33 1.47 1.71 0.27 0.07 3.72
grits (Gr.)
Dr. (wt%) 68.85 6.67 0.74 3.27 6.44 3.14 0.91 3.64 0.18 0.39 5.78
Gr. (wt%) 83.36 5.21 0.29 1.16 0.97 0.66 0.50 2.77 0.08 0.27 4.73
elevated concentration undermined the stability of volume structures. These results are similar to C3S (Alite) and C2S
of mortars and concretes, acting as an expanding agent [27, (Belite) elevated concentrations between the interval of
64, 65]. 20° and 28°–40° [27, 67–70], and corroborate the scanning
The sulfur and magnesium oxide concentration in the electron microscopy analysis.
dregs was greater than in the grits (Table 2), which can con- Dregs and grits’ X-ray patterns (Fig. 4b) confirmed the
fer elevated expandability on cement, leading to unfavorable presence of mineralogical compounds in their chemical
outcomes. This phenomenon can only be observed after the composition such as crystalline phases of calcium carbon-
assays for compression resistance and of the elastic modulus ate ( CaCO 3), pirssote ( Na 2Ca(CO 3)2·2(H 2O)), calcium
at 28 days for resistance were performed [65]. hydroxide (Ca(OH)2), and magnetite (Fe3O4).
Iron oxides (Fe2O3) and alkalis (K2O–Na2O) found in The thermal stability of the two material profiles
high concentrations in the dregs and grits were also used (Fig. 5) was high. The dregs’ TG curve (Fig. 5a) showed
as bases. The F e2O3 in non-elevated percentages helped the an initial weight loss of 13 wt%, related to water physi-
conversion of the silica into silicate, while the alkali acceler- cally adsorbed and to C aSO 4 ·2H 2 O dehydration. At
ated setting, being viable to substitute the gypsum ( CaSO4) 500 °C, an endothermic event, with a weight loss of 6
in industrial Portland cement production [27, 65, 66]. wt% was observed, probably related to calcium hydroxide
The clinker X-ray patterns (Fig. 4a) showed the phases and CaSO4·2H2O di-hydroxylation. The final weight loss
of the tricalcium silicate (3CaO S IO2) abbreviation C 3S; of 30 wt%, centered at 683 °C could be related to CaCO3
dicalcium silicate (2CaO S IO2) abbreviation C 2S; trical- and MgCO3 decomposition [71]. MgCO3 material decom-
cium aluminate (3CaO Al2O3) abbreviation C3A; iron alu- position occurs until 550 °C [72]; however, when calcium
minate and tetracalcium (4CaO Al2O3 Fe2O3) abbrevia- is present, MgCO3 decomposition temperature increased.
tion C4AF as the main crystalline phases identified in their
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856 Journal of Material Cycles and Waste Management (2020) 22:851–861
Fig. 5 Thermogravimetric curves (TG/DTG) with synthetic nitrogen flow (50 mL min−1) and a heating ratio of 10 °C min−1 dregs (a) and grits
(b)
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The initial weight loss of the grits (Fig. 5b) was 2 wt% Laboratory assays for mechanical requirements
related to water physically absorbed on the material sur-
face and a weight loss of approximately 40 wt% between The setting time assays remained within limits, except in the
600 and 800 °C, which can also be related to calcium car- 15 wt% substitution with the specific area of 0.40 m2 g−1,
bonate decomposition, calcite ( CaCO3), for CaO and CO2 which was below recommendations (Table 4) [47]. These
formation [16]. lower values for substitutions of 15 wt% can be explained
The pozzolanic activity assay showed electric conduc- by the elevated alkali, potassium oxide (K2O), and sodium
tivity of 0.31 mS cm−1 for dregs and 0.87 mS cm−1 for (Na2O) concentrations, accelerating the setting time and can
grits, showing that these materials do not possess pozzo- be related to the high specific area compared with the other
lanic activity, but do not hamper reactivity with cement. substitutions [26, 27, 65].
Given their elevated Blaine values, they are adequate for The Le Chatelier expandability in the adopted substitu-
addition to cement for pore filling [26, 27, 39]. tions and in the control remained within the limits recom-
The mass, specific area and fineness assays, with the mended by the norms [45, 60, 61] (Table 5). Non-expanda-
different dregs and grits percentages, compared with the bility was related to the low magnesia (MgO) concentration
reference (0 wt% materials), presented values within the in the materials (clinker, dregs, and grits), described in its
limits indicated by Brazilian norms (Table 3). However, EDX (Table 2), considering that the average MgO values
the clinker specific area, at the lower norm limit, showed represent between 0.8 and 6 wt% of the cement [27, 65].
low resistance in the mass, specific area, and fineness The results for mechanical compression resistance of
assays. the cylindrical specimens produced using the dregs and
The dregs and grits specific masses, above 3 g cm −3, grits substituting clinker assay (0, 2.5, 5, 7.5, 10, and 15
allow their mixture with clinker. Additionally, the high wt%) ruptured at 3, 7, and 28 days. The analysis of variance
values for the specific area of the dregs and grits favor the allowed the comparison of the average of the tension of each
filling of the pores, meaning that they can act as a filler. proportion for each age, according to the Tukey test at 5 wt%
The grits fineness index was greater than that of dregs, significance (Table 6).
which can compromise its homogenization during mixing There was a tendency to increase the compression resist-
with clinker [26, 27]. ance of the specimens as the percentage of dregs and grits
increased for all curing times. The evolution of growth rate,
based on the reference (0 wt% materials), of the specimens
with the dregs and grits’ incorporation were similar. All the
Table 3 Specific mass (Sp. Mass), specific area (Sp. Area), and fine- substitutions showed lower resistance with 0 wt% materials
ness index (Fin. Ind.) of the clinker, dregs, grits, and substitutions at 28 days.
Sp. Mass (g/ Sp. Area (m2/g) Fin. Ind. (wt%)
cm3) Table 4 Setting time of the Setting time (h:min)
clinker and substitutions
Clinker 3.00 0.25 0.26
Initial set Final set
Dregs 2.44 1.03 0.78
Grits 2.67 0.97 95.20 Clinker 1:45 2:40
2.5 wt% 2.5 wt%
Dregs 2.94 0.28 0.22 Dregs 1:55 2:47
Grits 3.05 0.32 1.28 Grits 1:15 2:15
5.0 wt% 5.0 wt%
Dregs 2.99 0.31 0.28 Dregs 1:20 2:25
Grits 3.01 0.31 2.46 Grits 1:30 2:45
7.5 wt% 7.5 wt%
Dregs 2.93 0.31 1.00 Dregs 1:11 2:43
Grits 2.99 0.30 5.36 Grits 1:40 3:26
10.0 wt% 10.0 wt%
Dregs 2.87 0.33 0.54 Dregs 1:16 2:37
Grits 3.00 0.36 2.72 Grits 1:24 2:56
15.0 wt% 15.0 wt%
Dregs 2.98 0.40 0.44 Dregs 0:32 3:10
Grits 2.95 0.35 3.96 Grits 0:55 2:42
Limits – ≥ 0.24 ≤ 12 Limits ≥1 h ≤ 10 h
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Table 5 Le Chatelier Le Chatelier of the specimen components, the lower their compression
expandability of the clinker and expandability (mm) resistance [27, 65, 73].
substitutions
Warm Cold
The evolution of the static elastic modulus to compres-
sion of the specimens increased with the clinker particle
Clinker 0.00 0.27 hydration with age. The evolution of the static elastic mod-
2.5 wt% ulus with the dregs and grits substitutions for the curing
Dregs 0.00 0.28 time was evaluated (Table 7).
Grits 0.00 0.32 The growth rate of the static elastic modulus of the
5.0 wt% specimen with incorporation of grits was similar to that
Dregs 0.00 0.31 of the reference (0 wt% materials). The substitutions of
Grits 0.00 0.31 2.5, 5, and 7.5 wt% did not significantly alter the elastic
7.5 wt% modulus at 28 days for dregs and the substitution of grits
Dregs 0.00 0.31 was similar to that of the reference at 28 days.
Grits 0.00 0.30 Positive environmental effects to both industries are
10.0 wt% expected with the partial substitution of clinker by dregs
Dregs 0.00 0.33 and grits such as landfilling reduction, materials’ recy-
Grits 0.00 0.36 cling, non-renewable extraction material reduction, as well
15.0 wt% as greenhouse gas emission reduction.
Dregs 0.00 0.40 The Portland cement manufacturing industry contrib-
Grits 0.00 0.35 utes to greenhouse gas emissions due to the large carbon
Limits ≤ 5 mm ≤ 5 mm dioxide volumes (CO 2) emitted during production, rep-
resenting between 5 and 7% of the global CO2 emissions
produced by mankind. Replacing the clinker by other via-
Table 6 Tukey test at 5 wt% significance of the compression resist- ble materials helps to reduce excessive extraction of non-
ance of the specimens with clinker and substitutions renewable and virgin raw materials, to produce sustainable
Samples Tension (MPa) cements and meeting the Kyoto Protocol for C O2 emission
reduction objectives [14, 22–25].
3 (days) 7 (days) 28 (days)
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