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Feasibility Study on Spent Pot Lining (SPL) as Raw Material in Cement Manufacture Process

A Al-Maqbali


SPL is a waste material that comes free from the production of Aluminum industrial. SPL is separated in two fractions: a carbon-rich fraction referred to as “first cut” and a refractories rich fraction referred to as “second cut”. One commonly used solution is the processing of SPL fractions in cement kilns. The primary reasons for the cement producer to process the SPL are the reduction in raw material costs from using the refractory as a replacement raw material, and the heating value from the contained carbon. A second important reason is that the fluoride lowers the melting point of clinker, which saves on input of fuel. What is of interest is that certain parts of the SPL are contributing to the clinker process. The fluoride parts act as fluxes that lower the melting point of clinker. Other parts act as a mineralizer that enhance the formation of complexes that form the clinker. These attributes are the main driver to use second cut SPL in cement process. Investigation was carried out with a typical SPL samples collected from Sohar aluminum company which was found to contain 10.23%Na2O, 0.22% K2O, 0.034 mg/Kg cyanide and 71.52 mg/kg fluoride respectively.
Different mix was designed with varying dosages of SPL. The burnability investigations of raw mix showed free lime content of 1.58 for 0%, 1.03 for 0.5%, 0.74 for 1%, 0.68 for 1.5% and 0.44 for 2% at 1450C. The result cement compressive strength of 21.8, 31.0 and 45.6 MPa at 2, 7 and 28 days. The performance characteristic showed conformity to OS: 7 2001 for 42.5 grade of Ordinary Portland Cement.

Keywords: SPL, clinker, burnability, free lime, compressive strength

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