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Clinkering and Early Age Hydration Characterization of Belite-Alite Calcium Sulfoaluminate (BACSA
Clinkering and Early Age Hydration Characterization of Belite-Alite Calcium Sulfoaluminate (BACSA
Abstract
Belite Calcium SulfoAluminate (BCSA) cements, also known as sulfobelite cements, have been developed as OPC
substitutes. BCSA cements contain belite as main phase (>50 wt%) and ye´elimite as the second content phase
(~30 wt%). BCSA are less calcite demanding materials than OPC, with the consequent diminution of carbon
dioxide emissions from decarbonation in the kiln. Although BCSA cements have been proposed as a sustainable
alternative to OPC, an important technological problem is associated to them: these materials develop low
mechanical strengths at intermediate hydration ages (3, 7, and 28 days). One of the proposed solutions to this
problem is the activation of BCSA clinkers by preparing clinkers with high percentage of coexisting alite and
ye'elimite. These clinkers are known Belite-Alite Calcium Sulfoaluminate (BACSA) cements. Their manufacture
may produce 15% less CO 2 than OPC. Alite is the main component of OPC and is responsible for early
mechanical strengths. The reaction of alite and ye´elimite with water will develop cements with high mechanical
strengths at early ages, while belite will contribute to later curing times. Moreover, the high alkalinity of BACSA
cement pastes/mortars/concretes will facilitate the use of supplementary cementitious materials with pozzolanic
activity that also contribute to decrease the CO 2 footprint of these ecocements.
In this work, four BACSA clinkers with different compositions (belite ~ 70-55 wt%, alite ~ 10-15 wt% and
ye’elimite ~ 10-15 wt%) were synthesized (at laboratory scale). Lime, gypsum, kaolin and sand were used as raw
materials and clinkering temperatures from 1280 to 1300 ºC were studied. Every BACSA clinker was chemically
and mineralogically characterized through X-ray fluorescence and laboratory X-ray powder diffraction
(LXRPD), the latter in combination with the Rietveld methodology to obtain the full phase assemblage. The
clinker with the targeted composition (belite ~ wt 60 %, alite ~ 13 wt% and ye’elimite ~ 10 wt%) was chosen to
perform the scaling-up (2 kg). To do so, the processing parameters (milling time and clinkering conditions) have
been optimized.
Finally, the hydration of the corresponding BACSA cement pastes (prepared with the scaled-up clinker and
anhydrite) was studied through thermogravimetric analysis (at very early hydration time) and LXRPD in
combination with the Rietveld methodology, at 1 and 7 hydration days to determine degree of hydration.
Originality
Our key challenge is to design “New formulations of optimised belite-alite calcium sulfoaluminate (BACSA)
which must develop mechanical strengths comparable to those of ordinary Portland cement, OPC, with a
reduction in CO 2 emissions of at least 15% when compared to OPC production.”
Because of that, BACSA clinkers with high amounts of alite and ye'elimite are desired. However, a good raw
meal combination is far from being well-established. This work reports a study of the different combinations of
belite-alite calcium sulfoaluminate raw materials with different mineralogical compositions and the scale-up of
the selected one. Both cement phase assemblage and hydration mechanisms of the corresponding cement pastes
are also being correlated.
Keywords: BACSA cement, clinkering, hydration, Rietveld Quantitative Phase Analysis, X-ray powder diffraction
Currently, Belite Calcium SulfoAluminate (BCSA) cements have been developed as OPC substitutes
(Morin et al., 2011; Cuberos et al., 2010; Gartner & Li, 2006; Álvarez-Pinazo et al, 2014; Álvarez-
Pinazo et al., 2013). BCSA cements contain belite as main phase (>50 wt%) and ye´elimite as
secondary main phase (~30 wt%). BCSA are less calcium carbonate demanding materials than OPC,
with the consequent decrease of carbon dioxide emissions from decarbonation in the kilns. In addition,
OPC clinkering temperature is ~1450 ºC, while for BCSA is ~1300 ºC. Moreover, these materials are
easier to grind, implying an energetic saving and indirect emission depletion. Although BCSA
cements have been proposed as a sustainable alternative to OPC, some important technological
problems are associated to them: i) these materials develop low mechanical strengths at intermediate
hydration ages (3, 7 and 28 days). ii) Weakness of these cements is that the basicity of the pastes is not
very high and therefore, the pozzolanic effect with fly ash or slag is expected not to be very effective.
One of the proposed solutions to this problem is the activation of BCSA with the production of
cements that contain alite jointly with ye´elimite, known as Belite Alite Calcium SulfoAluminate
(BACSA) cements. Their manufacture may produce 15% less CO 2 than OPC. Alite is the main
component of OPC and is responsible for early mechanical strengths. The reaction of alite and
ye´elimite with water will develop cements with high mechanical strengths at early ages, while belite
will contribute to strength developments at later ages (Pérez-Bravo et al, 2013; Liu et al, 2009; Lili et
al, 2009.; Li et al, 2007; Ma et al, 2006; Liu & Li, 2005; Ma et al, 2013). Furthermore, the high pH
values resulting from alite hydration could enhance the pozzolanic reaction facilitating the use of
supplementary cementitious materials. However, there are inherent difficulties in the production of
BACSA, due to the differences between the optimum formation temperatures of main phases. Alite
formation is favoured by the presence of melted phases and at least a temperature of 1350 ºC is
required. On the other hand, decomposition or melting of ye´elimite takes place over 1350 ºC (Puertas
et al, 1995; Fuertes & Fernandez, 1995; Li et al, 2014). Fortunately, the addition of minor quantities of
fluorite (Li et al, 2007; Blanco-Varela et al, 1997) and other minor elements such as Mg (Liu & Li,
2005), Cu (Ma et al, 2006), Mn (Lili et al, 2009), Ti (Liu et al, 2009) or Zn (Pérez-Bravo et al, 2013)
to raw materials will yield to the coexistence of these two phases by using clinkering temperatures of
~1300 °C. Minor elements act as fluxes by reducing the formation temperature of alite. Fluorite, in
addition, works as mineraliser by enlarging the crystallisation volume of this phase (Blanco-Varela et
al, 1997).
The main aim of this study is to prepare a BACSA cement with high contents of belite / ye’elimite /
alite and to understand hydration mechanisms at early ages. In order to do so, laboratory XRPD and
Rietveld methodology (De la Torre et al., 2001) are employed. The results are compared to those
obtained from thermogravimetric (TG) analysis.
2. Experimental
2.1. Materials
2.1.1. Clinkering
Four clinkers were prepared by mixing appropriated amounts natural raw materials of lime, sand,
gypsum and kaolin. Table 1 shows elemental composition of the raw mixtures, excluding CO 2 and
water. Table 1 also includes the clinker nomenclature used in this work and the targeted (nominal)
phase contents. These clinkers are labelled as BACSA_# referred to essay number.
Raw materials were mixed by hand in an agate mortar during 30 minutes. The clinkering was carried
out by pressing the raw mixtures into tablets of ∼3 g of 20 mm diameter. The tablets were placed on
Pt/Rh crucibles and heated at 900 °C for 30 min at a heating rate of 5 °C/min. Then, the temperature
was raised at the same rate to the final temperature (1300 °C) and held for 15 min. Finally, the clinkers
were quenched using forced air convection.
Table 1. Nominal elemental composition of raw mixtures (expressed as oxides) excluding H 2 O and CO 2 and
targeted phase content (both in wt%) of BACSA clinkers.
Clinker BACSA_1 BACSA_2 BACSA_3 BACSA_4
Oxide
CaO 59.3 62.1 60.9 61.2
Al 2 O 3 10.7 13.6 8.6 10.1
SO 3 2.0 3.3 4.9 3.5
Fe 2 O 3 4.9 1.6 1.6 1.6
SiO 2 23.3 24.5 24.0 23.6
Phase
C2S 55 50 50 45
C4 A3Ŝ 15 25 15 18
C3S 15 20 25 30
C 4 AF 15 5 5 5
CŜ --- --- 5 2
2.1.2. Scale-up
BACSA_4 was chosen to be scaled-up to 2 kg, for reasons discussed below, using the raw materials
described above. The raw meal was pre-homogenized for 90 min in a micro-Deval machine (A0655,
Proeti S.A., Spain) at 100 rpm with steel balls (9 balls of 30 mm, 10 balls of 18 mm and 20 of balls of
10 mm). The mixture was pressed into pellets of ~ 30 g of 55 mm of diameter. Six pellets were placed
in a large Pt/Rh crucible. The pellets were heated at 900 °C and held for 30 min (heating rate of 5
°C/min). Then, they were further heated at 1280 or 1300 °C and held for 15 min (at same heating rate).
Finally, the samples were quenched using forced air convection. The clinkered pellets were ground
until all clinker material crossed through a 75 μm sieve.
All the patterns were analyzed by the Rietveld method using GSAS software package (Larson and
Von Dreele, 1994) by using a pseudo-Voigt peak shape function (Thompson et al, 1987) with the
asymmetry correction included (Finger et al 1994) to obtain Rietveld Quantitative Phase Analysis
(RQPA).
Table 2. Weight losses from the TGA study on BCSA_4 cement pastes.
Theoretical Weight loss Weight loss
Pastes age (days)
weight loss* (%) RT-600 ºC (%) 600-1000 ºC (%)
1 33.3 19.5 0.7
7 33.3 20.6 0.9
* Theoretical weight loss due to the total initial free water.
2.2.3. pH measurement
A fraction of pastes was filtered in a Whatman filter (pore size of 8 μm) after 10 min of hydration. The
pH of the filtration waters was measured by using standard digital pHmeter (Álvarez-Pinazo et al,
2014)
Phase
ß-C 2 S 65.0(1) 44.9(3) 59.9(2) 51.8(2) 59.4(2)
γ-C 2 S 2.7(1) 12.2(2) 2.9(2) 8.5(2) 1.2(1)
C 4 AF 22.0(2) 8.2(2) 7.6(1) 7.0(1) 6.5(2)
CŜ - - 0.5(2) - 0.5(6)
o-C 4 A 3 Ŝ 3.5(1) 1.9(6) 9.7(2) 9.1(4) 10.4(1)
c-C 4 A 3 Ŝ - 7.9(7) 0.6(2) 3.0(4) -
C3S - 13.0(3) 13.1(2) 16.0(2) 14.3(2)
C 12 A 7 6.6(1) 2.1(8) - 2.3(1) 4.5(1)
Fluorellestedite - - 5.0(3) - 2.6(1)
C3A - - 0.8(7) 2.3(8) -
C 2 AS - 7.0(3) - - -
Free lime - 2.7(5) - - -
Small amounts of the room-temperature polymorph of dicalcium silicate, γ-C 2 S, were also found in all
clinkers. This phase is formed on cooling by the polymorphic transformation, β-C 2 S→γ-C 2 S, but it is
hydraulically inactive and therefore its presence is undesirable in clinkers. The formation of γ-C 2 S is
enhanced by i) prolonged holding times at high temperatures, ii) low cooling rates and iii) the absence
of foreign ions such as sodium or potassium which could stabilize the β-form. Also, small amounts of
mayenite and C 3 A were found in the clinkers. These phases are hydraulically very active in the
absence and presence of sulphates, consequently their presence in the clinkers has to be taken into
consideration to prepare the corresponding cements. Fluorellestedite (F-ellestedite) is present in
BACSA_3 however, this is an inert phase. Taking into account these results, the chosen clinker to be
scaled-up was BACSA_4 and RQPA of the scaled-up clinker is also reported in Table 3.
Figure 2 DTG curves of BACSA_4 cement paste after 1 and 7 days of hydration
Table 4. RQPA results (wt%) on cement pastes, as a function of hydration time obtained from LXRPD.
Phases to 1d 7d
ß-C 2 S 53.3(2) 52.2(2) 48.6(2)
γ-C 2 S 1.1(1) - -
C 4 AF 5.8(2) - -
CŜ 11.2(2) - -
o-C 4 A 3 Ŝ 9.3(1) 4.1(1) 4.1(2)
C3S 12.8(2) 1.2(2) 1.2(2)
C 12 A 7 4.0(1) 1.1(1) 0.7(1)
Fluorellestedite 2.3(1) 4.1(1) 4.1(2)
C-S-H - 0.6(1) 1.3(2)
CH - - -
AFm-type
- 2.6(1) 4.9(1)
phases
AFt - 35.3(2) 36.6(2)
katoite - 1.7(1) 2.5(1)
The fast emergence of ettringite may stimulate high mechanical strength values at early ages jointly
with the reactivity of C 3 S. The pH value of the pastes was measured to understand the effect in
dissolution of high hydraulic phases (ye’elimite, mayenite, alite and anhydrite), giving a value of
~12.6 (after 10 min hydration). This value is similar to that obtained for a BCSA cement without any
C 3 S in its phase assemblage (Alvarez-Pinazo et al, 2014). It is known that the depletion of dissolved
sulfate ions causes the increase of hydroxide concentration, and consequently a higher pH value
(Winnefeld & Lothenbach, 2010). However, as mentioned before portlandite (CH) was not observed at
any studied age.
4. Conclusions
The main goal of this contribution has been the preparation of a belite-alite-calcium sulfoaluminate
clinker with a designed phase assemblage, with high an alite/ye’elimite mass relation between 1.3 and
1.4. Furthermore, the hydration of this cement with anhydrite and w/c of 0.5, presented a high pH
value than can be attractive for use of fly ash as supplementary material.
Acknowledgements
This work has been supported by Junta de Andalucía (Spain) through the P11-FQM-7517 research
grant and FEDER/University of Málaga (FC14-MAT-23). D. Londono-Zuluaga thanks to Enlaza
Mundos 2013 program fellowship.
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