Description:“PORTLAND POZZOLANA CEMENT BOOSTER AND A PROCESS FOR PREPARATION THEREOF”
FIELD OF INVENTION
[001] This invention relates to portland pozzolana cement booster and a process for preparation thereof. The booster is high efficiency performance enhancer for Portland Pozzolana Cement (PPC).

[002] The purpose of the invention is to improve the hydration of Portland Pozzolana Cement (PPC) at early and later ages to achieve higher strength, enhance production and lower specific power consumption of cement mill in grinding of cement.
BACKGROUND OF INVENTION
[003] Background description includes information that may be useful in understanding the present invention. It is not an admission that any of the information provided herein is prior art or relevant to the presently claimed invention, or that any publication specifically or implicitly referenced is prior art.

[004] Portland Pozzolana Cement (PPC) is manufactured by grinding Clinker and Pozzolana with Gypsum or by uniformly blending fine Pozzolana and Portland cement. Pozzolana such as fly ash which is waste of Thermal power plant alone does not possess any cementing value itself but when they are combined with calcium hydroxide released from hydration of clinker phases (Tri-calcium silicate- C3S, Di-calcium silicate- C2S), it produces secondary Calcium silicate hydrate gel (CSH) compound which contributes to the durability and strength of Portland Pozzolana Cement (PPC).

[005] The initial mechanical strength gain of PPC is lower than OPC because fly ash slows down the hydration process of cement. Also, the presence of fly ash increases setting time hence delays de-shuttering of formwork compared with Ordinary Portland Cement (OPC).

PRIOR ART OF THE INVENTION

[006] There is no relevant prior art available for PPC in which accelerator with water reducer, self-curing property for better hydration and deagglomerator in such combination is available to enhance bonding property of cement-mortar at all ages (1, 3, 7 and 28 days). However, some related patent references available in the art are given below:

CA2586655:

[007] The invention relates to Improved Compression strength cement, which makes the use of raw glycerine as a cement additive in order to improve the compression strength thereof.

[008] Said glycerine is used as an aqueous solution in a concentration ranging between 10% and 90% by weight, preferably between 10% and 60% by weight. Said glycerine aqueous solution is added to the clinker.
US7638563:

[009] It is talking about Polycarboxylic acid concrete admixture. The polycarboxylic acid concrete admixture exhibits properties such as decreasing the concrete viscosity, improving the slump-retaining ability, and suppressing bleeding water, and is improved in the ability to cement compositions or the like. The above-mentioned polycarboxylic acid concrete admixture comprises a polycarboxylic acid polymer containing a polyalkylene glycol in the side chain, wherein the polycarboxylic acid polymer is obtained by polymerizing monomer components containing an alkyl (meth)acrylate monomer and a specific polyalkylene glycol unsaturated monomer and 19 to 65 mole % unsaturated carboxylic acid (salt) monomer, and it has a specific weight average molecular weight of 18000 or less.

US7405264:

[0010] It is related to Polycarboxylic acid copolymer, production method and use thereof.

[0011] It is suited for use as the polyhydric alcohol, which are polyglycidol, polyglycerol, trimethylotethane, trimethylolpropane, 1,3,5-pentanetriol, _ shows a peak having no shoulder in GPC, has a weight average molecular weight (Mw) of 5,000 to 300,000, shows in IR.

[0012] However, the above Referenced patents are not specific for PPC and not adding value in cementitious property for above mentioned invention in this category.

[0013] Thus, none of the known patents can fulfill the requirements of the instant invention for which it has been designed.

[0014] Further, various additives are available in the market for cement to alter the physical properties of the final cement. However, these additives usually have little holistic beneficial effect in respect to grinding efficiency, accelerator with water reducer, self-curing property, strength enhancing at all ages.

[0015] In view of the above, present invention has been introduced. This invention relates to development of additive of organic and inorganic based chemicals for PPC which is having self-curing property, accelerating hydration with lower water demand, facilitating finer grinding of cement result in increasing significant mechanical strength at all ages (1, 3, 7 and 28 days).
OBJECTS OF THE INVENTION
[0016] Primary object of the invention is to provide portland pozzolana cement booster and a process for preparation thereof.

[0017] Another object of the invention is to improve quality of Portland Pozzolana Cement (PPC),

[0018] Yet another object of the invention is to increase production and lower specific power consumption in grinding.

[0019] Another object of invention is to improve workability of cement.

[0020] Still another object of this invention is to provide portland pozzolana cement booster and a process for preparation thereof, which facilitates grinding and improves the 1, 3, 7 and 28-day strength of the PPC mortar.

[0021] These and other objects and advantages of the present invention will be apparent to those skilled in the art after a consideration of the following detailed description taken in conjunction with the accompanying drawings in which a preferred form of the present invention is illustrated.
SUMMARY OF THE INVENTION:
[0022] One or more drawbacks of conventional systems and process are overcome, and additional advantages are provided through the apparatus/composition and a method as claimed in the present disclosure. Additional features and advantages are realized through the technicalities of the present disclosure. Other embodiments and aspects of the disclosure are described in detail herein and are considered to be part of the claimed disclosure.

[0023] Portland Pozzolana Cement Booster (PCB) is homogenous mixture of organic-inorganic chemical compound in water. PPC is sustainable and durable green product compared to OPC but having slow and lower strength gain due to slow hydration. In view of premium quality strength PPC production with lower grinding energy, it is required to add unique additive to counter the drawback of lower strength. Portland Pozzolana Cement Booster (PCB) has been developed to add significant value in PPC; resulting in accelerated strength, lower water demand and self-curing property to improve workability and strength of mortar at all ages and facilitates for finer grinding that may result in increased production, lower CO2 emissions, natural resource conservation by reduced clinker consumption resulting in increased mines life compared to OPC.

[0024] Various objects, features, aspects, and advantages of the inventive subject matter will become more apparent from the following detailed description of preferred embodiments, along with the accompanying drawing figures in which like numerals represent like components.

[0025] It is to be understood that the aspects and embodiments of the disclosure described above may be used in any combination with each other. Several of the aspects and embodiments may be combined to form a further embodiment of the disclosure.

[0026] The foregoing summary is illustrative only and is not intended to be in any way limiting. In addition to the illustrative aspects, embodiments, and features described above, further aspects, embodiments, and features will become apparent by reference to the drawings and the following detailed description.
DETAIL DESCRIPTION OF PREFERRED EMBODIMENTS OF THE INVENTION:
[0027] While the embodiments of the disclosure are subject to various modifications and alternative forms, specific embodiment thereof have been shown by way of example in the figures and will be described below. It should be understood, however, that it is not intended to limit the disclosure to the particular forms disclosed, but on the contrary, the disclosure is to cover all modifications, equivalents, and alternative falling within the scope of the disclosure.

[0028] The present invention makes a disclosure regarding portland pozzolana cement booster and a process for preparation thereof.

[0029] Portland Pozzolana Cement Booster (PCB) is homogeneous mixtures of organic and inorganic compound. Introduced chemicals in PCB are long chain polymer, polyol and amino compound. The ratio range of PCB has been developed to make cost feasible and optimum performance of PPC near to OPC strength performance.

[0030] Its composition is suitable for an improved grinding process, self-curing property and significant increase in strength of PPC. The present invention is directed to work on improving the particle size distribution of PPC and flowability, acceleration of strength by increasing CSH gel formation at early and later ages and refining pore structure. The results obtained showed that with the addition of PCB can improve the grindability by decreasing agglomeration and reducing ball coating.

[0031] The Portland Pozzolana Cement Booster (PCB) is composed of uniform mixture of alkanolamine (A), triol (B), long chain organic-inorganic polymer (C) with water (D) in weight ratio. Ratios range of A, B, C, D are 2-5: 2-5: 5-10: 80-91 where A- TEA & MDEA, B- Glycerol & EDG (Ethylene Di Glycol), C- Calcium Lignosulphonate and D-Water.

TEA:-
[0032] Trolamine, which is also referred to as triethanolamine (TEA), is a tertiary amine and a triol. It is a bifunctional compound that exhibits both properties of alcohols and amines.

[0033] Triethanolamine or TEA, is an organic compound with the chemical formula N(CH2CH2OH)3. It is a colourless, viscous liquid. It is both a tertiary amine and a triol. A triol is a molecule with three alcohol groups. It is a colourless compound although samples may appear yellow because of impurities.

[0034] Triethanolamine is produced from the reaction of ethylene oxide with aqueous ammonia, also produced are ethanolamine and diethanolamine. The ratio of the products can be controlled by changing the stoichiometry of the reactants.

[0035] Triethanolamine is also used as organic additive in the grinding of cement clinker. It facilitates the grinding process by preventing agglomeration and coating of the powder at the surface of balls and mill wall. Triethanolamine is as follows:

MDEA:-

[0036] Methyldiethanolamine, also known as N-methyl diethanolamine and more commonly as MDEA, is the organic compound with the formula CH3N(C2H4OH)2. It is a colourless liquid with an ammonia odor. It is miscible with water, ethanol and benzene.

[0037] The enhancer of present invention is being added during grinding of PPC ingredients such as Clinker, Fly ash and Gypsum to provide benefits like improved particle size distribution, reduced residues and increased strength. The present invention is directed towards specific performance improver for PPC which exhibits both excellent grinding aid properties as well as hydration enhancing properties, reduces porosity and normal consistency.

[0038] Properties of PCB are given hereunder:

S. No. Parameters Details
1 State Liquid
2 Color Dark Brown
3 Density (gm./cm3) 1.11-1.20
4 pH 6.90 – 7.90

[0039] PCB performances as surface-active agent due to the orientation of hydrophobic groups adsorbed on the surface of cement particles, long chain polymer reduces water demand; polyol holds the water during mixing and releases it during cement hydration, reduction in porosity and formation of crosslinks among the grains solidified in free space.

[0040] Under the process of this invention, hydration studies of cement paste is carried out with and without PCB.

[0041] In the anhydrous state, four main types of hydraulic minerals are Alite(C3S), Belite(C2S), Aluminate(C3A) and Ferrite phase (C4AF). Also, reactive contents in PPC are small amounts of clinker sulfate (sulfates of sodium, potassium and calcium), Gypsum, amorphous silica & alumina. When water is added, the reactions occur are exothermic, that generate heat.

[0042] Hydration experiments results indicate that-

• Hydration reaction of Alite M3 and Ferrite phase was accelerated with PCB chemical.
• Ettringite, Tobermorite and Hydrogarnet phase formation increased with PCB chemical. This is strength giving phase in cement mortar.

[0043] On adding water, clinker sulphates and gypsum dissolve producing an alkaline, sulfate-rich solution, the (C3A) phase (the most reactive clinker mineral) reacts with water to form an aluminate-rich gel. The gel reacts with sulfate in solution to form small rod-like crystals of ettringite. Then, the alite and belite in the cement start to react with the formation of calcium silicate hydrate and calcium hydroxide. Ferrite reaction also starts quickly as water is added, but then slows down, because a layer of iron hydroxide gel forms, coating the ferrite and acting as a barrier, preventing further reaction. Pozzolana Cement Booster (PCB) also enhances solubility of ferrite.

[0044] PPC containing 0.02-0.04 % of Portland Pozzolana Cement Booster (PCB) exhibits a marked increase in 1, 3, 7 and 28 day compressive strength i.e. 8-15 % (1 day), 8-12 % (3 days), 10-13 %(7 days) and 8-10 %(28 days) strength increase from blank. PCB would be interground as a grinding aid with cement clinker during finish milling.

[0045] Thus, this invention provides deagglomerator, activator, water reducer and self-curing properties in combination to facilitate grinding, improve durability and strength of the PPC mortar at all ages.
WORKING EXAMPLE (For Process)
[0046] Portland Pozzolana Cement (PPC) prepared in Lab ball mill with and without PCB chemical at same percentage and composition of ingredients of PPC, grinding time and same SO3 % age maintained. Its performance evaluated and compared with blank/reference sample. Results of PPC with PCB chemical and without (Blank) indicate that:-
• Residue decreased by 3.0 % on 45 microns of PPC prepared with 0.02-0.04 % PCB chemical compared to blank sample (PPC without chemical).

• ~5% Particle size of PPC increased between 3-30 microns with PCB chemical.
• Water consistency is reduced by 3.0% on PCB use.
• Initial and Final setting time of PPC slightly increased (5 minutes) with PCB chemical.
• Both PPC samples passed in soundness test (Autoclave and Le-chattelier test).
• Compressive strength significantly increased at all ages (1, 3, 7 and 28 days). i.e. 8-15 % (1 day), 8-12 % (3 days), 10-13 % (7 days) and 8-10 %(28 days) strength increase from blank.
ADVANTAGES OF INVENTION
[0047] Portland Pozzolana Cement Booster (PCB) may help to substitute Ordinary Portland Cement (OPC) which is energy intensive product by making premium PPC which is durable green product, wherein lower CO2 emissions and reduced clinker consumption result in natural resource conservation and increased mines life. Also, PCB makes easier to grind which may increase production and lower specific grinding energy of cement.

[0048] PCB also adds significant value in cementitious property resulting in accelerated strength and self-curing property to improve workability of mortar at all ages and facilitates.

TEST RESULTS [To show better performance of invention over prior art(s)]
Composition % PPC (Blank) PPC (WITH PCB)
Clinker 57.08 57.08
Gypsum 7.92 7.92
FLYASH 35.00 35.00
PCB CHEMICAL 0.00 0.02-0.04
Total 100.00 100.02-100.04
Target SO3 % 2.80 2.80
Grinding Time in Minute 40+5 40+5
Chemical Analysis
% CaO 39.87 39.99
% SO3 2.66 2.65
%FCaO 0.73 0.76
% IR 33.48 33.37
% LOI 1.80 1.73
Physical Analysis
Water Consistency (%) 29.00 26.00
Blaine (m2/Kg) 370 374
Residue %
+ 45 µ 20.12 17.20
+90 µ 3.90 2.42
+212 µ 0.56 0.38
Setting Time (min)
Initial 145 150
Final 180 185
Soundness Test
AC Exp. (%) 0.0544 0.0555
LC Exp. (mm) 1.00 1.00
Comp. Strength (MPa)
01 Day 17.3 18.7-19.9
03 Days 24.1 26.0 - 27.0
07 Days 29.5 32.5-33.4
28 Days 42.9 46.4-47.2
PSD Analysis(%)
< 3 Mic. 7.02 8.25
3-30 Mic. 51.48 56.70
30-45 Mic. 13.80 13.10
> 45 Mic. 26.70 23.40
D (0.9) 83.40 67.20

[0049] Each of the appended claims defines a separate invention, which for infringement purposes is recognized as including equivalents to the various elements or limitations specified in the claims. Depending on the context, all references below to the "invention" may in some cases refer to certain specific embodiments only. In other cases, it will be recognized that references to the "invention" will refer to subject matter recited in one or more, but not necessarily all, of the claims.

[0050] Groupings of alternative elements or embodiments of the invention disclosed herein are not to be construed as limitations. Each group member can be referred to and claimed individually or in any combination with other members of the group or other elements found herein. One or more members of a group can be included in, or deleted from, a group for reasons of convenience and/or patentability. When any such inclusion or deletion occurs, the specification is herein deemed to contain the group as modified thus fulfilling the written description of all groups used in the appended claims.

[0051] It will be understood by those within the art that, in general, terms used herein, and especially in the appended claims (e.g., bodies of the appended claims) are generally intended as “open” terms (e.g., the term “including” should be interpreted as “including but not limited to,” the term “having” should be interpreted as “having at least,” the term “includes” should be interpreted as “includes but is not limited to,” etc.). It will be further understood by those within the art that if a specific number of an introduced claim recitation is intended, such an intent will be explicitly recited in the claim, and in the absence of such recitation no such intent is present. For example, as an aid to understanding, the following appended claims may contain usage of the introductory phrases “at least one” and “one or more” to introduce claim recitations. However, the use of such phrases should not be construed to imply that the introduction of a claim recitation by the indefinite articles “a” or “an” limits any particulars claim containing such introduced claim recitation to inventions containing only one such recitation, even when the same claim includes the introductory phrases “one or more” or “at least one” and indefinite articles such as “a” or “an” (e.g., “a” and/or “an” should typically be interpreted to mean “at least one” or “one or more”); the same holds true for the use of definite articles used to introduce claim recitations. In addition, even if a specific number of an introduced claim recitation is explicitly recited, those skilled in the art will recognize that such recitation should typically be interpreted to mean at least the recited number (e.g., the bare recitation of “two recitations,” without other modifiers, typically means at least two recitations, or two or more recitations). Furthermore, in those instances where a convention analogues to “at least one of A, B and C, etc.” is used, in general such a construction is intended in the sense one having skill in the art would understand the convention (e.g., “a system having at least one of A, B and C” would include but not be limited to systems that have A alone, B alone, C alone, A and B together, A and C together, B and C together, and/or A, B, and C together, etc.). In those instances where a convention analogous to “at least one of A, B, or C, etc.” is used, in general such a construction is intended in the sense one having skill in the art would understand the convention (e.g., “a system having at least one of A, B, or C” would include but not be limited to systems that have A alone, B alone, C alone, A and B together, A and C together, B and C together, and/or A, B, and C together, etc.). It will be further understood by those within the art that virtually any disjunctive word and/or phrase presenting two or more alternative terms, whether in the description, claims, or drawings, should be understood to contemplate the possibilities of including one of the terms, either of the terms, or both terms. For example, the phrase “A or B” will be understood to include the possibilities of “A” or “B” or “A and B”.

[0052] The above description does not provide specific details of manufacture or design of the various components. Those of skill in the art are familiar with such details, and unless departures from those techniques are set out, techniques, known, related art or later developed designs and materials should be employed. Those in the art are capable of choosing suitable manufacturing and design details.

[0053] The terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting of the present disclosure. It will be appreciated that several of the above-disclosed and other features and functions, or alternatives thereof, may be combined into other systems or applications. Various presently unforeseen or unanticipated alternatives, modifications, variations, or improvements therein may subsequently be made by those skilled in the art without departing from the scope of the present disclosure as encompassed by the following claims.

[0054] The claims, as originally presented and as they may be amended, encompass variations, alternatives, modifications, improvements, equivalents, and substantial equivalents of the embodiments and teachings disclosed herein, including those that are presently unforeseen or unappreciated, and that, for example, may arise from applicants/patentees and others.

[0055] While various aspects and embodiments have been disclosed herein, other aspects and embodiments will be apparent to those skilled in the art. The various aspects and embodiments disclosed herein are for purposes of illustration and are not intended to be limiting, with the true scope and spirit being indicated by the following claims.
, Claims:We Claim
1. Portland Pozzolana Cement Booster (PCB) comprises mixture of alkanolamine (A), triol (B), long chain organic-inorganic polymer (C) with water (D) in weight ratio, wherein A- TEA & MDEA, B- Glycerol & EDG, C- Calcium Lignosulphonate and D-Water.

2. The Portland Pozzolana Cement Booster (PCB) as claimed in claim 1, wherein the weight ratios of A, B, C, D are 2-5: 2-5: 5-10: 80-91.
3. The Portland Pozzolana Cement Booster (PCB) as claimed in claim 1 or 2, wherein the Portland Pozzolana Cement (PPC) containing 0.02-0.04 % of Portland Pozzolana Cement Booster (PCB), which improves workability of cement mortar and exhibits a marked increase in 1, 3, 7 and 28 day compressive strength i.e. 8-15 % (1 day), 8-12 % (3 days), 10-13 %(7 days) and 8-10 %(28 days) strength increase from blank.
4. The Portland Pozzolana Cement Booster (PCB) as claimed in claims 1-3, wherein the booster is added during grinding of Portland Pozzolana Cement (PPC) ingredients including Clinker, Fly ash and Gypsum to provide benefits of improved particle size distribution, reduced residues and increased strength.
5. Process for preparation of Portland Pozzolana Cement Booster (PCB) as claimed in claim 1 comprising steps of:
- Unloading the Portland Pozzolana Cement Booster (PCB) ingredient chemical in separate pre-storage tank, in which heating element in pre-storage tank is used to melt the ingredient chemical into liquid to make homogeneous solution of PCB,

- Supplying of Liquid Portland Pozzolana Cement Booster (PCB) ingredient to mixing tank as per design ratio,

- Mounting of Mixing tank with agitator, wherein the Mixing tank is connected with motor and mixing is carried out till homogeneous solution appears.
6. The process as claimed in claim 5, wherein mixing time is ~1.5-2.5 hours and Temperature of solution is in range of 25-50 0C for well working.
7. The process as claimed in claim 5 or 6, wherein during dosing in cement mill, mixing of Portland Pozzolana Cement Booster (PCB) solution is continuous.