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Salmia Beddu
Department of Civil Engineering, Universiti Tenaga Nasional,
Jalan IKRAM-UNITEN, 43000 Kajang, Selangor, Malaysia
B.Mahalingam
Department of Civil Engineering, SSN College of Engineering (Autonomous),
Rajiv Gandhi Salai (OMR) Kalavakkam- 603110, Tamilnadu, India
G.Elangovan
Department of Civil Engineering, University College of Engineering,
Thirukuvalai 610204, Tamilnadu, India
ABSTRACT
This paper reports an investigational study on the effect of calcium carbide kiln
dust (CCKD) in cement mortar and its resistance towards hydrochloric acid attack.
Mortar with various CCKD replacement levels from 5 to 40 percent by binder weight
were tested. The setting time, consistency, density, compressive strength and the
durability tests were evaluated to measure the effect of CCKD in mortar. The
durability was assessed in terms of loss of density and strength when the specimen
were cured in 5% hydrochloric acid (HCL) solution. The results indicate that CCKD
replacement levels from 5 to 20 percent performed on par with control mix in terms of
compressive strength, the loss in density and strength were around 30% under acid
curing. However, 30% and above CCKD replacement percentage showed low density
and compressive strength in both conditions. It is concluded that CCKD can be used
as an effective replacement for cement up to 20 percent without affecting the
performance.
Keywords: Compressive Strength; Density Loss; Calcium Carbide Kiln Dust;
Durability; Mortar.
Cite this Article: Sivakumar Naganathan, Masimawati Abdul Latif, Hashim Abdul
Razak, Kamal Nasharuddin Mustapha, Salmia Beddu, B.Mahalingam, G.Elangovan,
Mechanical Properties and Durability of Calcium Carbide Kiln Dust Mortar,
International Journal of Civil Engineering and Technology (IJCIET), 10 (1), 2019, pp.
315–326.
http://www.iaeme.com/IJCIET/issues.asp?JType=IJCIET&VType=10&IType=1
1. INTRODUCTION
The construction industry is growing rapidly with an estimated production of 5 billion tons
cement of by 2030. The cement production is extremely energy-intensive processes hence its
contributed towards 5% of global emission [1]. Turner et.al cited that for every ton of cement
produced, approximately 0.66 to 0.82 kg of carbon dioxide (CO2) is emitted [2]. This
scenario motivates more research on alternative to cement or partial cement replacement
which uses waste materials, hence reducing CO2 emission and good for the environment [3].
There are many research on the utilizations of waste in mortar such as fly ash [4-7] palm oil
fuel ash [8,9] and calcium carbide residue [10].
Generally, there are various types of by-products and wastes produced that require reliable
disposable mechanism and management. Approximately 4.2 billion tons of waste from
domestic, agricultural, industrial, and mineral sources are disposed of in landfill [11]. These
non-decaying wastes which increase over years, not only contaminate the environment but
also requires more land for disposal [12]. The cost for waste disposal also increases with the
constraint of landfill space [13]. Furthermore, waste disposal are now taxable by most
governments [14].
Calcium carbide is usually used in producing acetylene gas, fruits ripening agents and
desulfurizing iron. The calcium carbide (CaC2) is a chemical compound produced from coal
(C) and calcined limestone (CaCO3). The kiln uses electric furnace to heat the coal and
limestone at 2000ºC to 2100°c. The high temperature reduces the lime and carbon (C) to
calcium carbide (CaO) and carbon monoxide (CO) as shown in these equations:
(1)
( ) (2)
The heating process generates gases which contains particulate matter (PM) which is
filtered usually using fabric dust filter collector. The PM thus collected is calcium carbide kiln
dust (CCKD). The chemical composition of CCKD depends on the type of materials, fuel,
kiln and other operating parameters used but carbon and calcium compounds are major
chemical components (Agency 2005).
2. EXPERIMENTAL DETAILS
2.1. Material
This investigation used CCKD, ordinary Portland cement (OPC) confirming to Malaysian
standard MS 522: part 1: 2007 [16] manufactured silica sand, Sika Viscocrete 2199 type super
plasticizer (SP) and normal tap water. The physical and chemical properties of OPC and
CCKD are given in Table 2. The CCKD used was collected from a calcium carbide factory
located in Perak, Malaysia. The dry greyish CCKD was sieved passing sieve size 1.18mm to
remove any impurities and then kept in airtight container. The manufactured silica sand used
were in combination sizes of 8/16, 16/30, 30/60 and 50/100 in percentage derived from sieve
analysis conforming to ASTM C33-03(American Society for Testing and Materials 2001) as
shown in Error! Reference source not found.. The fineness modulus, specific gravity and
the maximum grain size of silica sand are 2.61, 2.69 and 2.36 mm respectively. It has 1.95%
water absorption determined according to ASTM C127-15(American Society for Testing and
Materials 2013a).
2.3. Testing
The specimen were separated into two groups. The first group was cured in normal tap water
until the test day for hardened density and compressive strength. The second group was cured
in normal water for 28 days and then transferred to 5% hydrochloric acid solution to assess
the effect of acid attack on the specimen.
The density of mortar cubes were determined according to BS 1881-114:1983 [19] and the
average of three specimen reported. The weight loss was then calculated using equation
given below:
( ) (3)
Where:
W1 = average weight of the specimen before immersion
W2 = average weight of the cleaned specimen after immersion
The compressive strength of CM and CCKD mortar mixes cubes cured in normal tap
water were determined after 1, 3, 7, 14, 28, 56, 90, 180 and 360 days age using 100kN
capacity Universal Compression Testing Machine with loading rate at 0.5kN/sec. The ASTM
C267-01 [20] test method B was used to investigate the CCKD mortar mixes resistance
towards acid attack at 28 and 62 days. The loss incompressive strength was calculated using
the following equation:
( ) (4)
Where:
fcw = average compressive strength of specimen cured in water
fch = average compressive strength of specimen immersed in hydrochloric acid
All the test results are reported from the average of three specimen.
Figure 10 shows the strength loss for all mixtures. Strength loss increases with increase of
CCKD content in the mixture at both days.
4. CONCLUSION
This investigation presented the mechanical properties and durability of calcium carbide kiln
dust mortar. The following conclusions are drawn from the investigation:
The replacement of CCKD increases the water needed for consistency. Furthermore, the
CCKD accelerates the initial and final setting times and decreases the flow.
The CCKD replacement in the range of 5 – 20% does not reduce the compressive strength
significantly. Hence, it is concluded that CCKD replacement of up to 20 % can be envisaged
in further investigation for the potential benefit of using CCKD in materials.
The loss of weight of CCKD mixtures under acid attack were less than that of control mix.
Hence, the CCKD replacement in mortar does well under aggressive acidic conditions.
ACKNOWLEDGEMENTS
The authors would like to express their sincere thanks to the Ministry of Higher Education
(MOHE), Malaysia for the support given through UM.C/625/1/HIR/MOHE/ENG/56 research
grant. Appreciation is also due to all the staff members of the Concrete Laboratory, University
of Malaya for assisting with the laboratory experiments.
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