A Revolution In the construction sector
Nanocement, is modified Portland cement particles that are covered with a nanoshell made of structured superplasticizer during the grinding of the clinker and fillers such as quartz sand, stone, stone wastes, slags and/or ashes.
"The fundamental innovation in nanocement is, the process of nanocapsulation of the standard Portland cement particles."
With the production of Nanocement, it is possible to reduce fuel consumption and CO2 emissions by 2 - 3 times without the reconstruction of cement facilities. The proposed technology is modified Portland cement particles that are covered with a nanoshell made of structured superplasticizer, that transform into Nanocement. The production of Nanocement allows for a change in the development strategy of the global cement industry and the opportunity to additionally obtain over 2 billion tons of cement annually. Furthermore, no new cement clinker burning plants are required, and no new limestone and clay quarries need to be developed.
This technology allows to convert large volumes of cheap quarry and desert quartz sand, as well as accumulated industrial waste (such as slags, ashes, etc.), into high-quality cement. It will allow to drastically reduce emissions into the atmosphere, increase cement shelf-life to a minimum of a year without deterioration of its properties, improve quality and longevity of concretes, reduce Portland cement consumption in concrete mixtures by 2-3 times, and reduce the overall costs of cement and concrete production. In addition, Nanocement grade characteristics are the highest in the history of global cement in terms of energy-saving and quality combined.
Take note of the intensive strength of the cement stone at the beginning of the hardening process. This is on the base of low clinker energy saving Nanocement formula.
Consequently, Nanocement 55 with only 55% mass of modified Portland cement (PC) demonstrated compressive strength in stone - 49.3 MPa and deflection strength - 6.3 MPa in two days of normal hardening, reaching compressive strength - 77.5 MPa, and deflection strength - 8.2 MPa in 28 days of hardening.
Dubai, United Arab Emirates
Take note of the production cost improvements: class C42.5 Nanocement is 43% cheaper to produce as compared to standard PC C42.5. Additionally, classes C62.5 and C72.5 are cheaper to produce but can be sold at a significant premium over standard PC.
Assumptions: Costs per ton in $ USD (2016) Clinker $48; Sand $6; Gypsum $18; Additive $1000
THE FUTURE OF THE WORLD CEMENT INDUSTRY AND CONCRETE TECHNOLOGY
Implementation of the low-clinker Nanocement technology offers real possibility to:
- Reduce specific NOX, SO2 and СО2 emissions from existing cement plants by several times;
- Reduce specific fuel consumption per ton of cement by 40-60 kg;
- Drastically improve cement quality by 1.5-2 times
- Increase output by 1.5-1.7 times at any cement plant without construction of clinker burning production areas - only due to development of mill houses;
- Create compact processing lines for modification of Portland cement clinker or cement into low-clinker Nanocements at concrete manufacturing plants;
- Increase the potential cement storage life from 2 months according to international and Russian standards for Portland cement up to a year and more for Nanocements;
- Reduce the cost of cement production by 20-25%;
- Produce cements of classes 62.5, 72.5 and 82,5 for the first time ever.
How is it produced
Nanocements are produced with the addition of more than 65% of mineral supplements, such as sand, ash, slag, tuff, etc.
Capsules of Nanocement are created by the mechanical activation of cement dispersion formed as composites. They consist of nuclear particles of cement, ranging in size up to 2-3 um and coated with thin membranes of modification material with a thickness in the range of 10-100 nm.
This process allows the increases of cement grading strength (class) up to 62.5 - 102.5.