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At least 55 records · Page 3

Development of Magnesium Oxysulfate Formulation for SRPPF Aqueous Recovery Liquid Solidification

The liquid effluent from the Savannah River Plutonium Processing Facility (SRPPF) Aqueous Recovery Processes will be solidified into a stable form that is acceptable by Waste Isolation Pilot Plant (WIPP) for disposal. The current Aqueous Recovery flow sheet proposes to solidify the liquid effluent using a grout formula that was developed and tested for the former Waste Solidification Building process. This Portland cement based mixture results in a high pH (~13) leachate from the solidified waste form which is not acceptable to WIPP in the large quantities expected from production at SRPPF. Various cementitious materials were previously evaluated as alternative grout formulations to Portland cement and a MgO-based mix was identified as a promising alternative. A magnesium oxysulfate (MOS) cement formulation comprised of reactive magnesium oxide (MgO), anhydrous magnesium sulfate (MgSO 4 ), and sand, as a non-reactive heat sink provided good mixability, similar density to the original Portland-cement based mix, and a leachate pH of 9.4, within the assumed WIPP brine pH range. However, the MOS formulation exhibited an appreciable amount of heat generation, which resulted in premature setting of a large-scale test.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

Characterization of Saltstone Grout Line Samples

During a prestart recirculation operation in the Saltstone Processing Facility (SPF), operations staff noticed hardened scaling falling into the hopper. As a result, SPF operators and Saltstone Engineering decided to postpone operation and conduct a process room hopper cleanout. During the cleanout effort personnel noted greater than normal buildup of damp solid material in the transfer line. A borescope investigation was conducted and confirmed buildup was present throughout the transfer line to the downstream valves. Savannah River National Laboratory personnel were asked to characterize the scale material and samples collected from the saltstone grout line and provide recommendations and/or further guidance as to whether additional corrosion testing is needed for useful equipment operating life information. Based on the samples characterized results, the plug material contained only the 60:40 slag:fly ash saltstone. Portland cement in the original 10:45:45 Portland cement:slag:fly ash mix may result in a less abrasive slurry compared to the 60:40 slag:fly ash mix because the slag is > 95 % crushed angular, sharp edged glass. Saltstone grout erosion and corrosion testing of A36 carbon steel is needed to determine if the 60:40 mix is more abrasive and corrosive for A36 carbon steel than the 10:45:45 mix.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

ASSESSMENT OF HIGH-VOLUME HARVESTED FLY ASH BLENDS FOR USE IN PRECAST CONSTRUCTION

Declining supplies of fresh fly ashes in some regions have further driven the importance of using harvested fly ash as a supplementary cementitious material and thus replacement for more energy-intensive ordinary Portland cement (OPC). Higher replacement rates of OPC with fly ash in general has traditionally been limited in precast operations due to stringent early-age strength requirements necessitated by initial prestress and lifting/handling of hardened components – often well within 24 hours after fresh concrete placement. Therefore, a series of mix designs were developed, as part of a larger framework for reassessing high-volume fly ash (HVFA) use in the context of precast construction, to demonstrate the feasibility of using larger fractions of harvested fly ash in concrete formulations suitable for precast fabrication demands. More specifically, a target minimum 24-hour compressive strength of 24.1 MPa (3500 psi) was set, in accordance with conventional precast structural design checks, while increasing the fly ash content to 40% replacement of OPC – at least a 15% increase above the traditional limit of 25%. The effect of using more sustainable Type IL cement in contrast to conventional Type III Portland cement (the traditional standard for precast use) – both in conjunction with HVFA use – was also examined. Early-age mechanical properties including compressive strength, modulus of rupture, and modulus of elasticity were evaluated within the aforementioned early-age window. Lastly, corresponding design equations were then reassessed for their applicability with respect to the high-early strength HVFA mixes examined herein.

Gombeda, Matthew J.↗

Physicochemical properties of the Portland cement-based mortar exposed to deep seafloor conditions at a depth of 1680 m

Achieving breakthroughs in marine technologies requires the development of infrastructures submerged in deep-sea environments, whose physicochemical effects on cement-based materials considerably differ from those of shallow seas. However, very few studies focused on the cement-based materials subjected to deep-sea conditions. This work investigates the changes in the compressive strength and phase composition of the cement mortar kept on the seafloor with a depth of 1680 m for 608 d. The mortar specimens salvaged from the seafloor exhibited severe visible damages, including softened mashy structures and significantly decreased compressive strengths. The obtained X-ray diffraction, scanning electron microscopy, and nuclear magnetic resonance data revealed that the dissolution of portlandite, decalcification of calcium (alumino) silicate hydrate, and formation of brucite, magnesium (alumino) silicate hydrate, a hydrotalcite-like phase, thaumasite, and ettringite likely contributed to the disintegration of mortar, which could be further accelerated by the low temperature of the deep-sea environment.

36 MATERIALS SCIENCE↗

Near-field infrared microscopy: A novel analytic mapping technique to nanocharacterize calcium silicate-based cement materials

Infrared imaging via scattering-type scanning near-field optical microscopy (s-SNOM) allows chemical mapping of organic and inorganic materials with nanoscale spatial resolution. However, its potential adaptation to the complex multiphase structure of Portland cement is yet to be explored. Here we demonstrate the successful implementation of s-SNOM to spatially resolve coexisting chemical phases in tricalcium silicate, Portland cement's main compound, with 20-nm resolution. We found that s-SNOM is sensitive to different anhydrous polymorphic phases, revealing nanoscale domains that are ‘invisible’ to other microscopic techniques. Furthermore, s-SNOM's ability to distinguish the unhydrated and hydrated phases signifies its great promise as an analytical tool to study the complex hydration process of cement. The key to s-SNOM's application was nano-modifying the surface roughness of the cement samples, allowing nanoscale infrared imaging without topographical artifacts. Our study opens a window for infrared spectral microscopy in cement and other porous inorganic materials.

36 MATERIALS SCIENCE↗

Synthesis and characterisation of alites from reduced basic oxygen furnace slags

Basic oxygen furnace slags (BOFS) are by-products of the steelmaking process. Several researchers have studied the production of Portland cement clinker and metallic iron from BOFS via a reductive treatment. }In this study, we applied a carbothermal reduction of BOFS in a technical-scale electric arc furnace and characterised the clinker-like products. Those clinker-like non-metallic products (NMPs) had a chemical and mineralogical composition comparable to clinker for ordinary Portland cement (OPC) and contained large elongated alite crystals as major component. The pure NMPs reacted more slowly and achieved a lower degree of hydration compared with commercial OPC. }If the reactivity of the products can be further increased by employing specific adaptations, it can be used as a full clinker substitute for OPC. Nevertheless, it is also an option to use the material without further modifications as a cement component or concrete addition, which contributes to the strength development in both cases.

36 MATERIALS SCIENCE↗

Efficiency of natural pozzolans, ground glasses and coal bottom ashes in mitigating sulfate attack and alkali-silica reaction

The use of pozzolans to partially replace Portland cement in concrete has generally demonstrated beneficial impacts on the durability characteristics of concrete for decades. In this paper a diverse range of pozzolans including natural pozzolans, ground glasses and industrial by-products such as coal ash (fly ash and bottom ash) and silica fume were investigated for their synergistic potential in binary or ternary blends with Portland cement in improving resistance to chemical sulfate attack and alkali-silica reaction (ASR). It is generally considered that pozzolans improve most of the durability issues encountered in concrete, including reducing the risk of sulfate attack or ASR. But this is not always the case. For example, it was found that ground glasses were very efficient in improving sulfate resistance, but their ability to mitigate expansion due to ASR was dictated by the equivalent alkalis content (Na{sub 2}O{sub e}) of the glass and high-alkali soda glass was generally not effective in this role. On the other hand, metakaolin, a highly reactive pozzolan, was highly effective in reducing ASR expansion, but may actually increase the damage due to sulfate attack when used at moderate replacement levels. Most pozzolans, such as low-CaO coal fly ash and ground coal bottom ash, silica fume, and pumice, were effective in controlling expansion due to both ASR and sulfate attack. The results demonstrated that the extent of the positive impact of using natural pozzolans on both properties was variable. The pozzolanic reactivity of materials alone was an unreliable indicator to assess the ability of the pozzolan to suppress expansion due to sulfate attack or ASR.

36 MATERIALS SCIENCE↗

The crystal structure of a new calcium aluminate phase containing formate

A new calcium aluminate phase containing formate ions was synthesized and its crystal structure determined. This new phase is indicated as M-phase and was firstly observed in Portland cement pastes hydrated in presence of Ca-formate and in excess of water. The crystal structure of the M-phase was successfully solved in the R-3 space group of the trigonal system on the basis of synchrotron X-ray single crystal diffraction data. The structural model was confirmed by Rietveld refinement of the powder diffraction data acquired on the synthesized pure sample. The crystal structure of the M-phase is similar to that of ettringite, being characterized by columns of AlO{sub 6} octahedra alternating with groups of three edge-sharing CaO{sub 7} polyhedra. The formate ions (HCOO){sup −} share two oxygens with Ca polyhedra and are located in the interspace between the columns. The crystal structure of the M-phase testifies the strong interaction occurring between small organic molecules as formate and the calcium aluminate components of Portland cement.

36 MATERIALS SCIENCE↗

Pozzolanic reactivity of natural pozzolans, ground glasses and coal bottom ashes and implication of their incorporation on the chloride permeability of concrete

It is well understood that the partial replacement of portland cement with pozzolans in sufficient proportions results in improved long-term performance of concrete. However, dwindling availability of the most widely used pozzolan in the construction industry, fly ash, is forecast due to the termination of coal-fired electricity power stations around the world, necessitating the exploration of alternative pozzolans. Experimental investigations are conducted to study the performance of traditional pozzolans such as fly ash, silica fume and natural pozzolans (metakaolin, pumice, perlite and lassenite) together with novel pozzolans, including ground glasses (high-alkali and low-alkali), and ground bottom ash. Twenty-one concrete mixtures are examined for compressive strength, electrical conductivity, electrical resistivity, chloride permeability, and chloride migration coefficient. The reactivity of pozzolans studied is also determined in terms of compressive strength in lime-pozzolan mortar using a modified lime-reactivity test method. Many of the materials tested demonstrate the potential to be used in place of fly ash. However, a wide variation in the performance of these materials is evident which highlights the need for a reliable test to determine the level of reactivity of a pozzolan. The results indicate that the 7-day strength in the modified lime-reactivity test provides a good indication of the pozzolanic reactivity of the material and of how the material can be expected to contribute to the strength and permeability of concrete. The use of electrical resistivity as an indicator of the performance of pozzolans in terms of strength development and chloride penetration resistance when used to partially replace portland cement in concrete is also discussed.

36 MATERIALS SCIENCE↗

Microstructure and water absorption of ancient concrete from Pompeii: An integrated synchrotron microtomography and neutron radiography characterization

There is renewed interest in using advanced techniques to characterize ancient Roman concrete due to its exceptional durability and low-carbon footprint. In the present work, samples were drilled from the “Hospitium” in Pompeii and were analyzed by synchrotron microtomography (μCT) and neutron radiography to study how the microstructure, including the presence of induced cracks, affects their water adsorption. The water distribution and absorptivity were quantified by neutron radiography. The 3D crack propagation, pore size distribution and orientation, tortuosity, and connectivity were analyzed from μCT results using advanced imaging methods. Porosity was also measured by mercury intrusion porosimetry (MIP) as a reference. Ductile fracture patterns were observed once cracks were introduced. Compared to Portland cement mortar/concrete, the Pompeii samples had relatively high porosity, low connectivity, and a similar coefficient of capillary penetration. In addition, permeability was predicted from models based on percolation theory and pore structure data to evaluate the fluid transport properties. Understanding the microstructure of ancient Pompeii concrete is important because it could inspire the development of modern concrete with high durability.

36 MATERIALS SCIENCE↗

Scalable electrified cementitious materials production and recycling

The production of Portland cement, the industry-standard cement, contributes ~8% of global CO 2 emissions through fossil-fuel heating and decomposition of limestone (the primary cement raw material). Decarbonization, e.g., via direct electrification, of this 200-year-old liming routine is extremely challenging at the industry scale. We propose a scalable electrochemical decarbonization approach to circumvent the limestone use by switching to carbon-free calcium silicates from abundant minerals and recycled concrete. Water electrolysis produces protons and hydroxides to drive a pH gradient that accelerates Ca 2+ ion leaching from calcium silicates and captures atmospheric CO 2 to form carbon-negative CaCO 3 , which serves as the feedstock for cement manufacturing or as the carbon-mineralized product for cement substitution with permanent carbon storage. Value-added co-products amorphous silica and green H 2 further enhance cement performance and supplant fossil fuels for net-zero transition, respectively. The products readily meet present-day regulatory standards and demands, and the approach readily synergizes with business-as-usual cement manufacturing and concrete construction, which are important for upscaling and structural safety, promising ready reception by the public and industries. Blended Portland cement produced through our approach with carbon-negative CaCO 3 and silica demonstrates enhanced resilience and achieves carbon neutrality or negativity when incorporating storage or circulation of CO 2 from cement plant flue gas, respectively. This low-cost, electrochemical cement production approach using abundant ubiquitous raw materials enables electrification, transition to clean fuel, and decarbonization at a gigaton scale.

36 MATERIALS SCIENCE↗

Hydration behavior of cements with reduced clinker factor in mixture with sulfoaluminate binder

CO{sub 2} regulation and raw material availability will strongly influence the future cement market and a wider use of composite cements containing limestone and pozzolan or slag is expected. In the present paper, the possibility to combine Portland cements (PCs) with reduced clinker factor with sulfoaluminate cement (CSA), is explored. Low Portland clinker cements are prepared in laboratory using different supplementary cementitious materials (limestone, slag, pozzolan and fly ash) and mixed with a sulfoaluminate cement: the hydration behavior of the resulting binders is investigated up to 90 days through a multi-technique approach involving X-ray diffraction, differential scanning calorimetry and nuclear magnetic resonance spectroscopy. Understanding the interaction mechanisms between SCMs and CSA/PC blends will support the development of innovative high performing binders based on CEM III or CEM V, or even on new standardized CEM II. Results highlight that slag is particularly suitable promoting late strength development.

36 MATERIALS SCIENCE↗

Experimental validation of multiphysics model simulations of the thermal response of a cement clinker rotary kiln at laboratory scale

Abstract An increasing demand for buildings, transportation systems and civil infrastructure development has driven expansion of cement consumption world‐wide, producing a significant increase in related global energy demand. With approximately 7% of the world‐wide industrial energy consumption (10.7 exajoules [EJ]), the cement industry is the third most energy intensive industrial processes and a key component for concrete, the most consumed composite material in the global construction industry. In cement manufacturing, the cement kiln accounts for most of the energy consumption in the production process. As the heart of a cement plant, the cement kiln is where the kiln feed primarily containing calcium oxide (CaO), silica (SiO 2 ), alumina (Al 2 O 3 ), and iron (Fe 2 O 3 ) are thermally and chemically transformed into clinker minerals. The presented work developed a multiphysics model, designed and built a laboratory‐scale rotary cement clinker kiln, and produced cement clinker at laboratory‐scale. The model was developed to study the interaction between the various thermal, fluid dynamic and chemical interactions involved in the sintering process used to form Portland cement clinker in an effort to reduce energy use. The analytical model was validated through experimental testing using a unique laboratory‐scale rotary cement kiln developed during the investigation. Also demonstrated was the feasibility of producing clinker at laboratory scale. This modeling and lab scale tests were designed to better understand the clinker sintering process so that operational and quality decisions can be made to optimize energy consumption without compromising cement clinker quality. The computational fluid dynamics modeling was developed in COMSOL Multiphysics 6.0. The characteristics of the combustion fluid flow, concentration of species, temperature and heat transfer were studied for a turbulent flow of methane (CH 4 ) gas and oxygen (O 2 ). Theory suggests that heat transfer impacts the cement production process but the multiphysics model more accurately describes the convection, conduction, and radiant heat transfer in the kilning process and thus allows for a better understanding of the energy exchange driving the chemical reactions that produce Portland cement. Clinker minerals were formed because of appropriate burning conditions implemented during experimental model validation.

Tabares, Juan David↗

Development of a stoichiometric magnesium potassium phosphate cement (MKPC) for the immobilization of powdered minerals

Ordinary Portland Cement (OPC)-based materials are not systematically adapted for immobilizing industrial hazardous waste, e.g. for aluminium powder or plutonium waste sludge. In such case, Magnesium Potassium Phosphate Cements (MKPC) represent an interesting alternative. }The originality of this research is to develop a formulation of a MKPC paste for hazardous waste immobilization, which incorporates a maximum amount of such waste, preferably in powdered form. To this purpose, a stoichiometric MKPC paste is selected, and its properties are improved by powdered waste addition. }Firstly, the physico-chemical mechanisms generating expansion in stoichiometric MKPC paste are analyzed. Swelling is attributed to a pH gradient in the paste, due to the progressive sedimentation of MgO particles in the fresh mix. }Secondly, over-stoichiometric MgO is replaced by varying amounts of minerals simulating the waste, of different mineralogy and granulometry, in order to achieve sufficient workability and no swelling. An optimal formulation is proposed, which incorporates powdered fly ash at a fine-to-cement mass ratio (F/C) of 1. Its mechanical performance and endogenous dimensional changes are comparable to typical over-stoichiometric pastes, and they stabilize between 7 and 28 days.

36 MATERIALS SCIENCE↗

On the use of limestone calcined clay cement (LC3) in high-strength strain-hardening cement-based composites (HS-SHCC)

Highlights: • Use of LC{sup 3} slightly reduces flowability and shortens the setting time of fresh matrices. • Highly polymerized C-A-S-H gel and abundant ettringite benefit flexural strength of LC{sup 3}-matrices. • Use of LC{sup 3} enhances the bond strength between fiber and high-strength matrix. • LC{sup 3}-based HS-SHCC yields similar flexural performance as the composite with Portland cement. High-strength strain-hardening cement-based composites (HS-SHCC) demonstrate excellent mechanical and durability properties. However, high cement content typical to HS-SHCC results not only in high carbon footprint, but also in excessive hydration heat and severe autogenous shrinkage. In this investigation, Limestone Calcined Clay Cement (LC{sup 3}) was used to produce sustainable HS-SHCC. The LC{sup 3} substitution resulted in higher energy consumption during mixing and in shorter setting times of the fresh, plain matrices. Although the LC{sup 3} substitution slightly reduced the compressive strength, the formation of highly polymerized C-A-S-H gel and abundant ettringite benefited the flexural strength of the plain matrices. Additionally, single-fiber pullout experiments showed that the use of LC{sup 3} led to increased fiber-matrix bond strength and pullout energy. Finally, the replacement of Portland cement by LC{sup 3} resulted in HS-SHCC with similar mechanical performance to the reference composite, indicating a high potential for using LC{sup 3} in high-performance cement-based composites.

36 MATERIALS SCIENCE↗

Engineered Barrier System R&D and International Collaborations – LANL (FY20): Spent Fuel and Waste Disposition

The United States Department of Energy’s Spent Fuel and Waste Disposition (SFWD) program is investigating the design and safety function of generic nuclear geologic repositories in a variety of geologic settings (salt, argillite, and crystalline rock). Different configurations and loadings of spent nuclear fuel and waste within disposal canisters are also being investigated, some of which have the potential to generate repository temperatures higher than previously considered (i.e., temperatures >100ºC) by foreign and domestic concepts. This report expands on engineered barrier material stability in a high temperature crystalline rock repository through high temperature hydrothermal experiments. Experiments were designed to develop engineered barrier system (EBS) concepts in a hightemperature crystalline environment in 1) bentonite-Grimsel Granodiorite interactions, 2) bentonite-cement reactions, and 3) interaction between waste canister materials and bentonite. Experiment results are applied to understanding long-term repository performance in terms of radionuclide isolation. One hydrothermal experiment was completed in the rocking autoclaves at LANL in FY-20: IEBS-6 (Grimsel Granodiorite + Wyoming bentonite + cured ordinary Portland cement + Grimsel Granodiorite synthetic groundwater, 250ºC/150 bar, 8 weeks). Several other experiments were planned but were delayed due to the COVID-19 pause in laboratory work. In addition, some characterization of the reaction products of experiments conducted in FY-20 was prevented by COVID-19. Mineral phase chemistry was not measured via electron microprobe analyses for IEBS-6. Quantitative X-ray diffraction results from IEBS-6 and HBT-1 were not completed. The missing analyses and discussion of the results will be included in next year’s report. New characterization that was completed includes scanning electron microscopy of reaction products from IEBS-6, quantitative X-ray diffraction results are presented from IEBS-1 through IBES-5, preliminary scanning electron microscope images and chemical analyses for IEBS-6, X-ray diffraction of the clay fraction from all experiments, measurement/imaging of mineral growth on the surface of steel coupons. Major observations pertaining to bentonite stability in a Grimsel Granodiorite environment include the stability of Na-montmorillonite at 250°C, the formation of trace CSH phases, and the formation of bentonite colloids on experiment cooling. The addition of a cured chip of Portland cement to the bentonite-Grimsel system results in slightly higher pH values and the formation of diverse secondary mineral phases that were not observed in the previous experiments (e.g., analcime, garronite, CSH phases). The new characterization efforts related to the interaction of stainless-steel coupons and bentonite clay focused on thickness and mineralogy of phases that formed at the steel surface. In Wyoming bentonite + Grimsel Granodiorite systems, newly formed minerals at the bentonitesteel coupon interface included alteration of the outermost steel edge to Fe,Cr-oxide phases, followed by Fe-rich phyllosilicates (Fe-saponite, chlorite) and interbedded Fe,Cr,Ni-sulfide phases (pentlandite). Hydrothermal experiments were completed to assess uranium-carbonate complexation at conditions relevant to high-temperature disposal. Autoclave solubility experiments were conducted at 150 to 250ºC with a range of carbonate and uranium concentrations. The experiment results were characterized via situ UV-Visible spectroscopy and synchrotron-based in situ XAS techniques. Results show a significant decrease in the stability of uranyl-carbonate complexes at temperatures above 100ºC along with the precipitation of uranium oxides. Further, at T > 200ºC, results show that uranyl-hydroxyl complexes control solubility of uranium instead of the previously predicted uranyl-carbonate species. These results are significant for understanding the mobility of uranium in the EBS, which will likely contain carbonate-rich fluids. International research efforts focused on three main areas: 1) participation in international conferences, 2) building collaborations with foreign repository programs, and 3) the initiation of an experimental program to complement the full-scale HotBENT test at the Grimsel test site. This experiment included Wyoming bentonite + low carbon steel + Grimsel Granodiorite synthetic groundwater and was run at the planned maximum temperature of the HotBENT test (200°C). Complete characterization of reaction products was hindered by disruptions to laboratory work but will be reported in the next FY. The experimental results obtained in FY-20 continue to document the wide-ranging effects of bulk composition and pressure-temperature conditions in the mineralogical and geochemical evolution of a high-temperature repository environment. Concepts developed will be used to inform models of long-term material stability in a generic crystalline rock-hosted repository.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

Early age hydration behavior of portland cement-based binders incorporating fly ash contaminated with flue gas desulfurization products

Fly ash co-mingled with flue gas desulfurization (FGD) products are currently discarded as off-specification materials based on their high SO3 content. However, previous studies have shown that performance of these fly ashes varies significantly based on FGD product type and as such they may be viable for use in low-CO2 concrete as supplementary cementitious materials (SCMs). In this study, fly ashes with three different types of FGD products including calcium sulfite hemihydrate, calcium sulfate (with some unreacted lime), and sodium sulfate (with some unreacted sodium carbonate) were evaluated. The early age hydration behavior in blended cementitious systems at 20% cement replacement level was studied using Vicat setting time tests, isothermal calorimetry, in-situ quantitative X-ray diffraction, and pore solution analysis. The cause of the setting time retardation and flash setting observed in fly ashes with calcium sulfite hemihydrate and sodium carbonate, respectively, were identified and suitable beneficiation options were suggested for the valorized use of these materials in low-CO 2 concrete.

36 MATERIALS SCIENCE↗