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Thermal treatment of kaolin clay to obtain metakaolin

Article  in  Hemijska Industrija · January 2010

DOI: 10.2298/HEMIND100322014I

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 BILJANA R. ILIĆ THERMAL TREATMENT OF KAOLIN CLAY
ALEKSANDRA A. MITROVIĆ TO OBTAIN METAKAOLIN
LJILJANA R. MILIČIĆ
Institute for Testing of Materials, The metakaolin was produced by thermal treatment (calcination) of the starting high-
Belgrade, Serbia -quality kaolin clay from Serbia. The optimal calcination parameters, for which nearly
complete dehydroxylation of the material was achieved, are: temperature 650 °C and
SCIENTIFIC PAPER heating time of 90 min. The conversion of the kaolinite to metakaolinite was confirmed
by XRD and IR analyses of the starting and thermally treated kaolin samples. The poz-
UDC 553.612:66.094.32 zolanic activity was determined by Chapelle test. The obtained value 0.65 g Ca(OH)2/g
of metakaolin indicates that produced metakaolin may be used as supplementary ce-
DOI: 10.2298/HEMIND100322014I
mentitious material.

Development of construction materials which of- Dtg = 1 − (M/Mmax) (2)

fers technical and environmental benefits is the main
where M and Mmax are residual and maximum sample
challenge of the new millennium. One of such materials
mass loss, respectively. The dehydroxylation of pure
is metakaolin (MK), pozzolanic addition, which is clas-
kaolinite (39.5% Al2O, 46.5% SiO2 and 14% H2O) in
sified as a new generation of supplementary cementitous
ambient atmosphere results in mass loss of about 14%
material. Supplementary cementitious materials (SCMs)
and Dtg = 1, which corresponds to mass in bound hyd-
are finely ground solid materials that are used to replace
roxyl ions in kaolinite.
part of the clinker in a cement or cement in a concrete
The development of pozzolanic properties in fired
mixture. Use of metakaolin in cement-based systems,
clays mainly depends on nature and abundance of clay
provides, beside technical [1,2], significant environmen-
minerals in raw materials, on calcination conditions and
tal benefits [3]. Metakaolin is unique in that it is not the
on the fineness of the final product [10–12]. The calci-
by-product of an industrial process nor is it entirely na-
nation temperature producing the reactive state is usual-
tural; it is derived from a naturally occurring mineral,
ly in the range of 600–800 °C, and plays a central role
and is manufactured specifically for cementing applica-
in the reactivity of the resulting MK product. On
tions. Metakaolin is usually produced by thermal treat-
prolonged heating, recrystallization and mullite
ment, i.e., calcination of kaolin clays within a definite
(3Al2O3⋅2SiO2) formation take place resulting in the
temperature range.
decline of material reactivity.
Serbia has high-quality kaolin clay deposits at Aran-
The main characteristic of produced metakaolin,
djelovac and Kolubara basin, and thus good potential to
for the use in cement based systems, is its pozzolanic
produce metakaolin from them.
activity, which is defined as ability of material to react
The main process important for production high
with calcium hydroxide in the presence of water to form
reactivity pozzolana from kaolin clay is calcination. The
compounds that have cementitious properties. Pozzola-
heating process drives off water from the mineral kao-
nic activity may be determined by direct [13–15] and
linite (Al2O3⋅2SiO2⋅2H2O), the main constituent of kao-
indirect methods [16]. Direct methods are based on the
lin clay, and collapses the material structure, resulting in
measurement of the amount of lime reacted, which is
an amorphous aluminosilicate (Al2O3⋅2SiO2), metakao-
determined by instrumental techniques such as thermo-
linite. The process is known as dehydroxylation [4], and
gravimetry (TG), differential thermal analysis (DTA),
may be presented by simple equation:
X-ray diffraction (XRD) and calorimetric analysis. Indi-
Al2O3⋅2SiO2⋅2H2O → Al2O3⋅2SiO2 + 2H2O↑ (1) rect methods are based on the strength development oc-
curring with reaction time. The values of pozzolanic ac-
The thermal transformation of kaolinite, which has
tivity indicate how good and effective pozzolan is.
been the subject of a large number of investigations [5–
The goal of this study is to determine optimal calci-
–8], has shown that the heating parameters such as tem-
nation parameters for obtaining metakaolin from domes-
perature, heating rate and time, as well as cooling para-
tic high-quality kaolin clay, for the use as supplemen-
meters (cooling rate and ambient conditions), signifi-
tary cementitous material.
cantly influence the dehydroxylation process.
The major quantitative criterion for evaluating the
EXPERIMENTAL
performance of kaolinite by thermal treatment is a de-
gree of the dehydroxylation, Dtg [9]: Properties of the starting clay
Our previous study [17] showed that starting clay
Corresponding author: B. Ilić, Institute for Testing of Materials, Bel-
is high quality kaolin clay, with kaolinite content of
grade, Bulevar vojvode Mišića 43, Belgrade, Serbia. about 80% and loss of ignitation (LOI) on the tempera-
E-mail: [email protected] ture 950±25 °C of 12.33%. Kaolin clay was collected
Paper received: 22 March 2010 from the location Vrbica (Arandjelovac basin). Repre-
Paper accepted: 13 April 2010

351
B.R. ILIĆ, A.A. MITROVIĆ, Lj.R. MILIČIĆ: THERMAL TREATMENT OF KAOLIN CLAY... Hem. ind. 64 (4) 351–356 (2010)

sentative 5-kg samples of kaolin clay were taken from Thermal behavior of the starting clay was investi-
the initial materials using the quartering method. Before gated using a Netzsch STA 409EP instrument. The
being characterized, the samples were dried to less than sample was heated from 20 to 1000 °C at a constant rate
0.5% moisture content, crushed and milled (to the par- of 10 °C/min in air.
ticle size of less than 43 μm). In order to confirm the characteristic bands of kao-
Chemical composition, determined by silicate me- linite in raw sample and the absence of these bands in
thod, and physical characteristics such as specific gra- thermally treated samples, a FTIR spectrophotometer,
vity, γsr, specific surface area, Sp, and fineness, R (given Nicolet 6700 Thermo Scientific, was used.
as residue on the sieve), determined according to stan- The pozzolanic activity of the thermally treated
dards SRPS EN 196-3 and SRPS EN 196-6, are given in samples (metakaolin) was evaluated according to Cha-
the Table 1. pelle test [18]. Metakaolin of a mass of 1 g was mixed
with 1 g Ca(OH)2 and 200 mL boiled water. The sus-
Table 1. Chemical composition and physical characteristics of pension was subsequently boiled for 16 h and the free
the starting clay Ca(OH)2 was determined by means of sucrose extrac-
Component Content, mass% tion and titration with HCl solution.
SiO2 48.00 Calcination/dehydroxylation procedure
Al2O3 31.75
Samples of about 50 g were heat treated in the la-
Fe2O3 4.38 boratory furnace at different temperatures (550, 600,
CaO 1.00 650 and 700 °C) and at different heating times (30, 60,
MgO 0.48 90, 120, 150 and 180 min). After heating, the samples
Na2O 0.16 were “quenched” to room temperature at ambient condi-
K2O 1.50 tions to avoid crystallization of amorphous metakaolin.
LOI 12.33 The weight of the samples before and after the
Physical characteristics thermal treatment was measured in order to determine
γsr, g/cm3
2.60 weight loss during calcinations process.
Sp, cm2/g 9180
RESULTS AND DISCUSSION
R, % (sieve, 0.043 μm) 4.90
Thermal behavior of the starting clay is presented
Applied experimental techniques in the Figure 1. The main changes revealed by TG and
Mineralogical composition of the starting and ther- DTA analysis are as follows [14]. At temperatures be-
mally treated clays was determined using a Siemens low about 200 °C release of water absorbed in pores and
D5000 diffractometer (CuKα radiation, Ni filter). on the surfaces occurs. Between 200 and 450 °C, mass

Figure 1. DTA/TG curve of the starting clay.

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B.R. ILIĆ, A.A. MITROVIĆ, Lj.R. MILIČIĆ: THERMAL TREATMENT OF KAOLIN CLAY... Hem. ind. 64 (4) 351–356 (2010)

loss attributed to the pre-dehydration process takes pla- Using mass loss values during calcination, and LOI
ce, as a result of the reorganization in the octahedral obtained by chemical analysis (Mmax), the degree of de-
layer. In the temperature range 450–650 °C, dehydroxy- hydrohylation calculated by Eq. (2) are presented in
lation of kaolinite and formation of metakaolinite takes Figure 2.
place, while at about 1000 °C, mullite was formed, as As can be seen, nearly complete dehydroxylation
indicated by an exothermic peak. The observed endo- was achieved after 90 min for temperature of 650 and
thermic peak with a maximum at 552 °C may be attri- 700 °C, for which the degree of dehydroxylation, Dtg, is
buted to dehydroxylation process. 0.97.
In order to obtain optimal calcination parameters, In order to confirm disappearance of kaolinite peaks,
the clay was subjected to thermal treatment at different after thermal treatment, the XRD patterns of starting
heating temperatures and times. The mass loss of start- and calcined clay were compared. The results are pre-
ing clay for given calcinations parameters is given in sented in Figure 3. It is evident (Figure 3a) that the ma-
Table 2. jor mineral constituents of the starting clay are kaolinite
As can be seen, for calcination temperatures of and quartz. The results of XRD measurements of the
550, 600 and 650 °C, mass loss increases up to 90 min, calcined clays, selected on the base on their degree of
while prolonged heating has a negligible effect on the dehydraxylation, are given in Figures 3b–3d. After ther-
mass loss. For all applied heating times at temperature mal treatment of clays at temperatures 600, 650 and 700
700 °C obtained values for mass loss are nearly the same °C and heating time 90 min, characteristic peaks for kao-
≈12%. It is evident that at calcination temperature 650 linite (2θ 12.41, 20.21 and 25.49°) [19] disappear, while
°C and heating time 90 min, mass loss is almost iden- peaks assigned to quartz (2θ 21.22 and 27.45°) remains
tical with the values obtained at 700 °C. If we take eco- unchanged.
nomic factors into consideration, the optimal parameters Besides XRD measurements, IR spectroscopy was
for calcination are temperature 650 °C and heating time applied to confirm kaolinite transformation during calci-
of 90 min. nation. IR spectra obtained for starting clay and ther-

Table 2. Mass loss (%) of kaolin clay for different calcination temperatures and times

Temperature, °C
Heating time, min
550 600 650 700
15 – – 10.72 11.90
30 9.26 10.56 11.22 12.00
60 10.49 11.42 11.73 12.05
90 11.11 11.80 12.00 12.07
120 11.24 11.80 12.03 12.15
150 11.33 11.74 11.92 12.11
180 11.51 11.76 – –

Figure 2. Dependence of degree of the dehydrohylation, Dtg, on calcination time for different temperatures of thermal treatment.

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B.R. ILIĆ, A.A. MITROVIĆ, Lj.R. MILIČIĆ: THERMAL TREATMENT OF KAOLIN CLAY... Hem. ind. 64 (4) 351–356 (2010)

3500

Q
3000

2500

I(Impulsi)
2000

1500 L

M
1000 Q

F
500
K Q

0 20 40 60 80
2θ
(a) (b)

3000 3500
Q

F
3000
2500
Q

2500
I(Impulsi)
I(Impuls)

2000

2000
1500
L
M L 1500

M
1000 Q 1000 Q

Q Q
500 500 K
K

0 20 40 60 80 0 20 40 60 80

2θ 2θ
(c) (d)
Figure 3. XRD Patterns of starting kaolin clay (a) and thermally treated (calcinated) at 600 °C for 90 min (b); at 650 °C for 90 min
(c) and at 700 °C for 60 min (d). K – kaolinite (Al2Si2O5(OH)4), Q – quartz (SiO2), L – mica (AlSi2O6(OH)2), F – feldspar
((K,Na)Si3O8), M – montmorillonite ((Na,Ca)0.33(Al,Mg)2(Si4O10)(OH)2⋅nH2O)).

mally treated samples are presented in Figure 4. The re- CONCLUSION

sults of IR spectroscopy of starting clay (Figure 4a)
show the characteristic bands of kaolinite [20,21]: OH− Metakaolin, pozzolanic additive, may be obtained
at 3700, 3650, 3620 cm−1; Al–OH at 913 cm−1; Si–O at by calcination of kaolin clay. The optimal conditions of
1032, 1008, 469 cm−1 and Si–O–AlVI at 538 cm−1. the thermal treatment are: calcination temperature of
Absence of the detectable Al–O–H bands at 913 650 °C and heating time of 90 min. Calcination results
cm−1, and the doublet at 3700 and 3620 cm−1, is evident in dehydroxylation degree of 0.97. The produced
from Figure 4b–4d. Absence of the band at 539 and 913 metakaolin has pozzolanic activity 0.65 g Ca(OH)2 / g
cm−1 and the appearance of a new band at 800 cm−1 can of metakaolin.
be related to the change from octahedral coordination of Acknowledgement
Al3+ in kaolinite to tetrahedral coordination in metakao-
linite. The bands at 1100 and 1200 cm−1 are assigned to This research has been supported by the Serbian
amorphous SiO2. Ministry of Science and Technological Development
For the optimal calcination parameters (tempera- (Project No. TR 19206A).
ture 650 °C and heating time 90 min) pozzolanic acti-
REFERENCES
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kaolin) [14]. Мaterijali i konstrukcije 48 (2005) 48–54.

354
B.R. ILIĆ, A.A. MITROVIĆ, Lj.R. MILIČIĆ: THERMAL TREATMENT OF KAOLIN CLAY... Hem. ind. 64 (4) 351–356 (2010)

(a) (b)

(c) (d)
Figure 4. IR spectra of starting kaolin clay (a) and thermally treated (calcinated) at 550 °C for 90 min (b); at 600 °C for 90 min (c)
and at 650 °C for 90 min (d).

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IZVOD
DOBIJANJE METAKAOLINA TERMIČKIM TRETMANOM KAOLINSKE GLINE
Biljana R. Ilić, Aleksandra A. Mitrović, Ljiljana R. Miličić
Institut za ispitivanje materijala ad, Beograd
(Naučni rad)
U radu su prikazani rezultati istraživanja dobijanja metakaolina ter- Ključne reči: Kaolin • Metakaolin •
mičkim tretmanom domaće kaolinske gline. Polazna sirovina je bila kaoli- Kalcinacija • Dehidroksilacija
nska glina sa ležišta Vrbica (Aranđelovački basen), čiji je sadržaj kaolinita Key words: Kaolin • Metakaolin •
oko 80% i gubitak žarenjem 12,33%. Diferencijalnom termičkom anali- Calcination • Dehydroxylation
zom (DTA/TGA) utvrđeno je da do dehidroksilacije i transformacije kaoli-
nita u metakaolinit dolazi u opsegu temperature 450−700 °C. Proces kalci-
nacije je praćen termičkim tretmanom kaolinske gline u laboratorijskim
uslovima na temperaturama 550, 600, 650 i 700 °C, različito vreme: 15,
30, 60, 90, 120, 150 i 180 min. Kao glavni kvantitativni kriterijum za
ocenu ponašanja kaolinita u procesu kalcinacije, korišćen je stepen de-
hidroksilacije materijala, Dtg. Optimalni parametri procesa kalcinacije, pri
kojima je postignut stepen dehidroksilacije 0,97, jesu: temperatura 650 °C
i vreme zagrevanja 90 min. Transformacije kaolinita u metakaolinit potvr-
đene su rendgenskom strukturnom analizom i IR spektroskopijom polazne
gline i termički tretiranih glina. Na difraktogramima termički tretiranih
glina nisu uočeni karakteristični pikovi kaolinita, dok IR spektri pokazuju
odsustvo karakterističnih veza kaolinita. Pucolanska aktivnost metakaoli-
na, određena direktnom metodom, pri optimalnim uslovima kalcinacije iz-
nosi 0,65 g Ca(OH)2 / g metakaolina. Na osnovu ovih istraživanja može se
zaključiti da je kaolinska glina sa nalazišta Vrbica pogodna za proizvodnju
metakaolina, odgovarajuće pucolanske aktivnosti, a koji se može primenji-
vati u svojstvu dopunskog cementnog materijala u sistemima na bazi ce-
menta.

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