Use Of Copper Slag Research Articles

Pressure Settlement Behaviour of Strip Footing Resting on Unreinforced and Tire Chips Reinforced Copper Slag

The slag and waste tires are among the major wastes associated with the mining and automobile sectors, respectively. The disposal of such large quantities of waste requires immediate attention. This manuscript focusses on the application of copper slag under unreinforced and reinforced conditions as a load-bearing filling material in shallow foundations. For this purpose, model footing tests were conducted on copper slag under central and eccentric-inclined loading. The locally available sand was used as a reference. The parameters studied included the placement density, type of loading, tire chip content, and depth of reinforced zone. The pressure settlement behaviour of the copper slag was superior to local sand under central vertical as well as under eccentric inclined loading conditions. Quantitively, the bearing capacity increased by up to 21 times, when compared to the locally available sand. Furthermore, when mixed with tire chips, the bearing capacity of the copper slag increased by up to 1.41 times to that of the unreinforced case. The leaching potential of the copper slag was evaluated using toxicity characteristic leaching procedure tests. It was observed that the concentrations of the leached elements were well below the regulatory limits prescribed by the US, EPA. Henceforth, it can be concluded that the use of copper slag as a load-bearing filling material not only prevents the disposal of this waste into valuable land but also works as a sustainable alternative to prevalent ground improvement methods.

Strength and durability studies on slag cement concrete made with copper slag as fine aggregates

The current investigation is an attempt to perform the strength and durability studies on slag cement concrete prepared by using copper slag (CS) as a fractional/full replacement for natural fine aggregates (FNA). Tests were performed for compressive strength, split tensile strength, acid attack, sulfate attack, water absorption, and voids. The degree of replacement of natural fine aggregates with copper slag was put at 20%, 40%, 60%, 80%, and 100% by volume. A control mix containing 100% natural fine aggregates were also prepared for comparison. The strength and durability of slag cement concrete mixes having varying copper slag content were analyzed based on the results. A considerable rise in compressive strength of concrete having a 40% copper slag fraction when compared to control was also observed. However, compressive strength declined beyond 40% substitution as a result of excess free water and was lowest for 100% substitution. The tensile strength exhibited similar behavior to that of compressive strength. On acid and sulfate exposure, change in mass accompanied by a reduction in compressive strength was shown by all concrete mixes. The results showed a decrement in water absorption with an increment in copper slag fraction up to 40% of natural fine aggregates. On further increment in copper slag fraction, a rapid increase in absorption was observed due to an increase in void content in concrete. Water absorption showed a similar trend to that of percentage voids. Therefore, the use of copper slag up to 40% fraction of natural fine aggregates is recommended to derive a concrete with sound strength and durability characteristics.

PERFORMANCE OF COPPER SLAG AS REPLACEMENT OF FINE AGGREGATE WITH DIFFERENT GRADES

Copper slag is the waste material that is generated during the manufacturing process of copper. As per the statistics for manufacturing of one ton copper leads to generation of 2.25 tons of copper slag. Although this material is adopted for different other purposes like land filling and abbrasive tools preparation, low quality tools and railway ballast materials. Inspite of all these application around the world only 18 percent of copper slag is used remaining 82% comes under wastage. but if We adopt the same copper slag material as a replacement of construction material in construction industry as may be full replacement or partial replacement of either cementing material or fine aggregates it will have a promising future. At the same time the remaining 82 % waste copper slag have the added valve in construction industry and at the same time land filling problem will get solve. From past 20 years so many researchers already proved that the the usage of copper slag as a replacement in concrete will possible due to same granular size of copper likely as of fine aggregate. Not only as fine aggregate replacement, the finely grained copper slag powder can also be adopted as partial replacement of cementing material to concrete and in the production of cement lime clinkers There are so many researches are carried around the globe on the usage of copper slag as replacement material, but in India a very few researches are carried. In this particular thesis mainly looked on to generate specific investigation data on the use of copper slag as fine aggregate replacement in partial basis.

Laboratory study on the use of copper slag and RAP in WMA pavements

This paper presents the results of an experimental investigation carried out on warm mix asphalt (WMA) incorporated with copper slag (CS) and reclaimed asphalt pavement (RAP) material. Both CS and RAP are considered as waste materials and cause a lot of environmental problems. Their use in asphalt pavements will solve the landfill problems associated with them. Also, to save energy and reduce carbon emissions, WMA technology was adopted in this study. A total of nine combinations of warm mixes were prepared with varying proportions of CS (0–15%) and RAP (0–30%). The use of CS improved Marshall stability, indirect tensile strength, and tensile strength ratio. The introduction of CS and RAP produced a balanced mix as CS improved mechanical properties due to high angularity, density, and lime content. In contrast, RAP decreased these properties except the Marshall quotient and resilient modulus. All the RAP–CS WMA mixes satisfied the minimum value of stability (9 kN) as required for dense bituminous macadam. Furthermore, it was concluded that the mechanical properties of RAP–CS WMA mixes decreased with each freeze–thaw (F–T) cycle. The CS-incorporated mixes showed better resistance against F–T cycles.

Rheology, shrinkage and pore structure of alkali-activated slag-fly ash mortar incorporating copper slag as fine aggregate

his study was conducted to investigate the effect of the use of copper slag (CS) as fine aggregate to replace natural sand (NS) at different volume replacement levels (namely, 0%, 20%, 40% and 60%) on the properties of alkali-activated slag-fly ash (AASF) mortars. In addition, both low calcium (LC) and high calcium (HC) alkali-activated slag-fly ash (AASF) mortars were used to studied the influence of the mass ratio of fly ash to fly ash and slag on the properties of mortars. The workability, mechanical properties, autogenous and drying shrinkage and pore structure of mortars were investigated. Results show that using CS to replace NS in AASF mortars at appropriate levels (i.e. 20% and 40%) slightly increases the fluidity, yield stress, consistency, and mechanical strength, while restraining the drying shrinkage and refining the pore structure of mortars. However, when the replacement ratio is increased to 60%, the mortar becomes inhomogeneous due to the high density of CS particles, leading to poor performance of mortars. The use of CS as fine aggregate at a suitable level in AASF mortars can reduce NS consumption while also providing an avenue for value added use of CS.

Analysis of Unconscious Properties and Strength Measurements for Concrete Containing Copper Slag-Review

The main aim of the environmental protection agencies and the government are to seek ways and means to minimize the problems of disposal and health hazards of by products. It is considered as a waste material which could have a promising future in construction industry as substitute of either cement or coarse aggregates or fine aggregates. Copper slag is one of the replacement mechanisms of material in concrete. Use of copper slag as a replacement for fine aggregate in concrete cubes various strength measurements was experimentally investigated in this study. Mainly contents of that M35 conventional concrete and copper slag as a replacement of fine aggregate in 10%, 20%, 30%, 40%,50%, 60%, 80%, and 100% and also Portland Pozzolana Cement is noted. In this regard, laboratory study including water absorption test, bond strength, and percentage of voids, compressive strength & bulk density were conducted in ppc cement concrete which made by copper slag waste as a replacement of fine aggregate and PPC. A substitution up to 40-50% as a copper slag as a sand replacement yielded comparable strength to that of the conventional concrete. However, addition of more copper slag resulted in strength reduction due to the increase in the free water content in the mix, cured period in a curing tank for later resulting at 28 and 60 days.

Life cycle assessment of a ceramic glaze containing copper slags and its application on ceramic tile

AbstractEven though copper slags have many possible applications, their disposal is still practiced, creating long‐term waste management problems. This led to the investigation of new products for residential applications, taking advantages of the interesting chemical properties of copper slag. This study aims to assess the environmental impact of the use of copper slag as secondary raw material in a ceramic glaze composition and to compare it with a traditional glaze. A manufacturing process was designed, through an industrial scale up operation from experimental laboratory data and the entire life cycle of the products was analyzed using the Life‐cycle assessment (LCA) methodology. Considering the production of a ceramic glaze containing copper slag, the most impacting process resulted the one related to frit production, due to the large amount of thermal energy necessary for the raw materials melting. The comparative LCA analysis carried out between the frit obtained from metallurgical slags and a traditional one, demonstrated that the innovative ceramic frit has a greater environmental advantage. The LCA analysis allowed to highlight the most impactful stages of an industrial process using copper slag as a secondary raw material for glaze production and to quantify the potential environmental advantages of this operation.

Use of waste copper slag filled jute fiber reinforced composites for effective erosion prevention

This work addresses the erosion performance of waste copper slag filled jute fiber reinforced polyester composites. The composites are prepared by two different fiber treatment methods such as sodium hydroxide (NT) and calcium hydroxide (CT) and the results are compared with the specimen prepared by untreated fiber (UT). The fiber dosage of 40% and the waste copper slag filler materials of 10% are used to prepare the composites. A compression molding machine with an optimum pressure of 17 MPa is used for the fabrication process. Erosion tests are conducted on an erosion test rig by varying the input process parameters such as impingement angle (30°, 60°, 90°) and jet pressure (70, 100, 130 m/s). The experimental result shows that use of copper slag filler particles increased the interfacial bond between the matrix and fiber resulting to erosion prevention. A regression model has been developed for each composite to predict the future values. Further, the desirability analysis was performed and found that the CT composite with impingement angle at 90° and jet velocity at 86.36 m/s could achieve lower erosion rate. Finally, the erosion mechanism of the eroded surface of the composite has been studied using scanning electron microscope and 3D surface profilometry images.

Investigating the Effects of Copper Slag and Silica Fume on Durability, Strength, and Workability of Concrete

Workability, strength, durability, economic considerations, and attention to sustainable development issues are some crucial factors in designing an appropriate mix. The use of copper slag as a partial replacement of cement is an effective method of pollution reduction and conservation of resources, since it reduces cement use. In addition, silica fume is used in combination with copper slag to make concrete structures more durable. The main purpose of this study was optimizing important variables of concrete mix design including cement factor, water-to-binder ratio (w/b), copper slag, and silica fume to improve concrete durability. To achieve this goal, an experimental research was carried out, based on standards, to optimize changes in the said fields. Concrete durability is determined by experiments considering electrical resistance of concrete, bulk electrical conductivity, and chloride migration coefficient. Interfacial transition zone and cement microstructure were evaluated using X-ray analysis and scanning electron microscopy. The results of this research indicated that simultaneous use of copper slag and silica fume with appropriate values of other factors (cement factor and w/b ratio) yields a more durable, workable and strengthened mix design. The optimized mix introduced a workable, durable, resistant, and economical mix design with 7% and 20% of cement replaced with silica fume and copper slag, respectively. This innovative study included simultaneous use of copper slag and silica fume as a replacement for cement.

Development of Alkali-activated Cementitious Material using Copper Slag

The paper presents results of an investigation conducted to study the feasibility of use of Copper Slag (CS) as aluminosilicate material for developing Alkali-activated Cementitious Material (ACM). The effect of addition of mineral admixtures such as Fly Ash (FA) and Metakaolin (MK) on the performance of alkali-activated CS was also investigated. In addition to a control mix which was prepared using 100% CS; two other mixes were also prepared by replacing CS with 30% FA and 30% MK respectively. These mixes were activated using alkali content of 5% and 7% by weight of binder. Sodium hydroxide and sodium silicate were used as alkali-activators. Compressive strength tests were performed on alkali-activated cement mixes at different curing ages. The pore-size distribution, mineralogy and microstructure of selected alkali-activated cement mixes were determined using Mercury Intrusion Porosimetry (MIP), X-ray Diffraction (XRD) and Scanning Electron Microscopy (SEM) with Energy Dispersive X-ray Spectroscopy (EDS). Test results indicate that CS has great potential as aluminosilicate material for developing ACM. Further, the addition of mineral admixtures in alkali-activated CS cement improves its performance; however, the addition of MK was found to be more effective than FA in terms of compressive strength and microstructure development.

Copper slag from different dumps in the Atacama Region used in mortars as partial replacement of cement

The use of copper slag as a partial substitute for cement in mortar preparation was studied. Copper slag samples were collected from three dumps in the Atacama Region (Northern Chile). Mortars of 40x40x160 mm (width, height, length) and curing times of 7, 28 and 90 days were used in mechanical testing. Tests were performed with 0% (control mortar), 5, 10, 15 and 20% copper slag as partial replacement of cement. The results of mechanical tests showed a gradual increase in compressive and flexural strength at 7, 28 and 90 days in mortars containing copper slag when compared with the control mortar. The major differences between the control and copper slag mortars are evident after 7 days, which indicates that the presence of slag in the blends has a retardant effect on the hardening process. On the other hand, at 90 days, compressive and flexural strength was very similar for both control mortar and mortars containing copper slag. Optimal compressive and flexural strength values are achieved with 5% of cement substitution by copper slag. The study concludes that the use of copper slag in mortars presents a viable alternative for partial cement replacement, and also contributes to mitigate adverse environmental effects of copper mining.

Moderate Dilution of Copper Slag by Natural Gas

To enable use of copper slag and extract the maximum value from the contained copper, an innovative method of reducing moderately diluted slag to smelt copper-containing antibacterial stainless steel is proposed. This work focused on moderate dilution of copper slag using natural gas. The thermodynamics of copper slag dilution and ternary phase diagrams of the slag system were calculated. The effects of blowing time, temperature, matte settling time, and calcium oxide addition were investigated. The optimum reaction conditions were identified to be blowing time of 20 min, reaction temperature of 1250°C, settling time of 60 min, CaO addition of 4% of mass of slag, natural gas flow rate of 80 mL/min, and outlet pressure of 0.1 MPa. Under these conditions, the Fe3O4 and copper contents of the residue were 7.36% and 0.50%, respectively.

Influence of intensive vacuum mixing and heat treatment on compressive strength and microstructure of reactive powder concrete incorporating secondary copper slag as supplementary cementitious material

In this study the effect of vacuum mixing and heat treatment on the compressive strength and microstructure of reactive powder concrete (RPC), made with secondary copper slag as partial cement replacement is investigated. The quickly cooled granulated copper slag was ground using a planetary ball mill. A low water-to-binder ratio of 0.185 was chosen. The series of concrete mixtures and cement paste samples were produced with copper slag contents from 0 to 20wt%. The pozzolanic activity of slag was determined by the Frattini test. The performance of RPC mixed under vacuum conditions and heat-cured was compared to that of RPC mixed at atmospheric pressure without heat treatment. The porosity evolution of RPC was investigated by mercury intrusion porosimetry.A higher workability of the fresh RPC was obtained by mixing under atmospheric pressure. The presence of copper slag in the RPC had no adverse effect on compressive strength for all treatments. The heat treatment decreases the porosity and enhances the RPC strength. Assessment of the pozzolanic activity by means of the Frattini test indicates low pozzolanic reaction of the slag after 15days. The presence of slag in the paste tends to decrease the total heat production of the paste. The use of copper slag as cement replacement in the RPC production decreases the energy consumption and reduces the carbon footprint.

Sustainable use of copper slag in self compacting concrete containing supplementary cementitious materials

Copper slag (CS) is an industrial by-product obtained in bulk quantity during matte smelting and refining process of copper metal. The current research is aimed to investigate the sustainable utilisation of CS as fine aggregates in Self Compacting Concrete (SCC) using fly ash (FA) and silica fume (SF) as Supplementary Cementitious Materials (SCMs). Total seven concrete mixes were cast in which one mix was binary blend containing 60% ordinary portland cement (OPC), 40% FA and 0% SF with 100% sand and 0% CS as control concrete. The other six mixes were ternary blends containing 60% OPC, 30% FA and 10% SF with 0, 20, 40, 60, 80 and 100% CS substitution. The fresh properties of SCC mixes were found to be escalating up to 100% CS substitution. The maximum improvements in compressive and splitting tensile strength with respect to control were obtained as 20% and 60% CS substitution. Ultrasonic pulse velocity of all ternary SCC mixes was found to be increased, whereas initial surface absorption and sorptivity reduced in comparison to control concrete. The results of scanning electron microscopy and energy dispersive spectroscopy illustrate the formation of uniformly distributed and compact C-S-H gel in presence of CS after 120 d, with Ca/Si ratio ranging between 0.77 and 1.11. The SCC mix with 100% CS substitution was found to be most economical with least consumption of embodied energy and emission of embodied carbon dioxide. This study authenticates that CS in combination with SCMs is promising alternative over the conventional sand in construction industry.

Experimental Investigation on Use of Copper Slag and Recycled Aggregate as a Fine Aggregate in Concrete

Experimental Investigation on Use of Copper Slag and Recycled Aggregate as a Fine Aggregate in Concrete

Alternative Reduction of Copper Matte in Reduction Process of Copper Slag

In order to make full use of copper slag and solve the problem of its storage, the direct reduction of copper slag to antibacterial stainless steel was proposed. However, mixture of copper matte in the product reduces the value of the alloy. In this article, we studied the changes of Cu2S and FeS in chemical reactions. The Fact-Sage software was used to calculate the ΔG of the reaction, the phase diagram of FeS–CaO–C system, Cu2S–CaO–C system and FeS–Cu2S–CaO–C system. Three reduction experiments have been done to verify the calculation results. Cu2S and FeS in alloy can be alternatively reduced to elemental metal. In reduction of matte, the recovery of metal is 73.96%, and the removal rate of sulfur is 99.11%. In reduction of copper slag, the recovery of metal is 88.50%. In reduction of matte in metal, the removal rate of sulfur is 99.64%. The sulfur is with the presence of CaS in slag eventually.

동 제련 슬래그를 사용한 시멘트 모르타르의 강도 및 황산저항 특성

동 제련 과정에서 발생되는 동 슬래그는 국내에서 년간 70만톤 이상이 발생되고 있어 산업부산물의 건설소재로서의 재활용에 대한 관심이 증가되고 있다. 이에 본 연구에서는 동 제련 슬래그의 3가지 유형의 입도형상과 잔골재로 사용된 강사의 대체 치환율 변화를 실험변수로 선정하여, 동 슬래그를 사용한 시멘트 모르타르의 강도 및 공극구조 특성, 황산 침지 저항성 등의 실험을 통해 건설용 골재로서의 사용가능성을 평가하고자 하였다. 실험결과 동 제련 슬래그 입도는 강도에 미치는 영향인자로 확인되었으며 동 제련 슬래그 잔골재 치환율 60 %인 경우가 가장 높은 강도를 보였다. 또한 잔골재를 동 제련 슬래그로 치환함으로 인해 기공크기가 감소되는 것으로 나타났으며, 황산에 대한 저항성도 증가되는 것으로 나타났다. Each year, more than seven hundred thousand tons of copper slag are generated in Korea as a byproduct during the production of copper. Due to the large amount of copper slag produced, there has been increased interest in the use of copper slag as a construction material. To evaluate the potential of copper slag as a construction material, laboratory evaluations were conducted in this study, and three particle shapes and replacement rates of river sand were selected as experimental variables. Strength, air-void characteristics, and sulfuric acid resistance were the three properties evaluated to assess whether copper slag can be used as a construction material. Test results indicate that the gradation of copper slag has an effect on strength, and the maximum strength was achieved when 60 % of river sand was replaced with copper slag. In addition, when compared with ordinary Portland cement mortar, replacing river sand with copper slag reduced air void size and increased sulfuric acid resistance.

Effect of copper slag addition on mechanical behavior of asphalt mixes containing reclaimed asphalt pavement

Annually, copper production and refining processes of generate large volumes of copper slag, and the disposal of this waste remains a major economic and environmental problem. This annual production causes an increase in the number and volume of landfills, as well as the quantity of slag that backs up landfills, it also produces leachates which contain metals such as Cu, Pb, Hg and SO2. In this research, friction and cohesive qualities of copper slag are exploited, in order to incorporate this slag as aggregate in asphalt mixes containing Reclaimed Asphalt Pavement (RAP). Results demonstrate that the use of copper slag in an addition percentage of 35% is favorable, because flow values increase and stability values decrease. The Marshall Quotient is reduced up to 27%, improving the performance of mixes with RAP and obtaining behavior similar to a traditional mixture. This improvement is also reflected in an 8% increase in the indirect tensile strength, which stands the use of copper slag as a solution in RAP applications with more demanding tensile and fatigue requirements.

Effect of secondary copper slag as cementitious material in ultra-high performance mortar

This research investigates the use of copper slag as supplementary cementitious material (SCM) in ultra high performance mortar (UHPM). Two secondary slag types from a plant in Belgium were utilized as SCM and were classified as a quickly cooled granulated copper slag (QCS) and a slowly cooled broken copper slag (SCS). Both materials were ground intensively using a planetary ball mill. A low water-to-binder ratio of 0.15 was chosen for the UHPM in this study. Various mortar and cement paste samples were produced with increasing copper slag content from 0 to 20wt% in steps of 5wt%. Particle size distribution (PSD) and specific surface area (SSA) of the copper slag were assessed using laser diffraction and the Blaine permeability test. The pozzolanic activity of copper slag was evaluated using the Chapelle test, strength activity index (SAI) and Frattini test.The results obtained, showed that the strength of mortars with different copper slag proportions was comparable to or even better than the control mixture at 90days. The increased fineness of the copper slag enhances the mortar strength. Using isothermal calorimetry, it was found that the addition of copper slag slows down the hydration of the cement pastes. The rate of pozzolanic activity of copper slag depends on temperature, curing age, and particle sizes.

Studies on Concrete Incorporating Copper Slag as a Fine Aggregate

This paper investigates the possibility of application of copper slag as a waste byproduct from metallurgical factory Krompachy (Slovakia Republic) as a fine aggregate in concrete up to 40-50% replacement of natural filler. Results of these studies confirmed that it is possible to produce concrete with a mean compressive strength of greater 50 MPa at 28 days hardening without any special additivies. Testing of mechanical properties of concrete samples was provided on the durability point of view up to 360 days. It can be concluded from the results, that use of copper slag as fine aggregate in concrete is technically viable for road construction engineering and have some economical benefits as soon as.