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IJCIET
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D.Jayganesh**,
J.Vijayaraghavan**,
Dr.J.Jegan****
ABSTRACT
Industries produce things with by-product. Proper handling of waste material resulting from the
industries has recently become environmental concern besides resource management. The effluent
from the copper making manufacturing industry is termed as slag. Numerous research works have been
done to evaluate the suitability of copper slag for reuse. In lieu of its physical and mechanical
properties, slag is reusable in the applications viz: Cement Clinker Production, Blended Cement,
Concrete, Fine aggregate, Replacement for cement, Replacement for both sand and cement, Corrosion
resistant and Reduce seismic force and earth pressure A comprehensive review of studies on the
reuse of copper slag is presented.
Key Word: Copper Slag, Review, Fine Aggregate, Admixture.
PREAMBLE
Day to day activities of human kind involve production of many things required for
consumption and other purposes. Industries form very important units in manufacturing essentials
goods. By product, which results from the process of making, invites care in the safe disposal. Mass
can neither be created nor destroyed is the law of conservation of mass. According to the above law,
total mass on the universe remains constant. As the water present in various forms (sea water, clouds,
rainwater, ice, water vapour, surface water and groundwater) in the hydrological cycle, raw material
used in the manufacturing process appears into product and by-product. The concept of reuse of
waste/by-product has now-a-days become both environmental concern and resources management.
89
International Journal of Civil Engineering and Technology (IJCIET), ISSN 0976 6308 (Print),
ISSN 0976 6316(Online) Volume 4, Issue 6, November December (2013), IAEME
Here an attempt has been made to compile the various studies done on the reuse of copper slag in
concrete.
The by-product discharged from the copper manufacturing industry is called as slag. About 2.2
tonnes of copper slag result in every ton of copper production. Approximately 24.6 million tons of
slag are generated from the world copper industry (Gorai et al, 2003). The copper slag is a by-product
of operation of reverberatory furnaces. Impurities form a less dense liquid floating on top of the copper
melt. These impurities include iron, lime, silica, and form the slag. The slag is skimmed off the top, while
the melted material which has up to 50 percent copper, is called matte. The copper matte goes through
a converter to blow forced air into it. The air forces silica back into the copper matte to collect the
impurities and make more slag. The slag is skimmed off and air cooled.
By virtue of Copper slags mechanical and chemical characteristics, it becomes usable material
in concrete as a partial replacement for Portland cement or as a substitute for aggregates. Copper slag
has a number of interesting mechanical properties such as excellent soundness characteristics, good
abrasion resistance and good stability for using as aggregate (Gorai et al 2003).
PRODUCTION OF COPPER SLAG
In the separation of copper, slag is a by-product obtained during the matte smelting and
refining of copper has been reported by Biswas and Davenport (2002). The major constituent of a
smelting charge are sulphides and oxides of iron and copper. The charge also contains oxides such as
SiO2, Al2O3 CaO and MgO, which are either present in original concentrate or added as flux. It is Iron,
Copper, Sulphur, Oxygen and their oxides which largely control the chemistry and physical
constitution of smelting system. A further important factor is the oxidation/reduction potential of the
gases which are used to heat and melt the charge stated by Gorai et al (2002). As a result of this process
copper- rich matte (sulphides) and copper slag (oxides) are formed as two separate liquid phases. The
addition of silica during smelting process forms strongly bonded silicate anions by combining with the
oxides.
This reaction produces copper slag phase, whereas sulphide from matte phase, due to low
tendency to form the anion complexes. Silica is added directly for the most complete isolation of
copper in matte which occurs at near saturation concentration with SiO2. The slag structure is
stabilized with the addition of lime and alumina. The molten slag is discharged from the furnace at
1000-1300C.When liquid is cooled slowly; it forms a dense, hard crystalline product, while a
granulated amorphous slag is formed through quick solidification by pouring molten slag.
Physical and Chemical composition
The physical and chemical properties of copper slag, reported elsewhere, are presented in table
1 and 2 respectively.
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ISSN 0976 6316(Online) Volume 4, Issue 6, November December (2013), IAEME
Table 1. Physical properties of copper slag
Brinda et al, (2010),
Brinda and Nagan,(2010)
Brinda and Nagan(2011)
Arino and
Mobasher(2010)
Chavan and
Kulkarni, (2013)
Irregular
----
----
----
Type
Air cooled
----
pecific gravity
3.91,3.68
3.5
----
43.20%
----
-----
----
3.47
----
-----
51 20
----
-----
0.075 mm to 4.75 mm
Between 6and 7
11 mg/l
Less than 50 mm
(<50%)
-----
----Between 6and 7
-----
Physical Properties
Particle shape
Appearance
Percentage of voids
Bulk density
Fineness modulus of copper
slag
Angle of internal friction
Particle size
Hardness
Chloride
----
The specific gravity varies from 3.5 to 3.91. Bulk density is in the order of 1.70 to 3.8 g/cc.
The Fe2O3 content in the slag fluctuates between 53 % to 68.29%. While the SiO2 content varying in
between 25.84% to 35%, the Al2O3 concentration is in the order of 0.22% to 5 %.
Table 2 Chemical composition of copper slag (% composition)
Sl. No
Chemical
Compounds
Fe2O3
68.29
53
55
53.45
SiO2
25.84
35
27
33
Al2O3
0.22
5.00
<3.0
2.79
CaO
0.15
3.30
1-3.5
6.06
Arino and
Meenakshi Sudarvizhi
Mobasher, (2010) and Elangovan (2011)
Alnuaimi
(2012)
MgO
0.2
----
----
1.56
Na2O
0.58
-----
-----
0.28
K2O
0.23
----
----
0.61
Mn2O3
0.22
-----
-----
0.06
TiO2
0.41
----
----
10
CuO
1.2
-----
<1
---
11
LOI
Insoluble
residue
6.59
----
----
----
14.88
-----
-----
----
12
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ISSN 0976 6316(Online) Volume 4, Issue 6, November December (2013), IAEME
CaO content is in the order of 0.15% to 3.30%. It indicates that has low lime content. Slag also
exhibits pozzolanic properties since it contains low CaO. Under activation with NaOH, it can exhibit
cementitious property and can be used as partial or full replacement for Portland cement. The
utilization of copper slag for applications such as Portland cement replacement in concrete, or as raw
material has the dual benefit of eliminating the cost of disposal and lowering the cost of the concrete.
The use of copper slag in the concrete industry as a replacement for cement can have the benefit of
reducing the costs of disposal and help in protecting the environment. Despite the fact that several
studies have been reported on the effect of copper slag replacement on the properties of Concrete,
further investigations are necessary in order to obtain a comprehensive understanding that would
provide an engineering base to allow the use of copper slag in concrete. This slag is currently being
used for many purposes. It is a glassy granular material with high specific gravity particle sizes.
USES OF COPPER SLAG
In order to proper disposal and the management of copper slag, suitability for reuse as a
resource management and environmental protection has been evaluated extensively. The copper slag
has the following applications
Numerous studies have been carried out on the possibilities of reusing the copper slag in the said
applications. The findings of the earlier researches with the findings are summarized in tabular form for
the quick understanding (Table 3).
Table 3. Research studies on copper slag with the experimental parameter and findings
Sl.No
1
Authors
Chavan abd
Kulkarni (2013)
Experiment
Observations
Investigation on the
effect of using copper
slag as a replacement of
fine aggregate on the
strength properties
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ISSN 0976 6316(Online) Volume 4, Issue 6, November December (2013), IAEME
2
Alnuaimi (2012)
Brindha, and
Nagan (2011)
Durability of copper
slag admixed concrete
Meenakshi
Performance of Copper
Sudarvizhi.S,
slag and ferrous slag as
Ilangovan. R (2011) partial replacement of
sand in Concrete
Brindha, and
Nagan (2010)
Brindha, Baskarn
and Nagan (2010)
Experimental study on
various corrosion and
durability tests on
concrete containing
copper slag as partial
replacement of sand and
cement
Ishimaru et al
(2005)
The fundamental
properties of concrete
using copper slag and
class II fly ash as fine
aggregates
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ISSN 0976 6316(Online) Volume 4, Issue 6, November December (2013), IAEME
9
Wu et al (2010)
10
Mobasher et al
Effect of copper slag on
(1996) and Tixier et the hydration of
al (1997)
cement-based materials
11
12
Ayano et al (2000)
13
Washington
Almeida Moura et
al (2007)
Investigated the
strength
14
Madhavi et al
(2007)
15
16
Dynamic compressive
strength of copper slag
reinforced concrete
Isa Yuksel
and
Turhan Bilir (2007)
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17
Ramazan Demirbog
and
Rustem Gul (2007)
18
Caroline
Morrison et al
(2003)
19
Evaluated the
applicability of copper
slag as a substitute for
sand of sand
compaction pile method
20
Teik-Thye Lim
and Chu (2006)
Feasibility of using
spent copper slag as fill
material in land
reclamation
21
Mobasher et al
(1996
22
Tixier et al (1997)
23
Caijun Shi
and Jueshi Qian
(1999)
Review
24
Arino and
Mobasher (1999)
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specimens without concern for degradation of
other properties
25
Sioulas and
Sanjayan (2000)
Use of slag-blended
cements in the
production of HSC
26
Washington
Almeida Moura et
al 2007
27
Ayano Toshiki et al
(2000)
Problems in using
The delay of setting time does not have a negative
copper slag as a
influence on durability.
concrete aggregate. One
of them is excess
bleeding attributed to
the glassy surface of
copper slag
28
Ke Ru Wu et al
(2001)
29
Potential use of
The mechanical performance of the standard
flotation waste of a
mortars prepared from the FWCS clinkers was
copper slag as iron
found to be similar to those of the iron ore clinkers
source in the production
of Portland cement
clinker
30
Mostafa Khanzadi
and Ali Behnood
(2009)
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31
Najimi et al (2011)
The performance of
copper slag contained
concrete in sulphate
solution
32
Jack et al (2003)
The effect of
carbonation on
mechanical properties
and durability of
concrete
CONCLUSION
Copper slag has harness in the range 6 to 7. The specific gravity varies from 3.5 to 3.91. Bulk
density is in the order of 1.70 to 3.8 g/cc. The Fe2O3 content in the slag fluctuates between 53 % to
68.29%. While the SiO2 content varying in between 25.84% to 35%, the Al2O3 concentration is in the
order of 0.22% to 5 %. Due to the physical and mechanical property, slag enjoys various reuse
applications. Reuse of copper slag has the dual benefit of safe disposal and judicial resource
management. Application in concrete as an admixture, replacement of cement and as a fine aggregate
has very good scope in the future. Further research is warranted to analyze the scope for reuse
extensively.
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56. D.Jayganesh, Dr. J.Jegan and Dr.P.Mariappan, Impact of Staging Height of Service Reservoir
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57. A.Raja Jeya Chandra Bose, Dr.T.R.Neelakantan and Dr.P.Mariappan, Peak Factor in the
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58. Dr. P. Mariappan, Wastewater Management in a Dwelling House- A Case Study,
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