CHRYSO® Overview
Founded in 1942, CHRYSO® is a technology leader who constantly develops innovative products, breaking technological barriers to add value to its customers’ businesses. With its well positioned international network, the CHRYSO® Group ensures a close and efficient response to its customers’ needs with a high level of expertise and know-how in the formulation of construction materials.
Concrete
n Admixtures (superplasticisers, plasticisers, air entrainers, set retarders, accelerators, water repellents)
n Mould release agents n Surface retarders
CHRYSO®’s Innovation and R&D
n Colouring agents
CHRYSO®’s central Research and Development laboratory is based south of Paris (France). Over 50 scientists and technicians work continuously on innovative and cost effective solutions. It has developed partnerships with various universities and public research institutes worldwide and close co-operation with customers on innovative technological programs.
n Curing agents n Fibres n Protection agents n Dust suppressants n Aesthetics offering Plaster
Construction
CHRYSO’s innovative solutions
n Grouts
CHRYSO offers a wide range of innovative and technological products for 4 main markets:
n Adhesives
Cement
n Cementitious repair mortars
n Activators n Chromium VI reducing agents n Air entraining agents n Specialty products
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In addition to CHRYSO®’s central Research and Development facility, most of our subsidiaries have dedicated product application laboratories which form part of our customer service offer. Furthermore, we have invested in modern industrial equipment in all our plants around the world, for the production of new generation polymers and formulated products. Our systems are constantly evolving and reacting to keep abreast of the rapidly changing production processes and product needs of the world cement manufacturers.
n Fluidisers n Mould release agents
n Grinding Aids
CHRYSO Southern Africa
CHRYSO Southern Africa
CHRYSO® is one of the world leaders in the development, manufacture and supply of chemical additives for concrete, cement and plaster.
n Waterproofing membranes and solutions n Coatings n Flooring n Resin mortars n Silicones and Sealants
A strong commitment to respect Environment and Safety Indeed, either in our customers’ process (formulation of biodegradable and vegetable based products, optimisation of recycled aggregates, Chromium VI reduction in cement, etc.) or in our industrial policy, CHRYSO® assesses each element and makes it a priority to respect and protect the Environment. CHRYSO®’s major objective has always been to constantly improve the quality of its products and services. In 1994, CHRYSO® was the first admixture company to be ISO 9001 certified. Since July 2003, many subsidiaries (France, South Africa, Italy, Turkey, Spain, etc.) have obtained ISO 9001: 2000 version certifications, and other quality, safety and environmental certifications.
CHRYSO is an active supporter of Sustainable Development: We aim at minimising the environmental impact of our industrial processes and take this issue into account in the design of our products.
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Specific process ECONOMICAL ADVANTAGES
CHRYSO Southern Africa
Mineral addition increase
Recution of CO CO22 emissions emissions Reduction
Maintenance costs savings
Blockages prevention
Storage improvement
TECHNICAL ADVANTAGES
Energy savings
Gain in capacity production
Setting time control
Chromium (VI) reduction
Improvement of cement workability
Air entrainment
Reduction of cement water demand
Increase of mineral addition
Increase of cement strengths
Pack set reduction
Cement handling improvement
Elimination of coating on grinding media
Improvement of the separator efficiency
CHRYSO® provides 5 different ranges of formulated additives to optimise cement or raw material production at all stages of the process.
Improvement of fineness
Increase of production capacity
Ball mill
Roller Press
Specific material
Vertical Mills
Quick Lime
Limestone
Slag
Standard material
Raw Meal
Aluminate cement
White cement
Masonry cement
Blended cement
Portland cement
CHRYSO Southern Africa
CHRYSO®
Selection Guide
All CHRYSO® formulated products are easy-to-use and ready-to-use. They can be dosed directly into the mill or onto the mill-feed belt. The optimum dosage is set with our technical assistance during trials. No dilution is required.
CHRYSO® Grinding Aids
CHRYSO® Activators
CHRYSO® Reductis
CHRYSO® Air Entraining Agents
CHRYSO® Specialty Products: Water reducers and set time retarders
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Improvement of particle size distribution
100
CHRYSO® Grinding Aids
n As the coating of grinding media is eliminated, grinding of each range of particle sizes is improved.
Also ble60 availa der in pow 40 form
40
Differential volume (%)
Cumulated volume (%)
Cumulated volume (%)
60
20 20 0
CHRYSO Southern Africa
In order to optimise cement or raw materials production at different stages of the manufacturing process, CHRYSO offers a full range of grinding aids for both cement and raw meal grinding.
0 0.04
0.04 0.1
1.0
Particle diameter (µm)
0.1
60
40
20
0 0.04
1.0
100.0
Without CHRYSO® Additives 100.0 ®
Particle diameter (µm) 500.0
500.0 With CHRYSO Additives
Economical advantages Industrial Trial with a standard CHRYSO Grinding Aid Cement mill output (Tph)
n Increase of mill productivity (from 10% to 25%) Thanks to CHRYSO
100
Grinding Aids properties on mill efficiency, productivity can be increased up to over 25% without any additional energy consumption.
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®
80 70
n Improve cement quality (pack set, blaine,
48 tph
50
+ 8 tph (+15%)
40
Standard CHRYSO Grinding Aid
Reference data
30
Pack set improvement allows for the reduction of
55 tph
60
n Fast truck loading and packing
n Reduce production costs.
500.0
With CHRYSO® Additives
Increase of productivity
Objectives n Increase grinding process productivity.
On account of the reduction of the electro-static effect of cement particles, is ® Withoutcement CHRYSOfluidity Additives increased. By way of consequence, With CHRYSO® Additives cement handling is improved and blockages are prevented.
Particle diameter (µm) Without CHRYSO® Additives
1.0 100.0
0.1
Improvement in pack-set and cement handling (silos, bulk tankers)
CHRYSO Southern Africa
80 80
Differential volume (%)
100 100
Differential volume (%)
for production process
Cumulated volume (%)
80
(No formulated GA)
20
interruptions due to blockages. Truck loading speed and packing are therefore improved thanks to better cement fluidity.
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3
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9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31
Day Separator return in Tph (ton per hour) Feed Tph (ton per hour)
particle size distribution, etc.)
n Enhanced powder flow dynamics and
Significant production cost reduction
reduction of pack set.
n Energy savings CHRYSO Grinding Aids modify the surface charges on the cement particles, therefore off-setting the Van Der Waals forces. As a consequence, the agglomeration of the cement particles is significantly reduced and the coating on media and mill internals is eliminated. As reagglomeration of the grinded particles is eliminated, the separator return is significantly reduced. ®
Technical advantages Prevention of cement agglomeration. Eliminates coating on grinding media. Prevents coating and build-up in seperator and transport system.
Particle
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Crushing in the mill
Van Der Waals Forces
Modification of the surface charge density to fight against Van Der Waals Forces
CHRYSO Grinding Aids improve clinker grinding efficiency. This allows for a shortened cement retention time in the mill which, in the end, leads to significant energy savings for each ton of cement produced. ®
n Maintenance cost reduction
Shortened cement retention time in the mill leads to a less intensive use of the grinding system, therefore reducing mill maintenance cost per ton of cement. More importantly, the reduction of coating in the mill as well as the improved power flow dynamics reduce the risk of stoppages caused by blockages (diaphragm and outlet grit cleaning, silo blockage etc.)
Industrial Trial with a standard CHRYSO Grinding Aid Cement mill output Tph
Energy consumption KWh/t
100 90
40
37 KWh/t
80
32 KWh/t
70
55 tph
60
48 tph
50 40
+ 8 tph (+15%)
Standard CHRYSO Grinding Aid
Reference data
30
(No formulated GA)
30
20
10
20 1
2
3
4
5
6
7
8
9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31
Day Feed Tph (ton per hour) Energy consumption in KWh/t
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CHRYSO® Activators more strengths with less clinker Also ble availa der in pow form
efficiency. This allows for a shortened cement retention time in the mill which, in the end, leads to significant energy savings per ton of cement.
Objectives n Increase cement strengths (early and final strengths), at equal cement composition, to meet all applicable standards: ASTM C465, EN 197-1 and other local standards.
They aim at either increasing strengths at equal cement composition and same cement fineness, or reducing clinker/cement ratio.
n Decrease clinker factor (percentage of clinker in
CHRYSO® Activators also deliver grinding properties which can be can adapted to our customers’ specific technical needs. CHRYSO® Activators are available in both chloride Economical advantages and chloride-free versions.
cement), while increasing SCM (supplementary cementitious materials): slag (S), fly ash (V/W), limestone (L/LL) and pozzolans (P/Q) in order to decrease cement production costs and CO2 emissions.
Savings on clinker Economical advantages The cost of SCM is lower than the cost of clinker.
Savings on clinker
By substituting SCM to clinker, the total cost of cement The costis of SCM iswhile lowerboosting than theperformance cost of clinker. reduced thanks to the By substituting SCM to ®clinker, the total cost of cement use of CHRYSO Activators. is reduced while boosting performance thanks to the Reduction of CO2 emissions ® use of CHRYSO Activators. CO2 emission is caused by the calcination of limestone Reduction of )CO emissions 2 (CaCO during the clinker manufacturing process. 3 CO2 emission is caused by the calcination of limestone As each ton of cement produced requires less clinker, (CaCO3 CO ) during the clinker manufacturing process. emissions are decreased. Therefore CO quotas can 2
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As eachbe ton of cement produced requires respected, CO taxes reduced orless C/Kclinker, ratio company 2 CO2 emissions are decreased. Therefore CO quotas can target achieved. 2 be respected, CO2 taxes reduced or C/K ratio company Significant reduction of the production costs target achieved. Energy savings
Significant reduction of the production costs
CHRYSO® Activators improve clinker grinding efficiency. This allows for a shortened cement savings n Energy retention time in the mill which, in the end, leads to ® significant energy savings ton of cement. CHRYSO Activators improveper clinker grinding
CHRYSO® Activators allow for up to 20% Energy consumption (KWh/ton). 7
Technical advantages CHRYSO Southern Africa
CHRYSO Southern Africa
CHRYSO® offers a full range of activators, designed to improve cement strengths.
Chloride-free All these technical benefits are also available in chloride-free version.
Improvement of particle size distribution As the coating of grinding media is eliminated, grinding of each range of particle sizes is improved.
Increase of early and/or long-term compressive strengths at equal cement composition and same cement fineness CHRYSO® Activators major property is to activate early strengths (1 and 2 days), final strengths (7 and 28 days) or both.
Mpa
60 50 40
Therefore, they can be used:
30
n when clinker reactivity is low and strengths are
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not complying with the standards specification,
n when the objective is to reach a higher cement strength class,
1 day strength 2 days strength 7 days strength 28 days strength
10 0
Reference Test
n when the objectives is to reach higher performance.
Clinker factor reduction CHRYSO® Activators are designed to meet multiple technical requirements:
n Increased mineral additions such as fly ash, pozzolans, GGBS (Ground granulated blastfurnace slag) or limestone, whilst complying with the cement standards, in order to decrease production costs and CO2 emissions, or increased strengths at equal cement composition.
With CHRYSO Activators
Mpa
45 40 35 30 25 20 15 10 5 0
1 day (Mpa) 7 days (Mpa) 28 days (Mpa) Control 21% 21% Pozz 27% Pozz 30% Pozz Pozz without + CHRYSO Activators additives
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CHRYSO® Cr VI reducing agent
High efficiency, even at low dosage rates CHRYSO® Reductis enables efficient reduction of Chromium VI, even at low dosage rates. For example, cement treated with maximum 50 ppm of CHRYSO® Reductis 50 per ppm of Cr VI, keeps Cr VI rate below 2 ppm during a minimum of 6 months.
Reduction of Cr VI – Industrial results CHRYSO® Reductis 50 dosage rate: 50 ppm
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Cr VI content (ppm)
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Objectives n Reduce the Chromium VI content in cement, on a long-term basis, to meet the European Directive 2003/53/CE requirements (CrVI content below 2 ppm).
CHRYSO® Reductis is a ready-to-use range, which can be dosed directly into the mill or onto the mill-feed belt. Standard pumping equipment can be used for dosing, therefore no additional investment is required.
No discolouring or staining concrete CHRYSO® Reductis range specific formulation ensures no colour modification of concrete (neither discolouring nor staining).
No changes of concrete mechanical strength, setting times, water demand or air entrainment The chemical formulations of the CHRYSO® Reductis range do not modify cement performances, such as initial and final strengths and setting times.
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1.3
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Technical advantages Ease of use and dosing
CHRYSO Southern Africa
CHRYSO Southern Africa
CHRYSO® Reductis is a range of liquid patented products, which offers a significant and durable reduction of Hexavalent Chromium, even at low dosages.
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Temperature resistance The formulation of the CHRYSO® Reductis range is stable, consistent and is not sensitive to temperature fluctuations. Even at low temperature (-20°C), the product does not separate.
Back-up solution compared to powder products The fluidity and stability of the CHRYSO® Reductis range prevents any blockage in the process. Moreover, storage period shelf-life is 12 months in its original packaging. CHRYSO Reductis 50 dosage is 60 times less than Iron Sulafte. ®
1.2 0.6
Blank T = 0
T=0
T = 1 month
0.5
0.4
0.3
T = 2 months T = 3 months T = 4 months T = 5 months
0.3 T = 6 month
0.3
0.3
0.3
T = 7 months T = 8 months T = 9 months
Aging time in bags 2 ppm limit (EU standard)
Economical advantages
No loss in cement productivity
Savings on installation equipment
CHRYSO® Reductis is a range of liquid products which prevents cement plant production from blockages which occur when using powder Cr VI reducer.
The methods of incorporation of CHRYSO® Reductis are standard. Therefore, there is no need to invest in any special material or installation to use this product range, making it an economical solution.
Cement plants can pursue production with this ready, easy-to-use and reliable back-up solution.
Savings on maintenance costs The fluidity and stability of CHRYSO® Reductis range prevents any blockage in the process. Therefore, maintenance costs due to blockages are suppressed.
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CHRYSO® Air Entraining Agents for masonry cement
n Produce masonry cement conforming to CHRYSO Southern Africa
the NF EN 413, ASTM C91 or other local standards.
n Stabilise air level while optimising the size
The CHRYSO® Air Entraining Agents range is specifically designed to entrain air in masonry cement.
CHRYSO Southern Africa
Objectives n Entrain air in masonry cement (up to 20%.
of the air voids and their dispersion.
Technical advantages Entrain and optimise air in mortars (up to 20%) CHRYSO® Air Entraining Agents range easily achieves air requirements for various masonry products. It improves mortar flowability, the consistency of air content and dispersion of the air voids.
Improve grinding capacity CHRYSO® Air Entraining Agents can be custom formulated to include grinding aids performance.
Improve powder transport CHRYSO® Air Entraining Agents also reduce the electro-static effect of cement particles. The cement produced is more fluid which prevents blockages and improves cement handling.
Increase water retention for mortars: Improve adherence on all surfaces
Improve setting times and 28-day strength
CHRYSO® Air Entraining Agents improve water retention for mortars. Consequence is a better adherence to any surface.
To meet our customer technical needs, CHRYSO® Air Entraining Agents can be specifically formulated to improve setting times and 28-day strengths.
Improve masonry cement waterproofing properties To meet ASTM standards, CHRYSO® adds waterproofing properties to its air entraining agents.
Increase freeze-thaw resistance and crack prevention Thanks to the air entrained in cement when using CHRYSO® Air Entraining Agents, the air voids act as expansion chambers which improve the frost resistance of the mortar and therefore prevent cracking.
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CHRYSO® Specialty Products tailor-made solutions for specific requirements
Performance of the regular water reducing additives on fly ash-based cement Water demand (according to EN standard)
n Water demand reduction n Flowability improved for raw material in wet process allowing water decrease and energy gain
Technical advantages Set time retarders CHRYSO Set Retarding Additives can extend initial set from a few minutes up to several hours depending on customers’ requirements. ®
In most cases, CHRYSO® Set Retarders do not affect early strengths. They improve long term strengths.
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W/C 0.32
0.30
0.30
0.28
0.26
0.24 0% 0.28
% of Fly Ash W/C without CHRYSO® specialty products W/C with CHRYSO® specialty products
0.26
0.24 0%
5%
% of Fly Ash W/C without CHRYSO® specialty products
the cement standards in which n According specialty products W/C withto CHRYSO
n According to the standards in which cement
cement strengths are evaluated on mortar at constant W/C ratio (generally W/C = 0.5):
CHRYSO® Water Reducing Agents can increase concrete strengths at constant consistency. They are also adapted to high W/C ratio > 0.3. Consequently, there is an enhancement of strengths at all ages in cement and concrete.
CHRYSO® Water Reducing Agents are
®
Some PFA or Pozzolana (increasing W/C ratio of the cement) can be used in higher proportion thanks to CHRYSO® Water Reducing Agent.
strengths are evaluated at constant consistency (W/C ratio adjusted): decreasing water demand of the cement at constant consistency.
n Increase of all cement strengths n Compensate the loss of strengths due to increased supplementary cementitious materials in the cement.
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CHRYSO Southern Africa
CHRYSO® Water Reducing Additives are formulated to reduce the water demand of cement reducing the W/C 0.32 standard consistance. This has a direct impact in the water demand in concrete improving workability and slump.
Objectives n Setting time improvement
Cement setting time shifts (caused by seasonal temperature variation) can be adjusted with CHRYSO® Set Retarding Additives.
Performance of the regular water reducing on fly ash-based cement
Water reducers Water demand (according to EN standard)
CHRYSO Southern Africa
CHRYSO® has developed a full range of tailor-made specialty products to meet our customers’ specific needs.
CHRYSO®
Technical assistance
Service offer
CHRYSO® provides a technical assistance team in every subsidiary in order to meet our customer's local specifications and requirements. Our teams are trained and have the standard technical expertise to respond to any particular grinding system issue: on customers’ sites during trials or to respond to specific demands of grinding system optimisation.
Installations (pump, tank, remote inventory system, etc.)
CHRYSO Southern Africa
Lab tests, specific studies and product developments in CHRYSO® laboratories In CHRYSO®’s International R&D Center (South of Paris), CHRYSO® has its own cement laboratories, with dedicated teams of experts. These premises and teams conduct lab tests for customers’ specific needs and develop new products in partnership with our R&D team.
Depending on customer demand, we provide different kinds of installations:
Dosing systems
Remote inventory systems
CHRYSO® provides and installs dosing systems on demand. Technical assistance is given for an efficient layout.
CHRYSO® offers a remote inventory system which comprises sensors installed on customer tanks and automatic delivery supply. This system:
Tanks
n Decreases the risk of GA shortage
CHRYSO® offers grinding aids tank installation in cement plants which reduces:
n Offers the customer the possibility to outsource
n Bulk deliveries costs compared to IBC supply
CHRYSO Southern Africa
CHRYSO ’s offer goes beyond formulated products but also provides a full range of services. In order to meet customer requirements, CHRYSO® provides specific lab studies and tailormade developments, technical assistance in the field and installation of dosing equipment, tanks and remote inventory systems. ®
logistics (automatic supply when a determined level is reached).
n IBC recycling costs
Each year, CHRYSO® tests and develops numerous tailor-made solutions, in order to offer our customers the most appropriate solutions to their specific requirements. Our local team of experts are available in order to be ever more efficient, faster to respond and closer to local customers’ specifications. Antenna
Customer’s needs
CHRYSO® products are tested on customers’ raw material, in our lab
Results do not conform to customer’s specifications
Customer’s specific demands
CHRYSO teams work on tailor-made solutions, in our lab
Results conform to specifications
GPRS modem or GSM
WWW
Tank level + follow up
Web server
Products proposed for plant testing
Cement additives logistic management
CHRYSO® Grinding Aids
®
CHRYSO® Activator
CHRYSO® Reductis
Results conform to specifications
Cement additives order supply
Cement additives tanks on customer's site
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CHRYSO® Southern Africa
CHRYSO® Eastern Africa Ltd.
26 Malcolm Moodie Crescent, Jet Park, Ext. 30, 1469 T: +27(0)11 395 9700 W: za.chryso.com Sharecall facility: 0861 CHRYSO
LR No.1208/10 Sameer Business Park, Block C, Unit C1 Mombasa Road 10032 00100 Nairobi W: ke.chryso.com
CHRYSO® Added value for cement Content
CHRYSO® Selection Guide CHRYSO® Grinding Aids for production process CHRYSO® Activators more strengths with less clinker CHRYSO® Cr VI reducing agents CHRYSO® Air Entraining Agents for masonry cement CHRYSO® Specialty Products, tailor-made solutions for specific requirements CHRYSO® Service Offer
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CHRYSO Southern Africa
CHRYSO® Overview
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