CALCIUM ALUMINATE
Calcium aluminate is a high-performance hydraulic cement used in specialized applications requiring rapid setting, high-temperature resistance, and chemical durability, such as in refractory materials for furnaces and kilns.
Calcium aluminate is produced by fusing calcium oxide and aluminum oxide at high temperatures, resulting in a white powder with a density of 2.98 g/cm³ and a melting point of 1605°C.
Calcium aluminate's unique properties make it ideal for applications in sewer systems, high-strength concrete mixes, and as a catalyst support material in chemical processes.
CAS Number: 12042-68-1
EC Number: 234-931-0
Molecular Formula: AlCaH7O
Molecular Weight: 90.11
Synonyms: 12042-68-1, Calcium aluminate, Calcium aluminum oxide, calcium;oxido(oxo)alumane, CALCIUMALUMINATE, MFCD00049722, Dialuminium calcium tetraoxide, calcium,oxido(oxo)alumane, EINECS 234-931-0, calcium dialuminate, Aluminum calcium oxide (Al2CaO4), Monocalcium aluminate, XFWJKVMFIVXPKK-UHFFFAOYSA-N, J-004335, Q6901369
Calcium aluminate is a white powder and exhibits a monoclinic crystalline form.
Calcium aluminate refers to a class of compounds derived from the combination of calcium oxide (lime) and aluminum oxide (alumina).
Calcium aluminate is made by fusing or sintering alumina and calcia contributing minerals to produce monoCalcium aluminate (CaAl2O4) clinkers that are subsequently powderized.
Calcium aluminate is density is 2.98 g/cc and its melting point is 1605°C.
The most common Calcium aluminate compound is Calcium aluminate, which is a hydraulic cementitious material.
The primary components of Calcium aluminate are Calcium aluminate phases, typically monoCalcium aluminate and diCalcium aluminate (CA2).
These compounds contribute to the cement's properties and performance.
Calcium aluminates are a range of materials obtained by heating calcium oxide and aluminium oxide together at high temperatures.
They are encountered in the manufacture of refractories and cements.
Calcium aluminate-based refractories are commonly used for lining tundishes in the steelmaking process.
Calcium aluminates are vessels used to control the flow of molten metal during continuous casting.
Calcium aluminate is sometimes used as a catalyst in the production of hydrogen peroxide.
Calcium aluminate helps in the conversion of anthraquinone derivatives to hydrogen peroxide.
Certain forms of Calcium aluminate may serve as a support material for catalysts in various chemical processes.
In the production of sulfuric acid, Calcium aluminate may be used in the construction of acid-resistant linings for equipment due to Calcium aluminate's resistance to acidic conditions.
Calcium aluminatees, which are used in high-temperature applications, may contain Calcium aluminate as a key component.
Calcium aluminate has been studied for its potential use in stabilizing hazardous waste materials, helping to immobilize certain contaminants.
Calcium aluminate can be used in the formulation of high-strength concrete mixes, contributing to enhanced compressive strength and durability.
In construction, non-shrink grouts containing Calcium aluminate may be used for applications where minimal volume change is desired, such as in the bedding of machinery.
Certain formulations of Calcium aluminate are used in oil well cementing.
These cements can provide high-temperature resistance and rapid setting in oil well construction.
Calcium aluminates may be used in the production of electrical insulating materials due to their ability to withstand high temperatures.
In geotechnical engineering, Calcium aluminate is sometimes used to stabilize soil and improve its load-bearing capacity.
Calcium aluminate-based compounds may be used in the formulation of chemical sealants for various construction and industrial applications.
In some formulations, Calcium aluminate is used in coatings designed to provide protection against corrosion in metal structures.
Calcium aluminates are cements consisting predominantly of hydraulic Calcium aluminates.
Alternative names are "aluminous cement", "high-alumina cement", and "Ciment fondu" in French.
They are used in a number of small-scale, specialized applications.
Calcium aluminate invented in 1908 by Bied[2] is sulfate-free and hardens to give mainly hydrated Calcium aluminates or carboaluminates (AFm phases: Aluminium Ferrite mono-substituted phases), sometimes accompanied with C–S–H as a minor component, while Ca(OH)2 (portlandite) is absent.
Calcium aluminate must not be confused with calcium sulfo-aluminate (CSA) cement containing calcium sulfate and invented later in 1936.
The main constituent, and also the most reactive phase, of Calcium aluminates is the monoCalcium aluminate (CaAl2O4 = CaO · Al2O3, also written as CA in the cement chemist notation).
Calcium aluminate usually contains other Calcium aluminates as well as a number of less reactive phases deriving from impurities in the raw materials.
Rather a wide range of compositions is encountered, depending on the application and the purity of aluminium source used.
Calcium aluminate is a super refractory material.
Calcium aluminate is far superior to Portland cement in its setting properties and its ability to withstand high temperatures and chemical attack.
Calcium aluminate is a type of cement made from a mixture of alumina and limestone at high temperatures.
Calcium aluminate has a long history of successful use in specialized cement applications, especially where resistance to very high temperatures, sulfates, and mild acids and alkalis are necessary.
Calcium aluminate can also work well where solid strengthening is required.
Calcium aluminate mainly consists of monoCalcium aluminate, other Calcium aluminates, and a couple of less reactive phases obtained from the raw materials’ impurities.
When applied as a specialty binder, Calcium aluminate displays excellent resistance to corrosion, heat, and abrasion
Calcium aluminate, alumina cements or high alumina cements are obtained by the reaction at high temperature of lime (from limestone) and alumina (contained in natural minerals like bauxite).
The Calcium aluminate obtained after cooling is a hard mineral: Calcium aluminate.
Ground into a fine powder, the clinker becomes Calcium aluminate which forms a paste when mixed with water.
The Calcium aluminate has the ability to harden very quickly: it forms a rigid solid within 24 hours.
Aluminum and calcium oxide are heated at high temperatures to create a group of minerals known as Calcium aluminates.
Depending on the purity level needed, lime and alumina or limestone and bauxite are combined to create Calcium aluminates, which, when cooled, leave behind hard Calcium aluminates.
Calcium aluminate can be utilized as an aggregate when crushed or screened, with the composition and color depending on the amount and purity of each source ingredient.
The clinker can harden very quickly yet in a controlled fashion in formulations when ground into a fine powder and used as a binder, which creates a paste when combined with water.
Additionally, Calcium aluminate contains trace levels of phosphorus, magnesium, iron, silicon, and manganese.
Calcium aluminate is added to the mix to provide concrete products with additional high-strength durability.
Calcium aluminate is a unique class of cement that is different than ordinary Portland cement (OPC), particularly due to the chemical make-up.
Calcium aluminate contains a far greater amount of alumina and a far less amount of silica.
Calcium aluminate is generally immediately available in most volumes.
Aluminates are compounds with a negatively-charged alumina ion and a metallic oxide with various industrial applications such as water treatment and ceramics manufacturing.
In December 2012, a team of researchers created a unique type of highly-reflective pigment composed of rare earth-doped cobalt aluminate that may have potential use as an energy-efficient exterior coating.
High purity, submicron and nanopowder forms may be considered.
American Elements produces to many standard grades when applicable, including Mil Spec (military grade); ACS, Reagent and Technical Grade; Food, Agricultural and Pharmaceutical Grade; Optical Grade, USP and EP/BP (European Pharmacopoeia/British Pharmacopoeia) and follows applicable ASTM testing standards.
Typical and custom packaging is available.
Additional technical, research and safety (MSDS) information is available as is a Reference Calculator for converting relevant units of measurement.
Calcium aluminate is produced by burning the raw materials of high grade crude aluminous bauxite and limestone in arc-furnace kiln.
Calcium aluminate is cement formed from the combination of limestone and alumina at high temperatures.
Calcium aluminate is used in specialized cement applications where resistance to extreme temperatures, mild acids and alkalies, sulfates and water are necessary.
Calcium aluminate is also used in situations where rapid strengthening is required.
Calcium aluminates are hydraulic cements obtained by pulverizing a solidified melt or clinker that consists predominantly of hydraulic Calcium aluminates formed from proportioned mixtures of aluminous and calcareous materials.
They are generally divided into three groups based on the alumina and iron oxide contents (Low Purity, Intermediate Purity and High Purity).
The cements of higher alumina content are suitable for higher-temperature applications.
Calcium aluminate may be known by many other names such as aluminous cement or high alumina cement (HAC).
Calcium aluminate was developed following the demand to produce sulfate-resistant cements.
Calcium aluminates were identified as excellent materials for dentistry, particularly for dental procedures contacting the dental pulp or root system.
Both calcium silicate and Calcium aluminates cause the biomineralization (precipitation of hydroxyapatite [HA] phenomena and shield dental tissues from the underlying cement (a foreign body material).
Calcium aluminate is known for its hydraulic properties, meaning it can set and harden underwater.
This makes Calcium aluminate suitable for various applications where conventional Portland cement may not be ideal.
Calcium aluminate has a rapid setting time compared to ordinary Portland cement.
This quick-setting characteristic can be advantageous in certain construction and repair applications.
Calcium aluminate exhibits good resistance to high temperatures.
Calcium aluminate is often used in applications where exposure to elevated temperatures is a concern, such as in refractory materials for industrial furnaces.
One of the primary uses of Calcium aluminate is in the production of refractory materials.
Refractories made from Calcium aluminate are used in industries like steelmaking, where resistance to high temperatures and harsh conditions is critical.
Calcium aluminate can be used in the formulation of specialized concrete mixes, such as those required for quick repairs, sewer applications, or other situations where rapid setting and high chemical resistance are necessary.
Calcium aluminate serves as a binder in the formulation of high-alumina castables used for lining kilns, furnaces, and other high-temperature equipment.
Calcium aluminate is known for its resistance to certain types of chemical corrosion, making Calcium aluminate suitable for use in environments where conventional cements may be vulnerable to attack by acids or sulfates.
Calcium aluminates are a special type of cements which have their composition mainly dominated by the presence of MonoCalcium aluminates.
Calcium aluminates are a special class of strong, high-performance heat-resistant cements.
Calcium aluminates have different chemical, physical and mineralogical properties than those of Portland cements (OPC).
The primary raw ingredients of Portland cement are limestone and clay.
The primary oxides derived from the raw materials are CaO and SiO2.
In the production of Calcium aluminate, on the other hand, bauxite is the raw material and source of alumina.
The aggregate of concrete produced by combining Calcium aluminate can be at lower temperatures in refractory cement.
The concrete can also display increased resistance to abrasion as well as sulfate attack.
Calcium aluminate cements are similar to the more familiar Portland cements in that they both require water for hydration, they both form concretes that set in about the same time, and they both require similar mix designs and placing techniques.
There are, however, important differences between the two cements.
First, Portland cements are made by reacting limestone and clay to produce calcium silicates, while Calcium aluminates (also called high-alumina cements) are made by reacting a lime-containing material with an aluminous material to produce Calcium aluminates.
Calcium aluminate is commonly used in the construction and repair of sewer systems.
Calcium aluminate is rapid-setting properties make it suitable for applications where a quick return to service is necessary.
In certain concrete applications, Calcium aluminate can be used in the formulation of mixes for expansion joints.
These joints accommodate the expansion and contraction of concrete due to temperature variations.
Calcium aluminate is used in bridge deck overlays, especially in situations where fast-setting concrete is required for rapid construction or repair.
When combined with other materials, Calcium aluminate can contribute to the production of high-performance concrete with specific engineering properties, such as increased strength and durability.
Calcium aluminate is a key component in the production of monolithic refractories, which are heat-resistant materials used in the linings of high-temperature industrial equipment like furnaces and kilns.
In environments where concrete is exposed to acids or aggressive chemicals, formulations containing Calcium aluminate may be used to enhance the material's resistance to chemical attack.
Calcium aluminate is also involved in the production of alumina (aluminum oxide).
In the Bayer process, which is a common method for extracting alumina from bauxite ore, Calcium aluminate is formed as a byproduct.
Calcium aluminate is used in various applications within the chemical and petrochemical industries where resistance to high temperatures and harsh chemical environments is crucial.
In the ceramic and glass industries, Calcium aluminate may be used as a binder or refractory material in the production of specialized products.
Calcium aluminates gain strength more rapidly than ordinary Portland cement (OPC).
Sometimes, a retarder is needed to ensure a longer workability.
In contrast to Portland cements, Calcium aluminates do not release calcium hydroxide (Ca(OH)2, portlandite, or lime) during their hydration.
The hydration reactions of Calcium aluminates are very complex.
The strength-developing phases are monoCalcium aluminate, dodeca-calcium hepta-aluminate (C12A7), and belite (C2S), a dicalcium silicate.
Calcium aluminoferrite (C4AF), monocalcium dialuminate (CA2), gehlenite, and pleochroite contribute little to the concrete strength.
The cement is made by fusing together a mixture of a calcium-bearing material (normally calcium oxide from limestone) and an aluminium-bearing material (normally bauxite for general purposes, or refined alumina for white and refractory cements).
The melting of the mixture is achieved at 1600 °C and is energy demanding.
The more elevated temperature explains a part of its higher production costs than for the clinker of ordinary Portland cement sintered at 1450 °C.
The liquified mixture cools to a vesicular, basalt-like clinker which is ground alone to produce the finished product.
Because complete melting usually takes place, raw materials in lump-form can be used.
A typical kiln arrangement comprises a reverberatory furnace provided with a shaft preheater in which the hot exhaust gases pass upward as the lump raw material mix passes downward.
The preheater recuperates most of the heat in the combustion gases, dehydrates and de-hydroxylates the bauxite and de-carbonates the limestone.
The calcined material drops into the "cool end" of the melt bath.
The melt overflows the hot end of the furnace into molds in which Calcium aluminate cools and solidifies.
The system is fired with pulverized coal or oil.
The cooled clinker ingots are crushed and ground in a ball-mill.
In the case of high-alumina refractory cements, where the mix only sinters, a rotary kiln can be used.
The special properties of Calcium aluminates make them of value in the construction, mining and refractory industries.
This book brings together new international research information on their performance.
As well as a state-of-the-art review, Calcium aluminate includes reports on studies of: mineralogy, hydration and microstructure; rheology of pastes, mortars and grouts; admixtures and blended; systems durability of high alumina cement concrete.
In addition to being used as a binder, Calcium aluminate is a key component in the formulation of high-alumina castable refractories.
These refractories are used in various industries for lining furnaces, kilns, and other high-temperature equipment.
Calcium aluminate is often used in the production of repair mortars, especially in situations where quick-setting and high-strength properties are required for structural repairs.
Gunning mixes, which are refractory materials applied using a pneumatic gun, may contain Calcium aluminate.
These mixes are used for repairing or coating refractory linings in various industrial applications.
In foundry applications, Calcium aluminate can be part of specialty refractory materials used for lining ladles and other equipment in the metal casting process.
Calcium aluminate may be used in soil stabilization applications.
Calcium aluminate can improve its engineering properties, such as strength and durability.
In certain concrete applications, Calcium aluminate is used to control the rate of hydration.
This can be particularly useful in situations where a delayed or extended setting time is desired.
Calcium aluminate is employed in chemical grouting applications, where Calcium aluminate is used to create a durable and impermeable barrier in the soil or rock.
Calcium aluminate is sometimes used in the formulation of fireproofing compounds for various applications, including building materials and coatings.
Some studies explore the use of Calcium aluminate-based materials in biomedical applications, such as bone cements for orthopedic surgeries.
Calcium aluminate can be a component of adhesives used for fixing ceramic tiles.
The rapid-setting properties are advantageous in applications where a quick bond is needed.
Calcium aluminates are used in certain dental restorative materials, including dental cements used for bonding.
Uses of Calcium Aluminate:
The major use of Calcium aluminate found for CaAl2O4 has been as a hydrous cement.
Alternative names are “aluminous cement”, “high-alumina cement” (HAC) and “Ciment fondu”.
Calcium aluminate is used in a number of small-scale, specialized applications.
Calcium aluminate is used as a precursor in the production of naphtha steam reforming catalysts, refinery gas steam reforming catalysts, aluminum chlorohydrate, secondary hydrocarbon steam reforming catalysts.
Calcium aluminate is also used in the production of refractory and cements.
Calcium aluminate is often used as coatings and linings for sewer pipes and water waste applications.
They also provide enhanced resistance to abrasion, acid, and biogenic corrosion, which can help extend the work life of sewer pipes.
The Calcium aluminate resistance is applied in ductile iron pipes for wastewater, concrete pipes for sewerage, and rehabilitation of sewer infrastructures.
Calcium aluminate can be used as binders in high-temperature refractory applications requiring high strength.
These binders are also used to regulate acid-resistant applications and quick setting mixtures.
Calcium aluminate is used as a catalyst in the production of hydrogen peroxide, facilitating the conversion of anthraquinone derivatives to hydrogen peroxide.
Certain formulations of Calcium aluminate are used in the production of phosphate-bonded refractories, which find applications in high-temperature processes.
In the oil and gas industry, Calcium aluminate may be used in oil well drilling muds to control fluid properties.
Calcium aluminate may serve as a catalyst in organic synthesis, contributing to various chemical transformations.
Calcium aluminate is used in certain paper production processes, particularly in applications where high-temperature resistance is required.
Calcium aluminate can be incorporated into abrasive products, providing hardness and resistance to wear.
Calcium aluminate is used in the formulation of insulating castables, which are materials designed to provide thermal insulation in high-temperature environments.
Calcium aluminate compounds may find applications in the pharmaceutical industry for specific formulations.
Included in adhesives used for fixing ceramic tiles, taking advantage of Calcium aluminate'srapid-setting properties.
Calcium aluminate compounds may serve as anti-caking agents in certain powdered or granular products to prevent clumping.
Utilized in the production of repair mortars for structural repairs where quick-setting and high-strength properties are crucial.
Calcium aluminate may be involved in catalytic cracking catalysts used in the petroleum refining industry.
Investigated for potential applications in electrochemical devices, including batteries and capacitors.
Research has explored the use of Calcium aluminate-based materials in biomedical applications, such as bone cements for orthopedic surgeries.
Calcium aluminate is used in the formulation of construction grouts for various applications, including filling gaps and voids.
Included in the production of high-temperature insulation materials for use in diverse industries.
Calcium aluminate is used in a wide range of building chemistry products, including tile adhesive, tile grouts, rapid floor screeds, bedding mortars, sealers, and floor leveling compounds.
Calcium aluminate is mixed with Portland cement to create the mineral base of these chemical products.
The mineral base may include a blend of admixtures, polymers, slag, lime, and light calcareous material.
Calcium aluminate is also widely used for creating chemical-resistant concrete often used in materials like industrial floorings.
In addition, Calcium aluminate can be added to construction concrete that needs robust strength development, even at low temperatures.
The Calcium aluminates used in the wastewater industry are typically manufactured with the fusion process.
Calcium aluminate is often used as mineral reagents or high-performance specialty binders across various sectors.
Because of their resilience to abrasion, heat, and corrosion, rapid hardening, and ease of grading variation control, Calcium aluminates serve as specialized binders in concrete and mortars for specialized applications.
By mixing them with additional high-quality components, unique hydraulic binders can be created.
They can also be found in non-hydraulic systems because they are used as mineral reagents.
Because of their low-temperature melting properties and capacity to absorb impurities in molten metal, some grades of Calcium aluminate, for instance, are utilized in metallurgical treatments (foundry, iron and steel industries).
Calcium aluminate is mainly used in refining ladle to remove the sulfide impurities from steel liquid and keeping good fluidity of slag.
Calcium aluminate is a cost effective additive in steel mills for slag-forming and desulphurizing.
Calcium aluminate is widely used by quality- conscious steelmakers in the world.
Calcium aluminate is used as a hydraulic cement, capable of setting and hardening underwater.
Calcium aluminate offers rapid setting compared to ordinary Portland cement.
A major application is in the production of refractory materials used in high-temperature environments like furnaces, kilns, and metal smelting operations.
Calcium aluminate is utilized in the construction and repair of sewer systems due to its quick-setting properties.
Calcium aluminate is used in overlays for bridge decks, providing quick-setting properties for rapid construction or repair.
Calcium aluminate is used to improve the engineering properties of soil, enhancing its strength and durability.
Essential for the production of high-alumina castable refractories, which line high-temperature industrial equipment.
Calcium aluminate is used in foundries for making specialty refractory materials that line ladles and other equipment in metal casting.
Formulations containing Calcium aluminate are employed in environments where concrete is exposed to acids or aggressive chemicals.
Calcium aluminate is used in the formulation of fireproofing compounds for various applications, including building materials and coatings.
Included in gunning mixes used for repairing or coating refractory linings in industrial applications.
Calcium aluminate is used in chemical grouting applications to create durable and impermeable barriers in soil or rock.
Calcium aluminate is used in certain dental restorative materials, including dental cements used for bonding.
Commonly Calcium aluminate is used for lining tundishes in the steelmaking process.
Certain forms of Calcium aluminate may serve as a support material for catalysts in various chemical processes.
Studied for Calcium aluminate'spotential use in stabilizing hazardous waste materials.
Calcium aluminate is used in the formulation of high-strength concrete mixes.
Calcium aluminate is used for applications where minimal volume change is desired, such as in the bedding of machinery.
Calcium aluminate is used in certain formulations for oil well cementing, providing high-temperature resistance and rapid setting.
Calcium aluminate is used in the production of electrical insulating materials due to its ability to withstand high temperatures.
Calcium aluminate is used to stabilize soil and improve its load-bearing capacity in geotechnical engineering.
Included in the formulation of chemical sealants for various construction and industrial applications.
Calcium aluminate is used in coatings designed to provide protection against corrosion in metal structures.
Calcium aluminate compounds may be used in certain paint and coating formulations, providing specific properties such as resistance to corrosion and high temperatures.
Investigations into the use of Calcium aluminate for photocatalytic applications have been reported, showcasing Calcium aluminate'spotential in environmental and energy-related processes.
In the formulation of adhesives for high-temperature applications, Calcium aluminate may be included to enhance the adhesive's performance under elevated temperatures.
Certain Calcium aluminate compounds can be used as metallic pigments in coatings, contributing to the visual appearance and corrosion resistance of the coated surface.
Calcium aluminate is utilized in the magnesium smelting process, where Calcium aluminate helps to control the impurities in the production of magnesium metal.
Calcium aluminate can be part of ceramic glazes, contributing to the aesthetic and functional properties of the glaze.
In water treatment processes, Calcium aluminate compounds may be employed for specific applications, such as adjusting pH or removing impurities.
Calcium aluminate-based materials have been explored for their potential use in thermal energy storage systems, where they can absorb and release heat.
Calcium aluminate is used in the formulation of linings for chemical-resistant equipment, providing protection against corrosive substances.
In certain construction and industrial applications, Calcium aluminate may be used in the production of soundproofing materials.
Calcium aluminate compounds are employed in specific processes within the glass industry, contributing to the quality and characteristics of the final glass product.
In the Bayer process for alumina production, Calcium aluminate is formed as a byproduct.
Calcium aluminate compounds may be involved in certain processes related to fertilizer production.
Calcium aluminate can be used as an expansion agent in concrete formulations, helping to control volume changes during setting and curing.
Calcium aluminate may be used as an additive in electrolytes for certain electrochemical applications.
In concrete production, Calcium aluminate may be included as an air-entraining agent to improve the freeze-thaw resistance of the concrete.
Production of Calcium Aluminate:
The production of Calcium aluminate involves several key steps, typically in an industrial setting. Here’s an overview of the process:
Raw Materials Preparation
Bauxite: Provides aluminum oxide (Al₂O₃).
Limestone: Provides calcium carbonate (CaCO₃).
Other materials: Sometimes, other minerals or additives are used to adjust the composition.
Calcination:
Mixing:
The raw materials (bauxite and limestone) are finely ground and mixed.
Heating:
The mixed materials are heated in a rotary kiln or electric furnace at high temperatures (around 1,400 to 1,800°C).
This process decomposes the limestone into calcium oxide (CaO) and carbon dioxide (CO₂) and converts the bauxite into aluminum oxide.
Formation of Calcium aluminate:
Reaction:
In the kiln, calcium oxide (CaO) reacts with aluminum oxide (Al₂O₃) to form Calcium aluminate compounds, such as Calcium aluminate (CaAl₂O₄) and other phases like calcium dialuminate (Ca₁₂Al₁₀O₃₈).
Cooling and Grinding:
Cooling:
The hot clinker or product is cooled, typically using air or water cooling systems.
Grinding:
The cooled material is then ground into a fine powder to produce Calcium aluminate or other Calcium aluminate products.
Quality Control and Packaging:
Testing:
The final product undergoes quality control tests to ensure it meets the required specifications.
Packaging:
The Calcium aluminate is packaged for distribution or further processing.
Summary of Steps:
Preparation of raw materials (bauxite, limestone, etc.)
Calcination (heating the mixture to high temperatures)
Formation of Calcium aluminate (chemical reactions in the kiln)
Cooling and grinding (producing fine powder)
Quality control and packaging (final product testing and distribution)
Applications:
Calcium aluminate produced through this process is used in various applications, including:
High-performance cements (e.g., Calcium aluminate for rapid-hardening and high-temperature resistance)
Refractory materials (for furnace linings and other high-temperature applications)
Construction and repair (for specialized concrete and mortar)
Thermal Properties of Calcium Aluminate:
Thermal Conductivity:
Low thermal conductivity, contributing to Calcium aluminate'suse as an insulating material in various applications.
Heat Resistance:
High resistance to heat, making it suitable for high-temperature applications such as in refractory materials and cement.
History of Calcium Aluminate:
The method of making cement from limestone (CaCO3) and low-silica bauxite (Al2O3) was patented in France in 1908 by Bied of the Pavin de Lafarge Company.
The initial development was as a result of the search for a cement offering sulfate resistance.
The cement was known as "Ciment fondu" and "Ciment électro-fondu" in French.
As indicated by Bied (1922), who was the inventor of this type of cement, the terms "Ciment fondu" ("fused cement") and "Ciment électro-fondu" ("electro-fused cement") refer only to the manufacturing process involving the melting of the base materials (CaO obtained after the decarbonation of CaCO3, and Al2O3).
This is because there is no temperature range in which Calcium aluminate is possible to observe the gradual softening and clinkerization of these materials, as is the case with Portland cement at around 1450 °C.
In the absence of a softening temperature, Calcium aluminates are obtained directly by fusion of the precursor materials, and Bied (1922) clearly indicated his preference for the appellation "ciment alumineux" ("aluminous cement") referring to its composition rather than to a manufacturing process.
Subsequently, Calcium aluminate'sother special properties were discovered, and these led to its future in niche applications.
By the 2010s, Calcium aluminate was found in the US market under the name FONDAG cement (FOND Aluminous Aggregate), sometimes referred to as ALAG (ALuminous AGgregate).
FONDAG cement is a mix of up to 40 percent alumina, and is stable at high temperatures and thermal cycling from −184–1,093 °C (−300–2,000 °F; 89–1,400 K; 160–2,500 °R)
Handling and Storage of Calcium Aluminate:
Handling:
Avoid Dust Inhalation:
Wear appropriate respiratory protection to avoid inhaling dust.
Protective Equipment:
Use gloves, eye protection, and long-sleeve clothing to avoid skin and eye contact.
Safe Practices:
Avoid generating dust; use local exhaust ventilation or dust extraction systems when handling or processing the material.
Training:
Ensure that personnel handling Calcium aluminate are trained in proper procedures and aware of potential hazards.
Storage:
Keep Dry:
Store in a dry, well-ventilated area to prevent moisture absorption which can affect quality.
Container Requirements:
Store in tightly closed containers to prevent contamination and exposure to air.
Labeling:
Ensure containers are properly labeled with hazard warnings and product information.
Separation:
Keep away from incompatible materials, such as acids and water, which could react or degrade the material.
Reactivity and Stability of Calcium Aluminate:
Reactivity:
Incompatibilities:
Avoid contact with acids, water, and strong oxidizers.
Reacts with acids to form aluminum salts and carbon dioxide.
Hazardous Reactions:
Can release toxic fumes if exposed to acids or moisture.
Stability:
Stable:
Calcium aluminate is generally stable under normal conditions of use and storage.
Decomposition:
Stable at standard temperatures, but excessive heat or moisture may cause degradation.
Safety Profile of Calcium Aluminate:
Calcium aluminate compounds can be irritating to the eyes and skin.
Direct contact may cause irritation, redness, or rash.
Calcium aluminate's important to use appropriate personal protective equipment, such as gloves and safety goggles, when handling these materials.
Dust or fine particles of Calcium aluminate may be generated during handling or processing.
Inhalation of these particles can irritate the respiratory tract.
Adequate ventilation and respiratory protection may be necessary in situations where airborne particles are present.
Under certain conditions, Calcium aluminate can decompose to release hazardous gases.
For example, exposure to strong acids can lead to the release of hydrogen gas.
Care should be taken to avoid incompatible substances and conditions that may result in hazardous reactions.
First Aid Measures of Calcium Aluminate:
Inhalation:
Move to Fresh Air:
If inhaled, move the person to an area with fresh air immediately.
Seek Medical Attention:
If respiratory irritation or difficulty persists, seek medical attention.
Skin Contact:
Rinse Thoroughly:
Wash affected skin with plenty of water and soap.
Remove Contaminated Clothing:
Take off any contaminated clothing.
Medical Attention:
Seek medical attention if irritation develops or persists.
Eye Contact:
Rinse Eyes:
Rinse eyes immediately with plenty of water for at least 15 minutes, holding the eyelids open.
Seek Medical Help:
Obtain medical attention if irritation persists.
Ingestion:
Rinse Mouth:
Rinse mouth with water.
Do Not Induce Vomiting:
Do not induce vomiting unless directed by medical personnel.
Seek Medical Assistance:
Get medical help immediately.
Fire Fighting Measures of Calcium Aluminate:
Water:
Can be used to cool containers and control dust.
Dry Chemical, Foam, or Carbon Dioxide:
Suitable for fires involving Calcium aluminate.
Unsuitable Extinguishing Media:
Avoid Water:
Direct water spray may cause dust to become airborne and exacerbate the problem.
Firefighting Procedures:
Wear Protective Gear:
Firefighters should wear self-contained breathing apparatus and full protective clothing.
Cool Containers:
Keep containers exposed to fire cool with water.
Hazardous Combustion Products:
Fumes:
May release fumes containing aluminum oxide, which can be harmful.
Accidental Release Measures of Calcium Aluminate:
Personal Precautions:
Protective Equipment:
Wear appropriate protective equipment to avoid dust inhalation and skin contact.
Ventilation:
Ensure adequate ventilation in the area.
Environmental Precautions:
Containment:
Prevent spills from entering waterways or soil.
Cleanup Methods:
Vacuum or Sweep:
Use a vacuum cleaner equipped with a HEPA filter or sweep up the material and place it in a suitable container.
Avoid Water:
Do not use water to clean up the spill as it can create dust.
Exposure Controls/Personal Protective Equipment of Calcium Aluminate:
Occupational Exposure Limits:
No specific limits:
Follow general industry guidelines for dust and particulate matter.
Engineering Controls:
Ventilation:
Use local exhaust ventilation to control dust.
Dust Control:
Employ dust suppression techniques.
Personal Protective Equipment:
Respiratory Protection:
Use N95 or P100 respirators if dust exposure is possible.
Eye Protection:
Wear safety goggles or face shields to protect against dust.
Hand Protection:
Use gloves to prevent skin contact.
Skin Protection:
Wear protective clothing to prevent skin exposure.
Hygiene Measures:
Wash Hands:
Wash hands thoroughly after handling.
Avoid Eating:
Do not eat, drink, or smoke in areas where Calcium aluminate is handled.
Identifiers of Calcium Aluminate:
IUPAC Name: Calcium aluminate
CAS Number: 12042-68-1
EC Number: 234-980-8
UN Number: Not specifically assigned; regulated under general hazardous material codes.
Chemical Formula: CaAl2O4
Appearance: Typically a white or off-white powder
Odor: Odorless
Density: Around 3.0 g/cm³ (varies by specific formulation)
Properties of Calcium Aluminate:
Melting point 1600°C
Density: 2.981
solubility: reacts with H2O
form: Powder
Specific Gravity: 2.981
color: White
Water Solubility: Insoluble in water.
Sensitive: Hygroscopic
Appearance: White or off-white powder
Odor: Odorless
Density: Approximately 3.0 g/cm³ (may vary depending on specific form or grade)
Solubility: Insoluble in water
Melting Point: Generally around 1,750°C (3,182°F) but can vary depending on the specific form of Calcium aluminate.
Specifications of Calcium Aluminate:
Calcium aluminate (CaAl₂O₄): Typically 60-70% of the total composition
Alumina (Al₂O₃): Usually 40-50%
Calcium Oxide (CaO): Approximately 35-45%
Other Components: May include small amounts of silica (SiO₂), iron oxide (Fe₂O₃), and other impurities
Appearance: White or off-white powder
Bulk Density: Around 2.5 to 3.0 g/cm³
Particle Size: Typically 100 mesh or finer; specific sizes depend on the application
Moisture Content: Generally less than 1% to prevent clumping and maintain consistency
