The Energy Consumption of Ready-Mixed Concrete Mixing: History
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Contributor:
Veerabadrasamy Arularasi
,
Thamilselvi Pachiappan
,
Siva Avudaiappan
,
Sudharshan Naidu Raman
,
Pablo Guindos
,
Mugahed Amran
,
Roman Fediuk
,
Nikolai Ivanovich Vatin

The production and utilization of concrete and concrete-based products have drastically increased with the surge of construction activities over the last decade, especially in countries such as China and India. Consequently, this has resulted in a corresponding increase in the energy used for the production of ready-mixed concrete. One approach to reduce the cost of concrete manufacturing is to reduce the energy required for the manufacturing process. The main hypothesis of this study is that the power required for mixing the concrete can be reduced through the use of mineral admixtures in the mix design.

  • ready-mixed concrete
  • energy consumption
  • mixing

1. Background

Energy consumption is a major issue that is faced globally in the current scenario. In all manufacturing industries, identifying and controlling the processes that consume more energy is a key element in optimizing energy consumption, which will save energy and increase cost-efficiency. Before applying all cost-saving methods to a single factory, all cost-saving methods should be carefully analyzed, because all manufacturing processes require different potential energy, resulting in different energy consumption and material savings [1][2][3]. Through the use of efficient materials and effective energy improvement technologies, the production cost of concrete can be reduced, thereby making the concrete manufacturing industry more successful [4]. An excellent energy-saving plan will reduce annual energy costs by 3 to 10% [1]. The use of energy-saving methods in the manufacturing industry can also reduce waste generated in the production process [3][5][6]. Energy guidelines are provided to identify technical deficiencies that consume more energy. These guidelines provide cost-effective practices that reduce the energy consumption of any product in the manufacturing process [7]. In addition, the task of all concrete manufacturers is to reduce energy costs without compromising product quality [8][9].
Cazacliu [10] explained the new method of concrete mixing and related energy consumption. This method explains the changes in the concrete mixture during the successive stages of concrete mixing. According to him, when concrete mixing is conducted in a closed chamber, power consumption is the only tool to identify the transition phase of the concrete mixture. The author has pointed out that the power consumption value has not been compared with the flow characteristics. Three mixer measurement methods were developed: mixing power, Orbiter (rotating microwave sensor), and Viscoprobe TM (the measurement of resistance on a spherical probe passing through the mixture) [11]. The research was based on on the relationship between the evolution of the microstructure of concrete components and the mixing time. Juez et al. [12] applied image analysis technology to monitor the mixing of concrete and observe the texture of the concrete. At the same time, the power consumption during the concrete mixing process was also recorded and correlated with the texture of the concrete with the captured images [13][14][15][16]. Chopin et al. [17] explained the increase in the homogenization time of superplasticizer concrete and its impact on concrete production. The mixing time for the SCC and HPC is increased due to the homogeneity factor. This research discusses the ability to control uniformity through power consumption measurements. Daumann et al. reported concrete mixing in single-shaft and double-shaft mixers on a laboratory scale [18][19]. The author explains the energy required for the homogenization of concrete in the mixer that can be used for different applications, including 3D-printing [20][21]. Certain characteristics of concrete mixtures will change in relation to one other, such as w/c ratio, mixing time, flow characteristics, aggregate particle size distribution curve, and compressive strength [18]. The application of energy to achieve the homogenization of different mixtures is variable. Only when all the mixtures are of the same homogeneity can the energy required for different concretes be compared.

2. Importance of Mixing

Mixing is the most important stage in concrete manufacturing and is one that consumes the most energy. A ready-mixed concrete factory produces different types of concrete. Mixing plays a vital role in distinguishing different types of concrete. Nowadays, the manufacturing of SCC and HPC has increased due to emerging high-rise buildings and large structures. The power consumption curve obtained during the mixing of concrete gives a better understanding of the microstructural evolution in the concrete mixture [10]. Mixing consists of the evolution of a wet granular state to a granular microstructure suspension [11]. The mixing process is a key element in achieving good quality concrete [18][22][23]. In the current scenario, adequate mixing is not carried out by the concrete manufacturer. There is a lack of knowledge concerning the new materials used in concrete manufacturing. The increase in HPC and SCC productivity provides an opportunity to use new materials in the concrete production industry [12][24][25]. Concrete manufacturers should pay attention to the characteristics and performance of new materials and use appropriate mixing times to obtain high-quality concrete. A longer mixing time is applied in order to properly homogenize the concrete mixture, which affects the mixing efficiency. The elimination of inhomogeneity in the concrete mixture is a result of the mixing efficiency, and thus the mixing of concrete is the important phase for obtaining a quality outcome. Improper mixing leads to weak concrete and structural failure, and it has been common in the construction industry since HPC and SCC came into existence [26][27]. The production of HPC and SCC has given a higher priority to introducing new material into manufacturing concrete; hence, increasing the mixing time should be avoided in order to ensure the quality of the concrete. In the manufacturing of HPC and SCC, concrete manufactures are asked to respect the mixing time of concrete [28][29].

3. Mixing Mechanism

Mixing is an important operation that eliminates the inhomogeneity in a mixture. ASTM 305 is commonly used all around the world for mixing procedures [30]. Two important factors that can occur during the mixing operation are intensive mixing and extensive mixing [31]. Intensive mixing reduces agglomeration of the particles held by surface tension. The agglomeration can be reduced when the strength of the inter-particle bond is subject to higher hydrodynamic stresses [32]. During intensive mixing, fine powder is converted into a viscous fluid. In extensive mixing, deformation of the fluid takes place, which increases the interface area between the particles, and hence the inhomogeneity is reduced. Shear history is important for all fresh concrete because the binder-rich SCC exhibits thixotropic and structural breakdown characteristics. In the mixing of fresh concrete, the mixing energy is closely related to the shear rate [33].

4. Production and Energy Consumption of Ready-Mixed Concrete

In high-speed construction, concrete production requires more attention because there is no optimal time for concrete mixing [34]. In the past 20 years, ready-mixed concrete plants have produced a large quantity of SCC and HPC. The problems encountered in concrete mixing are mainly concentrated in ready-mixed concrete plants [35]. Measuring power consumption during mixing is important because more than 200 m3 of concrete can be manufactured per day in one ready-mixed concrete plant. In the future, this may increase due to the development of urbanization. In the manufacture of ready-mixed concrete, ingredients are added at specific intervals. Cement, fine aggregate, coarse aggregate, fly ash, GGBS, and water are added one by one into the mixing chamber. As the ingredients are loaded into the mixing chamber, power consumption will increase. The maximum power consumption is obtained when all components are loaded. The first peak is obtained when the mixture of dry ingredients reaches homogeneity in the dry state. After adding water, when a homogeneous mixture is obtained in a wet state, the second peak is reached [10][11]. After the homogenization is obtained, the power consumption is gradually reduced, and then the concrete is discharged.

5. The Relation between Power Consumption and the Mixing of Concrete

Power consumption is an important factor in determining the different stages of concrete mixing in the mixing chamber [10]. The power consumption curve is the only tool to determine whether homogeneity is achieved. The homogeneity of concrete varies from one mixture to another [21]. This leads to differences in concrete energy consumption. The power consumption during mixing is divided into different stages. The first stage starts from an empty condition and proceeds to the loading condition. The power consumption will gradually increase during the subsequent loading. In the second stage, the ingredients will mix thoroughly in a dry state, followed by the addition of water, where the moisture is absorbed by the powder particles [10]. At first, the power consumption does not increase because it does not form any liquid bridge. In the third stage, because a liquid bridge is formed between the powder particles, the saturation rate increases, and the gradual mixing will cause a sudden increase in power consumption. Further mixing disintegrates the granular particles to form a paste. At this stage, power consumption will reach its peak. In the fourth stage, homogeneity of the mixture can be achieved by continuously mixing the ingredients, and the concrete can reach full saturation. The starting point of the fourth stage will show higher power consumption, which will gradually decrease once a homogenous mixture is obtained [21][22][36][37].

This entry is adapted from the peer-reviewed paper 10.3390/ma15124143

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