Production and properties of ferrite-rich CSAB cement from metallurgical industry residues

Thermodynamic modelling of cements clinkering process as a tool for optimising the proportioning of raw meals containing alternative materials

The valorisation of waste or by-products in Portland clinker production is a promising alternative for developing sustainable cements. The complexity of the chemical reactions during clinkering demands an adequate dosing method that considers the effect of feedstock impurities to maximise the potential substitution of natural resources by waste or by-products, while guaranteeing the clinker reactivity requirements. This study proposes a raw meal proportioning methodology for optimising co-processing of natural feedstocks with alternative raw materials in clinker production, intending to reduce the content of natural raw materials needed, while promoting an optimal clinker reactivity. A thermodynamic modelling sequence was developed considering the variability of raw materials composition and heating temperatures. The model was then validated by comparing simulation outcomes with results reported in previous studies. An experimental case study was conducted for validation of the proposed method using a spent fluid catalytic cracking catalyst (SFCC), a by-product from the oil industry as an alternative alumina source during clinkering. The modelling simulations indicated that substitution of natural feedstocks by 15 wt% SFCC promotes the formation of reactive clinkers with more than 54% tricalcium silicate (C3S). Mixes with the potential to form the highest C3S were then produced, and heating microscopy fusibility testing was applied for evaluating the clinkers' stability. The main factors governing the reactivity and stability of the clinker phases were the melt phase content, alumina modulus, and formation of C3S and dicalcium silicate (C2S). The self-pulverisation of clinker during cooling was observed in selected mixes, and it is potentially associated with high viscosity and low Fe content in the melt phase. The proposed framework enables optimisation of the dosing of raw meals containing alternative alumina-rich feedstocks for clinker production and allows a deeper interpretation of limited sets of empirical data.

Effect mechanism of steel slag on CO2 capture in hydraulic lime

Steel slag (SS) inhibits the early hydration of cement, limiting its application in cement-based materials. In this study, SS was used to prepare hydraulic lime (HL), and the effect of SS on CO₂ capture in HL was investigated. SS inhibited the carbonation of HL in the early stages but promoted carbonation in the later stages. Adding more than 10% SS inhibited the formation of hydration products, and the reduction of hydration products inhibited the carbonation product content, increased the porosity of the hydration mortar, promoted the later stage carbonation rate, and reduced the compressive strength. The carbonation area and captured CO₂ content of the mortars in SS-HL increased exponentially with an increasing carbonation curing age. With an increasing SS content, the carbonation area and the degree of CO₂ capture decreased then increased after 1 day and after 3 days of accelerated carbonation curing, respectively.

Optimizing activating solution and environmental leaching characteristics of Fe-rich alkali-activated Zn slag

In this work, slag from Zn processing was used to produce Fe-rich alkali-activated materials (AAMs) with low environmental impact. The interconnection between activating solution composition, compressive strength, and environmental leaching characteristics was assessed. The reaction products characterised with FT-IR, XRD, and SEM-WDS were represented by Fe-rich C-S-H gel of tobermorite-related structure. The local aggregation of Na and Mg suggests the minor role of these elements in the reaction product. The reaction product seems to be undependable on the alkali cation used in the solution. Besides, the hardening reaction took place fast, and the maximum compressive strength of 70 MPa was determined only after 1 day after mixing with silicate solutions. To decrease the economic and environmental impact, 1) simultaneous decreasing Na₂O/slag and SiO₂/slag ratios or 2) decreasing SiO₂/Na₂O ratio can be applied without prominent deterioration of the strength. Environmental leaching results showed an increase in the leached content of several metal(loid)s (e.g., As, Mo, Cr, Sb, Se, V) as a results of alkali activation, but also some immobilization effect for Ba, Pb and Zn. Also, the presence of liquid silica in the activating solutions or higher water content reduced the leaching of some elements.

Environmental behavior, human health effect, and pollution control of heavy metal(loid)s toward full life cycle processes

Heavy metal(loid)s (HMs) have caused serious environmental pollution and health risks. Although the past few years have witnessed the achievements of studies on environmental behavior of HMs, the related toxicity mechanisms, and pollution control, their relationship remains a mystery. Researchers generally focused on one topic independently without comprehensive considerations due to the knowledge gap between environmental science and human health. Indeed, the full life cycle control of HMs is crucial and should be reconsidered with the combination of the occurrence, transport, and fate of HMs in the environment. Therefore, we started by reviewing the environmental behaviors of HMs which are affected by a variety of natural factors as well as their physicochemical properties. Furthermore, the related toxicity mechanisms were discussed according to exposure route, toxicity mechanism, and adverse consequences. In addition, the current state-of-the-art of available technologies for pollution control of HMs wastewater and solid wastes were summarized. Finally, based on the research trend, we proposed that advanced in-operando characterizations will help us better understand the fundamental reaction mechanisms, and big data analysis approaches will aid in establishing the prediction model for risk management.

The Role of Brownmillerite in Preparation of High-Belite Sulfoaluminate Cement Clinker

High-belite sulfoaluminate cement (HBSC) clinker containing brownmillerite was prepared using the industrial raw materials limestone, aluminum tailings, aluminum ore waste rock, and anhydrite. The effect of brownmillerite on clinker sintering and clinker minerals and the mechanical performance of HBSC was investigated using thermal analysis, petrographic analysis, and quantitative X-ray diffraction (QXRD). Results indicated that brownmillerite promoted the formation of clinker minerals and stabilized calcium sulfoaluminate (C4A3$) through the substitution of Fe3+ for Al3+ in C4A3$, which increased the actual C4A3$ content and decreased the brownmillerite content compared to that of the designed theoretical mineral composition. However, the early compressive strength of HBSC pastes decreased with the increase in brownmillerite content due to the decrease in the total amount of early-strength clinker minerals. Brownmillerite also influenced belite (C2S) structures and increased the γ-C2S content with poor hydration activity, thus inhibiting the strength development of HBSC pastes. The proper amount of brownmillerite in HBSC clinker can ensure the early strength and strength development of HBSC pastes.

Preparation of Monoclinic Pyrrhotite by Thermal Decomposition of Jarosite Residues and Its Heavy Metal Removal Performance

Jarosite residues produced by zinc hydrometallurgical processing are hazardous solid wastes. In this study, monoclinic pyrrhotite (M-Po) was prepared by the pyrolysis of jarosite residues in H2S atmosphere. The influence of gas speed, reaction temperature, and time was considered. The mineral phase, microstructure, and elemental valence of the solids before and after pyrolysis were analyzed using X-ray diffraction, scanning electron microscopy, and X-ray photoelectron spectroscopy, respectively. The performances of the prepared M-Po on the removal of Zn and Pb from aqueous solution were evaluated. The results show M-Po to be the sole product at the reaction temperatures of 550 to 575 °C. Most of the M-Po particles are at the nanometer scale and display xenomorphic morphology. The phase evolution process during pyrolysis is suggested as jarosite → hematite/magnetite → pyrite → pyrite+M-Po → M-Po+hexagonal pyrrhotite (H-Po) → H-Po. The formation rate, crystallinity, and surface microtexture of M-Po are controlled by reaction temperature and time. Incomplete sulfidation may produce coarse particles with core–shell (where the core is oxide and the shell is sulfide) and triple-layer (where the core is sulfate, the interlayer is oxide, and the shell is sulfide) structures. M-Po produced at 575 °C exhibits an excellent heavy metal removal ability, which has adsorption capacities of 25 mg/g for Zn and 100 mg/g for Pb at 25 °C and pH ranges from 5 to 6. This study indicates that high-temperature sulfidation is a novel and efficient method for the treatment and utilization of jarosite residues.

The Incorporation of Steel Slag into Belite-Sulfoaluminate Cement Clinkers

The potential use of steel slag from treated steel slag in belite-sulfoaluminate cements was investigated in this study. Cement clinkers with two phase compositions were synthesized, allowing the incorporation of different amounts of steel slag. The phase composition and microstructure of cement clinkers at three different sintering temperatures were studied by X-ray powder diffraction and the Rietveld method, as well as scanning electron microscopy with energy dispersive spectrometry. The results showed that the targeted phase composition of clinkers was achieved at a sintering temperature of 1250 °C. However, a higher amount of perovskite instead of ferrite was detected in the clinker with a higher content of Ti-bearing bauxite. Apart from the main phases, such as belite, calcium sulfoaluminate, and ferrite, several minor phases were identified, including mayenite, perovskite, periclase, and alkali sulfates. In both clinker mixtures, a higher content of MgO in the steel slags resulted in the formation of periclase. Furthermore, the hydration kinetics and compressive strength at 7 and 28 days were studied in two cements prepared from clinkers sintered at 1250 °C. As evidenced by the results of isothermal calorimetry, the hydration kinetics were also influenced by the minor clinker phases. Cement with a higher content of calcium sulfoaluminate phase developed a higher compressive strength.

Potential of preparing cement clinker by adding the fluorine-containing sludge into raw meal

Fluorine-containing sludge from semiconductor industries were one kind of hazardous wastes, there was hardly effective treatment to realize its safe disposal and utilization. This paper evaluated the potential of preparing cement clinker by adding the sludge into raw meal by a series of experiments. The results revealed 2.0 % addition of the sludge markedly improved the burnability of the produced clinker, and promoted the formation of alite with more amounts and smaller size, but the 5.0 % addition of the sludge resulted in the abundant formation of interstitial phases to inhibit the formation of alite and belite. The better workability was gained with the addition of 2.0 %, and the optimal 28 d compressive strength was 50.76 MPa. The distribution of fluorine was higher in silicate phases, and it was mainly accumulated in the interfaces of silicate phases. Fluorine in the sludge was immobilized by calcium to form the binding forms of calcium fluoride in produced clinker and hydration products. The immobilization ratios of fluorine, copper, zinc and nickel were more than 99.5 %, and the addition of the sludge (≤5.0 %) into raw meal could not induce further environment hazards.

Building of the Al-containing Secondary Raw Materials Registry for the Production of Low CO2 Mineral Binders in South-Eastern European Region

The bottleneck in the process for increasing production of low CO2 mineral binders, based on BCSA (belite sulfoaluminate) clinkers, is the availability of Al-rich raw materials. For that purpose, a new registry of Al-containing secondary mineral residues (industrial and mine waste) has been developed and is presented in this paper. The methodology of creating the registry consists of three main steps: Gathering ideas, consolidation of ideas, and implementation. In order to achieve this, the following methodology was adopted: Analysis of similar registries by potential end-users and seeking potential solutions and tools to be used, and conducting 3 rounds of stakeholder consultations via workshops in order to determine crucial parameters and features the registry needs to contain. The key discussion points were about which data the registry needs to contain, who shall be the potential users, and what are the stakeholder’s expectations from the registry’s portal. Potential individual registry variables were identified as being relevant/irrelevant or available/unavailable, and potential solutions for the registry’s sustainability were explored. Each Al-rich waste/residue data entry is divided into 10 slots, describing legal status, location, quantities, chemical (REE included), mineralogical, physical and radiological properties, life-cycle assessment, additional data, and data relevancy. The registry will act as a matchmaking tool between producers/holders of Al-rich secondary raw materials and potential producers of cement clinkers.