Formation and hydration of eco-friendly cement using industrial wastes as raw materials

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.

Pore topology, volume expansion and pressure development in chemically-induced foam cements

Foam cement is an engineered lightweight material relevant to a broad range of engineering applications. This study explores the effects of aluminum chips on cement-bentonite slurry expansion, pressure development, and the evolution of pore topology. The terminal volume expansion under free-boundary conditions or the pressure build up under volume-controlled conditions are a function of the aluminum mass ratio, bentonite mass ratio, and aluminum chip size. X-ray CT images show that finer aluminum chips create smaller pores but result in a larger volume expansion than when larger sized chips are used; on the other hand, large chip sizes result in unreacted residual aluminum. Time-lapse CT images clearly show the sequence of processes which lead to the development of foam cement: gas bubble nucleation, bubble growth, capillary-driven grain displacement enhanced by the presence of bentonite, coalescence, percolation, gas leakage and pore collapse. These results illustrate the potential to customize the mixture composition of chemically-induced gassy cement to control expansion and pressure build up, and to minimize percolating discontinuities and gas release.

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.