Preparation of a Novel Cement from Red Mud and Limestone

Red mud (RM) is an industrial waste obtained from the Bayer process which is usually discharged into marine or disposed into a landfill causing pollution for the surrounding water, air, and soils. Thus, disposal of RM is an environmental concern, and it should be recycled effectively. Because RM consists of iron- and aluminum-rich phases, it is possible to be processed into cementitious material and utilized for construction purposes. This research fabricated a type of cement from the mixture of RM and limestone. The mixture was sintered at temperature of 1180 °C to obtain the clinker of the novel hydraulic cement with C2S, C3A, and C4AF minerals. In which, C2S, C3A, and C4AF are respectively belite, alite, and tetra-calcium aluminoferrite compounds that are characteristic hydraulic minerals of Portland cement clinker. The specifications of this cement were tested and evaluated in this study such as chemical and mineralogical compositions, fineness, specific surface area, mechanical strength after 3, 7, and 28 days.

Quantitative Analysis of Portland Cement Clinker with Rietveld Refinement: Implications of the Amorphous Matter

Six ordinary Portland cement (OPC) clinkers and one white cement clinker were analyzed with the Rietveld method, using ZnO internal standard (IC), to determine the presence of amorphous matter (AM). All clinkers contain abundant AM and have lower silicate phase contents when compared with the same clinkers analyzed without IC, whereas the abundances of the aluminate and ferrate phases were not affected by AM. The white cement clinker had the highest AM content. Determination of AM is important for complete characterization of the OPC clinker and might contribute to a better understanding of the mechanical properties of the clinker.

Features of The Processes of Clinker Formation When Using Solid Waste From Caprolactic Production As A Mineralizer

The possibility of using a soda-sulfate mixture - an alkaline waste from the production of caprolactam, as a mineralizing additive in a Portland cement raw mixture containing, as a silica-containing component, flotation tailings of the lead-concentrating plant of Almalyk MMC, has been studied. The effect of this additive on the processes of mineral formation during the synthesis of Portland cement clinker is shown. The possibility of additional recovery of residual non-ferrous metals - lead and copper - by sublimation and trapping of their chlorides has been established.

Industrial experience in the implementation of clinker-free binders of alkaline activation

Objective. Issues related to the search for new, less energy- and material- intensive binders have long been on the agenda of many world environmental forums, since the carbonate technology of Portland cement entails pollution of the surrounding atmosphere and habitat, and the price of this product is unjustifiably growing. In our opinion, alkaline cements could contribute to the construction industry. Within the framework of this work, research results have been obtained that confirm the effectiveness of the development of a clinker-free technology for producing alkaline-mixed binders and composites based on them using aluminosilicate additives, both natural and technogenic origin.Method. The methods of electron microscopy and differential thermal analysis make it possible to study the nature of the components and the processes of formation of the structure of the cement stone. Waste from the cement industry has the appropriate granulometric and chemical composition, the aluminosilicate mineralogy of the studied powders confirms their compliance with the ready-made raw mix of Portland cement clinker, which is the key to the possibility of their effective use.Result. The carried out differential thermal analyzes confirmed the presence of the following phases in the composition of cement stone on binding bonds "cement dust - alkaline activator" of zeolite, calcite, mica type muscovite, montrillonite, magnesium oxide, calcium sulfoaluminates, ettringite structure, calcium hydrochloraluminate, calcium hydrosilicate, calcium hydrosilicate calcium.Conclusion. The obtained regularities of the processes of formation of the structure of the cement binder "waste of the cement industry - Na2SiO3", will transform these developments to create strong and durable artificial building composites competing with concretes on Portland cement.

Calorimetric Studies of Alkali-Activated Blast-Furnace Slag Cements at Early Hydration Processes in the Temperature Range of 20–80 °С

In the hydration process of inorganic cements, the analysis of calorimetric measurements is one of the possible ways to better understand hydration processes and to keep these processes under control. This study contains data from the study of thermokinetic processes in alkali-activated blast-furnace slag cements compared to ordinary Portland cement (OPC). The obtained results show that, in contrast to ОРС, the heat release values cannot be considered as a characteristic of the activity of alkali-activated blast-furnace slag cements. In addition, it is concluded that in the case of OPC cements, cumulative heat release is a criterion for the selection of effective curing parameters, while in the case of alkali-activated blast-furnace slag cements, a higher heat rate (which increases sharply with increasing temperature from 20 to 40 °С) is a criterion. From the point of views of thermokinetics, the rate of heat release at temperatures up to 40 °С can be a qualitative criterion that allows to choose the parameters of heat curing of alkali-activated cement concretes. By introducing a crystallo-chemical hardening accelerator, such as Portland cement clinker, into the composition of alkali-activated blast-furnace slag cements, it is possible to accelerate the processes not only in the condensation-crystallization structure formation stage, but also in the dispersion-coagulation structure formation stage. Portland cement clinker increased the efficiency of thermal curing at relatively non-high temperatures.

Application of the system-object approach to simulation of the conversion of raw materials into a portlandcement clinker

The article discusses the construction of a simulation model of the abstract process of converting raw materials into Portland cement clinker in the UFOModeler simulation environment. An algorithm for generating a pseudo-random oxide (chemical) composition of components based on experimental data of real production and calculation for two-component and three-component raw mixtures has been developed. An algorithm for calculating the main indicators of the composition of clinker based on. The analysis of the obtained results is carried out.

Use of Design of Experiments (DoE) to Model the Sulphate Agent Amount of (Ultra)Finely Ground and Fast Hardening Portland Cement Clinker

This paper presents a model to calculate the sulphate agent amount and sulphate agent ratio for fine grounded and fast hardening Portland cement clinker. Despite sufficient knowledge about the influence of calcium sulphate on the hydration process of cement, the sulphate agent amount is mostly adjusted empirically. As a result, often a wide and unfeasible experimental matrix has to be tested. In this work, Design of Experiments (DoE) was used in combination with in-situ X-ray diffraction (XRD) tests to accurately adjust the sulphate agent of different finely ground cement by calculation. With only 42 tests, it was possible to analyse in total the influence of the sulphate agent, the grinding fineness and the use of C-S-H-seeds for the use in fast-hardening Portland cement-based systems. In addition, it was found that a hemihydrate to anhydrite content of 25/75 leads to a stabilisation of the hydrated system in the first 24 h of hydration. A model for the optimisation of the sulphate agent composition in dependency of the cement fineness could be determined. Furthermore, it was shown that the DoE also provides optimal results in material sciences in a resource-saving way.

Complex Shrinkage-Reducing Additives for Alkali Activated Slag Cement Fine Concrete

Optimization of complex shrinkage-reducing additives (further, SRA’s), consisting of ordinary portland cement clinker (further, OPC clinker), salt-electrolyte and surfactants, is provided for prevention of steel reinforcement corrosion due to shrinkage mitigation in alkali-activated slag cement (further, AASC) fine concrete. Modification of AASC by SRA included 0.3 % sodium lignosulphonate, 0.15 % sodium gluconate, 1.4 – 2.0 % NaNO3 and 6.5 - 7.7 % OPC clinker (by mass of granulated blast furnace slag) provides shrinkage reduction from 0.984 up to 0.560 – 0.605 mm/m (t=202 °С, R.H.=65 %). Unlike, SRA presented by the mentioned system with 1.50 - 1.59 % Na2SO4 and 4.0 - 4.65 % OPC clinker causes shrinkage mitigation from down to 0.625 - 0.640 mm/m. In addition, SRA with 1.80 - 2.05 % Na3PO4 and 4.0 - 4.6 % OPC clinker minimizes shrinkage to 0.713 - 0.700 mm/m. Shrinkage mitigation in modified AASC fine concrete is explained by less water, higher crystallinity of hydrated phases as well as by formation of minamiit (Na,Ca0.5)Al3(SO4)2(OH)6, calcium hydronitroaluminate ЗСаО∙А12О3∙Са (NO3)2∙10Н2О and calcium hydroxylapatite Са10(РО4)6(ОН)2 crystals versus salt-electrolyte, i.e. Na2SO4, NaNO3 and Na3PO4 agreeably. The 28 day compressive strength of modified AASC fine concrete is not less than the reference one (48.0 - 56.0 МPа).