1. Introduction
Growing industrialization and urbanization are recently noticed all over the world. This growing is associated with high production of industrial by-products. The huge amount of industrial by-products generated from the wide range of industries cause serious concerns to the environment and health. One of the industrial wastes is the carbon dust generated during the production of aluminum in the aluminum companies. Carbon dust is a by-product of anode manufacturing process usually generated during crushing of anode butts and cleaning of bath material during shot blasting process. It is super fine black powder. Aluminum companies usually generate large quantities of carbon dust. The carbon dust represents a main challenge to get rid of because of its environmental side effects such as air pollution due to its fineness, and the possible leaching to the groundwater. In addition, the carbon dust is usually dumped in landfills. The handling and transportation of the dust are also problematic. The high generation rate, the purity, and the finer particle size of this by-product lead to potential utilization in concrete production.
Since the civil infrastructures around the world are mostly made of reinforced concrete (RC), the production and use of concrete increase rapidly. The high production and consumption rate of concrete make it a good option to recycle the industrial wastes. On the other hand, cement industry contributes about five to eight percent of the annual greenhouse gas emissions. The production of one ton of Portland cement generates about one ton of CO
2 [
1]. Cement replacement with supplementary cementitious materials (SCM) or industrial byproducts make it possible considerably to reduce the greenhouse gas emissions, reduce the environmental impacts, and decrease the consumption of natural resources.
Various industrial by-products and solid wastes such as fly ash, slag, ceramic waste, bottom ash, granite dust, and marble dust are efficiently used in concrete production. The researchers studied this topic from different aspects. Some studies focused on the effect of using industrial byproducts on the strength of concrete. El-Dieb et al. [
1] investigated the feasibility of using ceramic waste powder (CWP) to replace cement on concrete production. Their results indicated that CWP could be used to replace cement in concrete mixes and to enhance its behavior based on the replacement level. They concluded that partially replacement of cement by 10% CWP was suitable for strength enhancement, between 10% and 20% was adequate to enhance the workability while a 40% replacement was sufficient to improve the durability. Elahi et al. [
2] investigated the mechanical and durability properties of high performance concretes containing SCM. Their results showed that silica fume performs better than other SCM used in the study for the strength development and bulk resistivity. Ali et al. [
3] investigated the feasibility of using waste carbon black as a filler in producing lightweight concrete. They concluded that the lightweight concrete produced by substituting sand by carbon black could be used in both structural and non-structural purposes. Chitra et al. [
4] showed that using carbon powder to replace cement enhanced the mechanical strengths of concrete and reduced its permeability. Schulze et al. [
5] examined the ability of using natural calcined clay with different levels of quality as a cement constituent. Their results showed that natural calcined clays are suitable to be used as SCM in cement production.
Other studies focused on the effect of these materials on the durability of concrete. Ashish [
6] studied the feasibility of using marble powder (MP) combined with SCM in concrete production. Two types of SCM namely silica fume and metakaolin were used to replace cement while the MP was used to replace sand. His results showed an enhancement in the durability of concrete because of 15% replacement of sand with MP combined with the use of SCM. Shah et al. [
7] investigated the carbonation resistance of cements containing SCMs. Their results showed that the carbonation rate was ruled by the clinker replacement level, relative humidity and w/c ratio. Slag showed superior carbonation resistance ability compared to the other used SCMs. Farnam et al. [
8] investigated the effect of SCM on damage caused by calcium oxychloride formation. They used several types of SCM to partially replace cement in cement paste production. Their results indicated that SCM improved the damage behavior of cementitious materials when exposed to CaCl
2. Mangi et al. [
9] studied the behavior of concrete with coal bottom ash (CBA) as SCM exposed to seawater. Their results showed that the compressive strength of concrete with SCM increased about 12% and 9% compared to control mix in water and seawater respectively at 180 days.
Other studies focused on the environmental aspect of waste utilization in concrete production. Zhang et al. [
10] evaluated the environmental impact of concrete with SCMs using proposed integrated functional unit combining durability and compressive strength. The results revealed that adding fly ash or silica fume enhanced the environmental behavior compared to the ordinary concrete. Yang et al. [
11] studied the feasibility of using various SCMs such as fly ash (FA), ground granulated blast-furnace slag (GGBS), and silica fume (SF) in reducing CO
2 emissions from concrete. Their results showed that the intensity of CO
2 decreased with increasing the dosage of the SCMs up to 15–20% replacement ratio. Vargas et al. [
12] investigated the environmental impacts of using copper-treated tailings (CTT) as SCM. Their results showed that at higher mechanical behavior, CTT mixtures owned better environmental indicators than mixtures without CTT. Viet et al. [
13] showed the ability of using fly ash (FA) generated from the thermal treatment solid waste as a CO
2 sequester and as SCM to develop green construction materials.
Other researchers focused on studying the feasibility of waste utilization in high strength concrete production. Pyo et al. [
14] investigated the feasibility of using two types of quartz-based mine tailings to substitute silica powder and silica sand in ultra-high performance concrete (UHPC) production. They found that the shape and size of tailings particles affected the characteristics of the UHPC. They concluded that even though adding the tailings materials negatively affected the strength of the UHPC, these materials showed the capability to minimize the limitations due to the high production cost of the raw materials. Kim et al. [
15] investigated the effect of using untreated coal bottom ash on the hydration kinetics of high-strength concrete. They found that incorporation of bottom ash in high-performance concrete for internal curing increased the degree of hydration in the cement matrix.
The above-mentioned studies reflect that utilization of industrial wastes in concrete production, which is a massive construction material, is considered a good solution for solving the environmental impact of these materials. The high generation rate, the purity, and the finer particle size of carbon dust encourage the authors to investigate the feasibility of using it in cementitious composites production to partially replace cement. The aim of this study is to characterize the carbon powder generated as a by-product by aluminum factories with respect to its chemical composition, morphology, and particle size distribution. In addition, comprehensive study was conducted to evaluate the use of carbon powder as cement replacement on the strength and microstructure of cement mortar.