Preparation, Hydration Characteristics, and Carbon Footprint Assessment of Sulfoaluminate Cement Prepared by Co-Utilization of Industrial Solid Wastes and Bauxite

Peng, Yanzhou; Miao, Xiaohang; Gao, Dejun; Fan, Chunhu

doi:10.3390/ma19102122

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Preparation, Hydration Characteristics, and Carbon Footprint Assessment of Sulfoaluminate Cement Prepared by Co-Utilization of Industrial Solid Wastes and Bauxite

¹

Hubei Provincial Key Laboratory of Disaster Prevention and Mitigation, China Three Gorges University, Yichang 443002, China

²

College of Civil Engineering and Architecture, China Three Gorges University, Yichang 443002, China

^*

Authors to whom correspondence should be addressed.

Materials 2026, 19(10), 2122; https://doi.org/10.3390/ma19102122

Submission received: 15 April 2026 / Revised: 8 May 2026 / Accepted: 13 May 2026 / Published: 18 May 2026

(This article belongs to the Section Construction and Building Materials)

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Abstract

This study evaluates the technical feasibility, environmental sustainability, and economic viability of producing sulfoaluminate cement (SW-SAC) by co-utilizing bauxite and industrial solid wastes—phosphogypsum, calcium carbide residue (CCR), and red mud—with the solid wastes accounting for approximately 75% of the raw meal. CCR replaces limestone as the primary CaO source, releasing H₂O instead of CO₂, while phosphogypsum supplies SO₃; the raw meal is directly calcined in a single step at 1300–1350 °C, 100–150 °C below that of ordinary Portland cement (OPC). Calcination temperature and holding time were optimized through phase analysis, microstructural observation, free lime (f-CaO) determination, and strength testing. SW-SAC meeting the 42.5 strength class was then prepared using phosphogypsum as a setting regulator and phosphorus slag or limestone powder as Supplementary materials. X-ray diffraction (XRD), thermogravimetry (TG), and scanning electron microscopy (SEM) were used to examine hydration products and microstructural evolution. The optimized clinker was dominated by ye’elimite (C₄A₃S̄

) and belite (C₂S). Phosphorus slag favored the formation of gel-like products at later ages, whereas limestone powder promoted ettringite (AFt) stabilization and monocarboaluminate (Mc) formation. SW-SAC exhibited a lower carbon footprint than both Type P·I Portland cement and conventional SAC, and a lower production cost than conventional SAC. These results demonstrate a promising low-carbon route for high-value utilization of industrial solid wastes.

Keywords: sulfoaluminate cement; phosphogypsum; calcium carbide residue; calcination regime; strength; hydration; carbon footprint

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MDPI and ACS Style

Peng, Y.; Miao, X.; Gao, D.; Fan, C. Preparation, Hydration Characteristics, and Carbon Footprint Assessment of Sulfoaluminate Cement Prepared by Co-Utilization of Industrial Solid Wastes and Bauxite. Materials 2026, 19, 2122. https://doi.org/10.3390/ma19102122

AMA Style

Peng Y, Miao X, Gao D, Fan C. Preparation, Hydration Characteristics, and Carbon Footprint Assessment of Sulfoaluminate Cement Prepared by Co-Utilization of Industrial Solid Wastes and Bauxite. Materials. 2026; 19(10):2122. https://doi.org/10.3390/ma19102122

Chicago/Turabian Style

Peng, Yanzhou, Xiaohang Miao, Dejun Gao, and Chunhu Fan. 2026. "Preparation, Hydration Characteristics, and Carbon Footprint Assessment of Sulfoaluminate Cement Prepared by Co-Utilization of Industrial Solid Wastes and Bauxite" Materials 19, no. 10: 2122. https://doi.org/10.3390/ma19102122

APA Style

Peng, Y., Miao, X., Gao, D., & Fan, C. (2026). Preparation, Hydration Characteristics, and Carbon Footprint Assessment of Sulfoaluminate Cement Prepared by Co-Utilization of Industrial Solid Wastes and Bauxite. Materials, 19(10), 2122. https://doi.org/10.3390/ma19102122

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Preparation, Hydration Characteristics, and Carbon Footprint Assessment of Sulfoaluminate Cement Prepared by Co-Utilization of Industrial Solid Wastes and Bauxite

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