Search Results (341)

This study examines magnesium potassium phosphate cements (MKPCs) modified with industrial wastes for extrusion-based 3D concrete printing, evaluating the rheological properties (workability, setting time), mechanical performance and printability of formulations incorporating secondary materials: Mg dross waste (up to 20 wt.%, replacing MgO), calcined sewage sludge (up to 10 wt.%, replacing KH₂PO₄), alternative fillers such as glass from municipal solid waste glass and from construction and demolition waste and ground blast furnace slag, benchmarked against volcanic ash. The baseline MKPC exhibited initial/final setting times of 34/109 min, good workability and compressive strengths of 29 MPa (1 day)/28 MPa (28 days). Optimal low-waste mixes (e.g., using municipal glass or 20 wt.% Mg dross) shortened the initial setting to 19–25 min (decreasing 24–42%), reduced the slump by 9–18% yet remained printable at laboratory-scale and achieved 1-day strengths > 23 MPa/28-day > 31 MPa (comparable or superior). Glass from municipal waste proved most promising, due to superior workability, lighter aesthetics and strength gains, supporting circular economy goals while substantially reducing material costs; higher waste levels compromised fluidity and buildability. Mineralogical analyses confirmed K-struvite formation alongside residual periclase, validating these formulations for upscaling sustainable 3D printing. Full article

To address the high-carbon emissions associated with the large use of Portland cement (PC) in traditional engineered cementitious composites (ECCs) and the resource constraints on supplementary cementitious materials (SCMs), this study proposes a strategy combining limestone calcined clay cement (LC³) as a PC replacement with the incorporation of hybrid synthetic fibers to develop low-carbon, environmentally friendly ECCs. The fundamental properties of the LC³-ECC were tested, and a sustainability analysis was conducted. The experimental results show that an increase in water-to-binder ratio (W/B) or superplasticizer (SP) dosage significantly enhanced fluidity while reducing the yield stress and plastic viscosity. An LC³-ECC with a W/B of 0.25, 0.45% SP and 2% polyethylene fibers exhibited the best tensile performance, achieving an ultimate tensile strain of 8.40%. In contrast, an increase in polypropylene fiber led to a degradation in crack-resistant properties. In terms of sustainability, replacing the PC with LC³ significantly reduced carbon emissions by 19.1–20.8%, while the cost of the limestone calcined clay cement–polypropylene fiber (LC³-PP) was approximately 50% of that of the limestone calcined clay cement–polyvinyl alcohol fiber (LC³-PVA). Furthermore, an integrated evaluation framework encompassing rheological, mechanical and environmental factors was established using performance radar charts. The dataset on the performance results and the developed assessment framework provide a foundation for optimizing the mixture proportioning of LC³-ECC in practical engineering applications. Full article

To evaluate the stability of fiber-reinforced cemented foamed backfill (FCFB) in complex underground mining environments, this study investigates the synergistic effects of fiber content and modified coal gangue (MCG) under acidic and high-temperature conditions. Through a systematic analysis of hydration processes, compressive strength, and deformation characteristics, the research identifies critical mechanisms for optimizing backfill performance. Calcination of MCG at 700 °C enhances gelling activity via amorphous phase formation, while modified aluminum dross (MAD) treated at 950 °C develops dense α-Al₂O₃ and spinel phases, significantly improving chemical stability. In acidic environments, the suppression of calcium silicate hydrate (C-S-H) is offset by the development of Al³⁺-driven C-A-S-H gels. These gels adopt a tobermorite-like structure, substantially increasing acid resistance. Mechanical testing reveals that while 1% fiber reinforcement promotes nucleation and densification, a 2% concentration hinders hydration. Compressive strength at 28 days shows constrained growth due to pore inhibition, and failure modes transition from multi-crack parallel failure (3-day) to single-crack tensile-shear failure. Under acidic conditions, strain concentration in the upper sample highlights a competitive mechanism between Al³⁺ migration and fiber anchorage. Ultimately, the coordinated regulation of MCG/MAD and fiber content provides a robust solution for roof support in challenging thermo-chemical mining environments. Full article

To improve traditional cement manufacturing, which generates a large amount of greenhouse gases, blending calcareous green algae and fly ash as cement replacement materials is expected to achieve nearly zero carbon emissions. As a calcareous green alga, Halimeda macroloba is a significant producer of biogenic calcium carbonate (CaCO₃), sequestering approximately 440 kg of carbon dioxide (CO₂) per 1000 kg of CaCO₃, with CaCO₃ production reported in relation to algal biomass. To assess the new low-carbon/low-waste cement production process, the proposed scenarios (2 and 3) are validated via Python-based modeling (Python 3.12) and Aspen Plus^® simulation (Aspen V14). The core technology is the pre-calcination of algae-derived CaCO₃ and fly ash from coal combustion, which are added to a rotary kiln to enhance the proportions of tricalcium silicate (C₃S) and dicalcium silicate (C₂S) for forming the desired silicate phases in clinker. Through the lifecycle assessment (LCA) of all scenarios using SimaPro^® (SimaPro 10.2.0.3), the proposed Scenario 2 achieves the GWP at approximately 0.906 kg CO₂-eq/kg clinker, lower than the conventional cement production process (Scenario 1) by 47%. If coal combustion is replaced by natural gas combustion, the fly ash additive is reduced by 74.5% in the cement replacement materials, but the proposed Scenario 3 achieves the GWP at approximately 0.753 kg CO₂-eq/kg clinker, lower than Scenario 2 by 16.9%. Moreover, the LCA indicators show that Scenario 3 has lower environmental impacts on human health, ecosystem, and resources than Scenario 1 by 24.5%, 60.0% and 68.6%, respectively. Full article

Biodiesel, which is a blend of fatty acid methyl esters (FAME), has garnered significant attention as a promising alternative to petroleum-based diesel fuel. Nevertheless, the commercial production of biodiesel faces challenges due to the high costs associated with feedstock and the non-recyclable homogeneous catalyst system. To address these issues, a solid catalyst derived from construction industry waste cement was synthesized and utilized for biodiesel production from waste cooking oil (WCO). The catalyst’s surface and physical characteristics were analyzed through various techniques, including Scanning Electron Microscopy-Energy Dispersive Spectroscopy (SEM-EDS), X-ray diffraction (XRD), X-ray photoelectron spectroscopy (XPS), and Fourier Transform Infrared Spectroscopy (FTIR). The waste-cement catalyst demonstrated remarkable catalytic performance and reusability in the transesterification of WCO with methanol for biodiesel synthesis. A maximum biodiesel yield of 98.1% was obtained under the optimal reaction conditions of reaction temperature 65 °C; methanol/WCO molar ratio 16:1; calcined cement dosage 3 g; and reaction time 8 h. The apparent activation energy (Ea) from the reaction kinetic study is 35.78 KJ·mol⁻¹, suggesting that the transesterification reaction is governed by kinetic control rather than diffusion. The biodiesel produced exhibited high-quality properties and can be utilized in existing diesel engines without any modifications. This research presents a scalable, environmentally benign pathway for WCO transesterification, thereby contributing significantly to the economic viability and long-term sustainability of the global biodiesel industry. Full article

Ultra-High-Performance Concrete (UHPC) is being increasingly utilized in major engineering projects due to its excellent mechanical properties, strong durability, and superior overall performance. Nevertheless, the widespread use of premium cementitious materials leads to high expenses and a substantial environmental impact. In this work, crushed recycled paste was calcined at 600 °C for two hours to produce calcined recycled fine powder (RFP) with varying hydration reactivity. UHPC was produced using the RFP in place of some of the cement. Chemical activation was accomplished by adding a composite activator system made up of Ca(OH)₂, Na₂SO₄, Na₂SiO₃·9H₂O, and K₂SO₄ in order to further improve the performance of UHPC. Particle size, viscosity, fluidity, mechanical properties, and hydration products were analyzed to establish the best activator type and dosage, as well as the ideal activation procedure for recycled fine powder. By mass replacement of cementitious materials, when 15.0% of the calcined recycled fine powder was added, the compressive strength of UHPC reached 149.1 MPa, a 23.2% increase over reference UHPC without calcined recycled fine powder. The results show that the calcined recycled fine powder ground for 60 min exhibits the highest activity. More hydrated products were formed in UHPC as a result of the addition of Ca(OH)₂. The compressive strength peaked at 162.2 MPa at an incorporation rate of 1.5%, which is 8.8% higher than UHPC without an activator. Full article

The construction sector faces pressure to decarbonise while addressing rising resource demands and agricultural waste. Ordinary Portland cement (OPC) is a major CO₂ emitter, yet biomass residues are often open-burned or landfilled. This study explores corncob ash (CCA) as a sustainable supplementary cementitious material (SCM), examining how calcination conditions influence pozzolanic potential and support circular economy and climate goals, which have not been adequately explored in literature. Ten CCA samples were produced via open-air burning (2–3.5 h) and electric-furnace calcination (400–1000 °C, 2 h), alongside a reference OPC. Mass yield, colour, XRD, XRF, LOI, and LOD were analysed within a process–structure–property–performance–sustainability framework. CCA produced in a 400–700 °C furnace window consistently achieved high amorphous contents (typically ≥80%) and combined pozzolanic oxides (SiO₂ + Al₂O₃ + Fe₂O₃) above the 70% ASTM C618 threshold, with 700 °C for 2 h emerging as an optimal condition. At 1000 °C, extensive crystallisation reduced the expected reactivity despite high total silica. Extended open-air burning (3–3.5 h) yielded chemically acceptable but more variable ashes, with lower amorphous content and higher alkalis than furnace-processed CCA. Simple industrial ecology calculations indicate that valorising a fraction of global CC residues and deploying optimally processed CCA at only 20% OPC replacement could displace 180 million tonnes CC waste and clinker avoidance on the order of 5–6 Mt CO₂ per year, while reducing uncontrolled residue burning and primary raw material extraction. The study provides an experimentally validated calcination window and quality indicators for producing reactive CCA, alongside a clear link from laboratory processing to clinker substitution, circular resource use, and alignment with SDGs 9, 12, and 13. The findings establish a materials science foundation for standardised CCA production protocols and future life cycle and performance evaluations of low-carbon CCA binders. Full article

Intensive calcination, selection and metallurgical joint comprehensive utilization of solid waste blast furnace gas ash generated by a Chinese iron and steel plant. The main valuable elements in the gas ash are Fe, Pb, Zn, and C, with contents of 22.46%, 3.22%, 10.57%, and 27.02%, respectively. The iron minerals are mainly magnetite and hematite/limonite. Lead exists primarily in the form of lead vanadate and basic lead chloride. Zinc is associated with oxygen, sulfur, and iron in the form of zinc ferrite crystals. The effects of calcination temperature, calcination time, and reducing agent dosage on gasification and reduction indices were investigated. Results showed that using a gasification and reduction calcination–magnetic separation process with weak magnetism, at a calcination temperature of 1150 °C, with 20% anthracite as the reducing agent and a calcination time of 2 h, the volatilization rates of lead and zinc reached 96.70% and 98.26%, respectively. When the roasted ore was ground to a particle size of D₉₀ = 0.085 mm, high-quality iron concentrate with 65.61% iron grade and low lead and zinc contents of 0.08% and 0.17% was obtained, meeting the quality requirements for iron concentrate. The tailings from iron selection can be used as additives in cement and other construction materials. This integrated process combining pyrometallurgy and mineral processing enables the efficient and comprehensive utilization of blast furnace gas dust. Full article

Calcium magnesium phosphate cements (CMPCs) were obtained starting from dolomite (alone or mixed with fly ash) thermally treated at two different temperatures. Dolomite calcination at 750 °C for 3 h determined the formation of a mixture of MgO and CaCO₃. The mixing of dolomite with fly ash and the increase in the calcination temperature at 1200 °C determined the formation of new compounds (calcium aluminum silicate and calcium magnesium silicates), which are present along with MgO and small amounts of CaO in the thermally treated material. These two precursors were mixed with KH₂PO₄ solution and borax (as a retardant admixture) to obtain the CMPCs. The setting time and compressive strengths of these CMPCs were assessed and the XRD analyses provided insights into their mineralogical composition after hardening and thermal treatment. The cements, as so or mixed with perlite, were applied on steel plates, to assess their behavior when put in direct contact with a flame. The compatibility of these materials with the steel substrate was evaluated by scanning electron microscopy (SEM). The direct contact with the flame up to 60 min provided information regarding the CMPCs’ ability to prevent the rapid increase in the substrate (steel plate) temperature. The findings indicate that CMPC pastes and composites containing perlite can offer a degree of protection for steel structures in the event of a fire. Full article

The construction sector has a very high share in solving the energy demand of the world and global warming problems. Therefore, it had to increase studies on building materials-based heat storage and thermal insulation. Foam concrete is one of them, but its thermal and mechanical properties need to be improved. So, in this study, calcined marl was used as a replacement material to evaluate its thermal performance in the production of foam mortars. The aims of this study are to determine the physical, mechanical, and thermal properties of foam mortars produced with blended cements containing calcined marl at 0, 10, 30, and 50% ratios and to obtain novel and optimum design data for the foam concrete market. In conclusion, the optimum calcined marl replacement ratio is up to 30% in terms of both thermal performance and mechanical properties of foam mortars. Due to calcined marl, this study presents a foam mortar design with economic and low-carbon. And, thanks to the mixed designs of foam mortars prepared with blended cement containing novel calcined marl additive, it is observed that they improve the thermal insulation and heat storage ability of foam mortars and provide sufficient strength. Full article

As the global cement industry moves toward energy efficiency and intelligent manufacturing, refined control of key processes like precalciner outlet temperature is critical for improving energy use and product quality. The precalciner’s outlet temperature directly affects clinker calcination quality and heat consumption, so developing a high-accuracy prediction model is essential to shift from empirical to intelligent control. This study proposes a TCN-BiLSTM hybrid neural network model for the accurate prediction and regulation of the outlet temperature of the decomposition furnace. Based on actual operational data from a cement plant in Guangxi, the Spearman correlation coefficient method is employed to select feature variables significantly correlated with the outlet temperature, including kiln rotation speed, high-temperature fan speed, temperature A at the middle-lower part of the decomposition furnace, temperature B of the discharge from the five-stage cyclone, exhaust fan speed, and tertiary air temperature of the decomposition furnace. This method effectively reduces feature dimensionality while enhancing the prediction accuracy of the model. All selected feature variables are normalized and used as input data for the model. Finally, comparative experiments with RNN, LSTM, BiLSTM, TCN, and TCN-LSTM models are performed. The experimental results indicate that the TCN-BiLSTM model achieves the best performance across major evaluation metrics, with a Mean Relative Error (MRE) as low as 0.91%, representing an average reduction of over 1.1% compared to other benchmark models, thereby demonstrating the highest prediction accuracy and robustness. This approach provides high-quality predictive inputs for constructing intelligent control systems, thereby facilitating the advancement of cement production toward intelligent, green, and high-efficiency development. Full article

Oxy-fuel combustion technology is a critical pathway for carbon capture in the cement industry. However, the high-concentration CO₂ atmosphere significantly alters multiphysics coupling in the calciner and systematic studies on its comprehensive effects remain limited. To address this, a Computational Particle Fluid Dynamics (CPFD) model using the MP-PIC method was implemented using the commercial software Barracuda Virtual Reactor 22.1.2 to simulate an industrial-scale oxy-fuel cement calciner and validated against industrial data. Under oxy-fuel combustion with 50% oxygen concentration in the tertiary air, simulations showed a 38.4% increase in the solid–gas mass ratio compared to conventional air combustion, resulting in a corresponding 37.7% increase in total pressure drop. Flow resistance was concentrated primarily in the constriction structures. Local temperatures exceeded 1200 °C in high-oxygen regions. The study reveals a competition between the inhibitory effect of high CO₂ partial pressure on limestone decomposition and the promoting effect of elevated overall temperature. Although the CO₂-rich atmosphere thermodynamically suppresses calcination, the higher operating temperature under oxy-fuel combustion effectively compensates, achieving a raw meal decomposition rate of 92.7%, which meets kiln feed requirements. This research elucidates the complex coupling mechanisms among flow, temperature, and reactions in a full-scale oxy-fuel calciner, providing valuable insights for technology design and optimization. Full article

This study investigates a comprehensive study on the mechanical and microstructural behavior of cementitious mortars modified with a combination of internal carbonation (via solid CO₂), calcined clay as a ceramic pozzolanic additive, and bio-based sheep wool fibers. The investigation aimed to explore sustainable routes for enhancing mortar performance while reducing the environmental impact of cement production. A series of mortars incorporating various combinations of dry ice, calcined clay, and wool fibers was prepared and tested to evaluate compressive and flexural strength, porosity, pore size distribution, phase composition, and microstructural morphology. Results demonstrated that internal carbonation significantly promoted matrix densification and compressive strength, increasing fc by approximately 8% compared to the reference. The addition of calcined clay further improved microstructural compactness, reducing total pore volume by 12%, while the incorporation of wool fibers enhanced post-cracking toughness by over 40% despite a 15–30% decrease in compressive strength. SEM and TGA confirmed the formation of calcite and reduced portlandite content, consistent with carbonation and pozzolanic reactions. The findings underscore the potential and limitations of multicomponent eco-modified cement mortars. Optimizing the balance between internal carbonation, pozzolanic reaction, and fiber stability is a key to developing next-generation low-carbon composites suitable for durable and resilient construction applications. Full article

Achieving net-zero greenhouse gas emissions by 2050 under the European Green Deal requires the full mobilisation of industry, especially energy-intensive sectors such as cement. This study provides an accurate quantification of the environmental performance of Ordinary Portland cement produced in mainland Portugal using industrial data and a cradle-to-gate life-cycle model compliant with EN 15804:2012+A2:2019. The results show that clinker is the main contributor and that the principal hotspots are associated with thermal and electrical energy supply and the calcination reaction. External factors such as the electricity generation mix materially influence results, so these processes should be accurately described and representative of the geographical boundaries associated with plant operation. Climate change is the most relevant impact category, and the carbon footprint is 733 kg CO₂ per tonne of cement, with 97% attributable to the identified hotspots. The choice of impact assessment methodology is crucial in life-cycle assessment, and EN 15804:2012+A2:2019 is not compatible with the earlier A1 revision, which affects comparability of Environmental Product Declarations. Overall, the study enhances the measurement and monitoring of sustainability within the cement sector by providing an explicit industry-wide environmental profile with clear system boundaries and hotspot resolution, enabling targeted mitigation. It also clarifies the methodological implications of Environmental Product Declarations, helping to avoid biased comparisons and supporting procurement, disclosure and policy tracking towards sectoral carbon neutrality. Full article

The cement industry accounts for nearly 8% of global anthropogenic CO₂ emissions, driven largely by energy-intensive clinker production. Valorising industrial and agricultural waste as Supplementary Cementitious Materials (SCMs) presents a viable mitigation strategy, aligning decarbonisation goals with circular-economy principles. This review employs a two-stage screening process and the Evaluation based on Distance from Average Solution (EDAS) method to assess 27 SCMs across technical, environmental, economic, and regulatory dimensions. The results establish a clear hierarchy: fly ash and metakaolin ranked highest, followed by ground granulated blast furnace slag, silica fume, and calcined clay. Life cycle assessment confirms these top-performing SCMs can reduce the global warming potential of cement production by 50–90% compared to ordinary Portland cement. While established SCMs like fly ash offer a balanced profile in durability, CO₂ reduction, and cost, the framework also identifies regionally abundant materials such as steel slag, bagasse ash, red mud, and Rice Husk Ash (RHA), which possess significant potential but require further processing and standardisation. The findings underscore that material consistency, robust regional supply chains, and performance-based standards are critical for large-scale SCM adoption, providing a replicable framework to guide industry and policy stakeholders in accelerating the transition to low-carbon, waste-valorised cement technologies. Full article