Green Materials for Cement Clinker: Assessing Alternative Raw Material Potential

TL;DR

This paper explores using recycled concrete and unconventional clay materials to produce cement clinker at lower temperatures, reducing environmental impact while maintaining performance.

Contribution

The study demonstrates that construction and demolition waste combined with bentonite and zeolite can replace traditional materials in clinker production at reduced temperatures.

Findings

Clinkers produced with alternative materials showed phase compositions similar to conventional ones.

C&DW acted as a silica source, replacing quartz sand in the process.

Short mechanical pretreatment improved cement mineral content, while longer treatments reduced performance.

Abstract

The production route for cement clinker, including the clinkerization protocol and temperature, is highly dependent on the selection of raw materials. Natural resource reserves used in cement manufacturing are steadily declining due to rapid urbanization and the growing demand for building materials. Consequently, there is an urgent need to identify alternative resources, potentially from cost-effective primary raw materials or waste products. This study aims to evaluate the feasibility of incorporating recycled concrete as construction and demolition waste (C&DW) with unconventional clayey materials (bentonite and zeolite) into clinker synthesis at a reduced temperature of 1300 °C. The effect of mechanical pretreatment of the clinker raw meal, applied for durations of 10 to 30 min, was investigated. Mix designs combining traditional and alternative raw materials, along with different mechanical pretreatment durations, were systematically tested to assess their impact on raw meal clinkerization and the resulting cement mechanical properties. Despite variations in raw meal composition, the produced clinkers consistently exhibited phase compositions comprising C3S, C2S, C3A, and C4AF, as confirmed by XRD, FTIR, and SEM/EDS analyses. Among the studied raw materials, clayey components played a dominant role in controlling the formation of the main cement minerals, demonstrating that zeolite and bentonite can effectively substitute standard clays. Additionally, C&DW did not impede clinkerization; rather, it functioned as a silica source, replacing quartz sand. Short mechanical pretreatments (10 min) enhanced the content of cement minerals, whereas longer treatments adversely affected clinkerization. This study offers new insights into cement clinker production at reduced temperatures through the use of C&DW combined with unconventional clayey materials. The clinkerization temperature was reduced by approximately 100 °C from the conventional 1400–1450 °C, while still producing cements with mechanical performance comparable to ordinary Portland cement (OPC). The resulting zeolite- and bentonite-based cements, either mechanically untreated or subjected to short pretreatment, are potentially suitable for structural concrete applications, while cements produced with longer mechanical pretreatments may be more appropriate for lower-demand or non-structural uses.

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