Valorization of FGD and Bauxite Residue in Sulfobelite Cement Production
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ORIGINAL PAPER
Valorization of FGD and Bauxite Residue in Sulfobelite Cement Production M. D. Kamitsou1,3 · D. G. Kanellopoulou1,3 · A. Christogerou1,3 · C. Kostagiannakopoulou2,3 · V. Kostopoulos2,3 · G. N. Angelopoulos1,3 Received: 2 November 2019 / Accepted: 30 March 2020 © Springer Nature B.V. 2020
Abstract Cement, the most used building material amounts to an annual world production of 3.5 Gt. Sulfobelite cements, SB, require lower kiln temperature and emit less CO2, compared to Ordinary Portland cement, OPC. The main difference of SB from OPC is the reduction of alite (CaO)3SiO2, the increase of belite (CaO)2SiO2 and the formation of yeelimite (CaO)4(Al2O3)3SO3, also called “Klein’s salt”. Industrial byproducts, such as Flue Gas Desulphurization gypsum, FGD and dry Red Mud, the so–called bauxite residue, BR can also be used as raw materials, decreasing the C O2 footprint. In the present study, SB cements were prepared in laboratory scale from FGD and BR, as well as, conventional raw materials. All compositions were characterized by XRD, Q–XRD, optical microscopy, SEM and were tested for their compressive strength, soundness, coagulation, etc. The main result of this work is that the studied industrial byproducts, FGD and BR, can be used as alternative raw materials for the raw meals of SB cements, accomplishing low–temperature clinkering at 1330 °C and lower quantities of conventional raw materials. Conclusions suggest that SB cements can be a promising eco–friendly building material and can be used in other applications such as 3-D printed building, rapid-setting mortars, rapid sealants, etc. Moreover, this is an attempt to apply circular economy in cement production utilizing the established production route of cement industries. Graphic Abstract
Keywords Sulfobelite cements · FGD gypsum · Bauxite residue · Byproducts · Circular economy
* M. D. Kamitsou [email protected] 1
Department of Chemical Engineering, University of Patras, 26504 Rio, Achaia, Greece
2
Department οf Mechanical Engineering & Aeronautics, University of Patras, 26504 Rio, Achaia, Greece
3
INVALOR: Research Infrastructure for Waste Valorization and Sustainable Management, University Campus, 26504 Rio, Greece
Statement of Novelty The present research focuses on the design and preparation of sulfobelite cements utilizing Flue Gas Desulfurization gypsum and Bauxite Residue, two byproducts that are globally produced in large quantities, contributing to natural resource savings. These cements are fired at 1330 °C, 120 °C approximately, lower than the manufacturing of OPC and the major phases are belite and a sulfate bearing phase,
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yeelimite. Moreover, the prepared innovative binders have comparable final properties and lower environmental impact compared to OPC as lower energy consumption and lower CO2 emissions are anticipated. Finally, this study applied effectively the circular economy principles, as the synergy of conventional raw materials and
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