Clinkering design of sulfobelite cements using clay overburden residue from bauxite mining

Abstract

Sulfobelite (belite-rich calcium sulfoaluminate (BCSA)) cements are promising alternatives to ordinary Portland cement (OPC) due to their lower carbon dioxide generation and lower energy consumption in the clinkering process. Additionally, they are cost effective because of their less-restrictive raw meal composition compared with that of calcium sulfoaluminate (CSA), in which expensive bauxites are used as the alumina source. Diverse mining residues have been proved to be reliable alumina sources for BCSA production, including the clay residues that cover bauxites (Belterra Clay (BTC)) in the Brazilian Amazon region. The clinkering settings of BCSA using a different (less alumina) BTC were examined in this work. The mineralogy of the BCSA clinkers was optimised by a design of experiments and studied using X-ray powder diffraction, scanning electron microscopy and thermal analysis. The raw meal composition, boron doping and firing temperature were investigated to obtain the optimal clinker composition. Hydration of the cement pastes was investigated by calorimetry and the strength development of mortars was tested and compared with that of a commercial OPC. The BCSA mortars produced with gypsum additions developed compressive strength comparable to that that OPC within 28 days. The main hydrated phase was ettringite, with minor amounts of kuzelite, straetlingite and gibbsite.