Cement Production Research Articles

An environmental approach to cement admixtures: Utilization of waste olive seed powder as a bio-polymeric admixture.

The integration of organic wastes into cement-based materials shows promise as a solution to mitigate environmental pollutants. It achieves this by minimizing waste sent to landfills and in some conditions decreasing Portland cement use. One of these organic wastes that produces positive effects when used in cement products is olive seed. In this study, the effect of a new generation bio-polymeric admixture on the physical and mechanical properties of cement mortars is examined in detail. The bio-polymeric admixture is prepared by grinding olive seeds in 0/125μm sizes. The olive seeds have been used as bio-polymeric admixture in cement mortars at different rates, i.e., 0, 0.2, 0.35, 0.5, 1 and 1.5% of total weight. The olive seed is characterized by XRD, FT-IR analysis and by determining extracts, pectin, cellulose, hemicellulose and lignin content. The characteristics of hydration products were analyzed by SEM/EDS and XRD investigations. Effect of bio-polymeric admixture addition on the unit weight, flowability, setting time, compressive and flexural strength and capillary water absorption was analyzed. The results suggested that the bio-polymeric admixture hindered the cement hydration at low usage rates but promoted at high usage rates. Accordingly, 28days compressive and flexural strength of test samples decreased. However, 1.5 wt% bio-polymeric admixture was associated with a slight increase of 150-days compressive strength. Bio-polymeric admixture improves the hydrophobicity property of the hardened mortar samples by declining effect on the water absorption. Another important effect of the bio-polymeric admixture contribution was also observed on the flowability property of the cement mortars. As the bio-polymeric admixture increased, the flow diameter values of the mortar were also significantly increased. The research outcomes suggested for the first time the beneficial effect of bio-polymeric admixture as a natural and bio-degradable alternative of chemical admixtures on especially flowability, set retarder and hydrophobicity of cement mortars with comparable mechanical properties.

Study on the mechanical property and durability of alkali-activated seawater and sea sand recycled aggregate concrete

This study investigates the potential of Alkali-Activated Seawater Sea Sand Recycled Aggregate Concrete (ASSRAC) as a novel sustainable construction material. By utilizing recycled aggregates from construction and demolition waste, seawater, sea sand, and alkali-activated materials such as fly ash and blast furnace slag, this innovative concrete aims to mitigate carbon emissions from cement production and optimize resource usage. The impact of recycled aggregate replacement rate, water-to-binder ratio, and sand type on the compressive strength of ASSRAC was examined through analysis of variance. Cylindrical axial compression and prism flexural tests were conducted to evaluate the long-term performance of ASSRAC under seawater immersion. The results indicate a decrease in compressive strength with higher recycled aggregate replacement rates and water-to-binder ratios, with recycled aggregates being the primary weak link. Additionally, increasing the water-to-binder ratio hampers hydration by diluting alkali activators, weakening polycondensation reactions. Under seawater immersion, ongoing reactions foster denser C-(A)-S-H structures, enhancing compressive strength and elastic modulus over time. Moreover, higher recycled aggregate replacement rates result in improved ductility, attributed to reactions between the old mortar on recycled aggregate surfaces and slag/fly ash at interfaces. For specimens immersed for 0 and 90 days, most theoretical models accurately predict results, except for the CEB-FIP model, which only accurately reflects the stress-strain curve at 180 days. The seawater-sea sand group's flexural strength initially exceeds that of the freshwater-river sand group due to accelerated early hydration, but this advantage diminishes over time due to high salt content.

The Role of Low-Carbon Fuels and Carbon Capture in Decarbonizing the U.S. Clinker Manufacturing for Cement Production: CO2 Emissions Reduction Potentials

Low-carbon fuels, feedstocks, and energy sources can play a vital role in the decarbonization of clinker production in cement manufacturing. Fuel switching with renewable natural gas, green hydrogen, and biomass can provide a low-carbon energy source for the high-temperature process heat during the pyroprocessing steps of clinker production. However, up to 60% of CO2 emissions from clinker production are attributable to process-related CO2 emissions, which will need the simultaneous implementation of other decarbonization technologies, such as carbon capture. To evaluate the potential of fuel switching and carbon capture technologies in decarbonizing the cement industry, a study of the facility-level CO2 emissions is necessary. This study evaluates the potential for using a single low-carbon fuel as an energy source in clinker production for cement manufacturing compared to conventional clinker production (which uses a range of fuel mixes). In addition, conventional carbon capture (operated with natural gas-based steam for solvent regeneration) and electrified carbon capture configurations were designed and assessed for net-zero emission targets. Carbon emissions reductions with and without biogenic emissions credits were analyzed to ascertain their impact on the overall carbon accounting. Results show that carbon emissions intensity of cement can vary from 571 to 784 kgCO2eq/metric ton of cement without carbon capture and from 166.33 to 438.66 kgCO2eq/metric ton of cement with carbon capture. We find that when biogenic carbon credits are considered, cement production with a sustainably grown biomass as fuel source coupled with conventional carbon capture can lead to a net-negative emission cement (−271 kgCO2eq/metric ton of cement), outperforming an electrified capture design (35 kgCO2eq/metric ton of cement). The carbon accounting for the Scope 1, 2, and biogenic emissions conducted in this study is aimed at helping researchers and industry partners in the cement and concrete sector make an informed decision on the choice of fuel and decarbonization strategy to adopt.

Production of lightweight geopolymer concrete with foam glass aggregate derived from cathode-ray glass waste

This work focused on producing an eco-friendly lightweight structure by recycling the cathode ray tube glass waste (CRT-GW)to prepare a foam glass aggregate (FGA) and using metakaolin to prepare a geopolymer binder (GP). The geopolymer binder replaces cement to decrease the release of gas generated during cement production. The silicon carbide (SiC) was used as a foaming agent at 1 wt% to prepare the FGA. The foaming temperature effect was investigated for the FGA characterization included: bulk density, volume expansion, apparent porosity, uniaxial compressive strength, and leaching tests for lead and barium. The foam glass aggregate was sintered at different temperatures 725 °C, 750 °C, 775 °C, and 800 °C. These temperatures were selected depending on heating microscopy analysis results, where the maximum expansion height was 119 % at 800 °C. The main characterization ranges of foam glass were: bulk density 0.58–1.26 g/cm3, volume expansion 8–77 (vol%), uniaxial compressive strengths 1.55–9.98 MPa, and thermal conductivity 0.063–0.097 W/m.K.The lightweight geopolymer (LWGP) was prepared with 30 vol% of FGA sintered at different temperatures and 70 vol% of GP. These samples hardened at room temperature. The bulk density and compressive strength were measured for the lightweight geopolymer samples after a curing time of 28 days. A higher compressive strength was 9.11 MPa with a bulk density of 1.21 g/cm3 for lightweight geopolymer-containing foam glass aggregate sintered at 775 °C.

Assessment of Various Mitigation Strategies of Alkali-Silica Reactions in Concrete Using Accelerated Mortar Test.

The widespread use of reinforced concrete continues to face challenges, particularly in mitigating alkali-silica reaction (ASR), due to its detrimental effects on concrete strength and durability. This paper investigates the effectiveness of using binary supplementary cementitious materials (SCMs) in mitigating ASR by incorporating metakaolin (MK) and waste glass powder (GP) as partial replacements for cement. Additionally, the potential of a new cement product, "NewCem Plus" (NCM), along with the use of basalt fibers and lithium, was evaluated through a 14-day accelerated mortar bar test following the ASTM C1260. This study also assessed concrete's properties such as its compressive strength and workability using the flow test. The results indicated that MK was effective, reducing expansion by 79%, 84%, and 88% with 10%, 20%, and 30% cement replacement, respectively, compared to the control mixture. On the other hand, GP showed a more modest reduction in expansion, with 10%, 20%, and 30% replacement levels reducing expansion by 20%, 43%, and 75%, respectively. Furthermore, the addition of lithium to MK significantly mitigated ASR, reducing expansion below the ASTM threshold. However, mixtures containing NewCem Plus, lithium, and basalt fibers showed minimal impact on ASR reduction. These findings underscore the viability of using binary or ternary blends of SCMs to mitigate ASR in concrete, encouraging their adoption in future concrete applications.

Effect of dusty clinker and alite crystal size on the properties of class G oil well cement slurries

AbstractHoning the quality of cement plays a pivotal role in the petroleum industry throughout drilling operations, undoubtedly. In cement plants, producing high-quality clinker is essential for improving oil well maintenance, reducing expenditures, enhancing safety, and more, demonstrating its importance in the long term. Despite tight control of clinker operational conditions, cement kiln operators can still produce dusty clinker. This work uniquely establishes the previously unexplored relationship between dusty clinker and the qualitative characteristics of class G oil well cement slurries, offering a practical solution to prevent the production of poor-quality cement in factories. All API tests were done according to API Specification 10 A. Furthermore, a thorough microscopic analysis was conducted on both standard and dusty clinkers to establish a connection between the properties of class G oil well cement slurries and the changes in crystal size observed in the minerals of dusty clinker. According to the studies conducted in this regard, changing the size of the cement particles has a considerable influence on the cement performance. Here, results revealed that increasing the alite (C3S) crystal size to 60–70 microns in dusty clinker led to a roughly 20-minute increase in the average thickening time. In addition, the compressive strength cured at 38 and 60 °C for 8 h, decreased by 1.47 and 2.89 MPa, respectively. More importantly, it was found that the average maximum consistency in dusty clinker oil well cement increased by almost 6.4 Bc over a 15 to 30-minute period.

Integrated Techno-Environmental Analysis of Finely Ground Silica Sand in Sustainable Mortar Production

The environmental impacts of cement production are becoming more urgent concerns. This study examined the mechanical characteristics of cement when it is partially replaced with finely crushed sand. The experimental program consisted of three different levels of sand fineness of 459 m2/kg, 497 m2/kg, and 543 m2/kg, as well as four substitution ratios of 10%, 20%, 30%, and 40%. A total of thirteen combinations were formulated and then evaluated. The results demonstrated that increasing sand fineness from 459 m2/kg to 543 m2/kg substantially impacted the compressive strength (CS), increasing it by up to 30%, and increasing the substitution ratio from 10% to 40% reduced the mechanical strength by roughly 40%. An extensive techno-environmental evaluation showed that replacing cement with finely crushed sand is technically feasible and environmentally advantageous. This technique can decrease carbon dioxide (CO2) emissions by around 40%, emphasizing its ecological benefits and coinciding with worldwide initiatives to decrease the environmental impact of construction materials. In summary, this study demonstrates the advantages of improving the mechanical characteristics of cement while minimizing its ecological footprint. It suggests that finely crushed sand can be used as a sustainable alternative in cement manufacturing, promoting the use of more environmentally friendly construction methods.

Cement and Alternatives in the Anthropocene

Globally, the production of concrete is responsible for 5% to 8% of anthropogenic CO2 emissions. Cement, a primary ingredient in concrete, forms a glue that holds concrete together when combined with water. Cement embodies approximately 90% of the greenhouse gas emissions associated with concrete production, and decarbonization methods focus primarily on cement production. But mitigation strategies can accrue throughout the concrete life cycle. Decarbonization strategies in cement manufacture, use, and disposal can be rapidly implemented to address the global challenge of equitably meeting societal needs and climate goals. This review describes (a) the development of our reliance on cement and concrete and the consequent environmental impacts, (b) pathways to decarbonization throughout the concrete value chain, and (c) alternative resources that can be leveraged to further reduce emissions while meeting global demands. We close by highlighting a research agenda to mitigate the climate damages from our continued dependence on cement.

A Review on Research Progress of Corrosion Resistance of Alkali-Activated Slag Cement Concrete.

China is the largest producer and user of Ordinary Silicate Cement (OPC), and rapid infrastructure development requires more sustainable building materials for concrete structures. Portland cement emits large amounts of CO2 in production. Given proposals for "carbon peaking and carbon neutralization", it is extremely important to study alternative low-carbon cementitious materials to reduce emissions. Alkali-activated slag (AAS) cement, a new green cementitious material, has high application potential. The chemical corrosion resistance of AAS concrete is important for ensuring durability and prolonging service life. This paper reviews the hydration mechanism of AAS concrete and discusses the composition of hydration products on this basis, examines the corrosion mechanism of AAS concrete in acid, sulfate, and seawater environments, and reviews the impact of its performance due to the corrosion of AAS concrete in different solutions. Further in-depth understanding of its impact on the performance of concrete can provide an important theoretical basis for its use in different environments and provides an important theoretical basis for the application of AAS concrete, so that we can have a certain understanding of the durability of AAS concrete.

Improving the Performance of Mortar under Carbonization Curing by Adjusting the Composition of Ternary Binders

As the most widely used building material, cement has attracted the attention of scholars because of its large carbon emission. To alleviate the problems of carbon emission and limited resource use caused by cement production, this study focuses on the performance of mortar after carbonization curing by regulating the composition of ternary binders. Testing involved mechanical parameters, carbon shrinkage, water absorption, hydration product, microstructure, adsorption of carbon dioxide, calcium carbonate content, and carbonization degree of mortar, as well as comparisons with the effect of calcium carbide slag and sintered red mud. We carried out several studies which demonstrated that carbonization curing and adjusting the content of calcium carbide slag and sintered red mud were beneficial to improve the mechanical properties, peak load displacement, slope, elastic energy, plastic energy, carbon shrinkage, carbon dioxide adsorption, calcium carbonate content, and carbonization degree of mortar, while the addition of calcium carbide slag and sintered red mud increased the water absorption of mortar, and the greater the dosage, the greater the water absorption. Meanwhile, adding 25%–50% calcium carbide slag and sintered red mud still had negative effects on the mechanical properties of mortar. But carbonation curing and the addition of calcium carbide slag and sintered red mud could promote the hydration reaction and consume calcium hydroxide formed by hydration to form calcium carbonate. When the dosage was 50%, the carbon dioxide adsorption capacity, calcium carbonate content, and carbonization degree of calcium carbide slag mortar were higher than those of sintered red mud mortar, which increased by 29.56%, 102.73%, and 28.84%, respectively. By comparison, calcium carbide slag and sintered red mud still showed superior carbon sequestration capacity, which was higher than fly ash and Bayer red mud. From the experiment, we came to realize that adjusting the composition of cementitious materials could realize the carbon sequestration of cement-based materials and promote the road toward low-carbon sustainable development of cement.

Relevant biochar characteristics influencing compressive strength of biochar-cement mortars

To counteract the contribution of CO2 emissions by cement production and utilization, biochar is being harnessed as a carbon-negative additive in concrete. Increasing the cement replacement and biochar dosage will increase the carbon offset, but there is large variability in methods being used and many researchers report strength decreases at cement replacements beyond 5%. This work presents a reliable method to replace 10% of the cement mass with a vast selection of biochars without decreasing ultimate compressive strength, and in many cases significantly improving it. By carefully quantifying the physical and chemical properties of each biochar used, machine learning algorithms were used to elucidate the three most influential biochar characteristics that control mortar strength: initial saturation percentage, oxygen-to-carbon ratio, and soluble silicon. These results provide additional research avenues for utilizing several potential biomass waste streams to increase the biochar dosage in cement mixes without decreasing mechanical properties.Graphical

Carbon Sequestration by Preparing Recycled Cement, Recycled Aggregates, and Recycled Concrete from Construction and Demolition (C&D) Wastes

As the world’s largest producer of construction waste, China’s recycling and related policies are of the biggest concern to the world. However, the effective disposal and reuse of this waste has become an important issue since currently China still has a very low recycling ratio compared to developed countries, and most of the waste concrete was only simply broken and used as low-grade recycled aggregates for subgrade cushion, cement stabilized crushed stone, and filler wall. In this paper, a concrete cycle model focusing on how to effectively recycle and utilize waste concrete is put forward to prepare high quality recycled concrete, especially through a series of technical means, such as effective separation, carbon sequestration, and reactivation. Producing high quality recycled concrete can not only replace traditional concrete but also effectively reduce the consumption and waste of raw materials. What’s more, the calculation results show a potential of significantly carbon sink; for every ton of recycled cement produced, the CO2 emission could be reduced by 0.35–0.77 tons compared to ordinary Portland cement, corresponding to a reduction of 47%–94%; and for every ton of recycled concrete produced, the CO2 emission could be reduced by 0.186 tons compared to normal concrete. A yearly CO2 sequestration of 1.4–3.08 gigatonnes could happen if the ordinary Portland cement could be replaced by the recycled cement around the world. Taking the currently accumulated construction and demolition (C&D) wastes globally, the production of recycled cement, recycled aggregates, and recycled concrete could induce a significant carbon sink in the world.

New Eco-Cements Made with Marabou Weed Biomass Ash

Biomass ash is currently attracting the attention of science and industry as an inexhaustible eco-friendly alternative to pozzolans traditionally used in commercial cement manufacture (fly ash, silica fume, natural/calcined pozzolan). This paper explores a new line of research into Marabou weed ash (MA), an alternative to better-known conventional agro-industry waste materials (rice husk, bagasse cane, bamboo, forest waste, etc.) produced in Cuba from an invasive plant harvested as biomass for bioenergy production. The study entailed full characterization of MA using a variety of instrumental techniques, analysis of pozzolanic reactivity in the pozzolan/lime system, and, finally its influence on the physical and mechanical properties of binary pastes and mortars containing 10% and 20% MA replacement content. The results indicate that MA has a very low acid oxide content and a high loss on ignition (30%) and K2O content (6.9%), which produces medium–low pozzolanic activity. Despite an observed increase in the blended mortars’ total and capillary water absorption capacity and electrical resistivity and a loss in mechanical strength approximately equivalent to the replacement percentage, the 10% and 20% MA blended cements meet the regulatory chemical, physical, and mechanical requirements specified. Marabou weed ash is therefore a viable future supplementary cementitious material.

Modern Methods of Asbestos Waste Management as Innovative Solutions for Recycling and Sustainable Cement Production

Managing asbestos waste presents a significant challenge due to the widespread industrial use of this material, and the serious health and environmental risks it poses. Despite its unique properties, such as resistance to high temperatures and substantial mechanical strength, asbestos is a material with well-documented toxicity and carcinogenicity. Ensuring the safe removal and disposal of asbestos-containing materials (ACM) is crucial for protecting public health, the environment, and for reducing CO2 emissions resulting from inefficient waste disposal methods. Traditional landfill disposal methods have proven inadequate, while modern approaches—including thermal, chemical, biotechnological, and mechanochemical methods—offer potential benefits but also come with limitations. In particular, thermal techniques that allow for asbestos degradation can significantly reduce environmental impact, while also providing the opportunity to repurpose disposal products into materials useful for cement production. Cement, a key component of concrete, can serve as a sustainable alternative, minimizing CO2 emissions and reducing the need for primary raw materials. This work provides insights into research on asbestos waste management, offering a deeper understanding of key initiatives related to asbestos removal. It presents a comprehensive review of best practices, innovative technologies, and safe asbestos management strategies, with particular emphasis on their impact on sustainable development and CO2 emission reduction. Additionally, it discusses public health hazards related to exposure to asbestos fibers, and worker protection during the asbestos disposal process. As highlighted in the review, one promising method is the currently available thermal degradation of asbestos. This method offers real opportunities for repurposing asbestos disposal products for cement production; thereby reducing CO2 emissions, minimizing waste, and supporting sustainable construction.

Influence of Infrastructural Choices Strategy on Organizational Performance of Cements Manufacturing Firms in Kenya

Purpose: To determine the influence of infrastructural choices strategy on organizational performance of cements manufacturing firms in Kenya. Methodology: A mixed methods approach was used in the investigation. The study utilized a concurrent triangulation research design. The unit of analysis comprised of seven (7) cement manufacturing firms, targeting all the 4192 employees from where a sample size of 365 employees was drawn. The data collection tools comprised of semi-structured questionnaires and interview guides. The interview guide was administered to the CEOs while the questionnaires were administered to the managers and non-managers. The study tools were piloted to assess their validity and reliability. The data was then analyzed both descriptively and inferentially using SPSS version 27. Quantitative data was analyzed using means and standard deviations while qualitative data was analyzed using content analysis. To make the number of variables more manageable, the data was subsequently subjected to exploratory factor analysis. Findings: The results of the study revealed that infrastructural choice strategies have been employed by cement manufacturing firms to a good extent. The regression results obtained also led to the rejection of the null hypotheses since infrastructural choice strategies were found to have a positive and significant influence on organizational performance. Unique Contribution to Theory, Policy and Practice: The study recommended, based on these results that the management of individual cement firms need to identify appropriate infrastructural choice strategies and leverage on them in order to achieve efficient and effective utilization of their scarce resources at organizational level.

Study on the Influence of Thermoplastic Microcapsules on the Sulfate Resistance and Self-Healing Performance of Limestone Calcined Clay Cement Concrete.

Limestone calcined clay cement (LC3), enhanced through reactions with volcanic ash and the interaction between limestone and clay, significantly improves the performance of cementitious materials. It has the potential to cut CO2 emissions by up to 30% and energy consumption in cement manufacture by 15% to 20%, providing a promising prospect for the large-scale production of low-carbon cement with a lower environmental effect. To effectively manufacture LC3 concrete, this study utilized limestone (15%), calcined clay (30%), and gypsum (5%) as supplementary cementitious materials (SCMs), replacing 50% of ordinary Portland cement (OPC). However, in regions abundant in sulfate, sulfate attack can cause interior cracking of concrete, reducing the longevity of the building. To address this issue, microcapsules containing microcrystalline wax, ceresine wax, and nano-CaCO3 encapsulated in epoxy resin were prepared and successfully incorporated into LC3 concrete. Sulfate resistance tests were conducted through sulfate dry-wet cycles, comparing samples with and without microcapsules. The findings revealed that the initial mechanical and permeability properties of LC3 concrete did not significantly differ from OPC concrete. LC3 concrete with added microcapsules (SP4) exhibited enhanced resistance to sulfate attack, reducing mass loss and compressive strength degradation. SEM images displayed a mesh-like structure of repair products in SP4. After 14 days of self-repair, SP4 exhibited a 44.2% harmful pore ratio, 98.1% compressive strength retention, 88.7% chloride ion diffusion coefficient retention, 91.12 mV maximum amplitude, and 9.14 mV maximum frequency amplitude. The experimental results indicate that the presence of microcapsules enhances the sulfate attack self-healing performance of LC3 concrete.

Setting reaction of a olivine-based Mg-phosphate cement

The cementitious properties of natural Mg-rich olivine when reacted with a phosphoric acid solution are investigated, as a function of acid concentration and liquid/solid mass ratio. The obtained cements are composed of residual olivine crystals and amorphous silica nanoparticles dispersed in a dense and compact newberyite (MgHPO4∙3H2O) matrix. The latter was mostly formed by packed micrometric tabular crystals, although evidence of the presence of a fraction of amorphous MgHPO4 was also found. Water content in the raw mix was observed to play a pivotal role on the reaction pathway, either promoting porosity or hindering the crystallization of the products. Up to 57 % of olivine reactivity, whose dissolution was promoted by the curing temperature (60 °C) and low pH, was achieved. All in all, these results indicate that the industrial mineral olivine may serve a viable source of Mg for the production of phosphate cements.

Optimization of Proportions of Alkali-Activated Slag-Fly Ash-Based Cemented Tailings Backfill and Its Strength Characteristics and Microstructure under Combined Action of Dry-Wet and Freeze-Thaw Cycles.

To enhance the application of alkali-activated materials in mine filling, cemented tailings backfill was prepared using slag, fly ash, sodium silicate, and NaOH as primary constituents. The effects of the raw material type and dosage on the backfill were examined through a single-factor experiment. Additionally, response surface methodology (RSM) was utilized to optimize the mixing ratios of the backfill, with a focus on fluidity and compressive strength as key objectives. The evolution of backfill quality and compressive strength under the combined effects of dry-wet and freeze-thaw (DW-FT) cycles was analyzed. The hydration products, microstructure, and pore characteristics of the specimens were analyzed using X-ray diffraction (XRD), scanning electron microscopy with energy dispersive spectroscopy (SEM-EDS), and nitrogen adsorption tests (NATs) across varying cycles. The results demonstrate that the optimal backfill composition includes 47.8% fly ash, 6.10% alkali equivalent, and a 1.44 sodium silicate modulus. The macroscopic behavior of the backfill under DW-FT coupling followed this progression: pore initiation → pore expansion → crack formation → crack propagation → structural damage. After a minor initial increase, the backfill strength steadily decreased. Microscopic analysis revealed that the decline in internal cementation products and the deterioration of pore structure were the primary causes of this strength reduction. Thus, the DW-FT coupling can cause significant erosion of the backfill. The technical solutions presented in this paper offer a reference for solid waste utilization and provide valuable insights into the durability of backfill under DW-FT coupling.

Efficiency Assessment of the Production of Alternative Fuels of High Usable Quality within the Circular Economy: An Example from the Cement Sector

This article aims to present the mechanisms regulating the waste management system of one of the European countries that affect the cement industry. This publication analyses the possibility of using selected fractions of municipal and industrial waste as alternative fuels, including an analysis of ecological costs and benefits. The methodology includes the analysis of production data and the calculation of savings resulting from the use of alternative fuels. On this basis, ecological aspects were also indicated that should be taken into account when analyzing the profitability of the investment. Production data from an example Polish cement plant were used to analyze the research problem. Based on the guidelines of environmental standards and technical specifications, the parameters that PASr alternative fuels should meet were calculated in the company laboratory. This fuel type was then calculated in terms of emission intensity and production efficiency. The research results obtained in this paper study emphasize that the change in cement clinker production technology toward the use of waste raw materials and secondary fuels does not lead to an increase in heavy metal emissions to the extent that would justify qualifying cement as a material requiring systematic control of its harmful impacts on humans and the natural environment. The conclusions show that the use of alternative fuels reduces CO2 emissions and production costs, without negatively affecting the efficiency and production volume. The average energy requirement for the production of 1 ton of cement is approximately 3.3 GJ, which corresponds to 120 kg of coal with a calorific value of 27.5 MJ per kg. Energy costs account for 30–40% of the total cement production costs. Replacing alternative fuels with fossil fuels will help reduce energy costs, providing a competitive advantage for cement plants that use it as an energy source. The presented considerations can provide an answer to all interested parties, including representatives of the executive and legislative authorities, on what path the sector should follow to fit into the idea of sustainable building materials and the circular economy.

Compressive Strength and Chloride Ion Penetration Resistance of GGBFS-Based Alkali-Activated Composites Containing Ferronickel Slag Aggregates

Various studies have reported the use of alkali-activated composites to enable sustainable development in the construction industry as these composites eliminate the need for cement. However, few studies have used ferronickel slag aggregates (FSAs) as an aggregate material for alkali-activated composites. Alkali-activated composites are environmentally friendly and sustainable construction materials that can reduce carbon dioxide emissions from cement production, which accounts for 7% of global carbon emissions. In the construction industry, various research was conducted to improve the performance of alkali-activated composites, such as changing the binder, alkali activator, or aggregate. However, research on the application of ferronickel slag aggregate as an aggregate in alkali-activated composites is still insufficient. In addition, the effect of ferronickel slag aggregate on the performance of alkali-activated composites when using calcium-based or sodium-based alkali activators has not been reported yet. Thus, this study prepared ground granulated blast-furnace slag-based alkali-activated composites with 0, 10, 20, and 30% FSA as natural fine aggregate substitutes. Then, the fluidity, micro-hydration heat, compressive strength properties, and resistance to chloride ion penetration of the alkali-activated composite were evaluated. The test results showed that the maximum temperature of the CF10, CF20, and CF30 samples with FSA was 35.4–36.4 °C, which is 3.8–6.7% higher than that of the CF00 sample. The 7 d compressive strength of the sample prepared with CaO was higher than that of the sample prepared with Na2SiO3. Nevertheless, the 28 d compressive strength of the NF20 sample with Na2SiO3 and 20% FSA was the highest, with a value of approximately 55.0 MPa. After 7 d, the total charge passing through the sample with Na2SiO3 was approximately 1.79–2.24 times higher than that of the sample with CaO. Moreover, the total charge decreased with increasing FSA content.