Primary life cycle inventory data for cement production, with relevance to sustainability assessment-Indian cases.

The data provided is primary data related to cement production collected from the six different cement plants in India. This serves as the inventory for conducting material flow analysis, supply chain forecasting, and life cycle assessment of cement and concrete systems. The dataset is given in three data sheets with information relevant to the steps followed in line with the life cycle assessment (LCA) methodology, i.e., inventory, characterization factors and impacts (here, carbon footprint and energy consumed). The data includes the amounts of raw materials (type and source), the electricity (source and amount) used in the clinker and other products produced, such as OPC (Ordinary Portland Cement), PPC (Portland Pozzolana Cement), PSC (Portland Slag Cement) and GGBS (Ground Granulated Blast Furnace Slag). The data is presented (in Sheet A and C) for the relevant functional unit, i.e., one tonne of material produced in each plant. Sheet B gives one of its kind data related to electricity produced (1 kWh) in the thermal power plant associated with the cement plant, also called as captive power plant. As the cement production process contributes to 8% of the anthropogenic CO2 emissions, it is important to understand the environmental impacts associated with it, and primary data generated are essential for assessing the impacts and to modify the processes with higher contribution to reduce the impacts. This dataset can, therefore, serve as a basis to collect the data from similar plants in any part of the world and benchmarking.

Thermal Reactivation of Hydrated Cement Paste: Properties and Impact on Cement Hydration.

In this research, the properties and cementitious performance of thermally activated cement pastes (referred to as DCPs) are investigated. Hydrated pastes prepared from Portland cement and slag blended cement were subjected to different thermal treatments: 350 °C for 2 h, 550 °C for 2 h, 550 °C for 24 h and 750 °C for 2 h. The properties and the reactivity as SCM of the DCPs were characterised as well as their effect on the mechanical performance and hydration of new blended cements incorporating the DCPs as supplementary cementitious materials (SCMs). It was observed that the temperature and duration of the thermal treatment increased the grindability and BET specific surface area of the DCP, as well as the formation of C2S phases and the reactivity as SCM. In contrast, the mechanical strength results for the blended cements indicated that thermal treatment at 350 °C for 2 h provided better performance. The hydration study results showed that highly reactive DCP interfered with the early hydration of the main clinker phases in Portland cement, leading to early setting and slow strength gain. The effect on blended cement hydration was most marked for binary Portland cement-DCP blends. In contrast, in the case of ternary slag cement-DCP blends the use of reactive DCP as SCM enabled to significantly increase early age strength.

Valorisation of "La Palma" Volcanic Ash for Making Portland-Blended, Alkaline and Hybrid Portland-Alkaline Cements.

The present work evaluates the feasibility of using volcanic fly ash (VFA) generated by the eruption of the Tajogaite volcano on the island of La Palma (Spain) in 2021, as a precursor in the preparation of cementitious materials with different Portland cement (PC) replacement levels (0%, 30%, 70% and 100%), in the absence (Blended Cement, BC) and presence of an alkaline activator (Hybrid Alkaline Cement, HAC, and Alkaline Cements, AC). Hydration kinetics (isothermal conduction calorimetry), paste mechanical strengths and reaction products were characterised by XRD, FTIR, TG/DTG and BSEM/EDX. The results obtained indicate that the strengths developed by the hybrid alkaline cements (HAC) are higher than those of the blended cements (BC), especially at the age of 2 days, where 25 MPa were obtained with the replacement of 70% PC by VFA. Alkaline cements (AC, 100% VFA) that were prepared with 8 M NaOH solution as the activator reached 40 MPa after 2 days. It was observed that in all the binders, depending on the initial composition of the binder mixture and the percentage of replacement and/or activator, VFA reacts to form cementitious gels, C-A-S-H and N-A-S-H type, which supports its use as a mineral addition to blended cement or as a precursor in the preparation of alkaline and hybrid alkaline cements.

Prolonging the Durability of Maritime Constructions through a Sustainable and Salt-Resistant Cement Composite.

This research investigates the long-term resilience of an environmentally friendly cement blend comprising Egyptian Ordinary Portland Cement OPC and Ground-Granulated Blast Furnace Slag GGBFS when exposed to a corrosive seawater environment. This scientific investigation explores the effects of exposure to seawater on various properties of cement pastes, encompassing parameters such as free lime content (FLC), chemically combined water content (CWC), bulk density (BD), total porosity (ϕ), total sulfate content, total chloride content, and compressive strength (CS). By contrast, Differential Thermal Analysis (DTA), FT-IR spectroscopy, and X-ray diffraction (XRD) analysis can be utilized to investigate the influence of exposure to seawater on the hydration products of GGBFS cement pastes over a period of up to one year. This analytical approach offers valuable insights into the alterations that occur in hydration products and their resilience when subjected to seawater conditions. The results obtained from this investigation reveal that all cement pastes incorporating GGBFS exhibit heightened resistance to deterioration in seawater, with slag cement containing 60 wt. % GGBFS and achieving a notable compressive strength of 85.7 Mpa after one year of immersion in seawater. These findings underscore the capacity of these cement blends to effectively withstand challenges in durability in marine environments.

A long-term study on structural changes in calcium aluminate silicate hydrates.

Production of blended cements in which Portland cement is combined with supplementary cementitious materials (SCM) is an effective strategy for reducing the CO2 emissions during cement manufacturing and achieving sustainable concrete production. However, the high Al2O3 and SiO2 contents of SCM change the chemical composition of the main hydration product, calcium aluminate silicate hydrate (C-A-S-H). Herein, spectroscopic and structural data for C-A-S-H gels are reported in a large range of equilibration times from 3 months up to 2 years and Al/Si molar ratios from 0.001 to 0.2. The 27Al MAS NMR spectroscopy and thermogravimetric analysis indicate that in addition to the C-A-S-H phase, secondary phases such as strätlingite, katoite, Al(OH)3 and calcium aluminate hydrate are present at Al/Si ≥ 0.03 limiting the uptake of Al in C-A-S-H. More secondary phases are present at higher Al concentrations; their content decreases with equilibration time while more Al is taken up in the C-A-S-H phase. At low Al contents, Al concentrations decrease strongly with time indicating a slow equilibration, in contrast to high Al contents where a clear change in Al concentrations over time was not observed indicating that the equilibrium has been reached faster. The 27Al NMR studies show that tetrahedrally coordinated Al is incorporated in C-A-S-H and its amount increases with the amount of Al present in the solution. Supplementary Information: The online version contains supplementary material available at 10.1617/s11527-022-02080-x.

A method for the mix design of low carbon concrete towards industrial production.

The introduction of newly developed blended cements into the mass market is essential to ensure an effective reduction of the carbon footprint related to cement production. To facilitate this process, formulating mix proportions using pastes and/or mortars rather than concrete can be a great advantage. However, for the upscaling towards industrial concrete it is then essential to maintain the target rheological and mechanical properties, something that is all too often challenging. In this work, a procedure facilitating such an upscaling was illustrated in the form of a flow chart. Specifically, best practices to obtain a good correlation between concrete prepared in a laboratory and one prepared in a plant were presented. This includes new data showing how to accommodate for possible differences in temperature and/or water content between both situations. The dataset of state-of-the-art correlations between mechanical performance and heat of hydration, considering w/b ratios relevant to practice, were expanded. This greatly facilitates the mix design of concrete with particularly low clinker contents, which in this work were illustrated with a blended cement containing only 50% clinker. Supplementary Information: The online version contains supplementary material available at 10.1617/s11527-022-02040-5.

Fracture Performance of Cementitious Composites Based on Quaternary Blended Cements.

This study presents test results and in-depth discussion regarding the measurement of the fracture mechanics parameters of new concrete composites based on quaternary blended cements (QBC). A composition of the two most commonly used mineral additives, i.e., fly ash (FA) and silica fume (SF), in combination with nanosilica (nS), has been proposed as a partial replacement for ordinary Portland cement (OPC) binder. Four series of concrete were made, one of which was the reference concrete (REF) and the remaining three were QBC. During the research, the main mechanical parameters of compressive strength (fcm) and splitting tensile strength (fctm), as well as fracture mechanics parameters and the critical stress intensity factor KIcS, along with critical crack-tip opening displacements (CTODc) were investigated. Based on the tests, it was found that the total addition of siliceous materials, i.e., SF + nS without FA, increases the strength and fracture parameters of concrete by approximately 40%. On the other hand, supplementing the composition of the binder with SF and nS with 5% of FA additive causes an increase in all mechanical parameters by approximately 10%, whereas an increase by another 10% in the FA content in the concrete mix causes a significant decrease in all the analyzed factors by 10%, compared to the composite with the addition of silica modifiers only.

Environmental Benefit Assessment of Blended Cement with Modified Granulated Copper Slag.

This study aimed to investigate the environmental impact of modified granulated copper slag (MGCS) utilization in blended cement production at a representative cement plant in China. Sensitivity analysis was performed on the substance inputs, and the life cycle impact assessment (LCIA) model was applied. A detailed comparative analysis was conducted of the environmental impact of cement production in other studies, and ordinary Portland cement production at the same cement plant. Results showed that calcination has the largest contribution impact of all the impact categories, especially in causing global warming (93.67%), which was the most prominent impact category. The life cycle assessment (LCA) result of blended cement was sensitive to the chosen LCIA model and the depletion of limestone and energy. In this study, producing blended cement with MGCS effectively mitigated the environmental impact for all the selected impact categories. Results also show a reduction in abiotic depletion (46.50%) and a slight growth (6.52%) in human toxicity. The adoption of MGCS in blended cement would therefore generally decrease the comprehensive environmental impact of cement, which contributes to the development of sustainable building materials.

Top-Down Production of Nano-Seeds from Activated Fly Ash Tuned for Enhancing the Early Strength in Blended Cements.

To achieve the new level of blended cement performance, the slurries of Class C and F fly ash were mechano-chemically activated in a vibro-mill with superplasticizer and nanosilica. The resulting activated products were tested in mortars replacing up to 30% portland cement. The activation process resulted in the formation of nano-seed clusters and micronized ash particles that both significantly improve the early strength of mortars as well as allow for the replacement of portland cement with industrial by-products. A small amount, 0.1% (of a binder weight), of nanosilica was used in selected compositions to improve the process of activation and facilitate the formation of nano-seeds. Due to an intensive activation of fly ash in the vibro-mill and the formation of nano-seed hydration products, the increase in the heat of the hydration flux and improvement of the mechanical properties such as compressive strength, especially in the early stages of hardening, were achieved. It is envisioned that fly ash activation and the use of supplementary cementitious materials as a precursor can induce a denser structure of cementitious matrix due to better particle packing realized with the application of the nano-seed product, nanosilica, ultra-fine particles of fly ash, and the formation of a refined C-S-H structure realized with the incorporation of the nano-seed particles.

The Influence of the Acceleration Admixture Type and Composition of Cement on Hydration Heat and Setting Time of Slag Blended Cement.

This article presents recent research on cements containing GGBFS and their modifications with accelerating admixtures. The initial setting time and hydration heat evolution results are presented for cement CEM II/B-S and CEM III/A manufactured with three Portland clinkers of various phase compositions. The research was carried out at 8 °C and 20 °C. The main objective is to assess the behavior of blended cements in cooperation with modern admixtures that contain nucleation seeds. The authors aimed to compare and evaluate different methods to reduce setting time, namely, the effects of temperature, the specific surface area of cement and GGBFS, the type of Portland clinker, the content of GGBFS, and presence of accelerators. Many of these aspects appear in separate studies, and the authors wanted a more comprehensive coverage of the subject. Those methods of reducing the setting time can be ranked: the most effective is to increase the temperature of the ingredients and the surroundings, the second is to reduce the GGBFS content in cement, and the use of accelerators, and the least effective is the additional milling of Portland clinker. However, of these methods, only the use of accelerators is acceptable in terms of sustainability. Prospective research is a detailed study on the amounts of C-S-H phase and portlandite to determine the hydration rate.

Mineralogical and Technological Characterization of Zeolites from Basin and Range as Pozzolanic Addition of Cement.

The present paper assesses petrographic, mineralogical, chemical, and technological features of different zeolitic tuff samples from various western USA districts of the Basin and Range Province containing mainly erionite, mordenite, clinoptilolite/heulandite and phillipsite. The aim of this characterization is to evaluate the pozzolanic activity of these samples according to European normative UNI-EN 196/5 (Fratini test) to program a possible use as addition for blended cements. Petrographic and mineralogical results show that the two phillipsite-bearing tuffs have a higher theoretical Cation Exchange Capacity (CEC) than the other samples; technological characterization shows a pozzolanic behavior for all the samples but higher for the tuff samples containing phillipsite, which shows a higher reactivity with CaO. All the samples could be thus advantageously employed for the preparation of blended cements, potentially reducing CO2 emissions by 70-90%.

Hydration Processes of Four-Component Binders Containing a Low Amount of Cement.

Results of research on hydration of four-component binders containing very high amounts of supplementary cementitious materials were presented. The samples were composed of blended pozzolana (a mix of conventional fly ash and spent aluminosilicate catalyst), cement (about 20 wt.% in the binder) and Ca(OH)2. Spent aluminosilicate catalyst was proposed as activating component which can improve properties of low-cement blends, while the role of Ca(OH)2 was to enhance pozzolanic reaction. Early and later hydration periods of such blends were investigated by calorimetry, TG/DTG, FTIR and X-ray diffraction. Initial setting time as well as compressive strength were also determined. It was concluded that enhancement of reactivity and improvement of properties of fly ash-cement binders are possible by replacing a part of fly ash with more active fine-grained pozzolana and introducing additional amounts of Ca(OH)2. The spent catalyst is mainly responsible for accelerating action during the first hours of hydration and for progress of early pozzolanic reaction. Fly ash develops its activity over time, thus synergic effect influences the later properties of composites. Samples containing blended pozzolana exhibit shorter initial setting times and higher compressive strength, as well as faster consumption of Ca(OH)2 compared to the reference. Investigated mixtures seem to be promising as "green" binders, alternatives to cement, after optimizing their compositions or additional activating procedure.

Properties of Blended Cement Containing Iron Tailing Powder at Different Curing Temperatures.

The properties of blended cement containing 0%, 20%, and 50% iron tailing powder (ITP) at 20 °C and 60 °C were investigated by determining the hydration heat, microstructure, and compressive strength. The addition of ITP decreases the exothermic rate and cumulative hydration heat of blended cement at 20 °C. The high temperature increases the hydration rate and leads to the hydration heat of blended cement containing 20% ITP higher than that of Portland cement. Increasing the amount of ITP decreases the non-evaporable water content and Ca(OH)2 content as well as compressive strength at both of the two studied temperatures. The addition of ITP coarsens the early-age pore structure but improves the later-age pore structure at 20 °C. The high temperature significantly improves the early-age properties of blended cement containing ITP, but it is detrimental to the later-age properties development. The reaction of ITP is limited even at high temperature. The large ITP particles bond poorly with surrounding hydration products under early high-temperature curing condition. The properties of blended cement containing a large amount of ITP are much poorer at high temperature.

Eco-Friendly, Set-on-Demand Digital Concrete.

Digital fabrication with concrete is considered to potentially revolutionize the construction sector and is often presented as a means to reduce its environmental footprint. However, at least in the case of concrete, it encounters significant challenges in terms of material design, since high paste volumes and Portland cement contents are normally used due to process requirements. In this article, the application to layered extrusion of a recently developed low clinker cement containing 50% Portland cement and 50% supplementary cementitious materials, such as limestone, burnt oil shale, and fly ash, is presented. It is found that an accelerator paste composed by Calcium Aluminate Cement (CAC) and anhydrite provides the required hydration and structural build-up for 3D printing, while not compromising the early and long-term compressive strength. Such a low clinker mortar can be successfully retarded, processed, pumped, and extruded just after mixing it in line with the accelerator paste. This accelerated mortar formulation contains only 303 kg/m3 of Portland cement, which is roughly half the amount used in current accelerated formulations used for digital fabrication with concrete.

Ternary and quaternary blends as partial replacement of cement to produce hollow sandcrete blocks.

Hollow sandcrete blocks constitute more than 90% of residential building construction in developing countries especially in West Africa. Over-reliance on dredged river sands and conventional ordinary Portland cement (OPC) contributes to environmental degradation and post-construction problems such as swelling and shrinkage-induced cracks prevalent in construction projects. The study investigates potential utilization of locally available materials such as laterite, calcite and calcined clay as ternary and quaternary blends to replace cement and quarry dust as 100% replacement of river sand with the aid of Taguchi-Response surface methodology approach. Optimum ternary blend of 24% calcined clay +1% calcite +75% OPC is recommended to achieve volume stability, higher compressive strength and higher flexural load capacity. Alternatively, ternary blends of 24% calcite +4% calcined clay +72% OPC can also be utilized. The improved mechanical properties were attributed to the Na- and Ca-rich aluminosilicates provided by the blended cements. Successful utilization of ternary and quaternary blended cements to produce stronger, durable and eco-friendly sandcrete blocks depends on utilization of high binder-to-aggregate ratio, optimal combination of the constituents, appropriate water-cement ratio and curing/production method. Partial and 100% replacement of river sand with granite dust is possible and contributes to reduction of environmental problems caused by river dredging as well as cleaner, ecofriendly construction. Ternary and quaternary blended cements is recommended to avert post-construction problems such as swelling and shrinkage-induced cracks prevalent in construction projects.

Influence of Cement Replacement with Fly Ash and Ground Sand with Different Fineness on Alkali-Silica Reaction of Mortar.

The alkali-silica reaction (ASR) is an important consideration in ensuring the long-term durability of concrete materials, especially for those containing reactive aggregates. Although fly ash (FA) has proven to be useful in preventing ASR expansion, the filler effect and the effect of FA fineness on ASR expansion are not well defined in the present literature. Hence, this study aimed to examine the effects of the filler and fineness of FA on ASR mortar expansion. FAs with two different finenesses were used to substitute ordinary Portland cement (OPC) at 20% by weight of binder. River sand (RS) with the same fineness as the FA was also used to replace OPC at the same rate as FA. The replacement of OPC with RS (an inert material) was carried out to observe the filler effect of FA on ASR. The results showed that FA and RS provided lower ASR expansions compared with the control mortar. Fine and coarse fly ashes in this study had almost the same effectiveness in mitigating the ASR expansion of the mortars. For the filler effect, smaller particles of RS had more influence on the ASR reduction than RS with coarser particles. A significant mitigation of the ASR expansion was obtained by decreasing the OPC content in the mortar mixture through its partial substitution with FA and RS.

Effect of Morphologically Controlled Hematite Nanoparticles on the Properties of Fly Ash Blended Cement.

Several types of hematite nanoparticles (α-Fe2O3) have been investigated for their effects on the structure and properties of fly ash (FA) blended cement. All synthesized nanoparticles were found to be of spherical shape, but of different particle sizes ranging from 10 to 195 nm depending on the surfactant used in their preparation. The cement hydration with time showed 1.0% α-Fe2O3 nanoparticles are effective accelerators for FA blended cement. Moreover, adding α-Fe2O3 nanoparticles in FA blended cement enhanced the compressive strength and workability of cement. Nanoparticle size and size distribution were important for optimal filling of various size of pores within the cement structure.

Pyroprocessing and the optimum mix ratio of rice husks, broken bricks and spent bleaching earth to make pozzolanic cement.

This paper presents the findings of an experimental investigation on optimizing pozzolanic activity of a blend of Rice Husks (RH), Spent Bleaching Earth (SBE) and Broken Bricks (BB) to form pozzolana that would have pozzolanic activity comparable to natural pozzolanas. Four ratios of RH, BB, and SBE were burnt in the Fixed Bed Kiln (FBK). The starting ratio had 20 kg of RH, 0 kg of BB and 4 kg of SBE. The amount of BB was increased by 2 kg each to a maximum of 6 kg as the mass of SBE was kept constant. The resultant ashes were subjected to various pozzolanic tests. This included; saturated lime test and compressive strength analysis. It was observed that the calcined blend with 10: 1: 2 mix of RH: BB: SBE exhibited the highest pozzolanic activity. This sample was mixed with acetylene lime sludge (ALS) in the ratio of 2:1 pozzolana: ALS. The compressive strengths for these cements were tested at 2 and 28 days of curing. The compressive strengths of this cement met the required EN standards for Portland pozzolana cement.

Leaching test procedure for assessing the compliance of the chemical and environmental requirements of hardened woody biomass fly ash cement mixtures.

The compliance of the chemical and environmental requirements for using woody biomass fly ash (WBFA) as a mineral admixture in cement-based materials was studied in terms of the use of the cement-biomass fly ash concrete where the fluids surrounding and interacting with it renew themselves over time. The study was preceded by a preliminary characterization of WBFA whose results showed that the European chemical requirements (EN 450-1, 2012) established for the reuse of coal fly ash in cement-based materials (there is no normative for WBFA) were met except for the chloride content. A blend with a quite high content of WBFA (30%) and Portland cement (70%) was prepared to test the leaching behaviour of the cement-biomass fly ash concrete. After that, cubic specimens were cast from a paste with water:solid ratio 0.5 and subsequently cured for 28 days at 20 °C. Monolith leaching tests were carried out on the specimens for heavy metals leachability, following the standard leaching test NEN 7345 that was modified to make it able to simulate an aggressive environmental context where the hardened cementitious material was supposed to be placed. The results have shown a good capacity of the cement-biomass fly ash material to immobilize the heavy metals (Cd, Cr, Cu, Ni, Pb, Zn) present in the WBFA. Also, the extrapolated releases of these metals after 100 years were found below the limits established by the Dutch Building Materials Decree. Thus, the reuse of WBFA in cement-based materials may be considered compatible with the environmental requirements.

Mechanical Activation of Granulated Copper Slag and Its Influence on Hydration Heat and Compressive Strength of Blended Cement.

Mechanical activation of granulated copper slag (GCS) is carried out in the present study for the purposes of enhancing pozzolanic activity for the GCS. A vibration mill mills the GCS for 1, 2, and 3 h to produce samples with specific surface area of 0.67, 1.03 and 1.37 m²/g, respectively. The samples are used to replace 30% cement (PC) to get 3 PC-GCS binders. The hydration heat and compressive strength are measured for the binders and derivative thermogravimetric /thermogravimetric analysis (DTG/TGA), Fourier transform infrared spectroscopy (FTIR), and scanning electron microscopy (SEM) are used to characterize the paste samples. It is shown that cumulative heat and compressive strength at different ages of hydration and curing, respectively, are higher for the binders blending the GCS milled for a longer time. The compressive strength after 90 d of curing for the binder with the longest milling time reaches 35.7 MPa, which is higher than the strength of other binders and close to the strength value of 39.3 MPa obtained by the PC pastes. The percentage of fixed lime by the binder pastes at 28 days is correlated with the degree of pozzolanic reaction and strength development. The percentage is higher for the binder blending the GCS with longer milling time and higher specific surface area. The pastes with binders blending the GCS of specific surface area of 0.67 and 1.37 m²/g fix lime of 15.20 and 21.15%, respectively. These results together with results from X-ray diffraction (XRD), FTIR, and SEM investigations demonstrate that the mechanical activation via vibratory milling is an effective method to enhance the pozzolanic activity and the extent for cement substitution by the GCS as a suitable supplementary cementitious material (SCM).