Use of Industrial Byproducts as Alumina Sources for the Synthesis of Calcium Sulfoaluminate Cements

Calcium sulfoaluminate (CSA) cements show some desirable environmentally friendly features that include the possibility of using several industrial byproducts as raw materials in their manufacturing process. Alumina powder, from the secondary aluminum manufacture, and anodization mud, from the production process of anodized aluminum, have proved to be suitable as partial or total substitutes for an expensive natural material like bauxite. CSA clinker generating raw mixtures, containing limestone, natural gypsum, bauxite, and/or one of the alumina-rich byproducts, were heated 2 h in a laboratory electric oven at temperatures ranging from 1150 to 1300 degrees C. Conversion of reactants into 4CaO center dot 3Al(2)O(3)center dot SO3 (the key component of CSA cements), evaluated using X-ray diffraction (XRD) analysis, increased with an increase of both burning temperature and byproduct concentration. When examined through thermogravimetric and XRD analyses, a synthetic CSA clinker (made from the raw mixture incorporating alumina powder as a total replacement of bauxite) mixed with 20% gypsum showed a hydration behavior almost similar to that of an industrial CSA cement containing the same amount of gypsum.