In order to save limited natural resources by utilising industrial by-products, this paper focuses on an entirely new application of fluidized bed combustion fly ash (FBCFA) into Portland composite cements. It is not currently used because undesirable ettringite, 3CaO·Al₂O₃·3CaSO₄·32H₂O, is formed during the hydration of FBCFA. Although the stability of ettringite has been the subject of much research, the solution is not yet fully clear. Ettringite is generally considered to be stable up to a temperature of 110°C; however, some investigators claimed that ettringite may already decompose at even ambient temperatures. To prove these statements, ettringite was prepared by the hydration of ye’elimite, 3CaO·3Al₂O₃·CaSO₄, and the system stored at laboratory temperature in two environments: in laboratory settings and in an environment of saturated water vapour. The mineralogical composition of ettringite was long term (up to 160 days of hydration) and was analysed by X-ray diffraction (XRD) and differential thermal analysis (DTA). The hydration of ye’elimite is a relatively complex process. Only approximately 30% of ettringite was formed under laboratory conditions that appeared to gradually convert into metaettringite. Within an environment of saturated water vapour, we observed the conversion of ettringite into monosulfate. Original ye’elimite was indicated as the dominant phase of both storages.

The fine powdered silica by-product of processing of aluminum fluoride (fertilizer plant, Lithuania) was used for zeolite synthesis as silica and aluminum source. The effect of sonication time and the time of hydrothermal synthesis on crystallinity of the synthesized zeolite were studied. This allowed the transformation of the by-product to the mixture of Na-P zeolite and Na-X zeolite. It was determined that ultrasonic-assisted hydrothermal action effected the "diamond" shape formation of Na-P zeolite with clear crystal edges. Na-P zeolite had the morphology of pseudo-spherical forms constituted by small plates when hydrothermal treatment (without sonication) was use for the preparation of zeolites. Moreover, it was determined that ultrasonic-assisted hydrothermal method effected a reduction in the crystal size compared with the zeolites which were synthesized only by using hydrothermal synthesis. The total amount of zeolites as high as 88-93% was achieved after 24 h of hydrothermal treatment followed or unfollowed by sonication. By using longer duration (20 min) of ultrasound pretreatment it is possible to reduce the duration of hydrothermal synthesis: from 24 h to 12 h of hydrothermal treatment. In this case, similar results of total amount of zeolites were detected. In the present work, low-cost raw materials, such as silica by-product have been investigated for the production of zeolites.

The presented study is focused on optimization and characterization of a high-alumina refractory aggregate based on natural raw materials—kaolins, claystone, and mullite dust by-product (used to increase the alumina and mullite contents, respectively). In total, four individual formulas with the Al₂O₃ contents between 45 and 50 wt.% were designed; the samples were subsequently fired, both in a laboratory oven and an industrial tunnel furnace. The effects of repeated firing were examined during industrial pilot tests. Mineral and chemical compositions and microstructures, of both the raw materials and designed aggregates, were thoroughly investigated by the means of X-ray fluorescence spectroscopy, powder X-ray diffraction, and optical and scanning electron microscopies. Porosity, mineral composition, and mullite crystal-size development during the firing process were also studied. Based on the acquired results, the formula with the perspective to be used as a new mullite grog, featuring similar properties as the available commercial products, however, with reduced production expenses, was selected. The quality of grog determines to a large extent the properties of the final product. Hence, optimization of aggregates for specific refractories is of a great importance. The production of engineered aggregates provides the opportunity to utilize industrial by-products.