The possibility of producing cement clinker using low-energy, resource-saving technologies is studied. The composition of industrial waste for low-energy-intensive production of Portland cement clinker at factories in Southern Kazakhstan is analyzed. The possibility of replacing the deficient iron-containing corrective additive with “Waelz clinker for zinc ores” is shown. “Waeltz clinker from zinc ores” as part of the raw material charge performs several tasks: it is a ferrous corrective additive, works as a mineralizer for clinker formation processes, introduces coal into the charge and allows one to reduce the consumption of natural fuel. The processes of burning raw mixtures, wholly or partially consisting of industrial waste, are completed at 1350 °C. This reduces the consumption of main burner fuel for clinker burning and reduces CO₂ emissions into the atmosphere. High-quality cement clinker is obtained based on raw material mixtures with Waeltz clinker from zinc ores from the Achisai Metallurgical Plant, phosphorus slag, coal mining waste from Lenger mines and sodium fluoride. The phase composition and microstructure of low-energy clinkers are revealed. Involving industrial waste in raw material circulation will reduce environmental pollution and improve the environment.

In the European Union, the Russian Federation, as well as in a number of other countries, cement production is regulated by legislation on the best available technologies. Mandatory requirements (technological parameters, BAT-AELs) are imposed, first of all, on the emissions limitation of inorganic dust, nitrogen and sulfur oxides. The majority of Russian cement plants are currently characterized by the nitrogen oxide emissions state-established technological indicators‘ excess. The technological indicators of the best available technologies and methods for reducing nitrogen oxide emissions operating in the Russian Federation and the EU countries are considered. It is demonstrated that the most efficient technologies are the staged fuel combustion and selective non-catalytic reduction (SNCR) of nitrogen oxides.

MATEC Web of Conferences, open access proceedings in Materials science, Engineering and Chemistry

The potential for creating composite cements by incorporating fly ash is demonstrated. Analysis revealed that the fly ash examined consists of 69.66 wt. % silicon oxide, 21.34 wt. % aluminum oxide, 1.57 wt. % calcium oxide and 2.78 wt. % iron oxide. Fly ash mainly consists of quartz (SiO₂), goethite (FeO(OH)) and mullite (3Al₂O₃·2SiO₂). The properties of the cement composition containing 5 to 25 wt. % fly ash were studied. Incorporating fly ash enhances system dispersion, promotes mixture uniformity, and stimulates the pozzolanic reaction. Compositions of composite cements consisting of 90% CEM I 42.5 and 10% fly ash were developed. The cement stone based on the obtained composite cement had a compacted structure with a density of 2.160 g/cm³, which is 9.4% higher than the control sample. It is shown that when composite cement containing 10% fly ash interacts with water, hydration reactions of cement minerals (C₃S, C₂S, C₃A and C₄AF) begin first. This is accompanied by the formation of hydrate neoplasms, such as calcium hydroxide (Ca(OH)₂) and calcium hydrosilicates (C-S-H). Fly ash particles containing amorphous silica progressively participate in a pozzolanic reaction with Ca(OH)₂, leading to the formation of additional calcium hydrosilicates phases. This process enhances structural densification and reduces the porosity of the cement matrix. After 28 days of curing, the compressive strength of the resulting composite cements ranged from 42.1 to 54.2 MPa, aligning with the strength classes 32.5 and 42.5 as specified by GOST 31108-2020.