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.

The main problem of cement production is to reduce energy consumption and reduce the amount of greenhouse gases CO2 emitted into the atmosphere. The prerequisite for solving the problem is: the use of man-made waste and unconventional raw materials in the composition of the charge and the reduction of limestone content from 85% to 70-75% as a source of CO2 gas. The article presents the results of the studied technogenic waste and the suitability of non-traditional raw materials such as tefritobazalt, coal mining waste, and lead slag. The chemical and mineralogical composition of the materials and their suitability for obtaining environmentally friendly clinker have been established. The possibility of obtaining cement clinker using low-energy resource-saving technologies is shown. Clinker formation processes in the developed mixtures are completed at a temperature of 1350 °C, which, with the coal contained in the waste, will reduce the consumption of fuel injectors and reduce CO2 emissions into the atmosphere. In the developed low-energy mixtures, the specific consumption of raw materials for obtaining 1 ton of clinker is reduced to 1516-1525 kg, which is significantly lower than in traditional raw mixtures. Alite crystals are large, reaching 100-140 microns. The content of clinker minerals is C3S-57.88%, C2S-18.82%, C3A-6.46% and C4AF-11.61%. Disposal of large-tonnage waste will reduce environmental pollution and improve the environmental situation in the region.

A structure of composite cement with 15 wt.% thermally activated clay shales has been developed. The phase composition and properties of aluminosilicate rocks of the Kazakhstan deposits—Mynaral and Kuyuk—have been studied. It has been shown that aluminosilicates are related to clay shales by their composition. The regularities of thermal activation processes of aluminosilicates have been established, and it has been shown that pozzolanic activity increases for all compositions with an increase in the heat treatment temperature from 700 to 900 °C. The clay shale of the Mynaral deposit is characterized by the highest activity. The physicomechanical properties of the obtained composite cements–including Portland cement clinker, gypsum, and thermally activated clay shale—have been studied. It has been shown that when replacing up to 15 wt.% Portland cement clinker with thermally activated clay shales, there is no decrease in the strength properties of the composite cement. The obtained results allow us to consider heat-treated clay shales as active mineral additives.

A composition of composite cement with the possibility of reducing the proportion of clinker to 15% by weight on aluminosilicate rocks has been developed. The object of the study is the production of composite cement using aluminosilicate rocks of the Kazakhstan deposits - Mynaral and Kuyuk. The patterns of thermal activation processes of polymineral clays and the compositions of the products of firing active mineral additives have been established. It has been established that the clay shale of the Mynaral deposit heat-treated at 900°C has the highest activity. The qualitative and quantitative phase composition of active mineral additives, the main physical and mechanical properties of the obtained composite cements have been studied and determined. It has been established that the best strength properties are possessed by composite cements with additives of 15% of clay shales fired at 800 - 900°C.

The feasibility of producing high-quality zinc phosphate cement based on a frit-sintered mixture of ZnO, SiO₂, MgO, and Bi₂O₃ oxides, with the addition of phosphorous slag and an aqueous solution of orthophosphoric acid as the mixing liquid, was demonstrated. The raw materials used for zinc phosphate cement preparation were investigated using various physicochemical analysis methods. It was found that the phosphorous slag contains silicon oxide (37.6%), aluminum oxide (4.49%), calcium oxide (42.4%), magnesium oxide (2.19%), as well as fluorine (1.94%) and calcium fluoride (4.91%). The slag predominantly consists of an amorphous glassy phase with minor inclusions of crystalline components. During the sintering process, the addition of 1.5–3.0 wt.% phosphorous slag to the frit promotes the formation of low-melting eutectics due to the presence of fluorides, resulting in a 100 °C reduction in the sintering temperature. An optimal zinc phosphate cement powder composition was developed, comprising: ZnO—83.0%, MgO—9.0%, SiO₂—3.5%, Bi₂O₃—3.0%, and phosphorous slag—1.5%. The resulting sintered product exhibited a whiteness of 97.8%, which exceeds that of the reference sample by 2.6%. Upon mixing the powder with the mixing liquid, zinc ions are released first, initiating a chemical reaction that leads to the formation of zinc, magnesium, and aluminum phosphates. The compressive strength of the resulting composite cements ranged from 101.8 to 111.9 MPa, fully complying with the requirements for cement grade as specified in GOST 31578-2012.

Ғылыми мақалада ақ цемент клинкер күйдіру процесінде температураның әсері мен алынған ақ клинкердің ақтық дәрежесін анықтау нәтижелері келтірілген. Зерттеу заманауи түрлі түсті цемент өндірісі үшін, құрғақ құрылыс қоспа алуда және сәулет бұйымдарды жасауда өзекті болып табылады. Зерттеуде 1450-1500 °C температурада екі компонентті шикізат қоспаларынан тұратын үш құрамдарды күйдіру кезінде клинкер минералдарының бос СаО байланыспаған мөлшері және ақтық дәрежесі анықталды. «Әктас + электротермофосфор шлагы» шикізат қоспаларынан алынған клинкердің бос CaO мөлшері 0,33-1,98 % болды. «Әктас + каолин Ангрен» шикізат қоспаларынан алынған клинкердегі бос CaO мөлшері 0,27-1,22 % көрсетті, ал «Әктас + каолин Көкшетау» шикізат қоспаларынан алынған клинкердің бос CaO мөлшері 0,54-0,81 % болғаны анықталды. Клинкерлердің ақтық дәрежесі «Әктас + электротермофосфор шлагы» шикізат қоспасы үшін 75-76 %, «Әктас + каолин Ангрен» шикізат қоспасы үшін 79,6-85 % және «Әктас + каолин Көкшетау» шикізат қоспасы үшін75,7-84,5 % болды. Нәтижесінже бос СаО-ның клинкер минералдарымен байланысуы ГОСТ 31108-2020 бойынша белгіленген 2 %-дан жоғары емес және ГОСТ 965-89 бойынша 1-3 сұрыпты ақ клинкер алуға толық мүмкін екендігі дәлелденді. Сонымен қатар, «Sastobe Technologies» ЖШС зауыт шламына 1 және 2 % CaF2, 1 және 2 % CaCl2, 2 және 4 % гипс және 5 және 10 % фосфор шлагы минерализаторларын қосу арқылы ақ портландцемент клинкерін алу зерттелді. 1500°C температурада күйдірілген клинкерлердің бос СаО-ның мөлшері СаОбос=2,02-11,2 % болды (2 %-дан жоғары), алынған клинкердің ақтық дәрежесі 71,5-88,7 % екендігі анықталды. Нәтижесінде клинкердің ақтық дәрежесі жоғары болғаны мен оның сапасы ГОСТ 31108-2020 талабына сәйкес келмейтіндігі айқындалды.