Abstract: A method of recycling cement kiln dust (CKD) generated during the direct manufacturing of cement. The recycling process utilizes the creation of a flowable slurry comprising CKD, a process aid, optionally other raw materials and water. The process aid is selected from the group consisting of sucrose, raffinose, lignin, methylglucopyranoside, lactose, fructose, sodium polyphosphate, trehalose and mixtures thereof, and is added to increase the flowability of the slurry and thereby simplifying recycling. The slurry is reintroduced into the cement kiln, wherein it is burned to create cement clinkers, that are subsequently ground to the fineness required for hardening when reacted with water.

Abstract: The lightly colored sulfoaluminous clinker contains: more than 55% by weight of calcium sulfoaluminate phase (C4A3S), more than 10% by weight of belite phase (C2S), less than 10% by weight of anhydrite (C{overscore (S)}), and contains practically no ferrite phase, nor a gehlenite phase (C2AS), nor free lime. It is prepared by a process of roasting carried out at temperatures comprised between about 1250° C. and 1350° C. It can be used for a wide range of applications by combining it with a source of calcium sulfate and/or Portland cement, to obtain binders having specific properties (color, setup time, mechanical strength, expansion or contraction . . . ).

Abstract: The invention relates to a process for the manufacture of cement, whereby a metal oxide known for its catalytic action in the reduction of nitrogen oxides NOx, selected from the group consisting of CuO, Co3O4, Mn3O4, Fe2O3, SnO2, NiO, ZnO, V2O5 and TiO2 is injected into the cement plant kiln flame and/or the precalcination zone flame if there is one.

Abstract: The invention in its various embodiments includes an apparatus and a method for improving combustion in a cement kiln system. The apparatus in one embodiment includes a precalciner and an oxygen source coupled to the precalciner. The method in one embodiment includes introducing oxygen into the precalciner of a cement kiln system.

Abstract: A dual-train or multi-train installation for the production of cement clinker from raw meal includes several cyclone suspension heat exchanger trains which provide substantially equal gas and meal loads of the following gas-solid suspensions through use of a vortex homogenization chamber (29), having an inlet opening (30) for the gas-solid suspension and having at least two outlets to a pair of pipes (28, 31) for the discharge of the thoroughly blended homogenized gas-solid suspension substreams. The vortex homogenization chamber (29) is positioned in a calcination stage (17), upstream of its branching and splitting between the several heat exchanger trains (A, B).

Abstract: A method and apparatus for production of cement clinker uses fragmented metallurgical slag, such as from blast furnace production of iron or steel, introduced into a rotary kiln at an infeed located between the kiln front feed end and the rear outlet end. The metallurgical slag combines with predominantly limestone feedstock material flowing inwardly from the feed end toward a burner pipe at the outlet end and intimately blends with the limestone material to become transformed into cement clinker as the blended materials progress through the kiln. Preferably, the metallurgical slag is introduced into the kiln through a kiln dust infeed apparatus present in many rotary kilns at a mid location.

Abstract: Hydraulic cement is made by a process in which (i) raw materials are crushed and ground, (ii) the crushed and ground raw materials and other components are burned and calcined to prepare a cement clinker, and (iii) the cement clinker is ground to a fine powder. A grinding aid is added to the cement clinker before it is ground in (iii). The grinding aid is an uncalcined direct process residue gel, which is an hydrolysis product of alkylhalodisilanes produced as by-products in the manufacture of alkylhalosilanes.

Abstract: The lightly colored sulfoaluminous clinker contains:

Abstract: The present invention describes a process for manufacture of high iron hydraulic cement clinker in production of cement and cementation binder for application in construction activity andin metallurgical industry for sintering of iron ore fines and making cold bonded briquettes and pellets. The process is cost effective and flexible for utilization of wide varieties of raw material consisting of lime and iron in production of high iron cements for different application.

Abstract: In order to provide a cement clinker production line with a calcinator connected to the rotary kiln and including a separate rotary drum-type reactor with the objective to safely burn even coarse secondary fuels in the drum-type reactor and also to evenly and effectively transfer the released heat energy to the cement raw meal, it is proposed in accordance with the invention to introduce into the rotary drum-type reactor on the inlet side for the solids a partial stream line of the tertiary air guided from the clinker cooler to the calcinator, a highly ignitable fuel, the low ignitable or low flammable secondary fuel and a partial stream line for the cement raw meal and to connect the exit side for the material on the rotary drum-type reactor via a line for carrying out the solid residues to the tertiary air channel and/or the rotary kiln exit gas channel of the calcinator and/or to the inlet chamber of the rotary kiln.

Abstract: A slag cement having an improved early strength and containing aluminosilicates, blast furnace slag, clinker and CaSO4, has a content of 70 to 95% by weight of blast furnace slag used in the ground form at >4,500 Blaine (cm2/g) with no more than half of this portion being substitutable by aluminosilicates such as fly ash, alumina, marl or the like, 0.1 to 2% by weight of clinker, sulfate in amounts of below 5% by weight, calculated as SO3, and 0.3 to 1% by weight of a superliquifier such as, e.g., naphthalene sulfonate.

Abstract: The present invention refers to a hydraulic binder made from Portland clinker containing calcium fluoroaluminate 11CaO.7Al2O3.CaF2, to which sodium aluminate, lime, and optionally, sodium bicarbonate are added. The added lime has not undergone the formation process of clinker. The cement mix that can be obtained with this binder has a very short hardening time, scarcely influenced by temperature variations during laying operations.

Abstract: In order to make sure, for cement clinker production lines with blown injection of dispersible solid fuels such as, for example, coal dust, into the calcinator which is provided with fuel, that an open flame does not occur at the fuel injection point, it is proposed according to the invention that the fuel is fed into a meal intake box that has a sloping raw meal chute and deflector slide and is arranged on the outside of the calcinator and connected to it through a wall opening and the fuel is pre-mixed with the pre-heated raw meal there, and then introduced via the deflector slide into the reaction section of the calcinator in order to form a gas-raw meal-solid fuel-suspension that is uniformly distributed.

Abstract: A method for the production of cement clinker comprises the introduction of vitrified slag into the feedstock stream prior to the clinkering zone. The addition of vitrified slag can increase the clinker output rates and/or reduce the energy requirements for maintaining the kiln temperatures. In one embodiment, the vitrified slag is a vitrified blast furnace slag.

Abstract: A process for producing building materials, such as asphalt, cement, concrete, mortar, or plaster board from liquid paint sludge containing water and paint solids produced from overspray in commercial paint booth operations. The preferred embodiment comprises adding the liquid paint sludge as the hydrating agent directly to the building material mix.

Abstract: Cement clinker, characterized in that it comprises Al2O3 and Fe2O3 wherein the mass ratio of Al2O3/Fe2O3 is 0.05-0.62, and alkali components and C2S wherein the content Y (mass %) of alkali components and the content X (mass %) of C2S satisfy the formula: 0.0025X+0.1≦Y≦0.01X+0.8. The production of the clinker allows the incorporation of alkali components into cement with an advantageous effect of enhancement of the hydration of belite and also with suppression of the lowering of flowability, which leads to the reuse of wastes containing alkali components as a cement raw material.

Abstract: A process for the production of Portland cement and white Portland cement using magnesium furnace slag, a waste product from the manufacture of magnesium metal, as a primary starting material. The furnace slag is blended with calcium oxide and silicon dioxide to form a feedstock which is heated to a temperature and for an amount of time sufficient to form clinker. The clinker is cooled, ground to a powder, and blended the clinker with powdered gypsum to form the Portland cement. White Portland cement may be produced by removing iron containing compounds from the slag, minimizing contamination of the material by iron compounds throughout the process, and cooling the clinker in a manner that minimizes oxidation of any remaining iron compounds in the clinker.

Abstract: A cement composition comprising a polymeric latex prepared by aqueous emulsion polymerization of a monomeric mixture comprising styrene and butadiene in the presence of a seed polymer prepared by aqueous emulsion polymerization of styrene and a salt of 2-acrylamido-2-methylpropanesulfonic acid.

Abstract: The invention in its various embodiments includes an apparatus and a method for improving combustion in a cement kiln system. The apparatus in one embodiment includes a precalciner and an oxygen source coupled to the precalciner. The method in one embodiment includes introducing oxygen into the precalciner of a cement kiln system.

Abstract: In the production of cement clinker or cement with the addition of a cement additive (40), such as for example slag, which is ground in a closed-circuit grinding installation into slag meal (32) of equal fineness to cement, in order to utilize excess slag capacity in a beneficial way in the cement clinker production process, an intermediate slag fraction (33, 34) withdrawn from a three-fraction classifying device (31) is added as a raw material component to the stock inlet of the rotary kiln (20) of the cement clinker production line, and at the same time the chemical composition of the remaining raw material components (10) is adapted to the added quantity (34) of the intermediate slag fraction.

Abstract: A process for forming crushable, “synthetic” rocks from waste gypsum involves collecting natural and synthetic gypsum waste in the form of flue gas desulfurization (“FGD”). The gypsum waste has a sludge-like consistency and is passed through an extruder where the moisture in the waste gypsum is drawn off and the waste is densified. The removal of moisture is accomplished under vacuum. The densified waste gypsum is extruded through a die to create three-dimensional shapes with preselected aspect ratios.

Abstract: The present invention discloses a process for producing both steam power and the fast-burnt cement clinker/fast burnt modified coal ash simultaneously in one apparatus, the fast-burnt cement clinker/fast-burnt modified coal ash prepared by said process as well as cement products prepared using them as active substance. It also discloses the apparatus suitable for embodying this process. Said process of the present invention possesses the technoligical features of fast-burning and fast-cooling and contributes a good hydraulic cementitious activity to the said fast-burnt cement clinker/fast-burnt modified coal ash which are capable of being directly used as active substance in cement production of high quality.

Abstract: In cement clinker production installations, especially with short rotary tubular kiln, in order to find a way in which the thermally highly stressed rotary kiln intake chamber can be protected from overstress and therewith the entire production installation can be reliably operated it is proposed, according to the invention, to introduce directly into the rotary kiln intake chamber, a finely granular non-preheated substance usable in the cement clinker production process, to suspend or disperse it there in the rotary kiln exhaust gas and thereby to continuously cool the kiln intake chamber, and to discharge the heated finely granular substance with the exhaust gas from the kiln intake chamber and to add it to the process raw meal or direct it elsewhere.

Abstract: The present invention relates to an improvement in cement for use in concrete of high strength and high flowability, mass concrete, shrinkage compensating concrete or concrete of high resistibility which are employed in the field of engineering and architecture or as building material through incremental launching method or wet formation. When the ratio of Al2O3 to Fe2O3 is regulated to a value of 0.05 to 0.62, the strength of concrete of high strength and high flowability can further be improved, and heat of hydration can be prevented, while improving the flowability of cement and maintaining a long-term strength thereof.

Abstract: Described herein is the use of a combination of organic additives that is particularly advantageous for the preparation of cementitious compositions having a high conservation of the degree of white, which contain in mass a photocatalyst that is able to oxidize, in the presence of light, air and ambient humidity, pollutant substances present in the environment, the said photocatalyst being, in particular, titanium dioxide prevalently in the form of anatase. The above combination of additives comprises the following: a melamine resin; a cellulose ether; a polymer chosen from among an ethylene polymer, an acrylic polymer, and a terpolymer comprising as co-monomers at least one ester of acrylic acid with an alcohol and at least one ester of vinyl alcohol with a carboxylic acid, or alternatively, an acrylic, styrene or butadiene latex; and a chemically modified starch.

Abstract: Within the known Müller-Kühne process and a corresponding installation, a utilization of a great variety of residual materials can be achieved with optimum process control, both in regard to the production of a raw powder and the fuel, whereby this is made possible in particular in that the raw powder components and the fuel components also are, with respect to the residual materials being used, stored separately, conditioned, and then mixed according to the formulation under strict monitoring. The flue gas is used for preheating the raw powder by adding the cold raw powder to it. This simultaneously removes sticky components from the flue gas. The raw powder preheated in this manner, and also the raw powder or dust recovered in subsequent dedusters are returned to the rotary drum kiln, whereby the solid and other fuels are used and burned with a mutually supportive flame at the opposite end of the rotary drum kiln.

Abstract: Concept for a self-compacting, self-levelling High Performance Concrete by addition of 2-10% palygorskite with an aspect ratio (length:diameter) of more than 35. The addition of palygorskite in combination with a superplasticiser lends itself to control of the ratio between viscosity and yield strength of the fresh concrete. Good visco-elastic properties, which assure high filling capacity, good flow properties and stability of the microstructure are obtained through this concept. Concrete produced in accordance with this invention is particularly characterised by its self-compacting properties, its filling capacity and its high stability during pumping even at high pumping pressures of 100 to 200 bars.

Abstract: This process for converting well drill cuttings into raw materials for the production of cement includes the steps of extracting limestone and clay, crushing and prehomogenizing the extracted materials, raw grinding and adjusting the composition by adding correctives, producing clinker in rotary kiln and cement grinding. Water based drill cutting sludge is introduced in the crushing and prehomogenizing step and oil-based drill cutting sludge is fed into the rotary kiln.

Abstract: Portland cement has hitherto been produced from finely ground raw meal with a residue on the 80 micron sieve of 10-20%, corresponding to a grain size ratio of 0.01-80 micron grains to 80.01-500 micron grains in the raw meal of 9:1 to 4:1. With the novel process, it should be possible to use coarse-ground raw meal. The process involves roasting the raw meal in which the grain size ratio in the basic raw meal components of the 0.01-80 micron grains to the 80.01-2000 micron grains is 1.5:1 to 1:9. The acidic raw meal components with a melting temperature of no higher than 1,300 C. are ground to the same grain size ratio. Also described are devices and processes for grinding and roasting raw meal. The advantages of the invention are reduced energy consumption during grinding of the raw meal, improved throughput of material through ovens and mills and improved cement characteristics.

Abstract: A method of treating cement clinker by grinding the clinker in a tubular mill while charging water, gypsum, and, optionally, also a water-reduction agent to the mill at the same time. The water has a pH of from about 9 to about 13. A microfill agent and/or a water-reduction agent is mixed with said the high pH-value water to form a slurry, which is added to the clinker during the grinding process together with microfill agent and/or water-reduction agent in a dry state. The high pH value of the water can be obtained by electrolysis.

Abstract: An exemplary process for grinding cement clinker using rollers comprises introducing cement clinker into grinding contact with rollers operative to grind the clinker into particles; and introducing to the clinker and/or rollers, in an amount of 0.001-0.5 percent based on the dry weight of clinker, a binding-densifying agent comprising at least one polymer having an average molecular weight of 50,000-500,000. The clinker may be ground alone or in combination with other agrillaceous or pozzolanic materials.

Abstract: A method of manufacturing cements based on calcium sulfoaluminate by forming a clinker through calcining a selection of typical cement precursor raw materials to temperatures of more than 1200.degree. C. in an industrial kiln, preferably with a preheater (typically of the cascading cyclone type) and precalciner, selected in such a manner that the clinker thus produced has a high content of calcium sulfoaluminate, tricalcium silicate and dicalcium silicate with no other calcium aluminates and, preferably during or prior to the grinding thereof, adding to the clinker thus produced (with the above recited basic components), effective amounts of calcium oxide or hydroxide and calcium sulfate, in order to activate said clinker. Upon said grinding, a temperature of about 100 to 125.degree. C.

Abstract: Calcium carbonate sludge from sugar beet refining is recycled for use as a blast cleaning medium; and contaminate blast cleaning media is employed in the manufacture of cement. Also disclosed herein is the use of pumice as an additive to enhance the efficiency of blast cleaning media.

Abstract: The invention relates to the production of cement clinker from cement raw material using a preheating zone, a calcination zone, a heating zone in which the calcined material is further heated whilst avoiding the formation of a molten phase, as well as a clinker burning zone and cooling zone from which part-quantities of the hot exhaust air are delivered as combustion air together with proportions of fuel to the clinker burning zone, the heating zone and the calcination zone. A reliable further heating while avoiding incrustations is achieved in the heating zone by constructing this zone in the manner of a flue stream reactor to which calcined material, fuel and combustion air are delivered in the lower end region of a rising first treatment zone at one point in each case and from which the heated material is precipitated essentially by the effect of gravity overlaid with centrifugal action.

Abstract: Processes for making cement which when used to make concrete can stabilize the concrete against alkali-silica reactivity (ASR) from alkali containing components. The process includes adding lithium containing materials in the front of a cement kiln along with the cement starting materials in an amount sufficient to minimize ASR.

Abstract: The invention is related to a method and an apparatus for producing cement clinker, in which the cement clinker is first of all burnt in a burning zone and then cooled in a cooling zone, wherein the cooling takes place at least partially by the delivery of fuel and steam, characterised in that in a first cooling phase the delivered fuel is mixed with the cement clinker and initially pyrolysed and the resulting pyrolysis products have a strong endothermic reaction with the steam, so that the cement clinker is quenched in such a way that at least 95%, preferably all, of the liquid phase contained therein is transformed into glass.

Abstract: A method and apparatus is provided for use in cement clinker production apparatuses, particularly those with a short rotary tubular kiln, in which pollutant containing raw meals are utilized, wherein a bypass vent or gas sub-vent, exhausts a sub-stream of the rotary kiln exhaust. It is proposed to introduce meal or processing dust as condensation nuclei into the upper region of the kiln inlet chamber, these nuclei being entrained by the vented gas sub-stream. This vented gas sub-stream is subsequently further cooled by the introduction of water and/or cool air prior to its de-dusting in a dust trap.

Abstract: The invention relates to an apparatus and a method for manufacturing clinker, such as cement clinker, in which the majority of the raw materials is present in a hydrous slurry.Initially, the slurry is dried in a gas suspension drier, and the raw materials are subsequently passed to a thermal unit in which the heating of the raw material is effected fairly quickly so that all organic compounds are destroyed in the thermal unit.Subsequent to being heated in the thermal unit, the raw material is directed to the kiln in which it is nodulized and burned into clinker.

Abstract: Sulfur oxides are removed from a preheater waste gas stream by reacting the sulfur oxides with lime recovered from the off gas stream in a calcining furnace. The method is particularly adaptable for use in a cement manufacturing plant wherein the sulfur dioxides in the waste gases result from the combustion of fossil fuels used for process heat.

Abstract: Methods for on-site remediation of contaminated natural resources and fabrication of construction products therefrom. A mobile treatment facility is provided at the site of the contaminated natural resources. Contaminated sediment, soil, pulp and/or liquids are obtained from the site and processed on-site to obtain a variety of construction materials, including coarse and fine particulate material, bricks, concrete products, pellets and aggregate material. Coarse, sand-like materials are fabricated from decontaminated clay-based based materials and used in the fabrication of concrete products. Waste streams are combined to optimize their mutually neutralizing properties. Contaminants such as inorganics and heavy metals are immobilized as water-insoluble complexes in the matrix of the resulting products. Organic contaminants are volatilized and/or burned off, and thermochemical reactions of inorganic contaminants are induced, in a high-temperature irradiation treatment.

Abstract: A Portland cement clinker free of C.sub.4 A.sub.3 S having the following proportions of clinker phases, in % by wt.:--C.sub.3 S: 40 to 80--C.sub.4 AF: <20--C.sub.2 S: <30--C.sub.3 A: <20and a SO.sub.3 content from 1.0 to 3.0% by wt., based on the clinker, obtained by burning a mixture of raw materials containing CaO, SiO.sub.2, Al.sub.2 O.sub.3, Fe.sub.2 O.sub.3 and an additive containing SO.sub.3 at temperatures from 1200.degree. to 1350.degree. C. centigrade, the use thereof and a Portland cement.

Abstract: Contaminated coal ash, for example flyash contaminated with carbon is introduced to hot clinker in a cooler downstream of a cement kiln; the carbon is combusted in the cooler to provide a cement clinker having an effective content of flyash free of carbon; this permits use of flyash contaminated with carbon without the need for separate special steps for carbon removal; volatile contaminants or contaminants having a volatile component, for example adsorbed ammonia are similarly removed in the cooler by volatilization.

Abstract: Novel cementitious systems comprised of gypsum, calcined clay, and clinker consisting essentially of hydraulic calcium silicates are disclosed which have the following properties: (1) a water demand of less than about 33% nc; (2) one-day strengths of at least about 1000 psi; and (3) low alkali functionality. By increasing the amount of calcined clay, the resulting cementitious system will sequentially gain the following properties: (1) alkali non-reactiveness; (2) alkali resistance; and (3) low chloride permeability. Novel methods of preparing the novel cementitious systems of this invention are also disclosed. The novel methods not only reduce production costs by decreasing fuel and raw material consumption, but they also allow the cement producer to proactively address significant environmental concerns related to the manufacturing process.

Abstract: Processes for making cement which when used to make concrete can stabilize the concrete against alkali-silica reactivity (ASR) from alkali containing components. The process includes adding lithium containing materials in the front of a cement kiln along with the cement starting materials in an amount sufficient to minimize ASR.

Abstract: A method and apparatus for controlling the temperature in a kiln in which cement clinker is manufactured. The temperature is controlled by controlling the fuel rate to the kiln. The fuel rate is adjusted according to a calculation that is made of the sulphur evaporation in the kiln, thereby obtaining a measure of the instantaneous temperature in the burning zone. The evaporation factor is calculated on the basis of measurements of the sulphur content in the cyclone material which passes to the kiln or a measurement of the sulphur content in the exit gases out of the kiln.

Abstract: The invention relates to a method and a plant for manufacturing mineralized portland cement clinker. The method and plant provides for preheating, calcining, burning and finally cooling the clinker. The mineralizer may e.g. be gypsum, fluorine, or a waste product containing these or other mineralizers. The mineralizer is added to the feedstock after the feedstock has been fed to the process, preferably after the cyclone which handles the feed to the calciner, i.e. the last cyclone in the preheater, or the lowermost preheater stage in a plant which does not incorporate a calciner.

Abstract: Novel cementitious systems comprised of gypsum, calcined clay, and clinker consisting essentially of hydraulic calcium silicates are disclosed which have the following properties: (1) a water demand of less than about 33% nc; (2) one-day strengths of at least about 1000 psi; and (3) low alkali functionality. By increasing the amount of calcined clay, the resulting cementitious system will sequentially gain the following properties: (1) alkali non-reactiveness; (2) alkali resistance; and (3) low chloride permeability. Novel methods of preparing the novel cementitious systems of this invention are also disclosed. The novel methods not only reduce production costs by decreasing fuel and raw material consumption, but they also allow the cement producer to proactively address significant environmental concerns related to the manufacturing process.

Abstract: A method for producing quick setting concrete is provided comprising hydrng a concrete dry mixture with carbonate solution to create a slurry, and allowing the slurry to cure. The invention also provides for a quick setting concrete having a predetermined proportion of CaCO.sub.3 of between 5 and 23 weight percent of the entire concrete mixture, and whereby the concrete has a compression strength of approximately 4,000 pounds per square inch (psi) within 24 hours after pouring.

Abstract: A design optimization process used to determine the proportions of sand, cement, coarse aggregate, water, fly ash, water reducers, air entraining agents and fillers needed to produce a concrete mixture that has desired strength and slump properties and a minimal cost. The optimization process comprises a combination of models that accurately reflect the properties of a concrete mixture based on the properties of its individual components. The process is further capable of optimizing the durability of the cementitious mixture and of accurately calculating the expected yield of the mixture.

Abstract: A process for utilizing waste by combining of the waste with a mineral based solid material forming an additive. This additive is included as an ingredient in the manufacture of Portland cement with the additive being added to the cement clinker after heat treating of the raw material constituents producing the cement clinker.