A method for processing water treatment residuals, or other amorphous aluminium oxide or aluminium hydroxide rich waste residuals, for use in the manufacture of hydraulic binders, comprising heating the residuals to remove water and oxidise organic material contained therein, comprising controlling the temperature of the residuals during heating such that they are heated to a temperature no higher than 800° C., more preferably no higher than 650° C., to ensure that aluminium compounds in the WTR, in particular aluminium oxide and aluminium hydroxide, remain in an amorphous state. The method may comprise controlling the temperature of the water treatment residuals such that they are heated to a temperature between 350° C. and 650° C., more preferably between 400° C. and 500° C.

A raw meal and clinker are provided based on animal by-products, such as bone ash. The resulting cement contains clinker phases such as: tricalcium phosphate (TCP), calcium sulfoaluminate (CSA), calcium aluminate phases (CA, CA.sub.2, CA.sub.6, C.sub.12A.sub.7, among others), hydroxyapatite (HA), and minor phases (anhydrite, lime, among others).

A raw meal and clinker are provided based on animal by-products, such as bone ash. The resulting cement contains clinker phases such as: tricalcium phosphate (TCP), calcium sulfoaluminate (CSA), calcium aluminate phases (CA, CA.sub.2, CA.sub.6, C.sub.12A.sub.7, among others), hydroxyapatite (HA), and minor phases (anhydrite, lime, among others).

Cement and concrete compositions are produced via metal hydroxides and metal oxides isolated from aqueous sources such as seawater or wastewater. Aqueous solutions are electrolyzed to produce an alkaline component stream having an elevated pH, which when mixed with mineralized seawater causes metal ions dissolved therein to precipitate out in the form of metal hydroxides such as Mg(OH).sub.2 and Ca(OH).sub.2. These metal hydroxide products are then utilized as feedstocks for production of cement and concrete structural elements, or are converted to metal oxides suitable for the same purpose. The hydroxide products are then subjected to pressure and prolonged exposure to carbon dioxide to accelerate carbonation of the hydrated product. The resulting carbonates exhibit sufficient compressive strength for use in making structural components for construction, while reducing or eliminating the carbon footprint associated with traditional methods of cement and concrete manufacturing. Excess demineralized alkaline component can be recycled for additional electrolysis, or returned to a neutral pH for use in water desalination processes or even returned to the environment.

Cement and concrete compositions are produced via metal hydroxides and metal oxides isolated from aqueous sources such as seawater or wastewater. Aqueous solutions are electrolyzed to produce an alkaline component stream having an elevated pH, which when mixed with mineralized seawater causes metal ions dissolved therein to precipitate out in the form of metal hydroxides such as Mg(OH).sub.2 and Ca(OH).sub.2. These metal hydroxide products are then utilized as feedstocks for production of cement and concrete structural elements, or are converted to metal oxides suitable for the same purpose. The hydroxide products are then subjected to pressure and prolonged exposure to carbon dioxide to accelerate carbonation of the hydrated product. The resulting carbonates exhibit sufficient compressive strength for use in making structural components for construction, while reducing or eliminating the carbon footprint associated with traditional methods of cement and concrete manufacturing. Excess demineralized alkaline component can be recycled for additional electrolysis, or returned to a neutral pH for use in water desalination processes or even returned to the environment.

The present invention relates to a novel cementitious product produced from steelworks slag additivation to obtain material having properties suitable for use in the partial or total clinker replacement for the production of different types of cement. The process, which is also object of this invention, aims to adapt the properties of steelworks slag, by means of thermochemical treatment, including and preferably, but not only, still in the liquid steelworks slag pot, taking advantage of the thermal input of steel processing, to form a greater amount of alite (essential compound to increase pozzolanicity), under controlled conditions. After additivation, preferably, but not exclusively, the additivated steelworks slag is subjected to quenching, comminution and concentration to stabilize the alite fraction, to release the present phases and to remove any excess contaminants, such as metallic iron.

The present invention relates to a novel cementitious product produced from steelworks slag additivation to obtain material having properties suitable for use in the partial or total clinker replacement for the production of different types of cement. The process, which is also object of this invention, aims to adapt the properties of steelworks slag, by means of thermochemical treatment, including and preferably, but not only, still in the liquid steelworks slag pot, taking advantage of the thermal input of steel processing, to form a greater amount of alite (essential compound to increase pozzolanicity), under controlled conditions. After additivation, preferably, but not exclusively, the additivated steelworks slag is subjected to quenching, comminution and concentration to stabilize the alite fraction, to release the present phases and to remove any excess contaminants, such as metallic iron.

The present invention relates to a novel cementitious product produced from steelworks slag additivation to obtain material having properties suitable for use in the partial or total clinker replacement for the production of different types of cement. The process, which is also object of this invention, aims to adapt the properties of steelworks slag, by means of thermochemical treatment, including and preferably, but not only, still in the liquid steelworks slag pot, taking advantage of the thermal input of steel processing, to form a greater amount of alite (essential compound to increase pozzolanicity), under controlled conditions. After additivation, preferably, but not exclusively, the additivated steelworks slag is subjected to quenching, comminution and concentration to stabilize the alite fraction, to release the present phases and to remove any excess contaminants, such as metallic iron.

A process for reforming the fly ash, including the heating step that heats a raw fly ash powder containing the unburned carbon at a temperature of 780 to 1000 C. to decrease the amount of the unburned carbon contained in the raw fly ash powder; and the cooling/classifying step that introduces the heat-treated fly ash in a state of being maintained at a high temperature as obtained through the heating step into a cooling/classifying apparatus so that the fly ash is separated into a fine grains and a coarse grains; wherein the cooling/classifying apparatus 3 used in the cooling/classifying step has a basic structure in which the gas flow for classification is introduced from the lower side and the gas flow Z for cooling/classification introduced into the apparatus is then discharged from the upper side; the heat-treated fly ash is brought into contact with the gas flow Z for cooling/classification, the fine grains contained in the heat-treated fly ash is lifted up and discharged out of the apparatus while the coarse grains contained in the heat-treated fly ash is allowed to stay in the apparatus 3, and the fine grains and the coarse grains are separated and cooled; and the fine grains discharged from the apparatus 3 is recovered by using a dust-collecting apparatus, and the coarse grains is recovered from the apparatus 3.

A process for reforming the fly ash, including the heating step that heats a raw fly ash powder containing the unburned carbon at a temperature of 780 to 1000 C. to decrease the amount of the unburned carbon contained in the raw fly ash powder; and the cooling/classifying step that introduces the heat-treated fly ash in a state of being maintained at a high temperature as obtained through the heating step into a cooling/classifying apparatus so that the fly ash is separated into a fine grains and a coarse grains; wherein the cooling/classifying apparatus 3 used in the cooling/classifying step has a basic structure in which the gas flow for classification is introduced from the lower side and the gas flow Z for cooling/classification introduced into the apparatus is then discharged from the upper side; the heat-treated fly ash is brought into contact with the gas flow Z for cooling/classification, the fine grains contained in the heat-treated fly ash is lifted up and discharged out of the apparatus while the coarse grains contained in the heat-treated fly ash is allowed to stay in the apparatus 3, and the fine grains and the coarse grains are separated and cooled; and the fine grains discharged from the apparatus 3 is recovered by using a dust-collecting apparatus, and the coarse grains is recovered from the apparatus 3.