A macro-cement and associated methods useful for preparing pastes, mortars, concretes and other cement-based materials having high workability, high density, and high strength are disclosed. A method of producing a macro-cement includes cement, supplemental cementitious materials (SCM's), including siliceous submicron-sized particles and nano-sized particles, and polymers in the form of liquid or dry chemical admixtures for concrete. The cement mixture may be used for making ultra-high performance concrete (UHPC).

A macro-cement and associated methods useful for preparing pastes, mortars, concretes and other cement-based materials having high workability, high density, and high strength are disclosed. A method of producing a macro-cement includes cement, supplemental cementitious materials (SCM's), including siliceous submicron-sized particles and nano-sized particles, and polymers in the form of liquid or dry chemical admixtures for concrete. The cement mixture may be used for making ultra-high performance concrete (UHPC).

A method for treating and utilizing bypass dusts from a cement production process involves a) contacting the bypass dust with an aqueous phase and mixing the same to obtain a suspension, wherein water-soluble components of the bypass dust are dissolved in the aqueous phase; b) performing a solid/liquid separation, in particular a vacuum filtration or a filter press filtration, to separate the solids contained in the suspension, wherein a brine remains; c) precipitating a partial amount of the heavy metals present in the brine, and optionally Ca, and separating the precipitate from the brine; and d) subjecting the brine to an electrocoagulation, wherein a flocculate containing the heavy metals remaining in the brine is separated.

A macro-cement and associated methods useful for preparing pastes, mortars, concretes and other cement-based materials having high workability, high density, and high strength are disclosed. A method of producing a macro-cement includes cement, supplemental cementitious materials (SCM's), including siliceous submicron-sized particles and nano-sized particles, and polymers in the form of liquid or dry chemical admixtures for concrete. The cement mixture may be used for making ultra-high performance concrete (UHPC).

A method of manufacture of Portland cement clinker is described in a dry process that captures the carbon dioxide emitted from the calcination of carbonate minerals, principally limestone. The process uses an indirectly heated, counter-flow reactor to pre-heat and calcine the cement meal to produce a separate calcined meal and carbon dioxide gas stream, with external heat being provided by the combustion of a secondary fuel stream with pre-heated air. This calcined meal is injected into the conventional rotary kiln, where the hot flue gas from combustion of the primary fuel with pre-heated air is used to fuse, react and sinter the powders to form granules of cement clinker. The clinker and carbon dioxide streams are cooled by the air pre-heaters.

Described are cementitious reagent materials produced from globally abundant inorganic feedstocks. Also described are methods for the manufacture of such cementitious reagent materials and forming the reagent materials as microspheroidal glassy particles. Also described are apparatuses, systems and methods for the thermochemical production of glassy cementitious reagents with spheroidal morphology. The apparatuses, systems and methods makes use of an in-flight melting/quenching technology such that solid particles are flown in suspension, melted in suspension, and then quenched in suspension. The cementitious reagents can be used in concrete to substantially reduce the CO.sub.2 emission associated with cement production.

A manufacturing process of a concrete product includes: (1) extracting calcium from solids as portlandite; (2) forming a cementitious slurry including the portlandite; (3) shaping the cementitious slurry into a structural component; and (4) exposing the structural component to carbon dioxide sourced from a flue gas stream, thereby forming the concrete product.

A process for producing a syngas containing CO and H.sub.2 from a stream of light hydrocarbons and from combustion flue gases from a cement clinker production unit comprising at least one calcining kiln (300), and a means for discharging the combustion flue gases (500) from the calcining kiln to the outside of said unit, said process comprising the following steps: at least some of the combustion flue gases (70) obtained in said clinker production unit are collected upstream of said means for discharging the combustion flue gases (500); a reaction stream (113) comprising a stream of light hydrocarbons (110) containing methane and the combustion flue gases (70) is prepared; said reaction stream (113) is sent to a tri-reforming reactor (1009) to obtain a syngas (114).

Reaction schemes involving acids and bases; reactors comprising spatially varying chemical composition gradients (e.g., spatially varying pH gradients), and associated systems and methods, are generally described.

Described are cementitious reagent materials produced from globally abundant inorganic feedstocks. Also described are methods for the manufacture of such cementitious reagent materials and forming the reagent materials as microspheroidal glassy particles. Also described are apparatuses, systems and methods for the thermochemical production of glassy cementitious reagents with spheroidal morphology. The apparatuses, systems and methods make use of an in-flight melting/quenching technology such that solid particles are flown in suspension, melted in suspension, and then quenched in suspension. The cementitious reagents can be used in concrete to substantially reduce the CO.sub.2 emission associated with cement production.