A method for making geopolymer cementitious binder compositions for cementitious products such as concrete, precast construction elements and panels, mortar, patching materials for road repairs and other repair materials, and the like is disclosed. The geopolymer cementitious compositions of some embodiments are made by mixing a synergistic mixture of thermally activated aluminosilicate mineral, calcium sulfoaluminate cement, a calcium sulfate and a chemical activator with water.

A method for making geopolymer cementitious binder compositions for cementitious products such as concrete, precast construction elements and panels, mortar, patching materials for road repairs and other repair materials, and the like is disclosed. The geopolymer cementitious compositions of some embodiments are made by mixing a synergistic mixture of thermally activated aluminosilicate mineral, calcium sulfoaluminate cement, a calcium sulfate and a chemical activator with water.

The Invention is related to increasing of early strength and final strengths of cements classified under EN and ASTM as Portland or CEM cements and also related to all clinker employing cements and to any kinds which employ calcium sulphates for set optimization and is for composing of new cements by only assessing new methods for production and is for composing of new cements by only assessing new methods to formation and inclusion of calcium sulphate resources which are used for set optimization. A new calcium sulphate resource is obtained by employing lower heats and this input is arranged to different dehydration levels at which they can be most efficient for the selected use. These different dehydration levels are called intermediate phases of dehydrate or hemihydrates or called as monohydrate.

The Invention is related to increasing of early strength and final strengths of cements classified under EN and ASTM as Portland or CEM cements and also related to all clinker employing cements and to any kinds which employ calcium sulphates for set optimization and is for composing of new cements by only assessing new methods for production and is for composing of new cements by only assessing new methods to formation and inclusion of calcium sulphate resources which are used for set optimization. A new calcium sulphate resource is obtained by employing lower heats and this input is arranged to different dehydration levels at which they can be most efficient for the selected use. These different dehydration levels are called intermediate phases of dehydrate or hemihydrates or called as monohydrate.

A composition and process for the manufacture thereof for use in a hybrid building material comprising at least in part Syngenite (K.sub.2Ca(SO.sub.4).sub.2.H.sub.2O) and Struvite-K (KMgPO.sub.4.6H.sub.2O). Specified constituents, including magnesium oxide (MgO), monopotassium phosphate (MKP) and stucco (calcium sulfate hemihydrate) are mixed in predetermined ratios and the reaction proceeds through multiple phases reactions which at times are proceeding simultaneously and in parallel and reaction may even compete with each other for reagents if the Struvite-K reaction is not buffered to slow down the reaction rate). A number of variable factors, such as water temperature, pH mixing times and rates, have been found to affect resultant reaction products. Preferred ratios of chemical constituents and manufacturing parameters, including predetermined and specified ratios of Struvite-K and Syngenite may be provided for specified purposes, optimized in respect of stoichiometry to reduce the combined heat of formation to non-destructive levels.

A composition and process for the manufacture thereof for use in a hybrid building material comprising at least in part Syngenite (K.sub.2Ca(SO.sub.4).sub.2.H.sub.2O) and Struvite-K (KMgPO.sub.4.6H.sub.2O). Specified constituents, including magnesium oxide (MgO), monopotassium phosphate (MKP) and stucco (calcium sulfate hemihydrate) are mixed in predetermined ratios and the reaction proceeds through multiple phases reactions which at times are proceeding simultaneously and in parallel and reaction may even compete with each other for reagents if the Struvite-K reaction is not buffered to slow down the reaction rate). A number of variable factors, such as water temperature, pH mixing times and rates, have been found to affect resultant reaction products. Preferred ratios of chemical constituents and manufacturing parameters, including predetermined and specified ratios of Struvite-K and Syngenite may be provided for specified purposes, optimized in respect of stoichiometry to reduce the combined heat of formation to non-destructive levels.

This disclosure provides products useful as construction materials and containing set gypsum and ammonium-exchanged vermiculite, including a gypsum panel having a gypsum core comprising set gypsum and ammonium-exchanged vermiculite and characterized by decreased heat shrinkage and increased resistance to fire damage in comparison to the gypsum panel that comprises vermiculite that has not been ammonium-exchanged. The disclosure further relates to methods for producing the gypsum panel and constructing building assemblies with the gypsum panels, including walls and ceilings.

This disclosure provides products useful as construction materials and containing set gypsum and ammonium-exchanged vermiculite, including a gypsum panel having a gypsum core comprising set gypsum and ammonium-exchanged vermiculite and characterized by decreased heat shrinkage and increased resistance to fire damage in comparison to the gypsum panel that comprises vermiculite that has not been ammonium-exchanged. The disclosure further relates to methods for producing the gypsum panel and constructing building assemblies with the gypsum panels, including walls and ceilings.

A comprehensive utilization method for iron separation tailings from magnetizing-roasted red mud includes the following steps: performing a wet magnetic separation for tailing discarding on iron separation tailings from magnetizing-roasted red mud, to obtain a rough concentrate and non-magnetic minerals; performing a purification by gravity separation on the rough concentrate to obtain a wet iron concentrate and light minerals; dehydrating the wet iron concentrate to obtain an iron concentrate; combining, and then dehydrating, drying, and disintegrating the non-magnetic minerals and the light minerals, to obtain iron extraction tailings; uniformly mixing the iron extraction tailings, and crushed, ground, and dried limestone, clay, and quartz sand separation tailings according to a predetermined ratio to obtain a cement raw meal; pressing, and then calcining and quenching the cement raw meal to obtain a cement clinker; and mixing the cement clinker and a gypsum followed by a dry grinding to obtain a silicate cement.

A comprehensive utilization method for iron separation tailings from magnetizing-roasted red mud includes the following steps: performing a wet magnetic separation for tailing discarding on iron separation tailings from magnetizing-roasted red mud, to obtain a rough concentrate and non-magnetic minerals; performing a purification by gravity separation on the rough concentrate to obtain a wet iron concentrate and light minerals; dehydrating the wet iron concentrate to obtain an iron concentrate; combining, and then dehydrating, drying, and disintegrating the non-magnetic minerals and the light minerals, to obtain iron extraction tailings; uniformly mixing the iron extraction tailings, and crushed, ground, and dried limestone, clay, and quartz sand separation tailings according to a predetermined ratio to obtain a cement raw meal; pressing, and then calcining and quenching the cement raw meal to obtain a cement clinker; and mixing the cement clinker and a gypsum followed by a dry grinding to obtain a silicate cement.