A quick-setting concrete mixture that uses calcium sulfoaluminate as a binder cement. In one embodiment, the disclosed concrete mixture may be prepared using a revolutionary drum mixer truck and may recycle surplus or leftover concrete. In one embodiment, the mixture may use air entrainment; such as liquid air entrainment or foam generated air entrainment, to manufacture the concrete mixture.

A quick-setting concrete mixture that uses calcium sulfoaluminate as a binder cement. In one embodiment, the disclosed concrete mixture may be prepared using a revolutionary drum mixer truck and may recycle surplus or leftover concrete. In one embodiment, the mixture may use air entrainment; such as liquid air entrainment or foam generated air entrainment, to manufacture the concrete mixture.

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.

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; the classifying step that introduces the heat-treated fly ash containing the unburned carbon in decreased amounts obtained through the heating step into a classifying apparatus in the state of being heated at a high temperature so as to separate the fly ash into a coarse powder and a fine powder; the fine powder recovering step that recovers the fine powder of the heat-treated fly ash obtained through the classifying step by using a dust-collecting apparatus; and the milling step that mills the coarse powder of the heat-treated fly ash obtained through the classifying step until a 45 m sieve residue becomes not more than 34% by mass, and then recovers the milled powder.

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; the classifying step that introduces the heat-treated fly ash containing the unburned carbon in decreased amounts obtained through the heating step into a classifying apparatus in the state of being heated at a high temperature so as to separate the fly ash into a coarse powder and a fine powder; the fine powder recovering step that recovers the fine powder of the heat-treated fly ash obtained through the classifying step by using a dust-collecting apparatus; and the milling step that mills the coarse powder of the heat-treated fly ash obtained through the classifying step until a 45 m sieve residue becomes not more than 34% by mass, and then recovers the milled powder.

The invention provides a process for producing a cement clinker comprising: (i) mixing one or more starting materials providing each at least one or more of CaO, SiO.sub.2, Al.sub.2O.sub.3, and Fe.sub.2O.sub.3; and, optionally, SO.sub.3, to form a raw meal comprising CaO, SiO.sub.2, Al.sub.2O.sub.3, and Fe.sub.2O.sub.3; and, optionally, SO.sub.3, wherein the molar ratios among the aforementioned oxides is given by Formula I: (CaO).sub.1(SiO.sub.2).sub.a(Al.sub.2O.sub.3).sub.b(Fe.sub.2O.sub.3).sub.c(SO.sub.3).sub.d, wherein: a is comprised from 0.05 to 1, b is comprised from 0.01 to 0.6, c is comprised from 0.001 to 0.25, and d is comprised from 0 to 0.3 and wherein at least 35% (p/p) of the starting materials of the raw meal have a critical microwaves absorbance temperature (Tc) comprised from 15 to 650 C. and a critical microwaves absorbance time (tc) comprised from 1 min to 1 h; (ii) heating the raw meal by irradiating with microwaves during 15 min to 3 h to reach a sintering temperature comprised from 300 to 950 C.; (iii) maintaining the microwave sintering temperature of step (ii) during 1 min to 3 h by further irradiating with microwaves; and (iv) cooling the clinker obtained in step (iii).

The invention provides a process for producing a cement clinker comprising: (i) mixing one or more starting materials providing each at least one or more of CaO, SiO.sub.2, Al.sub.2O.sub.3, and Fe.sub.2O.sub.3; and, optionally, SO.sub.3, to form a raw meal comprising CaO, SiO.sub.2, Al.sub.2O.sub.3, and Fe.sub.2O.sub.3; and, optionally, SO.sub.3, wherein the molar ratios among the aforementioned oxides is given by Formula I: (CaO).sub.1(SiO.sub.2).sub.a(Al.sub.2O.sub.3).sub.b(Fe.sub.2O.sub.3).sub.c(SO.sub.3).sub.d, wherein: a is comprised from 0.05 to 1, b is comprised from 0.01 to 0.6, c is comprised from 0.001 to 0.25, and d is comprised from 0 to 0.3 and wherein at least 35% (p/p) of the starting materials of the raw meal have a critical microwaves absorbance temperature (Tc) comprised from 15 to 650 C. and a critical microwaves absorbance time (tc) comprised from 1 min to 1 h; (ii) heating the raw meal by irradiating with microwaves during 15 min to 3 h to reach a sintering temperature comprised from 300 to 950 C.; (iii) maintaining the microwave sintering temperature of step (ii) during 1 min to 3 h by further irradiating with microwaves; and (iv) cooling the clinker obtained in step (iii).

The invention provides a process for producing a cement clinker comprising: (i) mixing one or more starting materials providing each at least one or more of CaO, SiO.sub.2, Al.sub.2O.sub.3, and Fe.sub.2O.sub.3; and, optionally, SO.sub.3, to form a raw meal comprising CaO, SiO.sub.2, Al.sub.2O.sub.3, and Fe.sub.2O.sub.3; and, optionally, SO.sub.3, wherein the molar ratios among the aforementioned oxides is given by Formula I: (CaO).sub.1(SiO.sub.2).sub.a(Al.sub.2O.sub.3).sub.b(Fe.sub.2O.sub.3).sub.c(SO.sub.3).sub.d, wherein: a is comprised from 0.05 to 1, b is comprised from 0.01 to 0.6, c is comprised from 0.001 to 0.25, and d is comprised from 0 to 0.3 and wherein at least 35% (p/p) of the starting materials of the raw meal have a critical microwaves absorbance temperature (Tc) comprised from 15 to 650 C. and a critical microwaves absorbance time (tc) comprised from 1 min to 1 h; (ii) heating the raw meal by irradiating with microwaves during 15 min to 3 h to reach a sintering temperature comprised from 300 to 950 C.; (iii) maintaining the microwave sintering temperature of step (ii) during 1 min to 3 h by further irradiating with microwaves; and (iv) cooling the clinker obtained in step (iii).

A rapid-setting composition includes fly ash and an activator solution for mixing with the fly ash. The activator solution has a silicate solution including a monovalent hydroxide. The activator solution when mixed with the fly ash produces a composition that has a final set time of no more than about 65 minutes.