A method of manufacturing an activated pozzolan composition includes: (i) grinding a natural pozzolan, alone or with another mineral component that is not cement clinker, to form a finely ground pozzolan component having a first d90 in a range of about 10 m to about 45 m and a first d10 less than about 5 m; and (ii) blending, without intergrinding, the finely ground pozzolan component with a coarse particulate mineral component comprised of coarse mineral particles not interground with the fine interground particulate component, the coarse particulate component having a second d90 greater than the first d90 and a second d10 greater than the first d10. The natural pozzolan can be one or more of natural pozzolanic deposits, volcanic ash, metakaolin, shale dust, calcined clay, trass, and pumice.

Various examples related to portland cement manufacturing using municipal solid waste incineration (MSWI) ash are provided. In one example, a method includes providing a raw kiln feed including MSWI to a kiln, forming ash-amended clinker (ACK) by heating the raw kiln feed in the kiln, and preparing ash-amended cement (AAC) from the ACK. The MSWI bottom ash can make up about 5% by mass or less of the raw kiln feed. The ACK can have a chemical composition that meets ASTM C150/ASTM C595, and the AAC can include arsenic, barium, copper, and lead consistent with defined Soil Cleanup Target Levels. In another example, a system includes a kiln, a kiln feed system that supplies raw kiln feed including MSWI bottom ash to the kiln, and a finish mill that grinds ACK formed by heating the raw kiln feed in the kiln to form AAC.

A method of recycling latex paint residual material, such as unused latex paint, includes the step of mixing with cement precursor material, thermally treating the mixture in a kiln to produce clinker, and mixing the clinker with gypsum to product cement. The cement may be used in conventional ways, such as to produce concrete.

A method of recycling latex paint residual material, such as unused latex paint, includes the step of mixing with cement precursor material, thermally treating the mixture in a kiln to produce clinker, and mixing the clinker with gypsum to product cement. The cement may be used in conventional ways, such as to produce concrete.

A method of recycling latex paint residual material, such as unused latex paint, includes the step of mixing with cement precursor material, thermally treating the mixture in a kiln to produce clinker, and mixing the clinker with gypsum to product cement. The cement may be used in conventional ways, such as to produce concrete.

A process for producing a modified fly ash comprising the steps of providing, as a raw material, the raw fly ash discharged from a pulverized coal combustion boiler; classifying the raw fly ash into a crude powder and a fine powder; removing the unburned carbon contained in the crude powder by heating the crude powder at a temperature in a range of 500 to 1000 C.; and mixing together the crude powder from which the unburned carbon has been removed and the fine powder to obtain a modified fly ash.

A process for producing a modified fly ash comprising the steps of providing, as a raw material, the raw fly ash discharged from a pulverized coal combustion boiler; classifying the raw fly ash into a crude powder and a fine powder; removing the unburned carbon contained in the crude powder by heating the crude powder at a temperature in a range of 500 to 1000 C.; and mixing together the crude powder from which the unburned carbon has been removed and the fine powder to obtain a modified fly ash.

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).