The present invention relates to the process of producing artificial aggregate from tailings from ore dams. The iron ore sandy tailings are mixed with a binder and, through the mixing and pelletizing process, form the artificial aggregate. The artificial aggregate produced has a spheroidal shape, a large size, a rough surface and a color that ranges between pink and dark red. This artificial aggregate is able to replace the natural aggregate, and can be used in the manufacture of a more resistant concrete, for the base and sub-base of roads, as a decorative element for gardens and beds, in addition to being a form of storage of ore dam tailings in the form of pellets, adding value to these tailings and reducing the environmental mining impacts.

A method for the manufacture of a high alumina hydraulic binder comprising hydrating a source of aluminium ions with a source of calcium ions in the presence of water to form mineral hydrates and subsequently heating said mineral hydrates to form said high alumina hydraulic binder.

The invention relates to a method of producing a binder comprising the steps of preparing (20) a residual material comprising amorphous alumina-rich and/or aluminium hydroxide-rich constituents, heating (30) the residual material to produce a fired material, the heating (30) of the residual material being at a temperature of >800° C.

The invention relates to the use of a hydraulic binder containing calcium aluminate, obtainable by a method in which a) prepared amorphous residual material rich in aluminium oxide and/or aluminium hydroxide is heated after the addition of a b) calcium ion-containing binder component and c) water, for the production of a constructing material.

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.

Methods of forming composite block briquettes of prefabricated thinsets, grouts, and self-leveling underlayment products having high sand content, and the resultant composite block briquettes. Processing conditions within a compacting tool are controlled to generate a press force that is applied to a prefabricated cementitious product having a high sand content, whereby the press force enables formation of sustainable prefabricated product briquettes having a high sand content. The controlled compacting processing conditions and parameters of the invention generate usable briquettes that break up and form the intended resultant product of the starting prefabricated cementitious product.

The invention relates to a method of producing a binder comprising the steps of preparing (20) a residual material comprising amorphous alumina-rich and/or aluminium hydroxide-rich constituents, heating (30) the residual material to produce a fired material, the heating (30) of the residual material being at a temperature of >800 C.

A method for the manufacture of a high alumina hydraulic binder comprising hydrating a source of aluminium ions with a source of calcium ions in the presence of water to form mineral hydrates and subsequently heating said mineral hydrates to form said high alumina hydraulic binder.