Materials 15 07403 v2
Materials 15 07403 v2
Materials 15 07403 v2
Article
Waste Glass Valorization as Raw Material in the Production of
Portland Clinker and Cement
Alina Bădănoiu 1 , Adriana Moant, ă 2 , Ovidiu Dumitrescu 1,3 , Adrian Ionut, Nicoară 1,3, * and Roxana Trus, că 1,3
1 Department of Science and Engineering of Oxide Materials and Nanomaterials, Faculty of Applied Chemistry
and Materials Science, University Politehnica of Bucharest, 011061 Bucharest, Romania
2 CEPROCIM S.A. Preciziei No. 6, 062203 Bucharest, Romania
3 National Research Center for Micro and Nanomaterials, Faculty of Applied Chemistry and Materials Science,
University Politehnica of Bucharest, 060042 Bucharest, Romania
* Correspondence: [email protected]
Abstract: The paper presents experimental results regarding the synthesis of Portland clinker starting
from raw mixes based on two types of clayey precursors, i.e., clay and marl (the most common types
of raw materials used in the cement industry), with and without glass waste content. The soda-lime
glass waste addition (5.36–5.59 wt %), used to control the silica ratio of the raw mix, improved the
raw mix burnability and decreased the calcination temperature (by 20 ◦ C), leading to a decrease in
fuel consumption and contributing to the reduction in CO2 emissions associated with clinker and
cement production. The clinkers obtained by the calcination of raw mixes with glass waste content at
1430 ◦ C with a 30 min plateau had a similar mineralogical composition and microstructure to the
clinkers obtained from the reference raw mixes and fulfilled the requirements of the specific standard
EN 197-1. The obtained clinkers were used to produce two types of Portland cement, i.e., a unitary
cement (CEM I) and a binary blended cement with slag (CEM II/B-S). The main characteristics of
these cements, i.e., loss on ignition, insoluble residue, sulfate and chloride contents, as well as the
Citation: Bădănoiu, A.; Moant, ă, A.; setting time and soundness, meet the conditions stipulated in the EN 197-1 standard. The values of
Dumitrescu, O.; Nicoară, A.I.; Trus, că, compressive strength, assessed on mortars after 2, 7 and 28 days of curing, allow the classification of
R. Waste Glass Valorization as Raw all CEM I cements in the 42.5 R class. In the case of CEM II/B-S cements, those obtained from raw
Material in the Production of mixes with clay can be classified in the 42.5 N class, while those obtained from raw mixes with marl
Portland Clinker and Cement. are classified in the 32.5 R class.
Materials 2022, 15, 7403. https://
doi.org/10.3390/ma15207403 Keywords: soda-lime waste glass; alternative raw material; raw mix; clinker; Portland cement;
Academic Editors: Michael I Ojovan slag; properties
and Ashutosh Goel
Various approaches are considered today to reduce the carbon footprint of this industry.
Among these, the use of alternative fuels, increasing the energy efficiency of kilns as well
as the production of cements with a low clinker content are solutions already applied at the
industrial level [1,4,6,7]. Several types of alternative raw materials are currently used in
cement plants for the production of Portland cement; among them, the most used materials
are slag (waste from the metallurgical industry) and fly ash (waste from coal-fired power
plants). Both can be used as raw materials for Portland clinker production or, more often,
as supplementary cementitious materials (SCM) intergrinded with Portland clinker and
gypsum [8–12].
Waste glass also represents an important environmental issue. The yearly production
of glass is 209 million tonnes [13], and due to their brittleness, glass products are easily
transformed in waste. The highest share in glass production is represented by container
glass, followed by flat glass, domestic glassware, reinforcement glass fibers, special glass
and other types of glass [13]. Part of the glass waste (culets) can be recycled in the manufac-
ture of new products, especially glass containers and domestic glassware. With reference
to the chemical composition of cullet glass used in the production process, 95% represents
soda-lime glass, borosilicate glass and lead glass; the remaining 5% is special purpose
glass [14].
The recycling of glass culets in the manufacture of new glass products is a complex
process, as the glass wastes should be sorted and cleaned before melting [15]. Therefore,
an important amount of waste glass is still landfilled. One possible recycling option for
waste glass is its use in the production of building materials such as glass fibers, foam glass,
geopolymers, intumescent materials and paints or mortars and concretes based on Portland
cement [16–20]. The use of glass waste as an alternative raw material in the production
of concrete is the most studied alternative. Crushed glass can be used for the total or
partial replacement of cement, sand or coarse aggregate [15,21]. Cementitious concretes
containing waste glass exhibit some superior properties as compared with normal Portland
concretes, i.e., resistance to acid attack, sulfate resistance, increased resistance to freeze–
thaw cycles and shielding properties against harmful gamma rays [16,22]. Nevertheless,
the high amount of alkalis present in the composition of waste glass can be deleterious for
the mechanical strength of the concrete if alkali–silica reaction (ASR) occurs between the
alkalis and reactive silica, potentially present in the used aggregates. This deleterious effect
is more intense for coarse glass particles (larger than 1 mm) used for the substitution of
natural aggregate in concrete production [16]. However, the ASR reactions can be mitigated
using cements containing various mineral admixtures (SCM) such as fly ash, slag or silica
fume [23].
Another option to use waste glass is as an alternative raw material in the production
of silicate cement [24–26]. This approach is less studied due to the complexity of the subject.
When cathode ray tube (CRT) glass, with high lead content, was used as raw material for
clinker production, the burnability of the raw mix was improved but resulted in Pb losses
(0.69% to 42.15% depending on the level of incorporation) [26]. Xie and Xi [24] used scrap
glass to replace part of the clayey component in the raw mix used to produce Portland
clinker. The raw mixes with waste glass had an improved burnability as compared with
conventional raw mix, but the cements obtained from these clinkers had flash setting and
poor strength development; the authors explain this by the increase in sodium calcium
aluminate (Na2 O·8CaO·3Al2 O3 ) content in clinkers, favored by the increase in alkali content
in the raw mixes with waste glass content.
This paper presents the synthesis and properties of Portland clinkers and cements
with and without waste glass content. We systematically assessed the influence of clayey
precursors, i.e., clay or marl, as well as the presence of waste glass (used as alternative raw
material to correct the silica content in the raw mixes) on the main properties of clinkers
and cement. The obtained clinkers were used to produce two types of Portland cement,
i.e., a unitary cement (CEM I) and a binary blended cement with slag (CEM II B-S), for
which we assessed the main properties (as required by the specific EN 197-1 standard). The
Materials 2022, 15, 7403 3 of 17
reported results extend the present knowledge regarding the use of waste glass as a raw
material for clinker production to the production of cements based on these clinkers with
slag addition. The use of slag reduces the alkali content in cement and can contribute to the
mitigation of potential alkali–silica reactions in concrete.
Raw LOI * SiO2 Fe2 O3 CaO MgO SO3 Mn2 O3 Na2 O K2 O Other Na2 Oechiv ***
Materials Al2 O3 Comp. **
Limestone 43.42 0.43 0.47 0.74 53.31 0.74 0.29 - 0.33 0.09 0.18 0.39
Clay 8.27 55.60 18.24 7.07 3.76 2.07 0.14 - 1.28 2.94 0.63 3.22
Marl 16.3 40.42 13.04 5.90 17.11 2.36 0.47 - 3.11 3.16 0.18 3.16
Pyrite ash 2.96 9.61 3.07 78.49 1.47 0.57 1.93 - 0.52 0.49 0.89 0.84
Sand 1.58 89.05 4.05 2.06 1.12 0.30 0.22 - 0.33 1.14 0.15 1.08
Waste glass - 71.30 1.86 0.32 10.13 2.17 - - 13.49 0.46 0.27 13.79
Slag 0.42 36.93 10.74 1.29 44.34 3.55 0.27 0.85 0.54 0.49 0.58 0.86
* Loss on ignition; ** TiO2 and Cr2 O3 for waste glass and TiO2 for the other raw materials; *** %Na2 Oechiv = %Na2 O +
0.658%K2 O [27].
The mineralogical compositions of limestone, clay and marl were assessed by X-ray
diffraction (XRD) (Figure 1).
As can be seen form Figure 1a, the main mineralogical compound assessed by XRD in
limestone is calcite (ICDD 083-0577).
The mineralogical composition of clay, assessed by XRD (Figure 1b), is illite (K,H3 O)
Al2Si3AlO10(OH)2—ICDD 00-026-0911), kaolinite (Al2(Si2O5)(OH)4—ICDD 079-1570), sodium
silicate aluminate hydrate (Na51 Al51 Si141 O384 (H2 O)7.83 —ICDD 076-0591) and traces of iron
silicate hydrate (Fe2 Si90 O183 H2 O—ICDD 043-0580).
The main minerals assessed in marl (Figure 1c) are calcite (CaCO3 —ICDD 083-0578),
kaolinite (Al2 O3 ·2SiO2 ·2H2 O—ICDD 003-0052), halloysite (Al2 O3 ·2SiO2 ·4H2 O—ICDD 002-
0043), sodium silicate aluminate hydrate (Na51 Al51 Si141 O384 (H2 O)7.83 —ICDD 00-076-0591)
and possibly traces of iron silicate hydrate (Fe2 O3.90 SiO2 .H2 O—ICDD 042-0424).
Given the fact that waste glass consists mainly of soda-lime glass culets, this material
has a high content of silica, lime and alkali (Na2 O equivalent of about 14%).
Materials 2022, 15, x FOR PEER REVIEW 4 of 19
Materials 2022, 15, 7403 Given the fact that waste glass consists mainly of soda-lime glass culets, this material
4 of 17
has a high content of silica, lime and alkali (Na2O equivalent of about 14%).
(a) (b)
(c)
Figure1.1.XRD
Figure XRDpatterns
patternsofof(a)
(a)limestone;
limestone;(b)
(b)clay;
clay;(c)
(c)marl.
marl.
2.2.Design
2.2. Designand andPreparation
PreparationofofClinkers
Clinkersand
andCements
Cements
Tovalorize
To valorizewaste
wasteglass
glassasasaaraw
rawmaterial
materialininthethemanufacture
manufactureofofPortland
Portlandcement,
cement,thethe
recipesof
recipes ofraw
rawmixes
mixeswerewere calculated
calculated considering
considering the substitution
substitution of of sand
sand (often
(oftenused
usedasasa
acorrective
correctiveaddition
additionfor for the
the silica
silica ratio)
ratio) with waste glass (WG). (WG). The calculus of the raw
The calculus of the raw
materialdosage
material dosagewas wasconducted
conductedto toobtain
obtainclinkers
clinkerswith
withaalime limesaturation
saturationfactor
factor(LSF)
(LSF)ofof
0.98, a silica ratio (SR) of 2.5 and an alumina ratio (AR) of 1.6. The compositionsof
0.98, a silica ratio (SR) of 2.5 and an alumina ratio (AR) of 1.6. The compositions ofraw
raw
mixesare
mixes arepresented
presentedininFigure
Figure2.2.
Theraw
The rawmix mixRc Rcisisobtained
obtained using
using clay
clay asas a silicate
a silicate aluminate
aluminate rawraw material
material andand
sandsand
to
to correct the value of the silica ratio, and in Gc, the sand is replaced by waste glass. Raw
correct the value of the silica ratio, and in Gc, the sand is replaced by waste glass. Raw mix
mixcontains
Rm Rm contains
marl andmarlsandand(tosand (to control
control the silicathe silicawhile
ratio), ratio),
in while
Gm, thein sand
Gm, was
the sand was
replaced
by waste glass.
replaced by waste glass.
The
Theraw
rawmaterials
materialswere werecrushed
crusheduntiluntilthe
thegrain
grainsizes
sizeswere
werebelow
below77mm, mm,and andthen
then
milled
milled in a laboratory mill (Ceprocim, Bucharest, Romania) with a rotary drumand
in a laboratory mill (Ceprocim, Bucharest, Romania) with a rotary drum anddis-
dis-
continuous operation, up to a fineness corresponding to 12% residue
continuous operation, up to a fineness corresponding to 12% residue on the 90 μm mesh on the 90 µm mesh
sieve (R90 = 12%). The raw mixes were then mixed with water (water to solid ratio of
0.28) and the resulting pastes were shaped into pellets, which were then dried at 100 ◦ C.
The thermal treatment was performed in an electric oven, with a rate of 4.83 ◦ C/min at
Materials 2022, 15, x FOR PEER REVIEW 5 of 19
sieve (R90 = 12%). The raw mixes were then mixed with water (water to solid ratio of 0.28)
Materials 2022, 15, 7403 5 of 17
and the resulting pastes were shaped into pellets, which were then dried at 100 °C. The
thermal treatment was performed in an electric oven, with a rate of 4.83 °C/min at differ-
ent temperatures and plateaus [9,28]. Free lime was assessed in these clinkers using the
ethylene glycol
different method [29].
temperatures and plateaus [9,28]. Free lime was assessed in these clinkers using
the ethylene glycol method [29].
Figure 2. Composition of raw mixes used for clinker and cement manufacture.
Figure 2. Composition of raw mixes used for clinker and cement manufacture.
In the case of raw mixes with glass waste, in order to optimize the technological
In
thermalthe treatment
case of raw mixes withsamples
parameters, glass waste, in order to optimize
of approximately thesubmitted
200 g were technological ther-
to different
mal treatment
heat treatments,parameters, samplestemperature
i.e., maximum of approximately1400 200◦ C/20 g were submitted
min plateau, 1430to different
◦ C/30 min
heat treatments,
plateau and 1450i.e., maximum
◦ C/30 mintemperature
plateau. The 1400 °C/20 min
optimal plateau,
thermal 1430 °C/30
treatment min plat-
conditions were
eau and 1450
selected °C/30
based onmin plateau.
the free limeThe optimal
content thermal
assessed treatment
in the obtained conditions were
clinkers, i.e., theselected
free lime
based on the
content free be
should lime content
lower thanassessed
2% [30–32].in the obtained
After clinkers,
determining thei.e., the free
optimal lime content
thermal treatment
should be lower
conditions, thethan
raw2% [30–32].
mixes After 10
(approx. determining the optimal
kg) were subjected to thermal
the optimaltreatment condi-
heat treatment
tions, the raw mixes (approx. 10 kg) were subjected to the optimal heat treatment and the
and the main characteristics of the clinkers (chemical and mineralogical composition,
main characteristics
microstructure) of the
were clinkers (chemical and mineralogical composition, microstruc-
assessed.
ture) wereTheassessed.
obtained clinkers with free lime content below 2% were used to prepare two types
of The obtained
Portland cement:clinkers
CEMwith free95%
I (with lime content
clinker andbelow 2% were
5% gypsum used toand
addition) prepare
CEM twoII/B-S
types
(65% ofclinker,
Portland 30% cement: CEM blast
granulated I (with 95% clinker
furnace slag and and5%5% gypsum
gypsum addition) and CEM
addition).
II/B-S (65%
In theclinker,
case of30% granulated
cements blast furnace
with additions (CEMslag and
II), in 5% gypsum
order to reduceaddition).
the alkali content of
theInfinal
the case of cements with additions (CEM II), in order to reduce the alkali
product (cement), we chose the granulated blast furnace slag (waste fromcontent
metallur-
of the final product (cement), we chose the granulated blast furnace slag (waste from
gical industry) because the alkali content of this type of material is lower (Na 2 =met-
O 0.54%;
allurgical
K 2 O = industry) because the alkali content of this type of material is lower (Na2O =
0.49%) than that of other types of supplementary cementitious materials (SCMs)
0.54%; K2Ofrequently
that are = 0.49%) used than in theofcement
that other industry.
types of supplementary cementitious materials
The cements were
(SCMs) that are frequently used in themade by thecement
intergrinding,
industry.in a laboratory ball mill, of clinker,
gypsum (CEM I) and slag (in the
The cements were made by the intergrinding,case of CEM II/B-S).inThe grinding was
a laboratory ballcarried
mill, of out until the
clinker,
cement fineness, expressed as a residue on the 90 µm mesh sieve,
gypsum (CEM I) and slag (in the case of CEM II/B-S). The grinding was carried out until was approximately 1%.
the cement fineness, expressed as a residue on the 90 μm mesh sieve, was approximately
2.3. Methods
1%.
The chemical composition of cements was determined using wet chemistry methods
2.3. Methods in EN 196-2 [33].
presented
The setting time and soundness of the studied cements were assessed on pastes
The chemical
according to thecomposition
methods presentedof cements wasstandard
in the determined ENusing
196-3wet[34],chemistry methods
and the mechanical
presented in EN 196-2 [33].
strengths were assessed on mortars prepared and cured according to the method described
in the standard EN 196-1 [35].
The microstructure of clinkers was assessed by scanning electron microscopy (SEM)
using a QUANTA INSPECT F50 microscope (Thermo Fisher, Eindhoven, The Netherlands),
with a field emission gun (FEG) with 1.2 nm resolution and a dispersive energy X-ray
The microstructure of clinkers was assessed by scanning electron microscopy (SEM)
using a QUANTA INSPECT F50 microscope (Thermo Fisher, Eindhoven, The Nether-
lands), with a field emission gun (FEG) with 1.2 nm resolution and a dispersive energy X-
ray spectrometer (EDS) with MnKα resolution of 133 eV. All images were obtained using
Materials 2022, 15, 7403
a secondary electron detector (ETD) at 30 kW acceleration voltage and the usual 3.5 spot.
6 of 17
Figure 3. Free lime assessed on the clinkers obtained by calcination at different temperatures and
Figure 3. Free lime assessed on the clinkers obtained by calcination at different temperatures and
plateaus (red line = maximum free lime content recommended in clinkers).
plateaus (red line = maximum free lime content recommended in clinkers).
As expected, the increases in the calcination temperature and plateau duration deter-
mineAstheexpected,
decrease inthe increases
free in the
lime content, calcination
both temperature
in reference clinkers (Rcand
and plateau
Rm) andduration
clinkers deter-
mine the from
resulting decrease in free
the raw mixeslime
withcontent, both(Gc
WG content in reference clinkers
and Gm). For (Rc
the raw and with
mixes Rm)waste
and clinkers
glass, the calcination temperature can be reduced by 20 ◦ C, i.e., the clinkers Gc and Gm
have a free lime content below 2% when the calcination is performed at 1430 ◦ C with a
30 min plateau. This decrease is explained by the lower melting point of soda-lime glass
(below 1000 ◦ C); the addition of this type of waste glass to cement raw mixes decreases the
eutectic temperature of these compositions [24].
eutectic temperature of these compositions [24].
Figure 4 shows the XRD patterns of the Rc and Rm clinkers obtained at 1450 °C with
a 30 min plateau and of clinkers with WG (Gc and Gm) calcined at 1400 °C with a 20 min
plateau and at 1430 °C with a 30 min plateau. As can be seen, in all clinkers, the crystalline
phases detected by XRD are alite (3 CaO.SiO2), belite (2 CaO.SiO2), calcium iron aluminum
Materials 2022, 15, 7403 7 of 17
oxide Ca2(Fe0,654Al1,346)O5 and 3 CaO.Al2O3, which are the main mineralogical phases usu-
ally assessed in Portland clinkers.
Interestingly, these analyses did not provide information regarding the formation of
◦ with a
new Figure
phases4with
shows the XRD
alkali patterns
content in theofclinkers
the Rc and RmWG,
with clinkers obtained at
as suggested ◦
in1450
otherCstudies
30 minThe
[7,24]. plateau
sameand of clinkers compounds
mineralogical with WG (Gc and Gm)incalcined
identified at clinkers
reference 1400 C arewithpresent
a 20 minin
plateau and at 1430 ◦ C with a 30 min plateau. As can be seen, in all clinkers, the crystalline
the XRD patterns of Gc and Gm clinkers. One can assume that alkali ions brought into the
phases detected
system by XRD
by the waste areaddition
glass are ·incorporated
alite (3 CaO CaO·solutions)
SiO2 ), belite (2(solid SiO2 ), calcium
in theiron aluminum
main miner-
oxide Ca2 (Fe0,654 Al1,346 )O5 and 3 CaO·Al2 O3 , which are the main mineralogical phases
alogical phases, i.e., alite, belite, calcium iron aluminate and tricalcium aluminate [30].
usually assessed in Portland clinkers.
(a) (b)
Figure
Figure 4.
4. XRD
XRD patterns
patterns of
of clinkers
clinkers obtained
obtained by
by calcination of raw
calcination of raw mixes
mixes with/without
with/without WG
WG content:
content:
(a) raw mix based on clay; (b) raw mix based on marl.
(a) raw mix based on clay; (b) raw mix based on marl.
Figure 5 presents
Interestingly, thesethe phasedid
analyses amounts resulting
not provide from theregarding
information Rietveld the
refinement
formation per-
of
formed on the samples in which the WG was introduced into the raw mix based
new phases with alkali content in the clinkers with WG, as suggested in other studies [7,24]. on clay
and the raw
The same mix based compounds
mineralogical on marl. One can notice
identified a clear decrease
in reference in C
clinkers are 3S amount
present in theinXRD
the
specimens with waste glass content as compared with the references, correlated
patterns of Gc and Gm clinkers. One can assume that alkali ions brought into the system with a
small
by theincrease in C2addition
waste glass S content.are incorporated (solid solutions) in the main mineralogical
phases, i.e., alite, belite, calcium iron aluminate and tricalcium aluminate [30].
Figure 5 presents the phase amounts resulting from the Rietveld refinement performed
on the samples in which the WG was introduced into the raw mix based on clay and the
raw mix based on marl. One can notice a clear decrease in C3 S amount in the specimens
with waste glass content as compared with the references, correlated with a small increase
in C2 S content.
SEM and EDS analyses performed on clinkers provide supplementary information
regarding their microstructure. The SEM analyses of the two reference clinkers with sand
and clay or marl as raw materials are presented in Figure 6.
One can notice the porous structure of clinker particles (some pores are indicated by
arrows in Figure 6a,d). At higher magnifications (Figure 6b,c,e,f), one can assess the main
specific phases, namely alite (3CaO·SiO2 ), being euhedral particles with clear edges and
smooth faces [38,39], and belite (2CaO·SiO2 ), being particles with round shapes [39,40]
partially covered with solidified melt (Figure 6f), as well as an interstitial phase (calcium
aluminate and calcium ferrite aluminate phases) with a specific elongated “honeycomb”
structure [39].
The EDS elemental maps presented in Figure 7 confirm the wide distribution of
calcium in all phases, of silicon in the euhedral and rounded particles, and of aluminum
and iron mainly in the interstitial phases. One can also notice in the analyzed micro-area
the presence of potassium localized mainly in the interstitial phases.
Materials 2022, 15, x FOR PEER REVIEW
Materials 2022, 15, 7403 8 of 17
onobtained
marl. Rc and Rm
by thermal were obtained
treatment at 1430 ◦ C,by thermal treatment at 1450 °C, 30 min; Gc and Gm w
30 min.
tained by thermal treatment at 1430 °C, 30 min.
Rc, 1450 °C, 30 min. plateau
B
The EDS elemental maps presented in Figure 7 confirm the wide distribution
C
cium in all phases, of silicon in the euhedral and rounded particles, and of aluminu
M
iron mainly in the interstitial phases. One can also notice in the analyzed micro-ar
presence of potassium localized mainly in the interstitial phases.
M
M A
The SEM images of the clinkers obtained by calcination at different temperatures and
The SEM images of the clinkers obtained by calcination at different temperatures and
plateaus of the raw mix with clay and WG are presented in Figure 8.
plateaus of the raw mix with clay and WG are presented in Figure 8.
Gc, 1400 °C, 20 min. plateau au
Both clinkers contain porous particles (Figure 8a,d). At higher magnifications, one
can assess the alite and belite particles partially covered with the solidified melt, as well
as the interstitial phase (calcium aluminate and calcium aluminate ferrite phases) with the
previously described morphologies.
The elemental mapping of Gc clinker obtained by thermal treatment at 1430 °C with
Materials 2022, 15, 7403 10 of 17
Both clinkers contain porous particles (Figure 8a,d). At higher magnifications, one
can assess the alite and belite particles partially covered with the solidified melt, as well as
the interstitial phase (calcium aluminate and calcium aluminate ferrite phases) with the
previously described morphologies.
The elemental mapping of Gc clinker obtained by thermal treatment at 1430 ◦ C with a
30 min plateau (Figure 9) shows the presence of Na (in low amounts), along with Ca, Si, Al
Materials 2022, 15, x FOR PEER REVIEW
and Fe. Sodium seems to be distributed in all phases present in the analyzed micro-area, 11 of 19
which could confirm its presence in the silicate and aluminate phases [41].
The SEM
The SEM images
images ofof clinkers
clinkers obtained
obtained by the calcination
by the calcination of raw mixes
of raw mixes with
with WG
WG andand
marl are
marl are presented
presented in
in Figure
Figure 10.
10.
The microstructure
The microstructure is similar to
is similar to the one assessed
the one assessed for
for the
the clinkers
clinkers with
with clay, having
clay, having
porous particles;
porous particles;moreover,
moreover, at higher
at higher magnifications,
magnifications, the alite,
the alite, belite belite and interstitial
and interstitial phases
phases
are are identified
identified in the studied
in the studied micro-area.
micro-area.
Based on the information presented so far, the clinkers with waste glass (Gc and Gm)
were obtained by the calcination of raw mixes at 1430 ◦ C with a 30 min plateau, and the
reference clinkers (Rc and Rm) were obtained by the calcination of raw mixes at 1450 ◦ C
with a 30 min plateau.
The oxide composition of these clinkers was assessed according to the methods pre-
sented in the EN 196-2 standard [33]. Based on these values, LSF, the silica ratio and the
alumina ratio, were calculated [41]. The alkali content is expressed as Na2 O equivalent.
The results are presented in Table 2.
As can be seen from Table 2 and Figure 5, all clinkers fulfill the requirements of the
EN 197-1 standard [42]:
- The sum of C3 S and C2 S (assessed by the Rietveld method) is between 79.20% and
84.80%, which represents more than two-thirds of the mass of clinker.
- The value of the CaO to SiO2 ratio is between 3.12 and 3.15 (the standard requires a
minimum value of 2).
Materials 2022, 15, 7403 11 of 17
- MgO content is between 1.6% and 1.99%, much lower than the maximum admissible
value of 5%.
Gm, 1400 °C, 20 min. plateau
The alkali content of the clinkers with WG is higher than those with sand, which was
expected given the higher alkali content in the waste glass (see Table 1).
A high content of alkalis in clinker/cement can negatively influence the properties
of the concrete produced with this cement due to potential reactions between the alkalis
released by the cement during hydration and the reactive silica which could be present
in aggregates (alkali–silica reaction, ASR). Thus, to reduce the effect of potential ASR,
careful selection of the aggregates, which should not contain reactive silica minerals,
is recommended.
Refractory index (IR) %C3 S+0.6%C3 A−0.61%C4 AF 1.3 ÷ 3 2.47 2.27 2.35 2.44 [25,41]
IR = 1.12%C3 A+1.45%C4 AF
AW = %C3 A + %C4 AF +
Coating tendency (AW) 28 ÷ 30 29.06 29.88 29.91 28.55 [25,41]
0.2%C2 S + 2%Fe2 O3
Fliq (for 1450 ◦ C) = 3%Al2 O3 +
Liquid phase (%) 2.25%Fe2 O3 + %MgO + %Na2 O 23 ÷ 28 26.86 28.27 27.48 27.68 [25]
+ % K2 O + %SO3
Table 4. Heat of reaction (calculated with Onoda formula) for the studied raw mixes.
Clinker Formula Rc Gc Rm Gm
QOnoda (kcal/kg) Q = 4.8%Al2 O3 + 7.14%CaO + 5.87%MgO-73 440.11 433.13 438.06 433.60
The values presented in Table 4 confirm the positive effect exerted by the replacement
of sand with waste glass, i.e., a reduction in the heat of reaction compared to reference
clinkers. Since most soda-lime glasses have a melting point below 1000 ◦ C, the addition
of this type of waste glass to cement raw mix decreases the eutectic temperature of these
compositions [24].
The reduction in the calcination temperature, and implicitly, the reduction in the
theoretical consumption of heat necessary for the clinker formation, have positive effects
Materials 2022, 15, 7403 13 of 17
on the environmental impact of clinker and cement production. This allows a decrease in
fuel consumption, thus reducing the production costs and at the same time contributing to
the reduction in associated CO2 emissions.
Table 5. The main chemical characteristics assessed for the cements obtained from studied clinkers.
All cements fulfill the conditions imposed by the EN 197-1 standard for these properties
(Table 6). The presence of waste glass in the raw mixes does not significantly affect the
initial setting time and soundness of cements. The cements based on marl seem to have a
slightly longer initial setting time as compared with those based on clay for both types of
cement, CEM I and CEM II/B-S.
Materials 2022, 15, 7403 14 of 17
Cement
Characteristic EN 197-1
CEM I Rc CEM I Gc CEM I Rm CEM I Gm
Initial setting time, min ≥75 180 180 200 210
Soundness, mm ≤10 0 2 2 2
CEM II/B-S Rc CEM II/B-S Gc CEM II/B-S Rm CEM II/B-S Gm
Initial setting time, min ≥75 190 200 220 210
Soundness, mm ≤10 0 0 0 0
Table 7. Calculated CO2 emissions associated with clinker and cement production.
CO2 Emissions Rc Gc Rm Gm
CO2 emissions due to lime decarbonation (kg/t clinker) 639.35 628.03 641.19 628.49
CO2 emissions due to the production of CEM I (kg/t cement) 607.38 596.63 609.13 597.07
CO2 emissions due to the production of CEM II/B-S (kg/t cement) 415.58 408.22 416.77 408.52
Initial setting time, min ≥75 180 180 200 210
Soundness, mm ≤10 0 2 2 2
CEM II/B-S Rc CEM II/B-S Gc CEM II/B-S Rm CEM II/B-S G
InitialMaterials
setting time,
2022, min
15, 7403 ≥75 190 200 220 15 of 17 210
Soundness, mm ≤10 0 0 0 0
(a)
(b)
Figure 11. Compressive strengths vs. time for CEM I and CEM II B-S, with sand or WG and based on
(a) clay; (b) marl.
4. Conclusions
The results obtained in this study allow us to draw the following conclusions.
- Soda-lime waste glass can be used as a raw material for Portland clinker and cement
production. The complete substitution of sand with waste glass, used for the control of
the silica ratio of the raw mix, improves the burnability and decreases the calcination
temperature by 20 ◦ C, contributing to the reduction in fuel consumption and thus
reducing the CO2 emissions associated with clinker and cement production.
- The clinkers obtained by the calcination of raw mixes based on clay or marl and with
glass waste addition had a similar mineralogical composition and microstructure to
the clinkers obtained from the reference raw mixes (with sand).
- All clinkers obtained in this study (with or without waste glass) fulfill the requirements
of the specific EN 197-1 standard, i.e., the sum of C3 S and C2 S is between 79.20% and
84.80%, the CaO/SiO2 ratio is higher than 2 and the MgO content (1.6–1.99%) is lower
than the maximum admissible value of 5%.
Materials 2022, 15, 7403 16 of 17
- Two types of cements were prepared by the intergrinding of obtained clinkers with
gypsum (CEM I—95% clinker and 5% gypsum addition) and with slag (CEM II/B-
S—65% clinker, 30% granulated blast furnace slag and 5% gypsum addition). The
main chemical characteristics of these cements, i.e., loss on ignition, insoluble residue,
sulfate and chloride contents, meet the conditions stipulated in the EN 197-1 standard,
the determined values being below the maximum limits imposed by this norm. As
expected, the alkali content of the cements obtained from the raw mixes with waste
glass is higher as compared with the reference (with sand), but the substitution of
clinker with slag in the case of CEM II/B-S leads to a decrease in the alkali content by
20% compared to CEM I.
- The initial setting time and soundness of all studied cements fulfilled the requirements
of the specific EN 197-1 standard. The values of compressive strength, assessed on
mortars after 2, 7 and 28 days of curing, permit the classification of all CEM I cements
in the 42.5 R class; in the case of CEM II/B-S cements, those obtained from raw mixes
with clay can be classified in the 42.5 N class, and those obtained from raw mixes with
marl are classified in the 32.5 R class.
Author Contributions: Conceptualization, A.B., A.M. and O.D.; Investigation, A.M., A.I.N. and R.T.;
Methodology, A.B., A.M., O.D. and A.I.N.; Supervision, A.B., A.M. and O.D.; Writing—original draft,
A.B. and A.M.; Writing—review and editing, A.M., A.B., A.I.N. and O.D. All authors have read and
agreed to the published version of the manuscript.
Funding: This work was supported by a grant of the Romanian Ministry of Education and Research,
CCCDI—UEFISCDI, project number PN-III-P2-2.1-PED-2019-2112, within PNCDI III.
Institutional Review Board Statement: Not applicable.
Informed Consent Statement: Not applicable.
Data Availability Statement: Not applicable.
Acknowledgments: The authors acknowledge the National Center of Micro and Nanomaterials for
the logistic support.
Conflicts of Interest: The authors declare no conflict of interest.
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