Composite mineralizers/fluxes for the production of alite/calcium sulfoaluminate clinkers

Abstract

A cement clinker composition incorporates calcium fluoride and iron oxide to reduce firing temperatures and increase strength. High fly ash, aluminum dross, aluminum scrap, high aluminum clays and combinations thereof may also be substituted for bauxite in the cement clinker composition

What is claimed: 
     
         1 . A cement clinker composition defined by oxide content, comprising:
 42-65 wt % CaO;   5-20 wt % SiO 2 ;   10-40 wt % Al 2 O 3 ;   0.5-5 wt % Fe 2 O 3 ; and   2-13 wt % SO 3 .   
     
     
         2 . The cement clinker composition of  claim 1 , including:
 50-55 wt % CaO;   9-13 wt % SiO 2 ;   20-30 wt % Al 2 O 3 ;   0.5-3 wt % Fe 2 O 3 ; and   5-10 wt % SO 3 .   
     
     
         3 . A cement clinker composition of  claim 2 , including between about 0.1 and 3 wt % fluoride compound and between about 0.5 and about 5 wt % Fe 2 O 3 . 
     
     
         4 . The cement clinker of  claim 3 , further including between about 10-35 wt % of a bauxite substitute selected from a group consisting of high fly ash alumina, aluminum dross, aluminum scrap, high alumina clays, kaolin, metakaolin, 1:1 silica to alumina clays and combinations thereof. 
     
     
         5 . The cement clinker composition of  claim 1 , including between about 0.1 and 3 wt % fluoride compound and between about 0.5 and about 5 wt % Fe 2 O 3 . 
     
     
         6 . The cement clinker of  claim 5 , further including between about 10-35 wt % of a bauxite substitute selected from a group consisting of high fly ash alumina, aluminum dross, aluminum scrap, high alumina clays and combinations thereof. 
     
     
         7 . A cement clinker composition, comprising;
 15-40 wt % C 3 S;   20-60 wt % C 4 A 3 Ś;   5-30 wt % C 2 S;   1-10 wt % C 4 AF; and   0.4-1.0 wt % CaF 2  as present in fluorellestadite and fluormayenite clinker phases fired at 1150-1350° C.   
     
     
         8 . The cement clinker of  claim 7 , further including between about 0.5-2.0 wt % Fe 2 O 3 . 
     
     
         9 . The cement clinker of  claim 8 , further including between about 10-35 wt % of a bauxite substitute selected from a group consisting of high fly ash alumina, aluminum dross, aluminum scrap, high alumina clays and combinations thereof. 
     
     
         10 . The cement clinker of  claim 7 , further including between about 10-35 wt % of a bauxite substitute selected from a group consisting of high fly ash alumina, aluminum dross, aluminum scrap, high alumina clays and combinations thereof 
     
     
         11 . The cement clinker composition of  claim 7 , including:
 20-35 wt % C 3 S;   40-55 wt % C 4 A 3 Ś;   10-25 wt % C 2 S;   1-4 wt % C 4 AF; and   0.6-0.8 wt % CaF 2  as present in fluorellestadite and fluormayenite clinker phases fired at 1200-1300° C.   
     
     
         12 . The cement clinker of  claim 5 , further including between about 0.5-2.0 wt % Fe 2 O 3 . 
     
     
         13 . The cement clinker of  claim 12 , further including between about 10-35 wt % of a bauxite substitute selected from a group consisting of high fly ash alumina, aluminum dross, aluminum scrap, high alumina clays, kaolin, metakaolin, 1:1 silica to alumina clays and combinations thereof. 
     
     
         14 . The cement clinker of  claim 11 , further including between about 10-35 wt % of a bauxite substitute selected from a group consisting of high fly ash alumina, aluminum dross, aluminum scrap, high alumina clays and combinations thereof. 
     
     
         15 . A cement clinker composition, comprising between about 0.1 and about 3.0 wt % fluoride compound and between about 0.5 and about 5.0 wt % Fe 2 O 3  and after firing at between about 1150° C. and 1350° C. including between about 15 and about 40 wt % alite and between about 20 and about 60 wt % calcium sulfoaluminate. 
     
     
         16 . The cement clinker of  claim 15 , further including between about 10-35 wt % of a bauxite substitute selected from a group consisting of high fly ash alumina, aluminum dross, aluminum scrap, high alumina clays, kaolin, metakaolin, 1:1 silica to alumina clays and combinations thereof. 
     
     
         17 . The cement clinker of  claim 15 , after firing at between 1200° C. and 1300° C.