A method of producing portland cement using the wastes of enrichment of polymetallic ores of "Achpolymetal" (Kentau, Kazakhstan) in the amount of 0.5 to 2.5% as a mineralizing additive in the raw mixture is proposed. This allows the clinker to be produced at a lower temperature (1300–1350 °C), resulting in lower fuel consumption and higher furnace productivity. The experimental clinker is better subjected to grinding, the electric power consumption for grinding cement decreases, the grinding bodies of cement mills decrease. In the waste, there are catalytic and modifying elements. Studies have shown that in the no-added raw mix the clinker formation processes are completed at 1450 °C. When 0.5 to 2.0% of the tailings are introduced, the complete binding of CaO is completed at 1400 °C, with the addition of 2.5% of tailings, lime binding is completed at 1300 or 150 °C lower than in the control non-additive raw mixture. In clinkers, only 1.09–1.32 % of free lime remains. The strength of cement when introduced into the raw mix from 0.5 to 2.0% of barite waste is increased. The compressive strength at 28 days of age for cement with an optimum dosage of 1‒2% of the tail increases from 414 kg/cm2 to 430‒432 kg/cm2 or by 3.9‒4.3%. Similarly, the strength of steamed samples increases by 4.7‒5.7%.
The article presents the obtaining results of clinkers of sulfate resistant and road cement during the production tests process. The usage of man-made wastes such as lead slag, coal mining waste as well as clay component and additives. X-ray, chemical analyzes of starting materials, clinkers and obtained cements were carried out. The regularities of charge compositions, saturation coefficient, modules, burning regimes on chemical and mineralogical composition and quality of clinkers and cements, improvement of rotary kiln operation, reduction of greenhouse gas emissions and fuel consumption are established. Various methods of analysis were used, calculations of raw mixtures composition were carried out according to the program "Shikhta" (designed to calculate the raw mix and the mineralogical composition of the clinker for the production of Portland cement. The program was developed in the V.G. Shukhov Belgorod State Technical University, Russia) and "Calculation of raw mixtures or CRM" (designed to calculate the raw mix of clinker. The program was developed in the M. Auezov South-Kazakhstan State University, Kazakhstan). The strength of factory and experimental cements was tested after 3, 7 and 28 days and after steaming.
The article analyzes the use of polymetallic ores' tailings as a basis for production of composite cements and concrete, having protective properties against gamma and X-rays radiation, as well as high strength and lifetime. The main practically significant result is: the development of scientific and technological production bases of new high-tech type of multicomponent hydraulic binders for concretes -composite cements; the identification of new hydration products in composite cements with addition of polymetallic ores' tailings; the development of optimal compositions of composite cements for concretes. It is established that the composite cements, that developed by us on the basis of polymetallic ores' tailings, meet modern requirements i.e. its improve the construction-technical properties of material, have positive effect to the environment situation and allow to reduce the production cost of the final product. Their technology is low metal-intensive and power-consuming. Studies of physical-chemical processes of composite cements structure formation with addition of polymetallic ores' tailings have been conducted using methods such as chemical, X-ray phase, differential-thermal and electronmicroscopic analysis methods.
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