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<p>Initial clinker burning tests were performed in a&#xa0;laboratory muffle furnace using various combinations and dosages of alternative raw materials. The raw mixes and clinkers produced were analyzed to test their suitability as Portland cement clinker. Selected formulations were then scaled up for pilot and industrial scale trials to verify their practical feasibility.</p><p>As part of the pilot tests, a&#xa0;promising raw mix was produced in two fineness grades in a&#xa0;raw mill at an Austrian cement plant. Firing took place in a&#xa0;7.2 m long pilot-scale rotary kiln with a&#xa0;diameter of 0.4 m (length-to-diameter ratio L/D of 18) heated directly by a&#xa0;natural gas burner. The clinkers produced were analyzed using X‑ray fluorescence (XRF), X‑ray diffraction (XRD), and clinker microscopy.</p><p>In subsequent industrial trials conducted over several days at an Austrian cement plant, a&#xa0;comprehensive process concept was developed that encompassed fuel selection, raw material dosing, kiln operation, and material handling. An inline analysis of the raw meal was performed, and the influence of the substitute raw materials on plant behavior—such as melting characteristics, raw meal behavior in the kiln, and ring formation—was systematically investigated. In addition, elevated levels of sulfur, magnesium oxide, heavy metals, and volatile organic compounds (VOCs) were monitored.</p><p>For the first time, a&#xa0;CEM&#xa0;I 42.5 cement with a&#xa0;CO<sub>2</sub> footprint approximately 30% below the Austrian average was produced. At substitution rates of up to 50%, the effects on clinker quality are currently under investigation. To date, no Portland cement clinker with such a&#xa0;high proportion of alternative raw materials has demonstrated a&#xa0;performance comparable to that of standard clinker. The cement produced is currently undergoing comprehensive chemical testing as well as mortar testing in accordance with EN 197‑1. Further objectives include industrial grinding trials to produce various cement types from the eco-clinker, as well as durability tests on concrete and the evaluation of its potential applications in the construction industry.</p>

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Ressourcen- und CO2-optimierte Herstellung innovativer Zementklinker – Zwischenbericht zum von der FFG geförderten Branchenprojekt der österreichischen Zementindustrie

  • 期刊论文

  • 出版模式：

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  • 发表日期：

    2026年5月27日

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  • Wolfram Waldl,
  • Cornelia Bauer,
  • Florian Gomernik,
  • Helmut Flachberger

摘要

Initial clinker burning tests were performed in a laboratory muffle furnace using various combinations and dosages of alternative raw materials. The raw mixes and clinkers produced were analyzed to test their suitability as Portland cement clinker. Selected formulations were then scaled up for pilot and industrial scale trials to verify their practical feasibility.

As part of the pilot tests, a promising raw mix was produced in two fineness grades in a raw mill at an Austrian cement plant. Firing took place in a 7.2 m long pilot-scale rotary kiln with a diameter of 0.4 m (length-to-diameter ratio L/D of 18) heated directly by a natural gas burner. The clinkers produced were analyzed using X‑ray fluorescence (XRF), X‑ray diffraction (XRD), and clinker microscopy.

In subsequent industrial trials conducted over several days at an Austrian cement plant, a comprehensive process concept was developed that encompassed fuel selection, raw material dosing, kiln operation, and material handling. An inline analysis of the raw meal was performed, and the influence of the substitute raw materials on plant behavior—such as melting characteristics, raw meal behavior in the kiln, and ring formation—was systematically investigated. In addition, elevated levels of sulfur, magnesium oxide, heavy metals, and volatile organic compounds (VOCs) were monitored.

For the first time, a CEM I 42.5 cement with a CO2 footprint approximately 30% below the Austrian average was produced. At substitution rates of up to 50%, the effects on clinker quality are currently under investigation. To date, no Portland cement clinker with such a high proportion of alternative raw materials has demonstrated a performance comparable to that of standard clinker. The cement produced is currently undergoing comprehensive chemical testing as well as mortar testing in accordance with EN 197‑1. Further objectives include industrial grinding trials to produce various cement types from the eco-clinker, as well as durability tests on concrete and the evaluation of its potential applications in the construction industry.