Ferric-rich sulfoaluminate cement (FR-SAC) prepared from solid waste has attracted more and more attention. However, the mineral compositions of solid waste-based FR-SAC clinkers are changeful due to the complex composition of raw materials. In this study, the influences of mineral composition and impurities in solid wastes on the mineral formation of FR-SAC clinker were investigated. The results showed that mullite in fly ash and sodium aluminosilicate in red mud did not decompose but easily reacted with other raw materials to form FR-SAC clinker. Al₂(SO₄)₃ in galvanic sludge decomposed before the formation reaction of FR-SAC clinker. The insufficient SO₂ involved in the reaction should be noted. Besides, Na₂O and K₂O promoted the decomposition of CaSO₄ and the formation of C₄AF. Most of the TiO₂ formed CaTiO₃, resulting in the increase of gehlenite and the decrease of C₂S and CaSO₄. These results can reduce the error when these solid wastes were used to prepare FR-SAC.

Solid waste-based calcium sulfoaluminate (SW-CSA) cement is a type of low carbon cement that uses solid waste as raw material. It is usually used to prepare lightweight porous concrete (LPC) due to its short setting time. However, high water absorption of LPC based on SW-CSA cement limits its extensive application. Water repellent can be mixed into binder material to reduce the water absorption of LPC, but it may affect the hydration properties of SW-CSA cement paste, which influences the performance of LPC correspondingly. Calcium stearate (CS), sodium oleate (SO) and sodium methyl siliconate (SMS) are three familiar commercial water repellents. To find the suitable internal mixing water repellent for LPC based on SW-CSA cement, the effects of three CS, SO and SMS on the water absorption, hydration, compressive strength, fluidity, and setting time of SW-CSA cement paste were explored. Besides, the properties of LPC with CS and SO added were also studied. The results indicated that using CS as the water repellent could reduce the 1 day water absorption of SW-CSA cement paste by 45.9% and the water absorption of LPC by 33.0%. It also reduced the setting time of SW-CSA cement paste and increased the final compressive strength of LPC, which was conducive to the preferred rapid setting and high compressive strength of LPC. The hydrophobicity of SW-CSA cement paste with SO was better than that of SW-CSA cement paste with CS. But using SO and SMS as the water repellent retarded the early hydration of SW-CSA cement and prolonged the setting time of SW-CSA cement and reduced the final compressive strength of SW-CSA cement paste. Therefore, SO and SMS can't be used as the internal mixing water repellent of LPC based on SW-CSA cement, while CS is a promising internal mixing water repellent of SW-CSA cement to prepare LPC.

Ferric-rich calcium sulfoaluminate (FR-CSA) cement is an eco-friendly cement. Fe₂O₃ exists in different minerals of FR-CSA clinker, e.g., Ca₄Al₂Fe₂O₁₀ (C₄AF), Ca₂Fe₂O₅ (C₂F), and Ca₄Al_6-2xFe_2xSO₁₆ (C₄A_3-xF_xS-). The mineral composition depends on the chemical composition of the raw materials and significantly determines the reactivity of FR-CSA cement. To optimize the phase composition of the FR-CSA clinker, chemical reagent raw mixtures with different amounts of CaO were used to prepare the FR-CSA clinker. X-ray diffraction (XRD) analysis, Rietveld quantitative phase analysis (RQPA), Fourier Transform Infrared spectroscopy (FT-IR), and scanning electron microscopy/energy-dispersive spectroscopy (SEM/EDS) were used to identify the mineralogical conditions of the FR-CSA clinker. The results indicated that the amounts of CaO in raw materials greatly affected the iron-bearing phase formation in the FR-CSA clinker. With decreasing CaO content involved in calcination reaction, the amounts of Fe₂O₃ incorporated in C₄A_3-xF_xS- increased up to 17.72 wt% (where x = 0.36). The findings make it possible to optimize the mineral composition of the FR-CSA clinker by changing the CaO content in raw materials. Furthermore, low CaO content in the raw material is beneficial to the formation of C₄A_3-xF_xS-, which enables the use of solid wastes containing low calcium for producing FR-CSA cement.