2026

Roy, Rahul; Hertel, Tobias; Rößler, Christiane; Pontikes, Yiannis

The addition of Bauxite residue in the raw mix introduces Na+ and Ti4+ into the crystalline phases of calcium-sulfoaluminate (CSA) clinkers. To mimic such a system, Na-Fe-ye'elimite (C₃.₉N₀.₁A₂.₈F₀.₂Ŝ) and Ti-ferrite (C₂F₀.₇₆A₀.₂₄T₀.₁) were synthesized at 1285 °C, 2 h, and 1320 °C, 3 h, respectively. Quantitative X-ray diffraction (QXRD) revealed solid solutions with minor Ca-aluminates phases, whereas electron backscattered diffraction-energy dispersive spectroscopy (EBSD-EDS) could distinguish Na-rich orthorhombic and Fe-rich cubic ye'elimite polymorphs. Isothermal calorimetry showed the Na-Fe-ye'elimite phase drives early heat evolution, whereas higher ferrite and gypsum (M > 0) prolong induction and attenuate the main hydration peak. In ferrite-free mixes, the cubic-ye'elimite polymorph dissolves fastest, but when ferrite exceeds 33 wt%, its Fe3+ release accelerates orthorhombic-ye'elimite dissolution, as confirmed by pore-solution analysis. After 28d, Na-Fe-ye'elimite is fully consumed at M (sulfate to ye'elimite molar ratio) ≥ 2 for ye'elimite-ferrite mixes, while ferrite remains partly inert, possibly from Ca2+/SO₄2− adsorb onto its Fesingle bondAl surface. Limiting ferrite to ≤33 wt% is recommended to achieve more densification of the microstructure for better performance.