Evaluating the Integration of Bio-based Waste into Cement Production: A Pathway to Sustainable Building

Rapid urbanization has increased the demand for building materials, depleting natural resources used in cement production and prompting the use of alternative and waste materials. This research verifies that eggshell powder waste can fully replace limestone in clinker synthesis. Five clinkers were produced using eggshell powder, aluminum sources (bentonite, zeolite, fly ash, and kaolinitic–illitic clay), Fe-slag, and quartz sand, with mechanical preprocessing (10–30 min) before sintering at 1300 °C. Experimental tests assessed the effects of mix design and mechanical activation on clinkerization, phase formation, temperature, and mechanical properties. XRD, FTIR, and SEM/EDS confirmed consistent phase compositions and primary cement minerals. Aluminum source raw materials contributed significantly to tricalcium aluminate and tetracalcium aluminoferrite formation. Eggshell and fly ash promoted tricalcium silicate and dicalcium silicate synthesis, enhancing cement strength at early and late ages. Longer mechanical pretreatments hindered clinkerization. Eggshell-based cements untreated or pretreated for 10 min are suitable for structural concrete; 20–30 min pretreatment is appropriate for low-demand or non-structural applications. The proposed methodology reduces clinker manufacturing temperature by about 100 °C from the typical range of 1400–1450 °C while maintaining mechanical properties comparable to ordinary Portland cement.