Sulfate-Resistant Clinker Base Cement with New Secondary Main Constituents: A Technical, Economic, and Environmental Analysis

The Spanish cement sector must adapt its production model to a green economy model. This study focuses on the use of new secondary main constituents (SMCs) suitable for a cement plant that specializes in sulfate-resistant (SR) cement production, defining a framework of technical conditions for their usage and their economic and environmental feasibility. Low-calcium-carbonate-content albero, steel slags, and iron silicate were the tested SMCs; however, they are not currently permitted in cement manufacture. CEM I 42.5 R-SR 3 (type I-SR) was mixed with 5%, 20%, and 30% of these new SMCs. XRF, XRD, leaching and other chemical tests, setting, and hardening tests were performed with no significant issues. Albero is the best option, on the whole, because of the following characteristics: availability, >100 Mt; proximity, 3 km; and acceptable compressive strength level. However, black slag cement with 30% SMC after 28 days shows the best performance, with a compressive strength of 41.3 MPa compared to 35.3 MPa for albero cement and 56.5 MPa for the type I-SR reference. Albero and steel slag at 30% content are the best option according to the cost savings of 32% (−31.5 EUR/t and −31.6 EUR/t, respectively) compared to the type I-SR reference. Regarding the carbon footprint, albero and steel slag at 30% content have the least impact, showing a 31% reduction (−254.8 kg CO2/t and −255.2 kg CO2/t, respectively) compared to the type I-SR reference. The studied SMCs meet the analytical conditions and—with the corresponding regulatory changes—offer potential cost savings for SR cement production, exhibiting a competitive advantage.