The integration of calcined clays as supplementary cementitious materials has emerged as a key pathway to reduce the cement industry’s CO₂ footprint. A central challenge, however, has been controlling the reddish coloration caused by hematite, which affects the visual quality of blended cements. Traditional approaches—such as oxygen depletion, fuel co-feeding, and quenching—either increase energy demand, raise emissions, or prove ineffective. 

We present a novel strategy employing inorganic modifiers (IM) co-calcined with clays in rotary kilns. Industrial and pilot trials conducted by FCT demonstrate that IM promotes the formation of iron-calcium compounds, eliminating hematite, stabilizing the desired grey color, and improving hydraulic performance. Additionally, the technique reduces water demand in concrete, supports strength development, and yields lower heat and CO₂ penalties compared to conventional methods. 

With minimal plant modifications required, the use of IM offers a cost-effective, scalable, and sustainable solution for color control and performance enhancement in calcined clay cements. 

Speaker: Paulo Mazzei is the Chief Business Development Officer for FCT Combustion globally.

Paulo graduated from Fundação Alvares Penteado, with a degree in mechanical engineering and is an International Trade specialist from Fundação Getulio Vargas, both in Brazil. For the last twenty years, Paulo has worked in process engineering and sales roles, at international companies in the cement and industrial minerals business. Paulo’s experience includes eight years in the sales and process department of Polysius, and seven years managing the sales department of Raymond Pulverizers in South America. 

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