Synthesis of gel crosslinked composite material from spent cathode carbon blocks and its application in modified asphalt binders

Abstract

The utilization of spent cathode carbon blocks (SCCB) from aluminum electrolysis has become challenging due to their content of highly toxic cyanides and environmentally harmful fluorides. To achieve reliable recovery and utilization of hazardous waste, targeted research has been conducted on the treatment of waste cathode carbon blocks and their potential application in asphalt pavement. Hydrogen peroxide (H2O2) is employed to remove cyanides from the waste cathode carbon blocks, meeting the construction requirements for transportation areas. Anhydrous calcium chloride is used as a calcium source to precipitate soluble fluorides in the solution. Finally, the waste cathode carbon blocks are gel-crosslinked using polyvinyl alcohol-polyvinyl pyrrolidone, addressing the release of fluorides beyond environmental tolerance. This results in the synthesis of a composite material consisting of calcium fluoride deposits and gel-encapsulated waste cathode carbon blocks (PSB), which exhibits good thermal stability in the temperature range of 0–217 °C. Through DSR and MSCR testing, it has been demonstrated that the gel-crosslinked waste cathode carbon block composite material improves the asphalt's sensitivity to temperature and enhances its resistance to rutting at high temperatures. The 1% PSB/SBS modified asphalt shows the best performance, compared to SBS, the complex modulus (G*) of the modified asphalt increased by 117.4% at 46 °C, and the recovery indices for creep at 64 °C improved by 39.28% (at 0.1 kPa) and 55.65% (at 3.2 kPa), and thermal gravimetric analysis of the asphalt confirms that the addition of PSB improves the asphalt's thermal stability. Fluorescence microscopy analysis reveals that the inclusion of PSB does not affect the morphological development of SBS swelling and plays a stabilizing and supporting role in the asphalt mixture.