Use of spent fluid catalytic cracking catalyst (FCC) in Limestone Calcined Clay Cement (LC3) systems: Studies in pastes and mortars

Abstract

This study evaluates the substitution of calcined clay for a waste from the petrochemical industry, spent fluid catalytic cracking catalyst (FCC), as a source of reactive aluminosilicates in Limestone Calcined Clay Cements (LC3) systems. Three carbonate types were used to make cement-type LC3: a high-purity calcium carbonate, waste from the marble industry, and another from a dolomite soil source. LC3 blends were prepared by mixing 50 wt% OPC, 5 wt% calcium sulfate dihydrate, 30 wt% FCC and 15 wt% from each carbonate source. A mixture than substituting the carbonate source for a siliceous source was prepared to analyse the influence of carbonate phases in LC3 systems. The hydration process of the LC3 blends was studied by X-ray diffraction, thermogravimetric analyses, isothermal calorimetry and FESEM. Mechanical properties were studied by measuring compressive strength at 7, 28 and 90 days. The obtained results corroborated that the mortars prepared with LC3 cements using the FCC obtained higher compressive strength than the control mortar prepared with ordinary Portland cement (OPC) at 28 and 90 curing days. It has been demonstrated that FCC is a by-product that can substitute calcined clay, and the different sources of carbonates such as high purity, waste or contaminated with magnesium do not interfere with the performance of this type of cement.