Pozzolanic activity of FCC catalyst waste slag (CWS) for cement and geopolymer production

Catalyst waste slag (CWS) is generated in large amounts when fabricating the catalyst required in the fluid cracking catalyst (FCC) process used for oil refining. Currently, CWS is landfilled. This paper characterizes the CWS and measures its pozzolanic activity. It determines whether the CWS can be used as partial Portland cement (PC) replacement for the first time in the literature. CWS is primarily composed of Al₂O₃ and CaO. It contains a negligible quantity of heavy metals that can be immobilised in a matrix. The raw CWS is totally amorphous and extremely reactive which results in flash set. Calcination is an effective method to control the reactivity of CWS. Reactivity increased when CWS was calcined between 300 and 600 °C and it peaked at 500 °C, but this caused flash set. Calcination at 800 °C lowers reactivity (as the highly disordered aluminium phases achieve a greater order) which allows for proper handling. Temperatures over 800 °C caused partial crystallization significantly lowering reactivity.

The 800°C-calcined CWS reached high mechanical index (6.25), comparable to other pozzolans such as fly ash and red mud, and greater than alum sludge. CWS combines lime profusely and develops more abundant cementing hydrates than similar pozzolans such as calcined alum sludge. The pozzolanic reaction of the 800°C-calcined CWS provides abundant cementing minerals including AFt and AFm phases, calcium aluminium carbonate hydrates and calcium aluminium hydrates.

The high reactivity of CWS and its prolific production of cementing phases in pozzolanic reactions indicate that it can be used as a supplementary cementitious material in PC and lime systems; and that it can be used as a precursor to produce low-carbon and geopolymer cements. CWS constitutes a reactive aluminium source which, in a PC system, participates in hydration reactions and can enhance the properties of the resultant materials.