Geopolymers based on spent catalyst residue from a fluid catalytic cracking (FCC) process

This paper assesses the use of alkali activation technology in the valorization of a spent fluid catalytic cracking (FCC) catalyst, which is a residue derived from the oil-cracking process, to produce geopolymer binders. In particular, the effects of activation conditions on the structural characteristics of the spent catalyst- based geopolymers are determined. The zeolitic phases present in the spent catalyst are the main phases participating in the geopolymerization reaction, which is driven by the conversion of the zeolitic material to a highly Al-substituted aluminosilicate binder gel. Higher alkali content and SiO2/Na2O ratio lead to a denser structure with a higher degree of geopolymer gel formation and increased degree of crosslinking, as identified through 29Si MAS NMR. These results highlight the feasibility of using spent FCC catalyst as a precursor for geopolymer production.This study was sponsored by research scholarship BES-2008-002440 and EEBB-2011-43847 from the Ministerio de Ciencia y Tecnologia of Spain, the European regional development fund (FEDER), and the Universitat Politecnica de Valencia (Spain). The participation of SAB and JLP was funded by the Australian Research Council through the Discovery Projects program, and also including partial funding through the Particulate Fluids Processing Centre, a Special Research Centre of the ARC. The authors wish to acknowledge the Advanced Microscopy Facility at The University of Melbourne for assistance with the electron microscopy experiments conducted in this study.Rodriguez Martinez, ED.; Bernal, SA.; Provis, JL.; Gehman, JD.; Monzó Balbuena, JM.; Paya Bernabeu, JJ.; Borrachero Rosado, MV. (2013). Geopolymers based on spent catalyst residue from a fluid catalytic cracking (FCC) process. Fuel. 109:493-502. https://doi.org/10.1016/j.fuel.2013.02.053S49350210

Oil-Based Mud Cutting as an Additional Raw Material in Clinker Production

Oil-Based Mud (OBM) cutting is a hazardous by-product generated during oil-well drilling. Its chemical composition suggests that it might be suitable as a raw material in cement manufacturing. It is rich in calcium oxide, silica, and aluminium oxide, which are the major oxides in raw materials for cement manufacturing. In this research, OBM cutting is used as a constituent of the raw meal for cement clinker production. Raw meal mixtures were prepared by mixing different ratios of raw materials increasing OBM content. The impact of the addition of OBM cutting on the resulting clinker has been investigated. The results demonstrate that OBM cutting could be recycled in the manufacturing of Portland cement clinker. Clinker prepared using OBM cutting had very similar properties to that prepared from limestone. This result could represent an opportunity for solving an environmental problem. The addition of OBM cutting lowers the calcination temperature, and increases the rate of carbonate dissociation. However, it also leads to a higher free lime in clinker, which is a result of the presence of trace elements, such as barium. Overall, its use as a raw material in cement production could provide a cost-effective, environment-friendly route for the management of OBM cutting

Sintering behavior of porous wall tile bodies during fast single-firing process

In ceramic wall tile processing, fast single-firing cycles have been widely used. In this investigation a fast single-firing porous wall tile mixture was prepared using raw materials from the North Fluminense region.Specimens were obtained by uniaxial pressing and sintered in air at various temperatures (1080 - 1200 °C) using a fast-firing cycle (60 minutes). Evolution of the microstructure was followed by XRD and SEM. The results revealed that the main phases formed during the sintering step are anorthite, gehlenite and hematite. It appears that the sintering process is characterized by the presence of a small amount of a liquid phase below 1140 °C. As a result, the microstructure of the ceramic bodies showed a network of small dense zones interconnected with a porous phase. In addition, the strength of the material below 1140 °C appeared to be related to the type and quantity of crystalline phases in the sintered bodies

Influência da distribuição granulométrica na estabilidade dimensional de placas cerâmicas de base vermelha Influence of particle size distribution on the dimensional stability of red ceramic tiles

As propriedades do revestimento cerâmico queimado estão intrinsecamente ligadas às características da massa, dentre estas se encontram o tamanho, a distribuição, o formato e o arranjo das partículas. O efeito da distribuição granulométrica de partículas sobre a estabilidade dimensional de placas cerâmicas para revestimentos de base vermelha foi estudado em três massas, todas continham no mínimo 57% de material advindo da Formação Corumbataí. Foram estudadas duas distribuições granulométricas - uma parecida com aquelas usadas no Pólo Cerâmico de Santa Gertrudes e, outra, com uma massa de grés. De uma maneira geral, granulações mais grossas, semelhantes à massa de Santa Gertrudes, variaram menos dimensionalmente quando as placas apresentaram médias e altas porosidades (absorção de água entre 3,0 e 10,0%). Já, granulações mais finas, similares a massas de grés, foram necessárias para a produção de placas de baixa absorção (menor que 3,0%).<br>The properties of final ceramic tiles are related with the mass characteristics, among them the size, shape, distribution and arrange of particles. The effect of particle size distribution on dimensional stability of red ceramic tiles was studied in three masses; all of them composed with, at minimum, 57% of Corumbataí Formation's materials. Two particle size distributions were investigated: the first was similar to the masses that are used in the Santa Gertrudes Ceramic Pole's factories and the other was similar to the stoneware mass. In general, masses with larger particle sizes, similar to that of Santa Gertrudes, had greater dimensional stability in the products with 3 to 10% of water absorption. On the other hand, in the manufacture of low porosity tiles (water absorption capacity < 3%) it is recommended the use of smaller grain size