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

Rodríguez, Erich D.; Bernal, Susan A.; Provis, John L.; Gehman, John D.; Monzó, J.; Payá, J.; Borrachero, M.V.

doi:10.1016/j.fuel.2013.02.053

Cited by 85 publications

(69 citation statements)

References 59 publications

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“…1), are also observed in the alkaliactivated pastes, suggesting that these phases are not participating in the activation reaction to any notable extent. This is consistent with the observations in fly ash based geopolymers, where mullite and quartz are also identified as unreactive compounds (19), and the results of Rodríguez et al (15) in alkali-activated specimens based on a Spanish SFCC material. In samples formulated with an Na 2 O/SiO 2 ratio of 0.20 (Fig.…”

Section: X-ray Diffractionsupporting

confidence: 92%

Section: Introductionmentioning

confidence: 96%

“…Preliminary work activating SFCC catalysts to form geopolymers (14,15) showed good mechanical strength in the activated SFCC specimens. This was attributed to the dissolution of the zeolite phases in the spent catalyst, promoting the formation of a crosslinked aluminosilicate type gel (15). The high reactivity of SFCC, along with its chemical composition rich in Al and Si, makes it a suitable precursor for production of geopolymers; however, there is not yet a good understanding of the mechanism of reaction of these materials, or detailed identification of the factors controlling their microstructural evolution.…”

Section: Introductionmentioning

confidence: 96%

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Synthesis of geopolymer from spent FCC: Effect of SiO2/Al2O<3 and Na2O/SiO2 molar ratios

Trochez¹,

Gutiérrez²,

Rivera³

et al. 2015

Mater. construcc.

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This paper assesses the feasibility of using a spent fluid catalytic cracking catalyst (SFCC) as precursor for the production of geopolymers. The mechanical and structural characterization of alkaliactivated SFCC binders formulated with different overall (activator + solid precursor) SiO 2 /Al 2 O 3 and Na 2 O/ SiO 2 molar ratios are reported. Formation of an aluminosilicate 'geopolymer' gel is observed under all conditions of activation used, along with formation of zeolites. Increased SiO 2 /Al 2 O 3 induces the formation of geopolymers with reduced mechanical strength, for all the Na 2 O/SiO 2 ratios assessed, which is associated with excess silicate species supplied by the activator. This is least significant at increased alkalinity conditions (higher Na 2 O/SiO 2 ratios), as larger extents of reaction of the spent catalyst are achieved. SiO 2 /Al 2 O 3 and Na 2 O/SiO 2 ratios of 2.4 and 0.25, respectively, promote the highest compressive strength (67 MPa). This study elucidates the great potential of using SFCC as precursor to produce sustainable ceramic-like materials via alkali-activation. RESUMEN: Sintesis de geopolimero basado en un catalizador gastado de craqueo catalitico (FCC): Efecto de las relaciones molares SiO 2 /Al2O 3 y Na 2 O/SiO 2 . Este artículo estudia la factibilidad de usar un catalizador gastado del proceso de craqueo (SFCC) para la producción de geopolímeros. Se evalúan las características mecánicas y estructurales de los geopolímeros producidos con diferentes relaciones molares (activador + precursor solido) de SiO 2 /Al 2 O 3 y Na 2 O/SiO 2 . La formación de un gel geopolimérico de tipo aluminosilicato se observa a las diferentes condiciones evaluadas, así como la formación de zeolitas. Un incremento en la relación SiO 2 /Al 2 O 3 genera geopolímeros de baja resistencia mecánica, a las diferentes relaciones molares Na 2 O/SiO 2 evaluadas, como consecuencia del exceso de especies silicato provenientes del activador. Este efecto es menos significativo al incrementar las condiciones de alcalinidad (mayores relaciones Na 2 O/SiO 2 ), ya que un mayor grado de reacción del catalizador gastado es alcanzado. Las relaciones SiO 2 /Al 2 O 3 y Na 2 O/SiO 2 de 2.4 and 0.25, respectivamente, promueven la mayor Resistencia a la compresión (67 MPa). Este estudio muestra el gran potencial de uso del SFCC como precursor en materiales cerámicos obtenidos por activación alcalina.

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Section: X-ray Diffractionsupporting

confidence: 92%

Section: Introductionmentioning

confidence: 96%

Section: Introductionmentioning

confidence: 96%

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Synthesis of geopolymer from spent FCC: Effect of SiO2/Al2O<3 and Na2O/SiO2 molar ratios

Trochez¹,

Gutiérrez²,

Rivera³

et al. 2015

Mater. construcc.

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“…These materials have an increasing interest in scientific and technological fields, and they are an excellent alternative to the extensive usage of OPC. Compared to OPC, they are more sustainable and have less environmental footprint, as well as, the required energy to be manufactured is less, generating between 60 and 80 % less CO 2 emissions [13].…”

Section: Introductionmentioning

confidence: 99%

“…Accordingly, geopolymer can be formulated using a silicate or aluminosilicate as precursors, while alkaline sources can include any soluble substance supplying alkali metal cations, raise the pH of the mixture of reaction, and accelerate the dissolution of the solid precursor (such as alkali hydroxides, silicates, carbonates, sulfates or aluminates). There are several research studies on geopolymers which used a wide variety of waste materials for their formulation: metallurgical slag, fly ash from thermal power, red mud from aluminum industry, ash from rice husk combustion, vanadium mining waste, ashes from palm oil, waste from ceramic and glass industry, among others [8][9][10][11][12][13][14]. Their properties depend on the composition of these secondary sources and on the used alkaline ion, and especially, on the polycondensation conditions reaction.…”

Section: Introductionmentioning

confidence: 99%

Geopolymers based on the valorization of Municipal Solid Waste Incineration residues

Giró-Paloma

Maldonado-Alameda

Formosa

et al. 2017

IOP Conf. Ser.: Mater. Sci. Eng.

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Use of municipal solid waste incineration bottom ash and crop by-product for producing lightweight aggregate J Giro-Paloma, V Ribas-Manero, A Maldonado-Alameda et al.-APC fly ashes stabilized with Portland cement for further development of road sub-base aggregates J Formosa, J Giro-Paloma, A MaldonadoAlameda et al. Abstract. The proper management of Municipal Solid Waste (MSW) has become one of the main environmental commitments for developed countries due to the uncontrolled growth of waste caused by the consumption patterns of modern societies. Nowadays, municipal solid waste incineration (MSWI) is one of the most feasible solutions and it is estimated to increase in Europe where the accessibility of landfill is restricted. Bottom ash (BA) is the most significant by-product from MSWI as it accounts for 85 -95 % of the solid product resulting from combustion, which is classified as a non-hazardous residue that can be revalorized as a secondary aggregate in road sub-base, bulk lightweight filler in construction. In this way, revalorization of weathered BA (WBA) for the production of geopolymers may be a good alternative to common reuse as secondary aggregate material; however, the chemical process to obtain these materials involves several challenges that could disturb the stability of the material, mainly from the environmental point of view. Accordingly, it is necessary that geopolymers are able to stabilize heavy metals contained in the WBA in order to be classified as non-hazardous materials. In this regard, the SiO 2 /Al 2 O 3 ratio plays an important role for the encapsulation of heavy metals and other toxic elements. The aim of this research is to formulate geopolymers starting from the 0 -2 mm particle size fraction of WBA, as a unique raw material used as aluminumsilicate precursor. Likewise, leaching tests of the geopolymers formulated were performed to assess their environmental impact. The findings show that it is possible to formulate geopolymers using 100 % WBA as precursor, although more investigations are needed to sustain that geopolymer obtained can be considered as nonhazardous materials. IntroductionNowadays, within a circular economy, waste is a pressing environmental, social, and economic subject, which is gradually accepted and revalorized as a secondary resource. From the last 20 years, waste incineration (waste-to-energy plants, WtE) has grown progressively; hence, the incineration of municipal solid waste (MSWI) residues has become an appreciated alternative in waste management. Thermal energy recovery is a key in the management model of MSW in Europe. This allows the energy recovery contained in the MSW, decreasing the managed fraction in landfills, according to the management hierarchy and guidelines of Directive 2008/98 / EC [1]. The MSWI has increased by 60 % since the last 20 years [2], allowing reducing the waste mass and volume, and it generates energy over combustion. Although a substantial waste reduction can be obtained, during the MSWI process, about 20 % of the non-combustib...

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The Capacity of Alkali‐Activated Industrial Wastes in Novel Sustainable Ceramic Membranes

Shiwa,

Khosravi,

Mohammadi

et al. 2024

ChemBioEng Reviews

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Novel ceramic membranes present unquestionable potential in wastewater treatment among the emerging technologies, while a few challenges such as cost, energy consumption, durability, and resistance in harsh mediums still limit their commercialization. Here, we review the capability of available industrial aluminosilicate waste materials in the fabrication of novel ceramic membranes using green and economical alkali‐activation synthesis method. The different sources of alkali‐activated aluminosilicate wastes including ashes, mining wastes, glass and ceramic wastes, slags, construction wastes, industrial byproducts, and agricultural wastes are introduced and the chemistry of geopolymers is reviewed. In this review, the major points are the following. 1) The alkali‐activated structures present reasonable chemical, frost, carbonation, and mechanical resistance as well as the ability to immobilize the toxic materials. 2) The synthesis aspects of porous and nonporous alkali‐activated ceramic membranes are explored by characterization methods. Furthermore, the durability analysis in harsh environments reveals that alkali‐activated ceramic membranes possess high resistance against acidic, alkaline, and other antifouling chemical washing methods. In summary, it is demonstrated that the studied membranes have an undeniable capability in the separation of organic solvents in the pervaporation process as well as toxic material removal from water with high ion‐exchange capacity.

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

Cited by 85 publications

References 59 publications

Synthesis of geopolymer from spent FCC: Effect of SiO<sub>2</sub>/Al<sub>2</sub>O<3 and Na2O/SiO2 molar ratios

Synthesis of geopolymer from spent FCC: Effect of SiO<sub>2</sub>/Al<sub>2</sub>O<3 and Na2O/SiO2 molar ratios

Geopolymers based on the valorization of Municipal Solid Waste Incineration residues

The Capacity of Alkali‐Activated Industrial Wastes in Novel Sustainable Ceramic Membranes

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