ECO-Zement: Reuse of fluid catalytic cracking waste from oil refineries in cement-based materials

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Efeito da incorporação de resíduo da indústria petrolífera nas propriedades mecânicas de argamassas

Publication . Costa, Carla; Geada, Rita

O presente artigo apresenta resultados preliminares de um projeto, em curso, no qual o objetivo final é investigar a viabilidade da utilização de um resíduo produzido na refinação do petróleo em materiais à base de cimento. Os valores do Índíce de Atividade - determinados com base nos valores da resistência à compressão de argamassas com substituição parcial de cimento pelo resíduo - mostraram que, ao fim de 7 dias de hidratação, o resíduo já apresenta atividade pozolânica em argamassas com incorporação de resíduo até 15%, e que esta atividade é também evidente nas argamassas com incorporação de 20% de resíduo ao fim de 28 dias de hidratação.

2012-03Conference object

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Tailor-made SCC incorporating spent equilibrium catalyst from oil refinery

Publication . Nunes, Sandra; Costa, Carla

The spent equilibrium catalyst (ECat) is a waste generated by the oil-refinery industry with very high pozzolanic activity and, therefore, has a great potential as an addition in SCC. This paper describes research on the use of factorial Design of Experiments (DoE) approach to design SCC mortar mixtures incorporating ECat. As such, a central composite design was carried out to mathematically model the influence of mixture parameters and their coupled effects on deformability, viscosity, compressive strength, resistivity and ultrasonic pulse velocity. Thereafter, a numerical optimization technique was applied to the derived models to select the best mixture, which simultaneously maximizes different engineering properties and eco-efficiency, while maintaining self-compactability.

2016Conference object

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Self-compacting concrete containing limestone and a waste oil refinery catalyst

Publication . Laginha, Inês; Raposeiro Da Silva, Pedro; Costa, Carla

This paper describes research on viability of producing self-compacting concretes (SCCs) with ternary blends of powder materials comprising cement, limestone powder (L) and a waste catalyst generated at the fluid cracking catalytic unit (FCC) by the oil-refinery industry. For this purpose, an experimental program was conducted to iteratively design mixture proportions of SCCs using 30% (v/v) limestone powder and 0-30% (v/v) of waste FCC catalyst as partial cement replacements in the powder materials blends. Tests of fresh-state SCCs were conducted for slump flow, V-funnel, and L-box. Compressive strength tests of hardened SCCs were conducted at 3, 7, 14 and 28 days of curing time. Results showed that SCCs containing high volumes - up to 60% (v/v) - of both additions, limestone and waste FCC catalyst, in powder materials blends achieve adequate self-compactability in compliance with European standard EN 206-9. Moreover, waste FCC catalyst incorporation in concretes composition leads to compressive strength gains. Besides standard requirements being fulfilled and the improvement in the concrete performance, the ample availability of the waste FCC catalyst (around 500 kton) in oil refineries worldwide make this waste a potential steady supply for the concrete industry. As such, large-scale manufacturing of innovative SCCs with recycle waste FCC catalyst is feasible in the future, making a significant contribution to lower the carbon footprint of the construction materials.

2014-01Conference object

Open access

Microscopy: a tool for quantitative pozzolanic activity in blended cements

Publication . Costa, Carla; Laginha, I.; Carvalho, P. A.

In the present study waste FCC catalyst has been incorporated in cement paste mortars with a 15:85 weight ratio. The microstructural evolution of the blended materials has been investigated by X-ray diffraction and scanning electron microscopy coupled with X-ray energy dispersive spectroscopy after curing times of 2, 7 and 28 days. Namely, the evolutions of the catalyst crystal structure and of the calcium content in the dispersed catalyst particles have been evaluated.

2013Journal article

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Effect of waste oil-cracking catalyst incorporation on durability of mortars

Publication . Costa, Carla; Ribeiro, M. Sofia; Brito, Nuno

This paper presents research on transport properties and alkali-silica reaction (ASR) susceptibility of mortars containing a pozzolanic waste generated in the fluid catalytic cracking (wFCC) unit by the Portuguese oil-refinery. For this purpose, two series of mortars were prepared by partially replacing cement with 5%, 10% and 15% of wFCC catalyst. The main difference between the two series of mortars is the sand reactivity used in their composition. The results revealed that wFCC catalyst blended cement mortars exhibit an increased resistance against capillary water absorption and chloride migration, as well as a considerable inhibition effect on deleterious ASR expansion. However, under the adopted experimental conditions the incorporation of wFCC catalyst in mortars decreases their carbonation resistance.

2014-10Journal article

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