Influence of Accelerators on Cement Mortars Using Fluid Catalytic Cracking Catalyst Residue (FCC): Enhanced Mechanical Properties at Early Curing Ages.

Supplementary cementitious materials (SCMs) have been used in the construction industry to mainly reduce the greenhouse gas emissions associated with Portland cement. Of SCMs, the petrochemical industry waste known as fluid catalytic cracking catalyst residue (FCC) is recognized for its high reactivity. Nevertheless, the binders produced using SCMs usually present low mechanical strength at early curing ages. This study aims to assess the effect of different accelerating additives (KOH, sodium silicate SIL, commercial additive SKR) on the mechanical strength of mortars containing FCC. The results show that after only 8 curing hours, the compressive strength gain of the FCC mortars containing SKR was over 100% compared to the FCC mortar with no additive (26.0 vs. 12.8 MPa). Comparing the compressive strength of FCC mortar containing SKR to the control mortar, the enhancement is spetacular (6.85 vs. 26.03 MPa). The effectiveness of the tested accelerators at 8-24 curing hours was KOH ≈ SIL < SKR, whereas it was KOH < SIL < SKR for 48 h-28 days. The thermogravimetric data confirmed the good compatibility of FCC and the commercial accelerator.

Reusing Construction and Demolition Waste to Prepare Alkali-Activated Cement.

Large amounts of waste are derived not only from construction processes, but also the demolition of existing buildings. Such waste occupies large volumes in landfills, which makes its final disposal difficult and expensive. Reusing this waste type is generally limited to being employed as filler material or recycled aggregate in concrete, which limits its valorisation. The present work proposes reusing construction and demolition waste to manufacture alkali-activated cement to improve its sustainability and recovery. Construction and demolition waste (C&DW) from a demolition waste collection plant in Valencia (Spain) was physically and chemically characterised. This residue contained large fractions of concrete, mortar, bricks, and other ceramic materials. X-ray fluorescence (XRF) analysis showed that its chemical composition was mainly CaO, SiO2 and Al2O3. X-ray diffraction (XRD) analysis revealed that it presented some crystalline products, and quartz (SiO2) and calcite (CaCO3) were the main components. Blends of C&DW and blast furnace slag (BFS) were alkali-activated with mixtures of sodium hydroxide and sodium silicate. The corresponding pastes were characterised by techniques such as thermogravimetry and scanning electron microscopy (SEM). The alkali-activated mortars were prepared, and the resulting mortars' compressive strength was determined, which was as high as 58 MPa with the 50% C&DW-50% BFS mixture. This work concluded that it is possible to make new sustainable binders by the alkali activation of C&DW-BFS without using Portland cement.

Hybrid Lime-Pozzolan Geopolymer Systems: Microstructural, Mechanical and Durability Studies.

This work studies the possibility of using geopolymer materials to enhance the mechanical and durability properties of hydrated lime-pozzolan mixtures, which gave rise to the so-called "hybrid systems". Two different waste types were used as pozzolan in the lime-pozzolan system: rice husk ash (RHA) and spent fluid catalytic cracking (FCC). The geopolymer fabricated with FCC was activated with commercial reagents (NaOH and Na2SiO3), and also with alternative sources of silica to obtain a lower carbon footprint in these mixtures. The alternative silica sources were RHA and residual diatomaceous earth (RDE) from the beer industry. The geopolymer mixture substituted the lime-pozzolan mixture for 30% replacement in weight. The hybrid systems showed better mechanical strengths for the short and medium curing ages in relation to the lime-pozzolan mixtures. Thermogravimetric analyses were performed to characterise the types of products formed in these mixtures. In the durability studies, hybrid systems better performed in freeze-thaw cycles and obtained lower capillarity water absorption values.