The effect of waste oil-cracking catalyst on the compressive strength of cement pastes and mortars

Epcat, one of the spent fluid catalytic cracking (FCC) catalysts from oil-cracking refineries, shows pozzolanic activity. In this study, pastes and mortars with Epcat were prepared and cured, and their compressive strengths after 3, 7 and 28 curing days were measured. The water/binder (W/B) ratios were 0.2, 0.25 and 0.3, and the replacement levels of cement by Epcat were 0, 5, 10 and 15 wt.%. Proper amount of superplasticizer was added into each mix to ensure similar workability. The results indicate that the presence of Epcat would increase the compressive strength of mortars substantially, but increase the compressive strength of the related pastes only slightly. Epcat mortars with W/B=0.25 show more strength-enhancing effect than those with W/B=0.3, and this effect increases with the catalyst content. Therefore, the mix (W/B=0.25) incorporated 15% Epcat exhibits the greatest compressive strength (92.3 MPa). For mortars with W/B=0.2, the strength-enhancing effect occurs only for those containing 5% catalyst; this effect becomes unclear when mixes containing 10% Epcat or more because high dosage of superplasticizer was added in obtaining proper workability and that affects the strength development. The improvement in the mechanical properties of mortars is attributed to the increase in the hydrated cement paste itself and, more importantly, improved bonds between the cement paste and aggregate.