The effect of spent FCC catalyst on early hydration (up to 48 h) of high aluminate cement (Al2O3 >70%) at different ambient temperatures (10, 20, and 30 °C) was investigated. Cement pastes with constant ratio of water/binder = 0.35 (binder = cement + addition) and containing 0, 5, 10, and 15% mass of addition as replacement of cement were studied. The hydration kinetics was determined by calorimetric measurements and the structure of hardened binders after 2 days of curing at an appropriate temperature was also investigated using X-ray, SEM, and thermal analysis methods. Due to the fact that hydration of aluminate cements is highly sensitive to temperature conditions as well as certain changes of temperature are inevitable in practice, the evaluation of the impact of the waste catalyst addition in such conditions is justified. On the basis of obtained results, it was stated that the temperature determines the early hydration of high aluminate cement and decides about the influence of waste aluminosilicate. The introduction of the discussed addition has a big impact on the kinetics of cement hydration closely related to the curing temperature. The presence of spent catalyst accelerates the hydration at the temperatures of 20 and 30 °C, but at the temperature of 10 °C this waste aluminosilicate acts as a retarding agent. The effect of the addition on the microstructure of hardened binders after 48 h of hydration is rather insignificant, especially at 20 °C, compared to the influence of the temperature on hydration. At the temperature of 10 °C, a formation of low amount of C2AH8 can be observed because of the presence of spent catalyst, while at the temperature of 30 °C the introduction of the mineral addition prevents the hydrogarnet formation.
1. Lee, WE, Vieira, W, Zhang, S, Ahari, KG, Sarpoolaky, H, Parr, C 2001 Castable refractory concretes. Int Mater Rev 46 3 145–167 .
2. Scrivener, KL, Capmas, A 1998 Calcium aluminate cements, Chap 13 PC Hewlett eds. Lea's chemistry of cement and concrete Wiley New York 709–778.
3. Antonovič, V, Pundienė, I, Stonys, R, Čėsnienė, J, Kerienė, J 2010 A review of the possible applications of nanotechnology in refractory concrete. J Civ Eng Manag 16 4 595–602 .
4. Parr C . Calcium aluminate cement—what happens when things go wrong. In: Technical Paper IRE annual conference, 2008, vol. 33, pp 1-11.
5. Bensted, J 2004 Scientific aspects of high alumina cement. Cem Lime Concr 3:109–133.
6. Smith, A, Chotard, T, Gimet-Breart, N, Fargeot, D 2002 Correlation between hydration mechanism and ultrasonic measurements in an aluminous cement: effect of setting time and temperature on the early hydration. J Eur Ceram Soc 22:1947–1958 .
7. Heikal, M, Morsy, MS, Radwan, MM 2005 Electrical conductivity and phase composition of calcium aluminate cement containing air-cooled and water-cooled slag at 20, 40 and 60°C. Cem Concr Res 35:1438–1446 .
8. Taylor, HFW 1998 Cement chemistry Thomas Telford London.
9. Hidalgo, A, Garcia, JL, Alonso, CM, Fernandez, L, Andrate, C 2009 Microstructure development in mixes of calcium aluminate cement with silica fume or fly ash. J Therm Anal Calorim 96 2 335–345 .
10. Pacewska, B, Nowacka, M, Wilińska, I, Kubissa, W, Antonovic, V 2011 Studies on the influence of spent FCC catalyst on hydration of calcium aluminate cements at ambient temperature. J Therm Anal Calorim 105 1 129–140 .
11. Payá, J, Monzó, J, Borrachero, MV 1999 Fluid catalytic cracking catalyst residue (FC3R). An excellent mineral by-product for improving early-strength development of cement mixtures. Cem Concr Res 29:1773–1779 .
12. Pacewska, B, Bukowska, M, Wilińska, I, Swat, M 2002 Modification of the properties of concrete by a new pozzolan—a waste catalyst from the catalytic process in a fluidized bed. Cem Concr Res 32:145–152 .
13. García de Lomas, M, Sánchez de Rojas, MI, Frías, M 2007 Pozzolanic reaction of a spent fluid catalytic cracking catalyst in FCC-cement mortars. J Therm Anal Calorim 90 2 443–447 .
14. Pinto, CA, Büchler, PM, Dweck, J 2007 Pozzolanic properties of a residual FCC catalyst during the early stages of cement hydration Evaluation by thermal analysis. J Therm Anal Calorim 87 3 715–720 .
15. Dweck, J, Pinto, CA, Büchler, PM 2008 Study of a Brazilian spent catalyst as cement aggregate by thermal and mechanical analysis. J Therm Anal Calorim 92 1 121–127 .
16. Payá J , Monzó J, Borrachero MV, Garcés P, Mellado A, Velázquez S, Soriano L, Zornoza E. Outstanding aspects on the use of spent FCC catalyst in binders. In: López FA, Puertas F, Alguacil FJ, Guerrero, A (eds) 1st Spanish National Conference on Advances in Materials Recycling and Eco—Energy, Madrid 2009, Paper S04-19, pp 160-163. http://digital.csic.es/handle/10261/18626.
17. Pacewska, B, Wilińska, I, Bukowska, M 2009 Calorimetric investigations of the influence of waste aluminosilicate on the hydration of different cements. J Therm Anal Calorim 97 1 61–66 .
18. Stonys, R, Pundienė, I, Antonovič, V, Goberis, S, Aleknevičius, M 2008 The effect of waste oil-cracking catalyst on the properties of MCC-type castable. Mater Sci 14 1 59–62.
19. Pacewska B , Wilińska I, Nowacka M, Pundiene I, Aleknevicius M. Studies on the influence of aluminosilicate additive on initiation steps of high calcium aluminate cement hydration. In: 10th International Conference Modern Building Materials, Structures and Techniques, Vilnius, 2010, vol 1, pp 228-233.
20. Aleknevičius, M, Antonovič, V 2009 Calorimetric investigations of high aluminate cement hydration in the presence of waste oil-cracking catalyst. Chem Technol 2 51 33–38.
21. Information of Górkal cement producer. www.gorka.com.pl.
22. Gawlicki, M, Nocuń-Wczelik, W, Bąk, Ł 2010 Calorimetry in the studies of cement hydration. Setting and hardening of Portland cement–calcium aluminate cement mixtures. J Therm Anal Calorim 100 2 571–576 .
23. Lou, W, Guan, B, Wu, Z 2010 Calorimetric study of ternary binder of calcium aluminate cement, Portland–limestone cement and FGD gypsum. J Therm Anal Calorim 101 1 119–127 .
24. Pacewska, B, Wilińska, I, Nowacka, M 2011 Studies on the influence of different fly ashes and Portland cement on early hydration of calcium aluminate cement. J Therm Anal Calorim 106 3 859–868 .
25. Oliveira, IR, Pandolfelli, VC 2009 Castable matrix, additives and their role on hydraulic binder hydration. Ceram Int 35:1453–1460 .
26. Bushnell-Watson, SM, Sharp, JH 1990 On the cause of the anomalous setting behaviour with respect to temperature of calcium aluminate cements. Cem Concr Res 20 5 677–686 .
27. Snellings, R, Mertens, G, Elsen, J 2010 Calorimetric evolution of the early pozzolanic reaction of natural zeolites. J Therm Anal Calorim 101 1 97–105 .
28. Hidalgo, LA, Garcia, JL, Garcia, OJ, Petit, S, Alonso, CM 2008 Microstructural evolution of calcium aluminate cements hydration with silica fume and fly ash additions by scanning electron microscopy, and mid and near-infrared spectroscopy. J Am Ceram Soc 91 4 1258–1265 .