REUSE OF WASTE CATALYST FROM PETROCHEMICAL
INDUSTRIES FOR CEMENT SUBSTITUTION
BY
MURITALA YUSUF
2004/18582EH
A PROJECT SUBMITTED TO
DEPARTMENT OF CHElVIICAL ENGINERING, FEDERAL
UNIVERSITY OF TECHNOLOGY, MINNA
NIGER STATE, NIGERIA. IN PARTIAL FULFILMENT OF THE
REQUIREMENT FOR THE AWARD OF BACHELOR OF
ENGINEERING (B. Eng) DEGREE IN CHEMICAL
ENGINEERING.
JANUARY, 2010.
'.
DECLARATION
I, Muritala Yusuf with matric number 2004/18582EH declare that this research project report is
my original work and has not been presented elsewhere to the best of my knowledge.
Muritala Yusuf. Date
ii
CERTIFICATION
This research project report by Muritala Yusuf has been examined and certified under the
Supervision of (Mrs.) M.D. Yahya to be adequate in scope and quality for the partial Fulfillment
of the requirement for the award of Bachelor of Engineering (B.Eng) in Chemical Engineering .
.... ~ ..................... . (Mrs.) M.D.YAHYA DATE
(Project Supervisor)
...........................................
Engr. 1.0. OKAFOR DATE
(Head of department)
............................................ . ....................... .
EXTERNAL EXAMINER DATE
iii
DEDICATION
This research project is dedicated first to Almighty Allah (S.W.T) for his love,
Provision and his guidance throughout my academic pursuit, my parents Alhaji and Alhaja
Muritala Omu- Iyadun and the entire family of Oladipo for their financial and moral support.
iv
ACKNOWLEDGEMENT
I must gladly express my profound gratitude to God for strength and the ability to observe and
complete undergraduate successfully. His grace and provisions were there even when the going
was though. I would not forget to appreciate those who, in one way or the other, rendered their
assistances towards my success during my undergraduate career.
My sincere gratitude goes to my project supervisor (Mrs.) M.D.YAHYA for her motherly advice
and directions throughout the project period, thank you ma, may God bless you and your family
~Amen). I also wish to acknowledge the contributions of the staff of Chemical Engineering
Department, Federal University of Technology Minna. Thanks for bringing me to the limelight.
My sincere appreciation goes to my parent Alhaji and Alhaja Muritala Omu iyadun, the entire
family of Omu-iyadun, Engr. Bashir .K. Oladipo, Alhaji Ahmmed .K.Oladipo, Abdulazeez .T.
Oladipo and the entire family of Oladipo, I so much thank you for your unrelenting efforts. May
God in His infinite mercies continue to be with you and give you guidance in life, may you reap
the fruit of your labour, Amen.
Furthermore, To my beloved sibling (Queen Lateefat and her Husband, Taofeek, Nurudeen,
Ismail, Abdulazeez, Abdulakeem, Saheed, Ibrahim and Hammed Omu-Iyadun) thank you all for
your support and encouragement throughout my program. Finally, To my dear friends, Kadir
jimoh, Adam,shittu Amidu ,Abdul-lateef Ayanwale, Salisu Barahu, and others for their technical
support and understanding May God bless youall.(Amin).
v
, ABSTRACT
The reuse of waste zeolite catalyst from petrochemical industries as partial substitute to cement
was researched on to convert waste to wealth. It was aimed at examining the physical and
chemical properties of the spent catalyst used ih fluid catalytic cracking unit (FCCU), an~ also to
explore an alternative way to reuse: Ecat and evaluating the impact of their uses on the
environment .The following analysis were conducted on the spent catalyst; the chemical
composition of spent zeolite catalyst by using Atomic Absorption Spectrometer (AAS), Flame
photometer shows that Ecat contains Mg, Oa, Na, Fe, K, ZI1 and Mn. Specific gravity test, Sieve
analysis test, Moisture content test and Bulk density test. The analysis revealed that Ecat contains
the following oxides: Si02 - 44 % ,Fe203 - 0.78 %, CaO - 0.004 %, Na20 - 0.99 % , K20 _
0.0363 %, ZnO - 0.006 %, The results gotten for the physical test of Ecat and fine aggregate
were shown in the tables respectively.
"i.
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TABLE OF CONTENT
Cover page .................................................................................................................. ..
Declaration ........................................ , ..................................................... 11
Certification .............................................................................................. iii
Dedication .................................. ,........................................ . ................. IV
Abknowledgeillent. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ................. v
Table of content. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . .................................. VI
Abstract. ................................................................ . . ...•..................... XI
CHAPTER ONE
1.0 Introduction ..................................................................................... l
1.1 Aim and Objective ................................................................ , ............ 2
1.2" Scopeofproject ................................................................ : ................ 2
CHAPTER TWO
2.0 Literature review .................................................................................. 3
2.1 Historical background ............................................................................. 3
2.1.1 Oil refinery. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . .......................... 3
2. 1.2 Fluid catalytic cracking unit (FCCU) ........................................................... 4
2.1.3 Catalyst. ...... : ..................................................................................... 5
2.1.4 Zeolite Catalyst. .............................................................................................. 5
vii
2.1.5 Portland cement ...... '" ........ , .............................................................................. 6
2.2 Properties of Cement and Catalyst. ........................................................... 7
2.2.1 Physical Properties of Cement. ........................................................... 7
2.2.2 Fineness ........................................................................ '" ........... 8
2.2.3 Soundness ................... ' .................................................................. 8
2.2.4 Setting Time ................................................................................... 9
2.2.5 Strengths ........................................................................ " ....... '" ... 10
2.2.6 Compressive strength ................................................... '" ...... '" ........ 12
2.2.7 Flexural strength ............................................................................ 12
2.2.8 Specific gravity test.. ......................................................................... 12
2.2.9 Physical Properties of Cement. .............................................................. 12
2.2.9.1 Hydration .......... ' ............................................................................. 12
2.2.9.2 Mineral Constituents of Cement. ........................................................... 13
2.3 Chemical Composition of Cement. ......................................................... 14
2.3.1 Heat ofI-Iydration ............................................................................ 15
2.3.2 Loss on Ignition .............................................................................. 16
2.4 Physical Properties of Catalyst. ............................................................. 16
2.5 Advantages of Zeolite ................................................... '" .......... " ...... 17
2.6 Enviromental Effect of Waste Zeolite Catalyst. ......................................... 17
2.7 Types of Cement alld Catalyst. ............................................................ 18
2.7.1 Types of portland cement and uses .................................................................... 18
viii
2.7.2 Types of zeolite catalyst and their uses ................................................... 20
2.7.3 Uses of zeolite catalyst ................................................................................ 20
2.7.2.1 Heating and Refrigeration .................................................................. 21
2.7.2.2 Detergents ...... ' ........................................................................ '" ... 20
2.7.2.3 Nuclear industry ............................................................................. 20
2.7.2.4 Gemstone ...................................................................................... 21
2.7.2.5 Space hardware testing ......................................................... '" ........... 21
2.7.2.6 Medical ....................................................................................... 21
2.7.2.7 Agriculture .................................................................................... 21
2.7.2.8 Animal husbandry ............................................................................ 22
2.7.2.9 Construction ................................................................................... 22
CHAPTER THREE
3.0 Experimental work ................................................................................ 23
3.l --', Materials used ............................................................................................... 23
3.2 List of apparatus and Equipment. ................................................................. 23
3.3 Preparation of digest ....................................... ' ....................................... 24
3.4 Quality test ......................................................................................... 24
3.4.1 Sieve analysis test. ............................................................................................... 24
3.4.2 Specific Gravity Test. ............................................................................... 24
3.4.3 Test for Moisture Content. ............................. , ......................................... 24
3.4.4 Bulk density test .................................................................................. 25
3.4.5 Deternlination of pH ............................................................................. 25
3.~.6 Determination of Bulk Density .................................................................. 25 ! l f'
3it7 Determination of Silicon (iv) Oxide ............................................................ 26
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3.4.8 Mix Proportion ..................................................................................... 27
3.4.9 Mixing ............................................................................................... 28
3.4.10 Casting and Compaction ........................................................................... 29
3.4.11 Curing ...................................................... :, ........................................ 29
CHAPTER FOUR
4.0 Results and discussion of results .................................................................. 30
4.1 Results ............................................................................................... 30
4.2 Discussion of result. ................................................................................. 37
CHAPTER FIVE
5.0 Conclusion and Recommendation ............................................................... 38
5.1 Conclusion ........................................................................................... 38
5.2 Recolllillendation ................................................................................... 38
References .......................................................................................... 39
Appendix ............................................................................................ 40
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