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

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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.

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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).

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, 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

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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

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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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