Structure and Properties of Phosphate-Based Geopolymer Synthesized with the Spent Fluid Catalytic-Cracking (SFCC) Catalyst.

As a common industrial by-product, the spend fluid catalytic-cracking (SFCC) catalyst was used to prepare phosphate-based geopolymer for the first time. The structure and property of geopolymer with phosphoric acid concentration ranging from 6 to 14 mol/L was characterized by compressive strength measurements, X-ray powder diffraction (XRD), Fourier Transform Infrared spectroscopy (FTIR), scanning electron microscopy (SEM), and Al and Si nuclear magnetic resonance (NMR). A stable binder was formed with the compressive strength in the range of 9.8 to 30.2 MPa when the acid concentration was between 6 and 12 mol/L. The higher concentration of acid can promote the dissolution of raw materials and formation of geopolymer gels. The coordination of silicon and aluminum in geopolymer gel synthesized with the SFCC catalyst and metakaolin is similar. Compared with the geopolymer with metakaolin, which forms more Si-O-Al bonds, in the networks of geopolymer with the SFCC catalyst, more Si(Al)-O-P bonds were formed. These results indicate that the SFCC catalyst can be an excellent raw material for the synthesis of phosphate-based geopolymer.