Recycling of waste spent catalyst in road construction and masonry blocks

Waste spent catalyst is generated in Oman as a result of the cracking process of petroleum oil in the Mina Al-Fahl and Sohar Refineries. The disposal of spent catalyst is of a major concern to oil refineries. Stabilized spent catalyst was evaluated for use in road construction as a whole replacement for crushed aggregates in the sub-base and base layers and as a partial replacement for Portland cement in masonry blocks manufacturing. Stabilization is necessary as the waste spent catalyst exists in a powder form and binders are needed to attain the necessary strength required to qualify its use in road construction. Raw spent catalyst was also blended with other virgin aggregates, as a sand or filler replacement, for use in road construction. Compaction, unconfined compressive strength and leaching tests were performed on the stabilized mixtures. For its use in masonry construction, blocks were tested for unconfined compressive strength at various curing periods. Results indicate that the spent catalyst has a promising potential for use in road construction and masonry blocks without causing any negative environmental impacts.