In the quest for sustainable construction materials, a team of researchers led by Carla Costa from the Lisbon School of Engineering (ISEL) at the Polytechnic University of Lisbon has made a significant breakthrough. Their study, published in the journal “Developments in the Built Environment” (translated as “Advances in the Built Environment”), explores the potential of upcycling a by-product from oil refineries into hydraulic lime mortars, offering a promising solution for the rehabilitation of historic buildings and a boon for the energy sector.
The research focuses on equilibrium catalyst (ECat), a by-product generated during the fluid catalytic cracking process in oil refineries. This process is crucial for converting heavy, high-boiling point oil fractions into lighter, more valuable products, but it also generates a substantial amount of spent catalyst. Traditionally, this by-product has been challenging to repurpose, often ending up in landfills.
Costa and her team employed a sophisticated statistical methodology known as Design of Experiments (DoE) to investigate how varying the content of ECat, along with other key mixing variables like water-to-binder ratio and water repellent dosage, affects the properties of hydraulic lime mortars. The goal was to optimize these mortars to maximize eco-efficiency while meeting regulatory and technological standards.
“The results are quite promising,” says Costa. “We found that ECat can be incorporated into hydraulic lime mortars at levels up to 56.6% by mass without compromising the mortar’s performance. This not only reduces the environmental impact of the built environment but also provides a viable solution for the oil industry’s spent catalyst by-product.”
The study’s findings highlight the potential for significant commercial impacts in the energy sector. By upcycling ECat, oil refineries can reduce disposal costs and potentially generate additional revenue streams from selling the by-product to the construction industry. Moreover, the use of these optimized mortars in building rehabilitation projects can contribute to the circular economy, promoting sustainability and technological innovation.
“The construction sector is always looking for sustainable and cost-effective materials,” explains Costa. “Our research shows that ECat-incorporated hydraulic lime mortars can be a game-changer, offering a sustainable alternative that meets the demands of modern construction while respecting the integrity of historic structures.”
This research not only opens new avenues for the construction industry but also underscores the importance of interdisciplinary collaboration. By bridging the gap between the energy and construction sectors, such innovations can drive forward the circular economy, fostering a more sustainable future.
As the world continues to grapple with the challenges of environmental sustainability, studies like this one offer a glimpse into a future where industrial by-products are not seen as waste but as valuable resources. The implications for the energy sector are profound, with the potential to transform waste management practices and contribute to a more sustainable built environment.
In the words of Costa, “This is just the beginning. The possibilities for upcycling industrial by-products in construction are vast, and we are excited to explore further innovations in this field.”