Development of sustainable conductive cementitious composite using graphite-coated spent catalyst waste

This study presents an innovative approach to developing sustainable conductive composites by coating graphite onto the surface of spent catalyst waste through nano-surface engineering techniques. The process ensures uniform adsorption of graphite onto the surface of the spent catalyst waste particles, followed by oven treatment and milling. This results in better integrity and effective bonding, leading to the production of graphite-coated spent catalyst waste (G-SCW). Scanning electron microscopy indicates the successful coating of spent catalyst waste with graphite. The research investigates the effect of G-SCW on the cementitious properties of paste and mortar. Incorporating G-SCW results in acceptable workability and setting time, while the compressive strength increases at early and later stages, with up to 20 % G-SCW content. The addition of GSCW in the mortar significantly reduces the electrical resistivity, resulting in a 63 % reduction in resistivity compared to the reference mix, thereby enhancing the conductivity. Hydration studies confirm the presence of pozzolanic reaction in blended paste, as evidenced by a decrease in calcium hydroxide content. The sustainability assessment indicates a substantial reduction in embodied carbon and possibly producing mortar with lower cement content. These findings suggest great potential for developing sustainable conductive mortar with G-SCW, enabling smart building construction, and supporting sensor networks for structural health monitoring.