Spent fluid catalytic cracking (FCC) catalysts were gathered from Iran’s petrochemical plants and calcined at 1250◦C that led to the stabilization of V2O5 in the liquid phase. Therefore, the calcining process at 1250◦C converts the hazardous spent FCC catalyst to the non-hazardous aluminosilicate raw material. In this work, two grades of mullite with 60 and 70 wt.% Al2O3 were synthesized successfully with the calcined spent FCC, calcined alumina and metallurgical alumina. The sintered samples had a high level of mullite phase along with high bulk density and low water absorption. Additionally, the samples that contain metallurgical alumina had a higher level of mullite phase content than the samples that contain calcined alumina. The considerable results of the synthesized mullites from this work present cost reduction of the synthetic mullite production that can consume all the spent FCC catalyst in Iran under the environmentally friendly process.
