Research article

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Crude oil, a natural hydrocarbon mixture, is a key energy source and the petrochemical industry’s primary feedstock. Its large-scale processing produces heavy oil fly ash (HOFA), a solid waste that demands effective management. This study explores HOFA’s valorization as a low-cost, carbon-based filler in isotactic polypropylene (iPP) composites. Composites containing 1–20 wt% HOFA were prepared by extrusion and injection molding, then subjected to tensile, impact, and structural analyses (differential scanning calorimetry (DSC), wide angle X-ray scattering (WAXS), microscopy). Mechanical testing revealed that even small HOFA additions raised Young’s modulus proportionately to filler content, consistent with typical filled-polymer behavior. Impact strength increased by roughly 25% at both 1 and 20 wt% loadings, while tensile strength and elongation at break remained comparable to neat iPP. DSC and WAXS demonstrated that HOFA acts as a nucleating agent, promoting the β-crystalline phase, known to enhance toughness, without significantly altering the melting or crystallization temperatures.
These findings confirm that HOFA, a waste by-product, can be an effective filler for iPP, improving stiffness and impact resistance without compromising other key properties. Its use offers both economic advantages, through reduced material costs, and environmental benefits by diverting industrial waste from disposal. This approach holds promise for developing sustainable, high-performance polymer composites.