Oil-based drilling cutting pyrolysis residues- phosphogypsum foamed ceramics: Basic properties, microsintering mechanism and heavy metals solidification

Abstract

Oil-based drilling cutting pyrolysis residues(ODPR) and phosphogypsum(PG) are typical types of industrial solid waste in China, characterized by low utilization rate and high output. The large amount of untreated accumulation will release heavy metals(HMs) and other pollutants, posing risks to the environment. Therefore, there is an urgent need to develop a high value-added building material product that can reduce environmental hazards while improving utilization rate. Based on this background, this study uses ODPR and PG as raw materials to explore their potential applications in the field of foamed ceramics. Research has shown that different sintering processes have a significant impact on the appearance and performance of products. By adjusting the preparation process, foamed ceramic products with excellent performance can be prepared. When the sintering temperature is 925℃, the foaming agent dosage is 3 %, and the raw material ratio ODPR:PG:Borax=35:45:20, a foamed ceramic product with a porosity of 60.95 %, water absorption rate of 3.4 %, compressive strength of 4.8 MPa, thermal conductivity of 0.8016 W/(m·k), and acid and alkali resistance of 98.57 % and 99.44 % can be prepared. The product meets the relevant requirements of “Fired heat preservation brick and block (GB/T 26538)” and “ General Specification for porous ceramic products (GB/T 16533)”. The HMs content test showed that the Ni and Pb contents in the pre-sintered blanks were the highest, at 0.6308 mg/kg and 0.3182 mg/kg, respectively. However, after high-temperature calcination, the solidification rate of HMs could reach up to 98.93 %, and the leaching amount was significantly reduced. The three further evaluation methods indicate that HMs in the pre-sintered blanks and foamed ceramic products do not pose significant ecological risks. The research results provide a green inorganic insulation material in the field of solid waste control and building materials.