Desenvolvimento de aplicações em cerâmica e pasta de cimento utilizando o cascalho de perfuração de poços de petróleo na construção civil.

Abstract

The Oil Exploration and Production (E&P) industry provides an important energy source for the world. However, there is worldwide concern regarding the environmental impacts of E&P activities. Drilling cuttings (DC) and drilling fluid are some of the main residues generated during the drilling of oil wells. This research aims to develop is to develop ceramic materials and supplementary cementitious materials (MCS) using the oil well drilling cascade in civil construction. This study used a DC from an onshore well in Candeias (Brazil), cuttings collected with water-based (DC1) and cuttings n-paraffin-based (DC2) fluid. A milling study of the gravel and clay was performed, varying the time (2, 5, 10, 15, and 20 min) and the rotation speed (200 and 300 rpm), in which physical, chemical, and mineralogical analyses were carried out by through analytical techniques of helium gas pycnometry, particle size analysis, consistency tests, X-ray fluorescence (XRF), X-ray diffractometry (XRD)/Rietveld, thermogravimetric analysis (TG/DTA) and environmental risk analysis. Co-processing studies were performed on ceramic materials replacement natural clay by CAP1 at levels of 15, 30, and 45%, with ceramic pieces being made by uniaxial pressing and sintered at a heating rate of 5 °C/min with a threshold of 750 °C, 850 °C and 950 °C held for 90 min. After sintering, the physical and mechanical properties were evaluated. The phases formed for the different temperatures were quantified using XRD/Rietveld. Cement pastes were produced by partially replacing early-strength Portland cement (CPV) with CAP1 and CAP2 in 0, 5, 10, 15, 20, 25, and 30%. The hydration of the pastes was evaluated by isothermal calorimetry, XRD/Rietveld, TGA/DTA, Fourier transform infrared spectroscopy (FTIR), water absorption, capillary absorption, and axial compressive strength after 1, 3, 7, 28 and 91 days of curing. In addition, it was evaluated the influence of milling on the CAP1 reactivity used as a supplementary cementitious material in ternary cement (TC). The hydration of TC pastes containing DC1 with different granulometric distributions was evaluated by isothermal calorimetry, XRD/Rietveld at 3 and 28 days, compressive strength, and absorption. DC2 was not evaluated as CT because it did not benefit from milling. The co-processing results using DC1 in the ceramic mass showed that the sintering temperature and the increase in the DC content directly influence the mechanical properties of the red ceramic, in this sense, the studied formulations are a feasible alternative for manufacturing bricks and tiles. The incorporation of benefited DC1 improved the hydration kinetics of TC compared to the reference pastes. After 28 days, TC pastes with a D50% diameter smaller than 11 μm reached at least 70% of the reference strength. Cement pastes demonstrate the potential for application between 5% and 25% in substitution of PC for DC1 and DC2. Besides mitigating an environmental problem, reducing costs with raw materials for manufacturing cementitious materials will benefit the environment by preserving mineral resources (clay and limestone deposits). In the analyzed scenarios, the results indicated DC1 as an alternative environmentally appropriate raw material for the manufacture of ceramics, and DC1 and DC2 can be used as SCM to produce cement paste and ternary cement.