Valorization of oil well drilling cuttings as a raw material in ceramic manufacturing

This study investigates the effect of clay replacement by oil well drilling cuttings (DC) in ceramic materials manufacturing. DC was added at 0, 15, 30 and 45 wt%. The raw materials were characterized by physical, chemical, and mineralogical analyses. Ceramic specimens were produced via uniaxial pressing and sintered at a constant heating rate (5 °C/min) for 90 min at three temperatures (750, 850, or 950 °C). Then, the samples were evaluated by linear firing shrinkage, apparent specific mass, water absorption, color, and flexural strength. Ceramic materials were analyzed by X-ray fluorescence spectrometry (XRF), thermogravimetric analysis (TG), Fourier transform infrared spectroscopy (FTIR), and X-ray diffractometry (XRD/Rietveld). Environmental risk assessment of ceramic products containing DC was investigated by leaching and solubilization tests. The results allow classifying the raw and the ceramic materials as non-hazardous and inert. Ceramics consisted mainly of quartz, illite, hematite, feldspar, primary mullite, and spinel. The sintering temperatures (from 750 up to 950 °C) and the increasing DC contents (up to 45%) directly affect the mechanical properties of the red ceramic, which are suitable to produce bricks, blocks and tiles. In the analyzed scenarios, the results indicated DC as an alternative raw material environmentally appropriate for the ceramic manufacturing. •Ceramic materials were sintered with DC and Clay at temperatures of 750, 850 and 950 °C.•The physical and mechanical properties of ceramic materials were studied.•Raw materials and ceramic materials were leached and solubilized.•Drilling cutting (DC) can be an environmentally friendly alternative raw material for ceramic manufacturing.