Exploitation of petroleum waste sludge with local bauxite

raw material for producing high-quality refractory

ceramics

The aim of this work is to exploit the petroleum waste sludge, through mixing with
different quantities of the natural raw bauxite, present in abundance in Al zubierah
area in Saudi Arabia, to manufacture high-quality refractory ceramics for use at high
temperature applications.
El objetivo de este trabajo es explotar el lodo de desecho de petróleo, mediante la mezcla
con diferentes cantidades de bauxita cruda natural, presente en abundancia en el área de
Al zubierah en Arabia Saudita, para fabricar productos de alta calidad Cerámica
refractaria para uso en aplicaciones de alta temperatura.

The oil sludge , which is the result of various oil industry processes like: drilling of
wells, collecting pools, transport, storage tanks and refining, is one of the most
important solid wastes, because it is a complex emulsion of various hydrocarbons,
water, heavy metals and solid particles.
El lodo de hidrocarburos, que es el resultado de varios procesos de la industria del
petróleo (perforación de pozos, la recogida de piscinas, de transporte, tanques de
almacenamiento y re fi Ning) es uno de los más importantes los residuos sólidos, es una
emulsión compleja de varios hidrocarburos, agua, metales pesados y partículas sólidas.
The solid wastes generated during different industries are increased day-by-day
causing harm to ecology system as dumped without remediation resulting in harmful
consequences.
Los residuos sólidos generados durante diferentes industrias se incrementan día a día
causando daño a la ecología como sistema de vertido sin remediación que resulta en
consecuencias perjudiciales.
The latest technological advances in the oil refining industry around the world,
especially in the Kingdom of Saudi Arabia, are in large quantities fuel waste from
refineries, the sludge is characterized by high carbon content, usually the form
Disposal of waste is associated with contamination of groundwater and in the
landscape, the ocean coast and rivers.
Los últimos avances tecnológicos en la industria de las refinerías de petróleo en todo el
mundo, especialmente en el Reino de Arabia Saudita, son en gran cantidad desechos de
combustible de las refinerías, el lodo se caracteriza por un alto contenido de carbono,
generalmente la forma de eliminar los desechos está asociada con la contaminación del
agua subterránea y en el paisaje, la costa oceánica y los ríos.
Some authors reported a way to use these sludge in the manufacture of new
environmentally friendly construction products, which can be used as bricks, tiles and
ceramic materials.
Through studies, its success in reducing the toxicity of some heavy metals through
their incorporation in the ceramic product.
The idea of exploitation and utilization of these huge quantities of solid waste,
associated with the various petroleum operations, can be directed to refractory
ceramics through their partial additions to bauxite mineral which is abundant natural
raw material in Saudi Arabia. The manufacture of such high-quality ceramic
materials will push in the contribution of the Saudi economic.
Algunos autores informaron una manera de utilizar estos lodos en la fabricación de nuevos
productos de construcción respetuosos con el medio ambiente, que pueden ser utilizados
como ladrillos, tejas y materiales cerámicos rojos.
Mediante estudios se informó su éxito en la disminución de la toxicidad de algunos metales
pesados mediante su incorporación en el producto de cerámica.
Por lo tanto, la idea de la explotación y la utilización de estas grandes cantidades de
residuos sólidos (lodos) asociados con las diversas operaciones de petróleo, puede ser
dirigida a cerámicas refractarias a través de sus adiciones parciales a la bauxita mineral
que es abundante materia prima natural en Arabia Saudita. La fabricación de materiales
cerámicos tales de alta calidad empujarán en la contribución de la Arabia económica.
Bauxite is the main sourc-+*e of aluminum.
The main components of bauxite are aluminum oxides which can be converted into
other aluminum products.
Is usually red or brown in nature, and is formed across the processes of ventilation,
filtration and sedimentation, and often contains impurities such as titania, silica, iron
oxide, aluminum silicate in addition to aluminum oxide.
Few countries of the world have huge reserves of bauxite, one of them is the Kingdom
of Saudi Arabia in which it is found in the area between Hail and Qassim, Million
metric tons of bauxite are available.
La bauxita es la principal fuente de aluminio.
Los principales componentes de la bauxita son óxidos de aluminio que se puede
transformar en otros productos de aluminio.
Es generalmente de color rojo o marrón en la naturaleza, y se forma a través de los
procesos de ventilación, fi filtración y sedimentación y a menudo contiene impurezas tales
como óxido de titanio, sílice, óxido de hierro, silicato de aluminio, además de óxido de
aluminio.
Son pocos los países del mundo tienen grandes reservas de bauxita, uno de ellos es el
Reino de Arabia Saudita en la que se encuentra en la zona entre Hail y Qassim (Zubaira)
millones de toneladas de bauxita están disponibles.
This work is multi valuable because it compromises between economic and
environmental impacts in addition to providing the market with a new product (high-
quality refractory ceramics used as lining of industrial furnaces in high temperature
industries e.g., cement, iron and steel, ceramics, glass …etc.).
Este trabajo es multi valiosa porque compromete entre los impactos económicos y
medioambientales, además de proveer el mercado con un nuevo producto (cerámica
refractaria de alta calidad se utilizan como revestimiento de hornos industriales en las
industrias de alta temperatura, por ejemplo, cemento, hierro y acero, cerámica, vidrio ...
etc.).

Some samples were made with different amounts of bauxite and oil mud, as you can see
in the Table 1.
the oil residue sludge and bauxite are dried and analyzed by x-ray before beginning the
mixing for each of the samples and observing which is best according to the amounts of
each compound.
Los lodos de residuos de petroleo y la bauxita son secadas y analizadas mediante rayos x
antes de comenzar la mezcla para cada una de las muestras y observar cual es mejor de
acuerdo a las cantidades de cada compuesto.

PROCESS:
For prepare the ceramic bodies… in this proyect first…
First were prepared some batches, in the table 1 we saw which of them, with differents
percentages of residual oil sludge and bauxite.

1. The molds are placed on a surface with a plastic and oil is added to the walls of the mold.
2. The mixture is deposited in the mold and the mixture is compacted in the mold.
3. After 5 hours drying in the mold, they are removed from the mold and wait 24 hours to
fully dry in the environment.

4. In accordance with the regulations, the refractory ceramics undergo another drying
process in the oven at 110ºC for approximately 18 hours.
However, in this process it was observed that it is actually a water evaporation process that
is present in the refractory ceramic and the objective is to eliminate it from the solid
composition of the refractory ceramic already manufactured.
5. To determine the compression break strength, any hydraulic press can be used, with the
ability to reach higher pressures than expected in the test.

6. Pressure is applied slowly. The increase in pressure continues until the moment of
rupture of the sample.

7. The calculation of the cold compression stress is defined by the following formula:

S = F_max / A
S = COLD COMPRESSION EFFORT
F_max = maximum applied force
A = Area perpendicular to the load line.

6 ** Determine the compressive breaking strength that any hydraulic press can use, in
accordance with ASTM C133-97

7. The calculation of cold bending stress (MOR) is defined by the following expression:

P = Is the maximum applied total breaking load

(in N)
L = Is the measurement between supports (in mm)
w = Is the width of the specimen (in mm)
l = its depth (in mm).

Finally the bodies were dried at 110°C in an electric dryer, then subjeted to different
cooking temperatures up to 1600°C.
EXPLAIN THE IMÁGENES
Here we can see how bauxite is mined as it is being brought into the industry.
Then we have an industrial dryer where, after mixing bauxite with petroleum mud, that
mixture is brought there.
And at the end we can see a portable DELTA XRF analyzer, this tool is to analyze bauxite
by X-ray.
----------
Here we have an example of industrial drying.
-----------------

PROPERTIES…

Thermal shock resistance (cycle)

6.2. Thermal shocks resistance
Table 7 shows the thermal shock resistance of the prepared ceramic
bodies at 1500 °C. The table shows that the prepared ceramic bodies for the mixes (M1-
M3) could resist more than 30 cycles of firing at 1000 °C and directly immersing in water
without any sign of cracks.
The prepared ceramic bodies from mixes (M4 and M5) were unable to resist more than 27
and 22 cycles.
Resistencia al choque térmico (ciclo)
6.2. Resistencia a los choques térmicos.
La Tabla 7 muestra la resistencia al choque térmico de la cerámica preparada
cuerpos a 1500 ° C. La tabla muestra que los cuerpos de cerámica preparados para las
mezclas (M1-M3) podrían resistir más de 30 ciclos de cocción a 1000 ° C y sumergirse
directamente en agua sin ningún signo de grietas.
Los cuerpos cerámicos preparados a partir de mezclas (M4 y M5) no pudieron resistir más
de 27 y 22 ciclos.

The ability of mixes (M1-M3) ceramic bodies to withstand thermal shocks is attributed to
its high content of bauxite ore as a source of aluminum oxide and silicon oxide, as well as a
significant proportion of petroleum waste sludge as a source of barium oxide and silicon
oxide. All these oxides are high temperature oxides, which react together to form mullite
(3Al2O3.2SiO2) and barium aluminate (BaO.Al2O3) minerals with low reversible thermal
expansion that enhancing their ability to stand against thermal shocks.
  La capacidad de las mezclas (M1-M3) de cerámica
los cuerpos para soportar choques térmicos se atribuyen a su alto contenido de mineral de
bauxita como fuente de óxido de aluminio y óxido de silicio, así como una proporción
significativa de lodo residual de petróleo como fuente de bario óxido y óxido de silicio.
Todos estos óxidos son óxidos de alta temperatura, que reaccionan juntos para formar
minerales de mullita (3Al2O3.2SiO2) y aluminato de bario (BaO.Al2O3) con baja
expansión térmica reversible que mejoran su capacidad de resistir los choques térmicos.