THE EFFECTIVENESS OF OIL SLUDGE INCLUSION IN CERAMIC MATERIALS

ABSTRACT

This article analyzed the preliminary physico-chemical analysis necessary for the replacement of raw materials used in the production of ceramic products with cheaper alternatives and the use of oil refinery sludge, which is considered industrial waste. Through the numbers obtained from oil sludge incineration, we have witnessed several patterns. Of course, the result expected from these studies has its importance in obtaining a quality product later.

АННОТАЦИЯ

В данной статье проанализирован предварительные результаты физико-химических анализов отходов нефтепереработки – нефтешлама. По содержанию основных компонентов нефтешлама можно использовать в качестве как альтернативное доступное сырья в составе масс для производства керамических материалов.

Keywords: oil sludge, mechanical mixtures, utilization, ceramics, sintering.

Ключевые слова: нефтешламы, механические смеси, утилизация, керамика, спекание.

Currently, the efficiency of all industrial sectors should be evaluated in terms of the balance between the mass of the main product and the volume of generated man-made waste. These include gypsum from phosphorus fertilizer production plants, coal fly ash from thermal power plants, and oil sludge waste from oil refineries [1, 2, 3].

Despite the continuous improvement of oil extraction and processing technologies, they have not yet reached the level of zero-waste production. Taking into account the large amount of waste produced in the process of oil extraction and their negative impact on the biosphere, it is an urgent task to develop new methods of disposal of oily waste. There are great opportunities for waste disposal in enterprises that produce ceramic materials, which is certainly related to the large-ton consumption of the construction industry [4].

Oil refining waste with organic additives can be used not only as a component, but also as a combustible additive in the production of ceramic materials. The group of combustible additives includes various types of solid and liquid fuels. They are included in the composition of the mass up to 3-5% by weight and make up ~ 30,0-50,0% of the total fuel requirement for burning products. The purpose of this is to strengthen the sintering process, to ensure uniform central and surface temperature of the mass during sintering, and at the same time to increase the strength of the products.

Table 1.

Characteristics of oil sludge

The oil refinery of Fergana region is one of the enterprises that have been operating for many years. Despite the continuous improvement of oil refining technologies, they have not yet reached the level of absolutely waste-free production. Therefore, taking into account the large accumulation of oil production waste and their negative impact on the biosphere, the development of new methods of their disposal is a very urgent problem.

Oil sludge is a complex physico-chemical mixture consisting of oil products, mechanical impurities (clay, metal oxides, sand) and water. The differences between the sludges are explained by the region where the oil from which they were processed and the process by which they were separated. Oil sludge is produced during production processes such as oil refining, extraction and transportation. This type of waste is a serious threat to the environment and must be disposed of or recycled.

 Figure 1. Infrared spectrum sequence of oil sludge:a) the oil sludge; b) dehydrated oil sludge; oil sludge burned at temperatures of - c) 300° C; d) 500° C; e) 650° C

Oil sludge can be formed as a result of all kinds of accidents (spills) in the process of cleaning oil from impurities and water. Depending on the method of formation and physico-chemical composition, oil sludge is divided into several types: a) formed at the bottom of various reservoirs after an oil spill; b) is formed in the process of oil production, more precisely, in the process of refining it. The fact is that the oil extracted from the well contains a lot of salts, precipitated solid hydrocarbons, mechanical impurities (including rock particles), and their cleaning is the primary task; c) collector oil sludge is the waste generated during oil storage and transportation in various tanks; d) soil formed from the combination of soil and oil spilled on it (the reason for this can be both a technological process and an accident).

In this article, oil sludge formed at an oil production enterprise in Fergana city is studied. The main characteristics of oil sludge are determined according to the standard and are listed in Table 1 [5].

Figure 2. Infrared spectrum of oil sludge burned at 650°C

Figure 1 shows the IR spectroscopic analysis of the oil sludge residues produced in the oil sludge extraction device of the "Fergana Oil Refinery Plant" LLC, workshop 5, obtained on the IRSpirit-T model SHIMADZU device in the laboratory of the Fergana Polytechnic Institute. It can be seen from the obtained IR spectra that the free water (3420 cm-1) in the initial (a) oil sludge was evaporated during dehydration. At the same time, organic functional groups (methyl, ethyl, aromatic, etc.) in spectra a, b, c from 2850 to 2954 cm-1 burned and coked at 500°C.

Table 2.

Elemental analysis

That is, in the IR spectral analysis of oil sludge burned at 650°C (Fig. 2), water and organic impurities in the oil sludge have completely disappeared, and we can find only mechanical impurities and inorganic signals in it. (1120/1111 cm-1 (O-Si-O), 611 cm-1 (Al-O₂), 593 cm-1 and 555 cm-1 (Fe-O)…).

 Figure 3. X-ray image of oil sludge fired at 650°C

When comparing the obtained analysis results, the changes of the functional groups in the initial and burnt oil sludge were also confirmed by the elementalanalysis of the oil sludge and the X-ray analysis of the residue of the oil sludge burnt at 650°C (Fig. 3).

Table 2 shows the elemental chemical analysis of oil sludge obtained on the PANalytical Epsilon4-10 device at the Institute of General and Inorganic Chemistry of the UzRFA (water was used as a solvent, helium gas was used), hydrogen, carbon, and oxygen elements were not taken into account due to the capabilities of the device.

It is known from the table that both in the oil slurry and when burned at 650°C, it mainly consists of elements such as residual iron, sulfur, chlorine, aluminum, silicon, and most of the iron is unbound. This amount of iron is small compared to the mechanical mixture in the total oil mud.

Conducted studies show that oil sludge waste is important in the production of ceramic products.

References:

1. Eminov A.M., Khamdamova S.S., Khokimov A.E. RECYCLING INDUSTRIAL WASTE INTO HIGH-PERFORMANCE CERAMICS // Universum: технические науки : электрон. научн. журн. 2023. 3(108). URL: https://7universum.com/ru/tech/archive/item/15145
2. Khokimov A.E. USE OF PHOSPHOGIPS IN SILICATES // Universum: технические науки : электрон. научн. журн. 2022. 5(98). URL: https://7universum.com/ru/tech/archive/item/13700
3. Абдрахимов В.З., Кайракбаев А.К. Исследование отходов нефтедобычи нефтяного шлама // Сборник научных трудов по итогам международной научно-практической конференции // Омск-2015. 168 с.
4. Holanda J.N.F., Pinheiro B.C.A. Processing of red ceramics incorporated with encapsulated petroleum waste // Journal of Materials Processing Technology, 209 (2009) 5606–5610. Accepted 17 May 2009, Brazil.
5. ГОСТ 6370-83. «НЕФТЬ, НЕФТЕПРОДУКТЫ И ПРИСАДКИ» , метод определения механических примесей.