A study on the oil-based drilling cutting pyrolysis residue resource utilization by the exploration and development of shale gas

Characteristics of heavy metal migration during pyrolysis of typical oily wastes and environmental risk assessment of pyrolysis residues

Solid-phase residues from pyrolysis of oily wastes (OS) are widely used due to their rich pore structure and strong adsorption capacity. In this study, pyrolysis residues (OS-P) were obtained from the pyrolysis treatment of four typical OS in Karamay, Xinjiang. The results indicate that the crystalline substances in OS-P mainly were SiO2, BaSO4, and graphite. The heavy metals of OS-P were higher than that of OS in the following order: Zn > Cu > Ni > Cr > Pb > Cd. The results of the improvement of Community Bureau of Reference (BCR) sequential extraction showed that the proportion of Cu, Ni and Cr in OS1-P in the residual fraction was higher than that of the other three OS. The residual fraction of Cu, Ni, and Cr in OS1-P increased from 16.0 %, 30.0 %, and 11.0 % to 66.1 %, 81.9 %, and 89.2 %, respectively. After pyrolysis treatment, the leaching concentration of heavy metals in the residue was reduced. Referring to the requirements for heavy metal control limits (GB 4284-2018), all heavy metals in OS-P showed low risk. Their potential ecological risk indices were 4.11, 3.13, 4.87 and 5.35, respectively, indicating that the potential ecological hazards of heavy metals from OS-P were slight. There was no significant effect on the histopathological changes of kidney, lung, liver, ovary and testis of mice, showing that the rational use of OS-P in production will not produce toxic effects on target animals. Based on risk assessment and safety evaluation, the application of OS-P is controllable, safe and reliable for resource utilization.

Preparation and characterization of high-performance ceramic proppant from recycling utilization of oil-based drilling cuttings pyrolysis residues

Oil-based drilling cutting pyrolysis residues (ODCPRs), bauxite, and sintering additives were applied to manufacture ceramic proppants with low density and high strength in this work. The effect of ODCPRs ratio, sintering temperature, holding time, and the content of additives on the performance of the proppants was comprehensively investigated, respectively. And the sintering mechanism of proppants was also discussed according to the phase, microstructure, and thermal behavior analyses. The results revealed that at the best sintering condition (1280 °C, holding for 60 min), and a mass ratio (ODCPRs: bauxite: MnO2 at 3:7:0.1), the well-developed granular corundum and acicular mullite formed inside the proppants and interspersed with each other to form a dense structure. The proppants presented low density and high strength as the bulk density of 1.48 g/cm3, the apparent density of 2.94 g/cm3, a breakage ratio of 5.25% under 52 MPa closed pressure, and the acid solubility of 4.80%, which could well meet the requirement of the standards of SY/T 5108-2014. This work provided a new pathway for recycling ODCPRs and the fabrication of high-performance proppants.

Thermal plasma vitrification treatment of oil-based drill cuttings: Product characterization and harmless transformation

Oil-based drill cuttings (OBDCs) are hazardous wastes associated with the process of oil and gas extraction. In this paper, OBDCs were treated using a self-designed plasma vitrification system. The basic physicochemical properties of the OBDCs were analyzed, followed by a plasma vitrification mechanism investigation of the OBDCs. The environmental pollution risk of the vitreous slags obtained from thermal plasma treatment was also evaluated with the heavy metal extraction toxicity procedure. The batch of vitreous slags with an average glass phase content of 98.60% had a dense and smooth surface and an oxygen-to-silicon (O/Si) ratio ranging from 3.68 to 4.32, according to the findings. The melting temperature and treatment duration have a great effect on the loss ratio on acid dissolution. The leaching concentrations of Pb and Zn were 0.0004 mg/L and 0.068 mg/L, respectively, consistent with the chlorination reaction promoted by thermal plasma. Fourier transform infrared spectroscopy analysis showed that there was no organic matter in the vitreous slag, achieving the goal of harmless transition. The specific energy consumption of vitreous slags was predicted and verified by response surface methodology (RSM). This study describes the vitrification process and harmless treatment of OBDCs by thermal plasma technology, and vitreous slags have great potential for resource utilization.

Investigation on the pollution release characteristics of subgrade base materials prepared by oil-based cutting thermal desorption residues

The preparation of oil-based cutting thermal desorption residues into subgrade materials is one of the methods of their resource utilization. While the environmental safety for subgrade materials is lack of discussions. In this study, through the semi-dynamic leaching tests, the leaching characteristics of pollutants from residues subgrade materials under extremely acidic conditions were simulated. According to Fick's second law, combined with the effective diffusion coefficient (D_e), the risk of pollutant leaching and release in residue subgrade materials were evaluated. The concentrations of naphthalene, anthracene, benzo(a)anthracene, dibenzo(a,h)anthracene, Cd, and Zn met the requirements of class III water quality in the Chinese standard GB/T14848-2017. The release of naphthalene, anthracene, benzo(a)anthracene, dibenzo(a,h)anthracene, and Cd of leaching was dominated by diffusion. The release of benzo(a)pyrene and Zn of leaching was mainly dissolution. Hence, based on the investigation, the release law and characteristics of pollutants were explored when thermal desorption residues were applied as subgrade materials, which provided an important reference basis for the resource and utilization of oil-based cutting thermal desorption residues.

Treatment of drilling fluid waste during oil and gas drilling: a review

Oil and gas exploration and development provide important energy sources for the world, and drilling fluid is an essential engineering material for oil and gas exploration and development. During the drilling of oil wells, drilling fluids are eventually discarded as waste products after many cycles. Abandoned drilling fluid constitutes one of the largest wastes generated during oil and gas exploration and development. Drilling fluid contains many chemicals, which turn into pollutants during use. Furthermore, when drilling is carried out to reach reservoir, the drilling fluid becomes contaminated with crude oil. It may also mix with groundwater containing salts and heavy metals. The resulting pollutants and harmful substances threaten the environment, humans, animals, and plants. The variety and complexity of drilling fluid waste have increased in recent years. Various countries and regions are paying more attention to the ecological environment, and effective methods are urgently needed to solve problems associated with of environmental pollution caused by drilling fluid wastes. At present, various physical, chemical, and biological methods have been proposed for the treatment of drilling fluid wastes: safe landfilling, stabilization/solidification treatment, physicochemical treatment, thermal treatment, supercritical fluid treatment, bioremediation, etc. All of these methods show promising characteristics, and they each have advantages and limitations; thus, treatment methods need to be selected according to the actual application scenarios. This critical overview is based on an extensive literature review, and it summarizes and expounds on the current drilling fluid waste treatment technologies and proposes views future potential and outlook.

Human carcinogenic risk analysis and utilization of shale gas water-based drilling cuttings in road materials

Water-based drilling cuttings (WDC) generated during shale gas development will endanger human health and ecological security. The modern analytical techniques are used to analyze the organic pollutants in WDC, and the human health and ecological security risks of harmful pollutants in WDC under specific scenarios are evaluated. The results showed that the content of organic pollutants in WDC was evaluated by human health and safety risk assessment. The comprehensive carcinogenic risks of all exposure pathways of single pollutant benzo(a)anthracene, benzo(a)pyrene, benzo(k)fluoranthene, and indeno(1,2,3-cd)pyrene were acceptable. However, the cumulative carcinogenic risk of exposure to dibenzo(a,h)anthracene particles via skin exposure was not acceptable. It was considered that only dibenzo(a,h)anthracene had carcinogenic effect, and the risk control limit of dibenzo(a,h)anthracene in WDC was 1.8700 mg/kg by calculation. As well as, the "WDC-cement" gel composite structure was deeply analyzed, and the physical and chemical properties and mechanism of organic pollutants in cement solidified WDC were analyzed, which provided theoretical support for the study of WDC pavement cushion formula. Based on the above conclusions and combined with the actual site, by studying and adjusting the formula of WDC pavement cushion, the WDC pavement cushion was finally designed by 6% cement + 50% WDC + 44% crushed stone. The 7d unconfined compressive strength met the requirements of the Chinese standard "Technical Guidelines for Construction of Highway Roadbases" (JTG/T F20-2015). Also, the process route of WDC as road cushion product was sampled and analyzed. In addition, the leaching concentration of main pollutants all met the relevant standards of China. Therefore, this study can provide a favorable way for the efficient, safe, and environmentally friendly utilization of WDC, and ensure the ecological environment safety and human health safety of WDC in resource utilization.

The effect of added organic matter on the soil formation of oil-based drill cutting pyrolysis residue

In order to explore the effects of added organic matters on the soil formation process of oil-based drill cutting pyrolysis residue, two experiment groups (pure and adding) were studied to indicate the soil microbial community and the function of nitrogen cycling. Samples were collected in the third and fourth years based on the plant growth. The 16S rRNA high-throughput sequencing technology and PICRUSt were used to study microbial communities and the function of nitrogen cycling. The results showed that MND1 (2.5-4.5%), Sphingomonas (1.4-2.4%), and other typical oil-degrading bacteria were discovered. The diversity of the microbial community decreased with the duration of the experiment. However, it was higher than that of the background soil. The relative abundance of microbial nitrogen dissimilation reduction (0.9-1.0‰) was the highest among the two experiment groups and the background soil. The second and third were denitrification and nitrogen fixation. Nitrification gene abundance was the lowest among the five main steps of nitrogen cycling. The addition of organic matters could improve soil formation of pyrolysis residues. This study provides scientific data for pyrolysis residue to restore soil functions.

Particular pollutants, physical properties, and environmental performance of porous ceramsite materials containing oil-based drilling cuttings residues

The mineral compositions of oil-based drilling cutting residues (ODCRs) were similar to that of clay, which could be used as raw materials for ceramsite. In this study, the maximum addition of ODCRs and the optimum calcination conditions were studied by single factor experiment. The microstructure, phase composition, and element distribution of ceramsite were studied by means of SEM, XRD and EDS. The ceramsite, with a 40% ODCRs content, was calcined at 1000 °C for 2 h. After cooling down, the ceramsite had good physical properties, including low density, low water absorption, and high compressive strength. The bulk density was 850-970 kg/m³, the water absorption was 2.1-10%, and the cylinder compressive strength was 6-11.8 MPa. And most of the heavy metals in ODCRs were effectively solidified. The organic toxic substances were completely burned. The leaching amount of harmful elements met the requirements of Chinese standards. The ceramsite would avoid secondary pollution to the environment. So the ceramsite made from ODCRs can not only improve the processing speed of ODCRs, but also be used as building materials, greening materials, industrial filter materials, etc., and increase its environmental and social benefits.

Leaching behavior of polycyclic aromatic hydrocarbons (PAHs) from oil-based residues of shale gas drill cuttings

Cuttings are the main solid residues which are generated from drilling operations. Due to the presence of heavy and radioactive elements, the environment risk posed by cuttings has attracted increasing attention. In this work, a short-term static immersion experiment was carried out to investigate the leaching of polycyclic aromatic hydrocarbons (PAHs) from oil-based residues of shale gas drilling cuttings. Furthermore, the effects of some relevant environmental factors controlling the leaching behavior were evaluated, including the different particle sizes, pH, extraction time, solid-to-liquid (S/L) ratio and dissolved organic matter (DOM) concentration. The results showed that (1) the concentrations of leached PAHs gradually increased with prolonged leaching time, but the cumulative amount of PAHs released during leaching was less than 3% of the total. (2) The Elovich, parabolic diffusion and power function models were found to fit the experimental data better than the first-order kinetic equation, indicating that the leaching of PAHs was controlled by the coupling of diffusion and chemical reactions at the source surface. (3) Different environmental factors had different impacts on the leaching of PAHs: the shaking time and presence of DOM increased leachability, the particle size and S/L ratio decreased leachability, and the pH did not affect the leachability of PAHs. Therefore, PAHs leaching was a complex process, and it is of scientific and environmental interest to conduct the leaching tests under the simulated environmental conditions.

Risk assessment of human exposure to heavy metals, polycyclic aromatic hydrocarbons, and radionuclides in oil-based drilling cutting residues used for roadbed materials in Chongqing, China

Oil-based drilling cutting residues (OBDCRs) contain many kinds of carcinogenic contaminants, such as heavy metal elements, polycyclic aromatic hydrocarbons (PAHs), and natural radioactive materials (NORMs), which are great risks for the environment and human health. This study investigated the chemical composition, the radioactive strength, the heavy metal contents, and the org matter contents in OBDCRs and estimated the health risks due to exposure to heavy metals, PAHs, and radionuclides in OBDCRs used for roadbed materials. From the measurements, it was found that the content values of benzopyrene (a), diphenylanthracene (a, h), and petroleum hydrocarbons exceeded the standard limit. The content values of Cu, Zn, As, and Ni were higher than 50% of the standard limit. If OBDCRs were directly used to make roadbed materials, the total carcinogenic risk values (CR_n) of As, benzoanthracene (a), benzopyrene (a), and dibenzoanthracene (a, h) were all higher than 10^-6. The average absorbed dose rate was higher than 80 nGy/h. There were greater risks of carcinogenic environment and potential harms to human health. To reduce the health risks, it is necessary to consider the strategy of the utilization of OBDCRs, the working time, and the service life of the recycled OBDCRs and establish a legal standard and liability for the utilization of OBDCRs as solid waste resources.

Study on In Situ Catalytic Cracking of Coal Tar by Plasma Preparation of the Pyrolysis Coke Catalyst

A two-stage pyrolysis fixed bed was used, and the vapor-modified pyrolysis coke was used as a carrier. A ZHPC catalyst was prepared by plasma calcination. Gas-phase tar produced by the pyrolysis of raw coal was subjected to in situ catalytic cracking to improve tar and gas yield. The effects of plasma calcination power, calcination time, and ZnO loading on in situ cracked products were studied. The prepared catalyst was characterized by X-ray electron spectroscopy, X-ray diffraction, Brunauer-Emmett-Teller, and scanning electron microscopy. The results showed that (1) compared with traditional catalysts, the catalyst prepared by plasma has better performance; (2) the optimal calcination time of the ZHPC catalyst is 5 min, calcination power is 60 W, and ZnO loading is 10%; (3) compared with raw coal pyrolysis, the optimal ZHPC catalyst on in situ catalytic cracking tar, gas yield increased by 66.16%; the cracking rate of tar increased by 54.46%, and the content of light components increased to 60.7%; (4) in situ catalytic cracking of tar with the optimal PC, the light tar has been greatly improved, in which the light oil, phenol oil, naphthalene oil, and wash oil have increased by 93.04, 126.31, 257.28, and 108.08%, respectively. The anthracene oil and asphalt have decreased by 26.98 and 58.71%; the tar cracking rate has increased.

An effective recycling direction of water-based drilling cuttings and phosphogypsum co-processing in road cushion layer

The technology used in the production and exploration of shale gas creates a new source of clean energy. However, during the processes, large amounts of water-based drilling cuttings (WDC) are generated. Phosphogypsum (PG) is a by-product from the industry of phosphate fertilizer. Approximately, 5 tons of PG are generated for the production of per ton of phosphoric acid. The pile up of WDC and PG lead to severe risks of nearby soil and surface water. This paper paid attention to the recycling of WDC and PG as major raw materials in the preparation of construction cushion layer. In the research, physical properties, microstructure, and environmental pollution of the road cushion layer prepared from WDC and PG were investigated. The results show that the physical properties of compactness and unconfined compressive strength are basic meet the China national standard. The WDC cushion layer mainly constitutes of AFt, C-S-H, and plate-like Ca(OH)₂ around the mineral phases. The leaching test revealed that the contaminants in the layer do not exceed the limits allowed by the "National Overall Discharge Standard of Sewage" (GB 8978-1996). This paper therefore outlines the effects that provide an effective way for the utilization of WDC and PG.

Selecting a suitable model for collecting, transferring, and recycling drilling wastes produced in the operational areas of the Iranian offshore oil company (IOOC) using analytical hierarchy process (AHP)

Waste from drilling operations of oil and gas wells in the event of poor management, in addition to imposing costs, can lead to environmental problems. This research was aimed at providing a suitable model for collecting, transferring, and recycling the drilling wastes produced in the operational areas of the Iranian offshore oil company. Data analysis was performed using the Expert Choice and template selection using the analytical hierarchy process method. Based on the results of this study, the method of collecting waste in a cutting skip (weight = 0.576) was identified as a suitable option in the waste-collecting sector. In the waste transfer sector, the waste shipments from the west of the Persian Gulf to Kharg Island (weight 0.623) and the transfer of waste from the Eastern areas to Lavan island (weight 0.625) were selected as suitable options. Among the waste recycling options, the thermal method with of 0.433 was chosen as a top priority.

Performance of desulfurization ash for the preparation of grouting fire prevention material

The accumulation of desulfurization ash from coal-fired power plants can lead to serious waste of land resources and environmental safety problems. This work presents an experimental study on the feasibility of recycling original desulfurization ash as the main raw materials, and a new green grouting material was prepared. The results indicate that a desulfurization ash-based grouting fire prevention material which was prepared according to the following ingredient design (a water-to-solid ratio of 1.0:1 and a hydroxyethyl cellulose content of 0.09% desulfurization ash, 12% quicklime, 0.6% Na₂SO₄, and 0.05% triethanolamine, 80 °C curing). The slurry's viscosity meets requirements, and its suspension, liquidity, and consolidation strength are better than those of clay under the same conditions. In addition, the grouting material's inhibitor ratio is increased with temperature increase, which means it has good flame retardancy. Environmental performance tests concluded that when desulfurization ash as-recycled admixture is used for the preparation of grouting fire prevention material, from the technique point of view, the environmental safety of them is very good.

Static decontamination of oil-based drill cuttings with pressurized hot water using response surface methodology

Separating organic pollutants from oil-based drill cuttings (OBDC) is the current trend for its safe disposal. In this study, pressurized hot water extraction (PHWE) was adapted to decontaminate OBDC for the first time. Two typical OBDC samples, i.e., diesel-based drill cuttings (OBDC-A) and white oil-based drill cuttings (OBDC-B), were statically extracted in a homemade batch autoclave. Response surface methodology (RSM) with a central composite design (CCD) was applied to investigate the effects and interactive effects of three independent operating parameters (temperature, extraction time, and water volume) and to ultimately optimize the PHWE process. The results suggested that temperature is the dominant parameter, followed by water volume and extraction time. Interactive effects among the three parameters are present in the PHWE of OBDC-A but absent in the PHWE of OBDC-B. The suitable conditions for the effective PHWE of OBDC-A were found to be a temperature of 284-300 °C, water volume of 15-35 ml, and extraction time of 20-60 min. The corresponding conditions were 237-300 °C, 15-35 ml, and 20-60 min for the PHWE of OBDC-B. These different phenomena are caused by the different characteristics of the two OBDC samples. All of the polynomial models obtained from the RSM experiments are very valid and can adequately describe the relationship among the three independent operating parameters and responses. The experimental results also confirmed that PHWE is a more efficient separation technique for decontaminating OBDC than single organic solvent extraction or low-temperature thermal desorption because PHWE integrates the advantages of both these processes.