Valorization of oil-based drilling cuttings as a substitute for bauxite in fracturing proppants application

This study aimed to increase the scale of oil-based drilling cuttings (OBDCs) resource utilization in the ceramic industry. The sintering process and mechanism were explored based on the analysis of physicochemical properties, phase transitions, and microstructure. The results showed that (1) The main ceramic-technological characteristics of the OBDC were determined, which belonged to high-silica solid waste with a high Si–Al ratio and a low acid–base ratio of oxides. (2) The low meltability temperature of the OBDC could largely influence the determination of the sintering temperature range for ceramic products. (3) The chemical components OBDC provided were involved in the formation of molten phases, which could affect dimensional accuracy and mechanical properties. Meanwhile, the dolomite promoted the formation of closed pores and enhanced lightweight performance. (4) Before 800°C, dolomite decomposed and reacted with SiO₂ to form silicate, and then a new feldspar crystal appeared. After 1000°C, orthoclase completely melted into the molten phase, only two phases of quartz and diopside existed in the material until 1150°C. When the temperature was higher than 1350°C, the glass transition of the phase was basically intensified. (5) In the analyzed scenarios, the results indicated OBDC can only be doped in low contents and degrades the ceramic material properties.