RU2804370C1 - Composite building material - Google Patents

Abstract

FIELD: construction.

SUBSTANCE: invention can be used in road construction, during the construction of embankments and soil embankments of construction and production sites of oil and gas fields, when filling landfills of household and industrial waste, filling industrial sites, backfilling and reclamation of quarries, sludge pits, sludge accumulators, waste landfills and artificial land excavations. The technical result of the invention is to reduce the use of cement in the manufacture of building materials with high bulk density and compressive strength, which is achieved due to the fact that a composite building material containing drill cuttings, sand, cement, and additionally contains a surfactant, oil destructor, dolomite flour, filler - crushed stone and gravel from rocks, slag crushed stone, ash and slag mixture and gypsum, with the following component ratio, wt.%: sand - 10-30; cement - 5-10; drill cuttings - 50-70; surfactant - 0.5-1.5; oil destructor - 0.5-1.5; specified filler - 1-10; dolomite flour -1-3.5.

EFFECT: reduced use of cement in the manufacture of building materials with high bulk density and compressive strength.

6 cl, 3 tbl

Description

The invention relates to the field of construction, and can be used in road construction, during the construction of embankments and soil embankments of construction and production sites of oil and gas fields, when filling landfills of household and industrial waste, filling industrial sites, backfilling and reclamation of quarries, sludge pits, sludge accumulators, waste landfills and artificial land excavations [C04B28/04, C04B18/00, C04B18/049].

A METHOD FOR MANUFACTURING ARTIFICIAL SOIL LITHOGROUND is known from the prior art.

[RU2682920C1, publ. 02/06/2018], which consists of mixing raw materials, which use drilling waste and/or drilled rock, or soil contaminated with hydrocarbons and/or oil-containing waste, with sand and cement. After increasing the viscosity of the stirred mass, an aqueous dispersion of polyvinyl acetate (PVAD) with a polyvinyl acetate concentration of 10-15 wt is added to it. % and continue stirring until the mass is homogenized. The components are used in the following ratio, in% of the original volume of raw materials: raw materials - 100, sand - 10-100, cement - 0.1-30, PVAD - 0.1-2.0. It is preferable to use cement in the form of a dry mixture with soluble silicate with a volume ratio of cement to silicate from 10:1 to 1000:1. In addition, during stirring, additional sorbent and/or quicklime is added in an amount of 0.01-10% of the original volume of raw materials. The invention makes it possible to impart increased plastic properties to the granules obtained during processing (and the massif as a whole), leading to an increase in the resistance of the material to atmospheric aging, destruction under load and frost resistance of the material to an indicator of at least 20 cycles, during which the material does not lose its strength characteristics for more than than 25% of the original ones.

Also known from the prior art is a METHOD FOR PROCESSING DRILLING CUTS FROM OIL WELLS [WO2007102743, publ. 09/13/2007] wherein the slurry waste contains drill cuttings, drilling fluid and, in an embodiment, oil components; this method includes the following steps: adding an anti-setting substance to the original suspension; loading the suspension into the mixing tank; adding a combination of binding materials and, if necessary, water to form a set mixture, encapsulating solids, drilling fluid and petroleum products, which is carried out so that the solids, drilling fluid and petroleum components do not leach into the environment after setting, while an anti-retardation agent setting aids in setting and/or curing of said setting product.

Also known from the prior art is a ROAD-BUILDING COMPOSITE MATERIAL - “SOIL CONCRETE” [RU2015107333A, publ. 03.03.2015] characterized by the fact that it contains drill cuttings, cement as the main binder in the amount of 4-16% by weight of the mixture, a desiccant and mineral filler, as well as improving additives, while ground construction lime is used as a desiccant in the amount of 1 -3% by weight of the mixture, and as a mineral filler - natural sand in an amount of 20-75% of the weight of the mixture and, if necessary, crushed stone or other frame filler in an amount of 40-60% of the total volume, drill cuttings can be used at a density of 1 ,10 to 1.85 kg/dm and any humidity, while ensuring the optimal structure of the hardened material and the optimal moisture content of the mixture during compaction by assigning the composition of “Soil Concrete” and the content of components, taking into account their properties.

The closest in technical essence to the COMPOSITE BUILDING MATERIAL [RU2720523C1, publ. 10/01/2019] which contains: drill cuttings 100%, sand 10-20% of the volume of drill cuttings, Portland cement or Portland slag cement of at least strength grade M300 8-15% of the volume of drill cuttings, quicklime 5-7% of the volume of drill cuttings , ash and slag mixture 5-10% of the volume of drill cuttings, spent drilling fluid 5-7% of the volume of drill cuttings.

The main technical problem of the analogues and the prototype is the high consumption of cement in the preparation of building materials, due to the lack of the required amount of surfactants in the composition of the above materials.

The objective of the invention is to eliminate the shortcomings of the prototype.

The technical result of the invention is to reduce the use of cement in the manufacture of building materials with high bulk density and compressive strength.

The specified technical result is achieved due to the fact that a composite building material containing drill cuttings, sand, cement, characterized in that it additionally contains a surfactant - surfactant, oil destructor, dolomite flour, filler - crushed stone and gravel from rocks, crushed slag stone , ash and slag mixture and gypsum, with the following ratio of components, wt.%:

sand - 10-30;

cement - 5-10;

drill cuttings - 50-70;

Surfactant - 0.5-1.5;

oil destructor - 0.5-1.5;

specified filler - 1-10;

dolomite flour -1-3.5.

In particular, the plasticizer LST is used as a surfactant.

In particular, the plasticizer LSTM-2 is used as a surfactant.

In particular, superplasticizer C-3 is used as a surfactant.

In particular, the plasticizing-air-entraining additive ShchSPK is used as a surfactant.

In particular, the plasticizing-air-entraining additive GZhK-10 is used as a surfactant.”

Implementation of the invention.

The composite building material contains feedstock (which is drill cuttings - drilling waste and oil-containing waste), sand, cement, surfactants, oil destructors, filler and dolomite flour in the following ratio of components, wt. h.%:

sand - 10-30; cement - 5-10; drill cuttings - 50-70; Surfactant - 0.5-1.5; oil destructors - 0.5-1.5; placeholder - 1-10; dolomite flour - 1-3.5.

Brief description of the components of the recipe.

1. Sand - used as the main filler.

The sand used for the recipe can be:

1.1. Sand is a natural inorganic bulk material with a grain size of up to 5 mm, formed as a result of the natural destruction of rocks and obtained during the development of boulder-gravel-sand, gravel-sand and sand deposits.

1. 2 Enriched sand: Natural inorganic bulk material with a grain size of up to 5 mm, with an improved grain composition and a lower content of dust and clay particles, obtained using special equipment.

1.3 Fractionated sand: Natural inorganic bulk material divided into two or more fractions using special equipment.

According to technical characteristics, sand, enriched sand and fractionated sand must comply with the requirements of GOST 8736.

Other types of sands are also used, including homogeneous, fine and dusty ones in accordance with GOST 25100.

2. Cement - used as a binder.

Cement is used as a binder. Brands M100 – M500 are used. In terms of technical characteristics, cements must comply with GOST 55224, GOST 31108, GOST 30515, GOST 25328-82, GOST 22266-2013.

3. Drilling waste and oil-containing waste act as drill cuttings (raw materials). These materials are formed as a result of drilling oil and gas wells. The materials include: drill cuttings, water, crude oil, oil-water emulsion, water-based or hydrocarbon-based drilling fluid. Physical state: liquid and paste-like (thick).

4. Surfactants – used as an additive (reagent) for processing mineral materials.

Surfactants are used to treat drill cuttings; to improve the physical, mechanical and technological properties of mixtures, it is advisable to introduce surfactant additives with water. The use of surfactant additives - plasticizers like LST and LSTM-2, superplasticizers like S-3 and 10-03, plasticizing-air-entraining additives like ShchSPK (b.PASH) and GKZh-10 (GKZh-11).

5. Oil destructors (biological products) - used as an additive (reagent) to neutralize (destruct) hydrocarbons.

If there is a high content of petroleum products (more than 10%) in the feedstock, it is necessary to pre-treat the raw material with biological products-oil destructors or quicklime construction grades I and II according to GOST 9179.

6. Filler.

The filler can be: crushed stone and gravel from rocks, crushed stone from slag, ash and slag mixtures and gypsum.

7. Dolomite flour - used to increase binding capacity.

Dolomite limestone flour is used. Classification of flour: limestone (dolomite) flour grade A; limestone (dolomite) flour grade B; limestone (dolomite) flour grade C. According to technical characteristics, flour of any grade must meet the requirements of GOST 14050-93.

The recipe for preparing a composite building material is selected based on the quality characteristics of the initial mineral materials (unique for each individual batch), which are formed as a result of drilling oil and gas wells. The materials include: drill cuttings, water, crude oil, oil-water emulsion, water-based or hydrocarbon-based drilling fluid. Physical state: liquid and paste-like (thick). When selecting a recipe, you should strive to obtain a material of optimal composition with a minimum amount of binder.

An assessment of the quality characteristics of each batch of mineral materials is carried out according to points 2 – 5 of Table 1 - Technical characteristics of mineral materials.

Table 1

No.
p/p INDICATOR NAME INDICATOR VALUE 1 2 3 2 Hazard Class III, IV, V 3 Humidity, % no more than 10 4 Oil/petroleum products content no more than 0.1 5 Specific effective activity of natural radionuclides, Bq/kg, not more than: for non-urban roads and objects - 1500 for populated areas – 740

The hazard class in Table 1 is determined according to the criteria for classifying waste into hazard classes I - V according to the degree of negative impact on the environment (approved by Order of the Ministry of Natural Resources of Russia dated December 4, 2014 N 536).

In case of deviation of quality characteristics from the declared indicators, averaging is carried out and the indicators are brought to acceptable parameters by adding additional materials and/or pumping out the liquid fraction (water/oil-water emulsion/oil), or adding process water.

Method for producing composite building material.

First option. Production at landfills for the disposal and neutralization of oil-containing waste and drilling waste.

The accumulation of raw materials is carried out in a specialized landfill structure - a map. When raw materials accumulate in the well, it may be necessary to pump out the liquid phase (watered drilling fluid) followed by a chemical coagulation procedure. If this decision is made, pumping is carried out to a separate flow chart. For chemical coagulation, the consumption rate of dry coagulant is 0.5-1.2 kg per 1 m ³ of liquid phase.

Next, the calculated amount of raw materials is moved from the accumulation map to the preparation map. Then, according to the approved recipe, all other components except cement are added. The mixed mixture is temporarily stored in the card. In the case of preparing the “Remediat” material with a given strength grade M20 - M100, cement is added to the mixture at the moment when it becomes possible to transport the “Remediat” to the places of use. The removal time should be no more than 7 - 10 hours after final preparation (adding cement and mixing). In the case of preparation of strength grades M5 and M 10, cement is added at any time without reference to the time of removal.

The transfer of raw materials to the preparation card is carried out by an excavator. An excavator or bulldozer is used to move sand, gravel, crushed stone, and ash and slag mixtures into the preparation map. The required amount of water is supplied by gravity from the service water tank. Pumping of watered drilling mud is carried out using pumping stations or an excavator bucket. Collection and loading of the finished Remediat material is carried out by an excavator. Transportation is carried out by dump trucks or other cargo vehicles.

Second option. Production at well pads in sludge pits of production and exploration oil and gas wells

At the preliminary stage, if necessary, chemical coagulation of the liquid phase is carried out, which has accumulated in a significant volume in the sludge pit. Coagulation can be carried out in a barn. Clarified process water is pumped out from the slurry pit and transferred for use, as a rule, for supply to the formation pressure maintenance system and for use in the technological process of preparing drilling fluids. For chemical coagulation, the consumption rate of dry coagulant is 0.5-1.2 kg per 1 m ³ of liquid phase.

Next, if necessary, the sludge pit is divided into technological cells or split strips. In this case, the strip prepared earlier will serve as a platform for work and entry of equipment. Dividing into cells is carried out by transverse and longitudinal filling of cutting sand strips. Cutting strips are constructed from the soil available at the well pad or from imported sand.

Next, using an excavator, structurizers are introduced layer by layer onto the surface of the sludge pit (on the feedstock), with cement being added last. The working mixture is mixed repeatedly with an excavator bucket. At the end of mixing, the mixture in the cell is leveled.

The finished material “Remediat” is used on site when liquidating a sludge pit, or can be exported for use in other places in accordance with the technical specifications “Material “Remediat” TU No. 23.99.19–001–0132491087–2022.

Third option. Production on highway rights-of-way.

The soil intended for the construction of the subgrade is subject to processing.

The highway mixing method includes the following operations:

- organization of a site for preparing the working mixture;

- rough leveling of the imported material over the entire thickness of the base, taking into account compaction;

- distribution of binder;

- mixing the material with cement, adding water and final mixing of the mixture;

- temporary sedimentation tank for storm drains, fire shield, diesel generator for lighting.

The raw materials and structurers delivered to the production site are leveled by a bulldozer and distributed over the soil surface. Then mixing is carried out once to a depth of up to 1 m from the total poured layer.

Next, the prepared mixture is leveled. Cement is spread over the mixed layer of the mixture. If the humidity is exceeded, it is necessary to dry the mixture by maintaining a technological break or additional mixing.

Surfactant additives are introduced into the soil in the form of an aqueous solution with an excavator bucket and mixed with the soil, after which the soil is profiled and rolled.

Following the distribution of the binder, the mixture is finally mixed with an excavator, after which the working mixture is considered ready. Next, it is profiled with a bulldozer. After this, clay, gravel and sand are placed, which act as a protective layer for the road, or Remediate material of increased strength, grades from M60 to M100, is placed.

Fourth option. Production in mobile soil mixing tanks.

At the preliminary stage, chemical coagulation of the liquid phase is carried out, which is carried out directly in the tonar or in a separate specialized container. Clarified process water is pumped out of the tank and transferred for use, as a rule, for supply to the formation pressure maintenance system, or for use in the technological process of preparing drilling fluids.

The process of mixing the feedstock and structurers is carried out in a tonar or other specialized container through the use of a manipulator bucket or an excavator bucket. It is also possible to carry out mixing with a specialized mixing attachment, in which case it is necessary to use the ladle and the mixing attachment alternately.

The finished material “Remediat” is used on site when liquidating a sludge pit, or can be exported for use in other places in accordance with the technical specifications “Material “Remediat” TU No. 23.99.19–001–0132491087–2022. In the case of preparing the Remediat material with a given strength grade M20 - M100, cement is added to the mixture at the moment when it becomes possible to transport the Remediat material to the places of use. The removal time should be no more than 7 - 10 hours after final preparation (adding cement and mixing). In the case of preparation of strength grades M5 and M 10, cement is added at any time without reference to the time of removal.

The technical result of reducing the use of cement in the manufacture of building materials with high bulk density and compressive strength is achieved through the use of a set of components included in the composition of the composite building material.

The use of surfactants, which can be: plasticizers like LST and LSTM-2, superplasticizers like S-3, plasticizing-air-entraining additives like ShchSPK and GKZh-10 can save from 6 to 20% of cement. The use of these surfactants to achieve a technical result has been confirmed experimentally, while the possibility of using other types of surfactants with similar functions is not excluded.

The use of sand, cement (with specified strength grades), mineral materials, oil destructors (and/or quicklime), aggregates and dolomite flour ensures high bulk density and compressive strength of the final product.

An example of achieving a technical result.

The compositions of the claimed composite building material in two versions (1,2) and the compositions of analogue materials (3) and prototype (4) are given in Table 2.

According to the stated solutions of the prototype and analogue: in the METHOD FOR MANUFACTURING ARTIFICIAL SOIL LITHOGRUNT [RU2682920C1, publ. 02/06/2018] (3) wt content. h.% of cement, depending on the manufacturing option of the material, can vary from 1 to 13%; in COMPOSITE BUILDING MATERIAL [RU2720523C1, publ. 10/01/2019] (4) wt content. h.% of cement, depending on the manufacturing option of the material, can vary from 6 to 9.5%. In the stated solution, the content by weight. h.% of cement, depending on the manufacturing option of the material, can vary from 5 to 7.5%. Thus, the stated technical result is confirmed; in embodiments of manufacturing a composite building material, the upper limit of the percentage of cement is reduced by 21% for (3) and the lower limit of cement content is reduced by 17% for (4).

table 2

Name of components, wt. h.% (1) (2) (3) (4) sand - thirty 10 43 13 cement - 5 8 10 9.3 drill cuttings - 50 70 4 67.2 Surfactant - 1.5 0.5 oil destructors - 0.5 0.5 quicklime - 6.2 Filler (crushed stone) - 10 8 dolomite flour - 2 3 PVAD - 1 ash and slag mixture - 4.3

Tests of building materials (1-4) were also carried out for bulk density and tensile strength (shown in Table 3).

Table 3

Coverage indicators (1) (2) (3) (4) Standard indicators Ultimate compressive strength, MPa 0.98 1.96 2 0.75 0.8-2.0 Bulk density, kg/dm ³ 1 1.2 1.4 1 At least 1

Analysis of the tests shows that, simultaneously with a reduction in the use of cement, the claimed solution allows maintaining high (normative) figures for bulk density.

Claims (13)

1. A composite building material containing drill cuttings, sand, cement, characterized in that it additionally contains a surfactant - surfactant, oil destructor, dolomite flour, filler - crushed stone and gravel from rocks, slag crushed stone, ash and slag mixture and gypsum, with the following ratio of components, wt.%: sand - 10-30; cement - 5-10; drill cuttings - 50-70; Surfactant - 0.5-1.5; oil destructor - 0.5-1.5; specified filler - 1-10; dolomite flour - 1-3.5. 2. Composite building material according to claim 1, characterized in that the LST plasticizer is used as a surfactant. 3. Composite building material according to claim 1, characterized in that the plasticizer LSTM-2 is used as a surfactant. 4. Composite building material according to claim 1, characterized in that superplasticizer C-3 is used as a surfactant. 5. Composite building material according to claim 1, characterized in that the plasticizing-air-entraining additive ShchSPK is used as a surfactant. 6. Composite building material according to claim 1, characterized in that the plasticizing-air-entraining additive GZhK-10 is used as a surfactant.