Abstract 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. Seven batches were prepared using different weight proportions of local bauxite and petroleum waste sludge (100–0 wt%), (80–20wt%), (60–40 wt%), (50- 50 wt%), (40–60 wt%), (20–80 wt%) and (0–100 wt%), respectively referred to M1, M2, M3, M4, M5, M6 and M7, the samples were prepared through solid-state technique to form cylindrical bodies by means of hydraulic pressing. The prepared bodies were dried and fired at different temperatures up to 1600 °C. The chemical and mineralogical compositions of raw bauxite and petroleum waste sludge were investigated using X-ray fluorescence (XRF) and X-ray diffraction (XRD) techniques. Their microstructure was depicted using scanning electron microscope (SEM) attached with energy dispersive X-ray unit (SEM+EDAX). The various technological properties of the ceramics bodies fired at different temperature (800–1600 °C) were tested. These properties involve; sintering parameters (bulk density and apparent porosity) tested using kerosene displacement method, the linear change tested by measuring the dimension shrinkage, mechanical properties (cold crushing strength) tested using an automatic compression machine as well as the refractory properties; permanent linear change, thermal shock resistance, refractoriness (Segar cone test) and load- bearing capacity. All tests were carried according to the international standard specifications. The chemical analysis using (XRF), and mineralogical investigation using (XRD), confirm that the petroleum waste sludge composed mainly from barite mineral (BaSO4), kaolinite (Al2(Si2O5(OH)4) and quartz (SiO2) while raw bauxite composed mainly from bohmite (AlO(OH)), gibbsite (Al(OH)3) and kaolinite. According to the International Standards, the used bauxite belongs to the high-quality bauxite grade (HQB). The firing temperature affects differently on the shape of the prepared bodies i.e., while the ceramics bodies prepared from M1-M5 keep their forms even at 1600 °C those of M6 and M7 have been fused at only 1400 °C. The technological properties of the prepared ceramic bodies are influenced by both firing temperature and the content of petroleum waste sludge. Ceramic bodies of M3 batch composed of 60 wt% of bauxite and 40 wt% of petroleum waste sludge was considered as the optimum among the investigated samples since they satisfy the requirement of the International Standards of refractory ceramics. This work is doubly valuable since it uses an available and cheap raw bauxite and consumes petroleum waste sludge (decreasing air pollution) to produce high-quality refractory ceramics with economic impact.

中文翻译：

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利用当地铝土矿原料利用石油废污泥生产优质耐火陶瓷

摘要 这项工作的目的是利用石油废污泥，通过与沙特阿拉伯 Al zubierah 地区大量存在的不同数量的天然铝土矿混合，制造用于高温应用的高质量耐火陶瓷。使用不同重量比例的当地铝土矿和石油废污泥 (100-0 wt%)、(80-20wt%)、(60-40 wt%)、(50-50 wt%)、(40-60 wt%)、(20–80 wt%) 和 (0–100 wt%)，分别指 M1、M2、M3、M4、M5、M6 和 M7，通过固态技术制备样品以形成圆柱体通过液压加压。将制备的物体干燥并在高达 1600°C 的不同温度下烧制。使用 X 射线荧光 (XRF) 和 X 射线衍射 (XRD) 技术研究了原料铝土矿和石油废污泥的化学和矿物组成。使用附有能量色散 X 射线装置 (SEM+EDAX) 的扫描电子显微镜 (SEM) 描绘了它们的微观结构。测试了在不同温度（800-1600°C）下烧制的陶瓷体的各种技术性能。这些属性涉及；用煤油置换法测试的烧结参数（堆积密度和表观孔隙率），通过测量尺寸收缩测试的线性变化，使用自动压缩机测试的机​​械性能（冷压强度）以及耐火性能；永久线性变化、抗热震性、耐火度（Segar 锥试验）和承载能力。所有测试均按照国际标准规范进行。使用 (XRF) 进行化学分析，使用 (XRD) 进行矿物学研究，证实石油废污泥主要由重晶石矿物 (BaSO4)、高岭石 (Al2(Si2O5(OH)4) 和石英 (SiO2) 组成，而生铝土矿则由主要来自勃姆石（AlO(OH)）、三水铝石（Al(OH)3）和高岭石。根据国际标准，所用铝土矿属于优质铝土矿级（HQB）。烧成温度对形状的影响不同即M1-M5制备的陶瓷体在1600℃下仍保持其形状，而M6和M7的陶瓷体仅在1400℃下熔化。制备的陶瓷体的工艺性能受两种烧制的影响石油废污泥的温度和含量。由 60 wt% 铝土矿和 40 wt% 石油废污泥组成的 M3 批陶瓷体被认为是研究样品中的最佳样品，因为它们满足国际耐火陶瓷标准的要求。这项工作具有双重价值，因为它使用可用且廉价的原铝土矿并消耗石油废污泥（减少空气污染）来生产具有经济影响的高质量耐火陶瓷。