High-Value Utilization of Waste Drilling Mud to Synthesize MFI Zeolite

While the petroleum industry undergoes structural adjustments in supply and demand alongside a green and low-carbon transition, water drilling mud generated during oil extraction poses severe environmental challenges. Consequently, addressing the solid waste pollution and disposal issues associated with drilling mud has become critical. In this study, ZSM-5 zeolite was synthesized using water drilling mud as a silicon and aluminum source, inexpensive n-butylamine as a template agent, and a combined approach of alkali-melting activation pre-treatment and seed-directed hydrothermal synthesis. By adjusting key parameters such as water content, template agent dosage, and seed addition, optimal synthesis conditions were determined. Based on these conditions, a series of ZSM-5 zeolites with varying silicon-to-aluminum ratios were synthesized. Characterization results from XRD, TEM, SEM, and N2 adsorption–desorption experiments revealed that all prepared samples exhibited high crystallinity, regular morphology, and high specific surface area. 27Al MAS NMR results indicated that almost aluminum species were located at the framework structures with four-coordination. In the 1,3,5-triisopropylbenzene cracking reaction, the conversion rate increased with decreasing silicon-to-aluminum ratio, consistent with variations in acid amount. These findings achieve high-value utilization of waste drilling mud, offering a novel pathway for low-cost synthesis of high-performance ZSM-5 zeolite. This breakthrough injects fresh momentum into the petroleum refining industry’s green sustainable development, fostering a win–win scenario that harmonizes ecological conservation with industrial profitability.