Repurposing steel byproducts for sustainable utilization as a novel weighting agent in drilling fluids

Drilling fluids require weighting materials to increase density, ensuring wellbore stability and pressure control. This study proposes heavy steel waste (HSW), a byproduct of steel manufacturing, as a sustainable alternative to traditional weighting agents like barite and hematite. HSW was characterized using particle size analysis, XRD, XRF, and SEM, revealing a high iron content (98.11%) and a porous, agglomerated structure. Its performance was evaluated in water-based drilling fluids by testing rheology, stability, filtration, and filter cake quality. Results showed that HSW exhibits comparable rheological behavior to barite and hematite, effectively maintaining fluid stability and wellbore integrity. Additionally, HSW produced superior filter cake properties, indicating better fluid loss control. These findings suggest that HSW can serve as an efficient and environmentally beneficial weighting material, offering a cost-effective solution while promoting industrial waste reuse and reducing reliance on conventional materials in drilling operations.