CA2578318C - Methods of stabilizing drill fluids and drill cuttings, compositions and uses thereof - Google Patents
Methods of stabilizing drill fluids and drill cuttings, compositions and uses thereof Download PDFInfo
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- CA2578318C CA2578318C CA002578318A CA2578318A CA2578318C CA 2578318 C CA2578318 C CA 2578318C CA 002578318 A CA002578318 A CA 002578318A CA 2578318 A CA2578318 A CA 2578318A CA 2578318 C CA2578318 C CA 2578318C
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- wax
- hydrocarbon
- drill cuttings
- jojoba
- blended mixture
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Classifications
-
- E—FIXED CONSTRUCTIONS
- E01—CONSTRUCTION OF ROADS, RAILWAYS, OR BRIDGES
- E01C—CONSTRUCTION OF, OR SURFACES FOR, ROADS, SPORTS GROUNDS, OR THE LIKE; MACHINES OR AUXILIARY TOOLS FOR CONSTRUCTION OR REPAIR
- E01C3/00—Foundations for pavings
- E01C3/003—Foundations for pavings characterised by material or composition used, e.g. waste or recycled material
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B09—DISPOSAL OF SOLID WASTE; RECLAMATION OF CONTAMINATED SOIL
- B09B—DISPOSAL OF SOLID WASTE
- B09B3/00—Destroying solid waste or transforming solid waste into something useful or harmless
- B09B3/20—Agglomeration, binding or encapsulation of solid waste
- B09B3/25—Agglomeration, binding or encapsulation of solid waste using mineral binders or matrix
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B09—DISPOSAL OF SOLID WASTE; RECLAMATION OF CONTAMINATED SOIL
- B09C—RECLAMATION OF CONTAMINATED SOIL
- B09C1/00—Reclamation of contaminated soil
- B09C1/08—Reclamation of contaminated soil chemically
-
- C—CHEMISTRY; METALLURGY
- C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
- C09J—ADHESIVES; NON-MECHANICAL ASPECTS OF ADHESIVE PROCESSES IN GENERAL; ADHESIVE PROCESSES NOT PROVIDED FOR ELSEWHERE; USE OF MATERIALS AS ADHESIVES
- C09J195/00—Adhesives based on bituminous materials, e.g. asphalt, tar, pitch
- C09J195/005—Aqueous compositions, e.g. emulsions
-
- E—FIXED CONSTRUCTIONS
- E01—CONSTRUCTION OF ROADS, RAILWAYS, OR BRIDGES
- E01C—CONSTRUCTION OF, OR SURFACES FOR, ROADS, SPORTS GROUNDS, OR THE LIKE; MACHINES OR AUXILIARY TOOLS FOR CONSTRUCTION OR REPAIR
- E01C7/00—Coherent pavings made in situ
- E01C7/08—Coherent pavings made in situ made of road-metal and binders
- E01C7/18—Coherent pavings made in situ made of road-metal and binders of road-metal and bituminous binders
- E01C7/182—Aggregate or filler materials, except those according to E01C7/26
-
- E—FIXED CONSTRUCTIONS
- E01—CONSTRUCTION OF ROADS, RAILWAYS, OR BRIDGES
- E01C—CONSTRUCTION OF, OR SURFACES FOR, ROADS, SPORTS GROUNDS, OR THE LIKE; MACHINES OR AUXILIARY TOOLS FOR CONSTRUCTION OR REPAIR
- E01C7/00—Coherent pavings made in situ
- E01C7/08—Coherent pavings made in situ made of road-metal and binders
- E01C7/18—Coherent pavings made in situ made of road-metal and binders of road-metal and bituminous binders
- E01C7/26—Coherent pavings made in situ made of road-metal and binders of road-metal and bituminous binders mixed with other materials, e.g. cement, rubber, leather, fibre
- E01C7/265—Coherent pavings made in situ made of road-metal and binders of road-metal and bituminous binders mixed with other materials, e.g. cement, rubber, leather, fibre with rubber or synthetic resin, e.g. with rubber aggregate, with synthetic resin binder
-
- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
- C08L2666/00—Composition of polymers characterized by a further compound in the blend, being organic macromolecular compounds, natural resins, waxes or and bituminous materials, non-macromolecular organic substances, inorganic substances or characterized by their function in the composition
- C08L2666/66—Substances characterised by their function in the composition
- C08L2666/72—Fillers; Inorganic pigments; Reinforcing additives
- C08L2666/74—Aggregates
Abstract
Methods of stabilizing oil-based drilling fluids and hydrocarbon-contaminated drill cuttings are described. In addition, methods of using hydrocarbon-contaminated drilling fluids and stabilized drill cutting compositions are also described. These methods include the use of use oil-based drilling fluids and cuttings and stabilized oil-based drilling fluids and drill cuttings in road construction for dust suppression and as a fuel source. In addition, methods of disposing of stabilized drill cuttings are provided.
Description
METHODS OF STABILIZING DRILL FLUIDS AND DRILL CUTTINGS, COMPOSITIONS AND USES THEREOF
FIELD OF THE INVENTION
Methods of stabilizing oil-based drilling fluids and hydrocarbon-contaminated drill cuttings are described. In addition, methods of using hydrocarbon-contaminated drilling fluids and stabilized drill cutting compositions are also described. These methods include the use of use oil-based drilling fluids and cuttings and stabilized oil-based drilling fluids and drill cuttings in road construction for dust suppression and as a fuel source. In addition, methods of disposing of stabilized drill cuttings are described.
BACKGROUND OF THE INVENTION
In the past, the disposal of drill fluids and drill cuttings has been a significant issue for drill site operators. For example, in a typical drilled well in the oil industry, upwards of 100 m3 of drill cuttings may be produced from a single well. Typical drill cuttings and drill fluids will also contain a variety of contaminants such as hydrocarbons, salts, metals, soaps and other agents that may have been added to the drilling fluid to assist in the drilling and hydrocarbon recovery processes or from contaminants from the formation that have become mixed with the drilling fluid.
In particular, in a typical drilling process, recovered and dried drill cuttings may include up to approximately 50 %(w/w) hydrocarbon contaminants for very small particle drill cuttings or 0-20 % (w/w) for larger particle size drill cuttings. The contaminating hydrocarbons may range in viscosity from highly viscous bitumens through to less viscous lighter fractions. Drill fluids may also contain significant quantities of hydrocarbons that have originated either from manufacture of the original drill fluid composition or from the formation.
In the past, drill fluids are usually disposed of by transporting the used drill fluids to a processor that removes the solid fraction through chemical and mechanical means. The remaining fluid is usually then sold to asphalting companies. Transporting used drill fluids and drill cuttings is difficult due to the liquid or semi-liquid nature of these materials.
Acceptable methods of disposal of drill cuttings are usually dictated by various jurisdictional regulations and will usually require that the drill cuttings are properly remediated into the local soil or alternatively, removed to a landfill site.
Current methods for adsorbing or absorbing contaminating hydrocarbons prior to remediation often include mixing the drill cuttings with cellulose based materials such as sawdust. The use of sawdust, as a method of remediating drill cuttings, however requires very large volumes of sawdust in order to effectively stabilize the drill cuttings. For example, 100 m3 of drill cuttings may require approximately 200 m3 of sawdust in order to effectively stabilize the cuttings which significantly affects the transportation and disposal costs of the drill cuttings. The presence of cellulose material in oil based drilling fluid cuttings will also limit the use of those stabilized cuttings in other applications.
Further still, either disposal method, may lead to certain environmental contamination as the various contaminants may ultimately leach into the local groundwater, particularly as the sawdust decomposes. Moreover, the cost of transportation of drill cuttings to a landfill and/or the cost of soil remediation is significant.
However, as is known, road construction is not subjected to the same environmental regulations that either a local drilling site or landfill may be. That is, at a local drill site, as a result of the relative concentration of contaminants within drill cuttings, the regulations are relatively strict concerning acceptable levels of contaminants that may be contained within a particular area without proper remediation or disposal. In contrast, during the construction of a road, the same standards do not apply. That is, it is well known that government agencies use hydrocarbons and/or chlorides mixed with gravel aggregates to provide dust suppression in gravel or dirt roads.
At a drill site, acceptable levels of hydrocarbons present within the soil would be relatively low whereas in providing dust suppression to a gravel or dirt road significantly higher levels of hydrocarbons in the form of crude oil can be laid down over large areas where it is known that certain quantities of the hydrocarbons will, over time leach away from the road to the local environment.
As a result, there has been a need for effective disposal methods wherein drill fluids and drill cuttings are disposed of in a manner that meets environmental regulations and that does not increase the overall cost of disposal. More specifically, there has been a need for a disposal method in which drill fluids and drill cuttings provide a useful product wherein the contaminants may be encapsulated or incorporated with other products to reduce the likelihood of such contaminants leaching to the environment and that may otherwise provide useful and beneficial properties to the road. The use of oil based drilling fluids and cuttings can provide a low cost alternative to traditional disposal methods.
In addition, the disposal of used rubber tires and asphalt shingles is a significant environmental issue with there continuing to be a need for effective uses of these materials.
SUMMARY OF THE INVENTION
In accordance with the invention, there is provided a method of disposing of drill cuttings by incorporating the drill cuttings into a road. In particular, there is provided a method of disposal of hydrocarbon-contaminated drill cuttings in a road comprising the steps of:
mixing hydrocarbon-contaminated drill cuttings with virgin aggregates to form a blended mixture;
and incorporating the blended mixture into the road. The degree of hydrocarbon contamination of the drill cuttings may be less than 15 % (w/w) (hydrocarbon/drill cuttings). Hydrocarbon-contaminated drill cuttings may also be mixed with virgin aggregates to 5-25 % (w/w).
In various embodiments, the blended mixture is incorporated as the base course of a road and/or the blended mixture is further mixed with asphalt cement to form asphalt concrete and the asphalt concrete is incorporated into the top course of a road. The blended mixture may also be mixed to a consistency enabling effective use of the blended mixture for dust suppression within a road.
In a further embodiment, the hydrocarbon-contaminated drill cuttings are mixed with blending materials selected from, for example, any one of or a combination of elastomeric materials such as recycled rubber, viscous hydrocarbons such as recycled asphalt shingles and/or waxes.
In another embodiment, the invention provides a method of disposal of hydrocarbon-contaminated drill cuttings in a road comprising the steps of: mixing hydrocarbon-contaminated drill cuttings with an elastomeric material, viscous hydrocarbon and/or wax to form a blended mixture of a desired consistency; and incorporating the blended mixture into the road.
FIELD OF THE INVENTION
Methods of stabilizing oil-based drilling fluids and hydrocarbon-contaminated drill cuttings are described. In addition, methods of using hydrocarbon-contaminated drilling fluids and stabilized drill cutting compositions are also described. These methods include the use of use oil-based drilling fluids and cuttings and stabilized oil-based drilling fluids and drill cuttings in road construction for dust suppression and as a fuel source. In addition, methods of disposing of stabilized drill cuttings are described.
BACKGROUND OF THE INVENTION
In the past, the disposal of drill fluids and drill cuttings has been a significant issue for drill site operators. For example, in a typical drilled well in the oil industry, upwards of 100 m3 of drill cuttings may be produced from a single well. Typical drill cuttings and drill fluids will also contain a variety of contaminants such as hydrocarbons, salts, metals, soaps and other agents that may have been added to the drilling fluid to assist in the drilling and hydrocarbon recovery processes or from contaminants from the formation that have become mixed with the drilling fluid.
In particular, in a typical drilling process, recovered and dried drill cuttings may include up to approximately 50 %(w/w) hydrocarbon contaminants for very small particle drill cuttings or 0-20 % (w/w) for larger particle size drill cuttings. The contaminating hydrocarbons may range in viscosity from highly viscous bitumens through to less viscous lighter fractions. Drill fluids may also contain significant quantities of hydrocarbons that have originated either from manufacture of the original drill fluid composition or from the formation.
In the past, drill fluids are usually disposed of by transporting the used drill fluids to a processor that removes the solid fraction through chemical and mechanical means. The remaining fluid is usually then sold to asphalting companies. Transporting used drill fluids and drill cuttings is difficult due to the liquid or semi-liquid nature of these materials.
Acceptable methods of disposal of drill cuttings are usually dictated by various jurisdictional regulations and will usually require that the drill cuttings are properly remediated into the local soil or alternatively, removed to a landfill site.
Current methods for adsorbing or absorbing contaminating hydrocarbons prior to remediation often include mixing the drill cuttings with cellulose based materials such as sawdust. The use of sawdust, as a method of remediating drill cuttings, however requires very large volumes of sawdust in order to effectively stabilize the drill cuttings. For example, 100 m3 of drill cuttings may require approximately 200 m3 of sawdust in order to effectively stabilize the cuttings which significantly affects the transportation and disposal costs of the drill cuttings. The presence of cellulose material in oil based drilling fluid cuttings will also limit the use of those stabilized cuttings in other applications.
Further still, either disposal method, may lead to certain environmental contamination as the various contaminants may ultimately leach into the local groundwater, particularly as the sawdust decomposes. Moreover, the cost of transportation of drill cuttings to a landfill and/or the cost of soil remediation is significant.
However, as is known, road construction is not subjected to the same environmental regulations that either a local drilling site or landfill may be. That is, at a local drill site, as a result of the relative concentration of contaminants within drill cuttings, the regulations are relatively strict concerning acceptable levels of contaminants that may be contained within a particular area without proper remediation or disposal. In contrast, during the construction of a road, the same standards do not apply. That is, it is well known that government agencies use hydrocarbons and/or chlorides mixed with gravel aggregates to provide dust suppression in gravel or dirt roads.
At a drill site, acceptable levels of hydrocarbons present within the soil would be relatively low whereas in providing dust suppression to a gravel or dirt road significantly higher levels of hydrocarbons in the form of crude oil can be laid down over large areas where it is known that certain quantities of the hydrocarbons will, over time leach away from the road to the local environment.
As a result, there has been a need for effective disposal methods wherein drill fluids and drill cuttings are disposed of in a manner that meets environmental regulations and that does not increase the overall cost of disposal. More specifically, there has been a need for a disposal method in which drill fluids and drill cuttings provide a useful product wherein the contaminants may be encapsulated or incorporated with other products to reduce the likelihood of such contaminants leaching to the environment and that may otherwise provide useful and beneficial properties to the road. The use of oil based drilling fluids and cuttings can provide a low cost alternative to traditional disposal methods.
In addition, the disposal of used rubber tires and asphalt shingles is a significant environmental issue with there continuing to be a need for effective uses of these materials.
SUMMARY OF THE INVENTION
In accordance with the invention, there is provided a method of disposing of drill cuttings by incorporating the drill cuttings into a road. In particular, there is provided a method of disposal of hydrocarbon-contaminated drill cuttings in a road comprising the steps of:
mixing hydrocarbon-contaminated drill cuttings with virgin aggregates to form a blended mixture;
and incorporating the blended mixture into the road. The degree of hydrocarbon contamination of the drill cuttings may be less than 15 % (w/w) (hydrocarbon/drill cuttings). Hydrocarbon-contaminated drill cuttings may also be mixed with virgin aggregates to 5-25 % (w/w).
In various embodiments, the blended mixture is incorporated as the base course of a road and/or the blended mixture is further mixed with asphalt cement to form asphalt concrete and the asphalt concrete is incorporated into the top course of a road. The blended mixture may also be mixed to a consistency enabling effective use of the blended mixture for dust suppression within a road.
In a further embodiment, the hydrocarbon-contaminated drill cuttings are mixed with blending materials selected from, for example, any one of or a combination of elastomeric materials such as recycled rubber, viscous hydrocarbons such as recycled asphalt shingles and/or waxes.
In another embodiment, the invention provides a method of disposal of hydrocarbon-contaminated drill cuttings in a road comprising the steps of: mixing hydrocarbon-contaminated drill cuttings with an elastomeric material, viscous hydrocarbon and/or wax to form a blended mixture of a desired consistency; and incorporating the blended mixture into the road.
In a further embodiment, the invention provides for the use of hydrocarbon contaminated drill cuttings stabilized with elastomeric materials, viscous hydrocarbons and/or waxes for dust suppression in roads. The elastomeric materials and viscous hydrocarbons, in various embodiments may be selected from any one of or a combination of recycled rubber crumb and recycled asphalt shingles.
In a further embodiment, the invention provides a method of stabilizing hydrocarbon-contaminated drill cuttings comprising the step of mixing hydrocarbon-contaminated drill cuttings with blending materials to form a blended mixture of a desired consistency.
In yet a further embodiment, the invention provides a method of stabilizing hydrocarbon contaminated drill fluids comprising the step of mixing hydrocarbon-contaminated drill fluids with blending materials to form a blended mixture of a desired consistency.
Blended mixtures and compositions prepared in accordance with the invention may also be used as a fuel source.
In a further embodiment, the invention provides a method of stabilizing hydrocarbon-contaminated drill cuttings comprising the step of mixing hydrocarbon-contaminated drill cuttings with blending materials to form a blended mixture of a desired consistency.
In yet a further embodiment, the invention provides a method of stabilizing hydrocarbon contaminated drill fluids comprising the step of mixing hydrocarbon-contaminated drill fluids with blending materials to form a blended mixture of a desired consistency.
Blended mixtures and compositions prepared in accordance with the invention may also be used as a fuel source.
DETAILED DESCRIPTION
Methods of stabilizing oil-based drilling fluids and hydrocarbon-contaminated drill cuttings are described. In addition, methods of using hydrocarbon-contaminated drilling fluids and stabilized drill cutting compositions are also described. These methods include the use of use oil-based drilling fluids and cuttings and stabilized oil-based drilling fluids and drill cuttings in road construction for dust suppression and as a fuel source. In addition, methods of disposing of stabilized drill cuttings are provided. Within this description, drilling fluids generally include oil-based drilling fluids, frac fluids and production fluids such as hydrocarbon based fluids and/or synthetic oils or silicate oils.
Methods of Stabilizing Oil-Based Drilling Fluids and Drill Cuttings In one embodiment, oil-based drilling fluids and/or hydrocarbon-contaminated drill cuttings are blended with elastomeric hydrocarbon materials, viscous hydrocarbons including asphalts and/or waxes as a means to stabilize drill fluids or cuttings for subsequent uses.
Within this description these materials are collectively referred to as blending materials. The blending materials are mixed with the drilling fluid or drill cuttings to absorb excess free oil contained within the drilling fluid or drill cuttings. In addition to absorbing free oil, the blending materials may be added in proportions such that the consistency of the resulting mixture is suitable for a variety of uses.
Such uses may be to improve the ease of handling of the stabilized drill fluid or cuttings for remediation of the mixture to the ground, for use in road construction, dust suppression and/or as a fuel source.
Generally, drill cuttings removed from a well will be a loose, slippery and fluid mixture of rock particles coated with varying amounts of hydrocarbons and other contaminants.
After mixing with the blending materials in appropriate proportions in accordance with the invention, the resulting mixtures will have the general appearance of granular, dry rock.
Depending on the specific hydrocarbon contaminants and proportions used, the resulting mixtures may be clumpy.
Mixtures may be created by any suitable mechanical mixing apparatus including disking machines, mechanical stirring equipment and other equipment known to those skilled in the art.
After creating mixtures of the desired solid or semi-solid consistency, the mixtures may be handled by conventional handling equipment for materials of a similar consistency.
Preferred blending materials include recycled elastomeric hydrocarbon materials such as recycled rubber from tires. Viscous hydrocarbons may include recycled asphalt shingles, natural asphalts = CA 02578318 2007-02-23 such as gilsonite, and/or waxes. Within this application, wax generally refers to both refined paraffin materials and other source materials occurring in nature and described in the literature as wax materials. Examples of waxes and viscous hydrocarbons include but are not limited to montan wax, ceresine wax, beeswax, candelilla wax, carnauba wax, castor wax, chinese wax, hydrogenated jojoba oil, jojoba wax, jojoba oil, jojoba esters, lanolin, lignoceric acid, ozokerite, ouricury wax, paraffin (from crude oil) and shellac.
The blending materials may be mixed with the drill fluid or drill cuttings at an appropriate proportion to reduce the free oil content within the drill fluid or drill cuttings and thereby impart further binding properties to the aggregate and/or asphalt cement for a road construction application.
In a road construction or road dust suppression application, the amount of added blending materials may be at any suitable proportion to produce a desired consistency of the aggregate and/or asphalt cement. In other words, sufficient blending material may be added to create a "dry" mixture where substantially all free oil is absorbed, or to maintain a "wet" or "semi-wet"
mixture.
In an alternate application, the amount of blendng material added may be sufficient to create a blended drill cutting/blending material composition having a consistency wherein excess free oil on the drill cuttings is absorbed to the extent that the blended composition is sufficiently "clean"
or "dry" to enable it to be buried in the ground.
Importantly, in comparison to the use of past materials to affect hydrocarbon absorption, substantially smaller volumes of blending materials may be added to the drill cuttings to absorb free oil. In the past, for example, a 200% volume of sawdust may be required to absorb free oil relative to a given volume of drill cuttings, whereas in accordance with the present invention, a 10% volume of blending material may only be required to absorb free oil on similar drill cuttings.
As can be readily understood, such a substantial reduction in blending material quantities will significantly lower the volume of the mixtures, which substantially reduces the handling and transportation costs of the materials.
In various embodiments, a blending of 3-5% by weight of such materials relative to the drill fluid or drill cuttings can provide a desired consistency to enable effective handling of the material.
Methods of stabilizing oil-based drilling fluids and hydrocarbon-contaminated drill cuttings are described. In addition, methods of using hydrocarbon-contaminated drilling fluids and stabilized drill cutting compositions are also described. These methods include the use of use oil-based drilling fluids and cuttings and stabilized oil-based drilling fluids and drill cuttings in road construction for dust suppression and as a fuel source. In addition, methods of disposing of stabilized drill cuttings are provided. Within this description, drilling fluids generally include oil-based drilling fluids, frac fluids and production fluids such as hydrocarbon based fluids and/or synthetic oils or silicate oils.
Methods of Stabilizing Oil-Based Drilling Fluids and Drill Cuttings In one embodiment, oil-based drilling fluids and/or hydrocarbon-contaminated drill cuttings are blended with elastomeric hydrocarbon materials, viscous hydrocarbons including asphalts and/or waxes as a means to stabilize drill fluids or cuttings for subsequent uses.
Within this description these materials are collectively referred to as blending materials. The blending materials are mixed with the drilling fluid or drill cuttings to absorb excess free oil contained within the drilling fluid or drill cuttings. In addition to absorbing free oil, the blending materials may be added in proportions such that the consistency of the resulting mixture is suitable for a variety of uses.
Such uses may be to improve the ease of handling of the stabilized drill fluid or cuttings for remediation of the mixture to the ground, for use in road construction, dust suppression and/or as a fuel source.
Generally, drill cuttings removed from a well will be a loose, slippery and fluid mixture of rock particles coated with varying amounts of hydrocarbons and other contaminants.
After mixing with the blending materials in appropriate proportions in accordance with the invention, the resulting mixtures will have the general appearance of granular, dry rock.
Depending on the specific hydrocarbon contaminants and proportions used, the resulting mixtures may be clumpy.
Mixtures may be created by any suitable mechanical mixing apparatus including disking machines, mechanical stirring equipment and other equipment known to those skilled in the art.
After creating mixtures of the desired solid or semi-solid consistency, the mixtures may be handled by conventional handling equipment for materials of a similar consistency.
Preferred blending materials include recycled elastomeric hydrocarbon materials such as recycled rubber from tires. Viscous hydrocarbons may include recycled asphalt shingles, natural asphalts = CA 02578318 2007-02-23 such as gilsonite, and/or waxes. Within this application, wax generally refers to both refined paraffin materials and other source materials occurring in nature and described in the literature as wax materials. Examples of waxes and viscous hydrocarbons include but are not limited to montan wax, ceresine wax, beeswax, candelilla wax, carnauba wax, castor wax, chinese wax, hydrogenated jojoba oil, jojoba wax, jojoba oil, jojoba esters, lanolin, lignoceric acid, ozokerite, ouricury wax, paraffin (from crude oil) and shellac.
The blending materials may be mixed with the drill fluid or drill cuttings at an appropriate proportion to reduce the free oil content within the drill fluid or drill cuttings and thereby impart further binding properties to the aggregate and/or asphalt cement for a road construction application.
In a road construction or road dust suppression application, the amount of added blending materials may be at any suitable proportion to produce a desired consistency of the aggregate and/or asphalt cement. In other words, sufficient blending material may be added to create a "dry" mixture where substantially all free oil is absorbed, or to maintain a "wet" or "semi-wet"
mixture.
In an alternate application, the amount of blendng material added may be sufficient to create a blended drill cutting/blending material composition having a consistency wherein excess free oil on the drill cuttings is absorbed to the extent that the blended composition is sufficiently "clean"
or "dry" to enable it to be buried in the ground.
Importantly, in comparison to the use of past materials to affect hydrocarbon absorption, substantially smaller volumes of blending materials may be added to the drill cuttings to absorb free oil. In the past, for example, a 200% volume of sawdust may be required to absorb free oil relative to a given volume of drill cuttings, whereas in accordance with the present invention, a 10% volume of blending material may only be required to absorb free oil on similar drill cuttings.
As can be readily understood, such a substantial reduction in blending material quantities will significantly lower the volume of the mixtures, which substantially reduces the handling and transportation costs of the materials.
In various embodiments, a blending of 3-5% by weight of such materials relative to the drill fluid or drill cuttings can provide a desired consistency to enable effective handling of the material.
Road Construction As is known, a typical road construction includes a sub-grade of supporting native rock, soil, sand, clay or other material onto which a base course generally comprising a depth of crushed gravel or aggregate is placed and compacted. The aggregate will usually range in depth from 12 inches to several feet depending on the engineering requirements of the road and may include various additives that provide dust suppression if the road is not to be sealed.
In a sealed road, a surface course of a concrete (usually an asphalt concrete) is applied and compacted over the aggregate to seal and bind the upper surface of the road.
As is known, asphalt is a complex mixture of hydrocarbons primarily comprised of bitumen which in itself is generally comprised of asphaltenes as the dispersed phase and maltenes as the continuous phase. Mixed with various aggregates or mixtures of aggregates, varying blends of asphalt concrete can be produced depending on the desired qualities for the road surface.
In accordance with the invention, drill cuttings are incorporated into a road bed either as part of the base course or surface course in conjunction with appropriate quantities of aggregates and/or asphalt. The use of drill cuttings as described herein is particularly effective in dust suppression for gravel roads. Drill fluids as described herein are also particularly effective in dust suppression.
As noted above, drill cuttings may include hydrocarbon contaminants or diluents coated upon the native rock chips removed from the drilled well.
In a first embodiment, the drill cuttings are blended with aggregate to 5-25 %
(w/w) for use as the base course of a road bed with or without a surface course. The blended drill cuttings and aggregate may be applied to the road bed in the usual manner with graders and compaction vehicles. In this embodiment, as a result of the hydrocarbon contaminants, the blended drill cuttings and aggregate provide effective dust suppression when used in an unsealed road.
In a second embodiment, drill cuttings are blended with aggregate to 5-25 %
(w/w) and blended with asphalt cement such that the asphalt cement is 4-8 % (w/w) of the total mass of the resulting asphalt concrete.
In a sealed road, a surface course of a concrete (usually an asphalt concrete) is applied and compacted over the aggregate to seal and bind the upper surface of the road.
As is known, asphalt is a complex mixture of hydrocarbons primarily comprised of bitumen which in itself is generally comprised of asphaltenes as the dispersed phase and maltenes as the continuous phase. Mixed with various aggregates or mixtures of aggregates, varying blends of asphalt concrete can be produced depending on the desired qualities for the road surface.
In accordance with the invention, drill cuttings are incorporated into a road bed either as part of the base course or surface course in conjunction with appropriate quantities of aggregates and/or asphalt. The use of drill cuttings as described herein is particularly effective in dust suppression for gravel roads. Drill fluids as described herein are also particularly effective in dust suppression.
As noted above, drill cuttings may include hydrocarbon contaminants or diluents coated upon the native rock chips removed from the drilled well.
In a first embodiment, the drill cuttings are blended with aggregate to 5-25 %
(w/w) for use as the base course of a road bed with or without a surface course. The blended drill cuttings and aggregate may be applied to the road bed in the usual manner with graders and compaction vehicles. In this embodiment, as a result of the hydrocarbon contaminants, the blended drill cuttings and aggregate provide effective dust suppression when used in an unsealed road.
In a second embodiment, drill cuttings are blended with aggregate to 5-25 %
(w/w) and blended with asphalt cement such that the asphalt cement is 4-8 % (w/w) of the total mass of the resulting asphalt concrete.
The blending of drill cuttings with aggregate may be achieved through use of appropriate mixing equipment including reclaimers either at the road construction site, aggregate quarry or an asphalt plant.
The actual proportions of drill cuttings relative to aggregate are determined through assessment of the relative amounts of and properties of the hydrocarbon contaminants.
Generally, more viscous hydrocarbon contaminants can be incorporated at a higher weight % whereas less viscous more volatile hydrocarbon contaminants are incorporated at a lower weight %.
Fuel Source Mixing blending materials into oil wet drill cutting or used oil based drilling fluids may allow for the blended materials to be used as a solid or semi-solid fuel source. As many blending materials have a relatively high heat value, various mixtures of drill cuttings and drill fluids are highly effective as fuels. In particular, it should be noted that the heat value of resulting mixtures can be increased through the addition of particular blending materials and notably higher when compared to what they would be if mixed with cellulose or wood based materials. Resulting mixtures can effectively compete with coal as an efficient and low cost fuel source. Comparative BTU values of various fuels are shown in Table 1 and demonstrate that the selection of particular blending materials can significantly increase total heat value of a blended mixture as compared to sawdust.
Table 1-Comparative BTU values of various fuels COMPARTIVE BTU
VALUES
ASPHALT 15,500 BTU/LB*
CHARCOAL 12,800 BTU/LB
ETHANOL 11,500 BTU/LB
SUBBITUMINOUS COAL 10,500 BTU/LB
LIGNITE COAL 7,300 BTU/LB
OIL (NO. 6 FUEL OIL - 151,000 BTU/GAL
'BUNKER C) TIRE - CHIP FUEL 14,200 BTU/LB*
TIRE - DERIVED FUEL 15,500 BTU/LB*
RUBBER - DERIVED FUEL 16,000 BTU/LB**
WOOD (WET -'HOG FUEL') 4,375 BTU/LB
The actual proportions of drill cuttings relative to aggregate are determined through assessment of the relative amounts of and properties of the hydrocarbon contaminants.
Generally, more viscous hydrocarbon contaminants can be incorporated at a higher weight % whereas less viscous more volatile hydrocarbon contaminants are incorporated at a lower weight %.
Fuel Source Mixing blending materials into oil wet drill cutting or used oil based drilling fluids may allow for the blended materials to be used as a solid or semi-solid fuel source. As many blending materials have a relatively high heat value, various mixtures of drill cuttings and drill fluids are highly effective as fuels. In particular, it should be noted that the heat value of resulting mixtures can be increased through the addition of particular blending materials and notably higher when compared to what they would be if mixed with cellulose or wood based materials. Resulting mixtures can effectively compete with coal as an efficient and low cost fuel source. Comparative BTU values of various fuels are shown in Table 1 and demonstrate that the selection of particular blending materials can significantly increase total heat value of a blended mixture as compared to sawdust.
Table 1-Comparative BTU values of various fuels COMPARTIVE BTU
VALUES
ASPHALT 15,500 BTU/LB*
CHARCOAL 12,800 BTU/LB
ETHANOL 11,500 BTU/LB
SUBBITUMINOUS COAL 10,500 BTU/LB
LIGNITE COAL 7,300 BTU/LB
OIL (NO. 6 FUEL OIL - 151,000 BTU/GAL
'BUNKER C) TIRE - CHIP FUEL 14,200 BTU/LB*
TIRE - DERIVED FUEL 15,500 BTU/LB*
RUBBER - DERIVED FUEL 16,000 BTU/LB**
WOOD (WET -'HOG FUEL') 4,375 BTU/LB
= CA 02578318 2007-02-23 For example a kerosene equivalent oil used for drilling fluid would generate a cutting which when stabilized with rubber crumb and/or asphalt shingles and/or wax would provide a fuel source approaching or exceeding 7300 BTU. A solids laden drilling fluid stabilized in such a manner would also provide a superior fuel source to coal when blended with elastomers and/or wax.
The above-described embodiments of the invention are intended to be examples only.
Alterations, modifications and variations may be effected to the particular embodiments by those of skill in the art without departing from the scope of the invention which is defined by the following claims.
The above-described embodiments of the invention are intended to be examples only.
Alterations, modifications and variations may be effected to the particular embodiments by those of skill in the art without departing from the scope of the invention which is defined by the following claims.
Claims (22)
1. A method of disposal of hydrocarbon-contaminated drill cuttings in a road comprising the steps of:
a. mixing hydrocarbon-contaminated drill cuttings with aggregates to form a blended mixture of a desired consistency; and b. incorporating the blended mixture into the road.
a. mixing hydrocarbon-contaminated drill cuttings with aggregates to form a blended mixture of a desired consistency; and b. incorporating the blended mixture into the road.
2. A method as in claim 1 wherein the degree of hydrocarbon contamination of the drill cuttings is less than 50% (w/w) (hydrocarbon/drill cuttings).
3. A method as in claim 1 wherein the degree of hydrocarbon contamination of the drill cuttings is 7-15 % (w/w) (hydrocarbon/drill cuttings).
4. A method as in claim 1 wherein in step b the blended mixture is incorporated as the base course of a road.
5. A method as in claim 1 wherein the blended mixture is mixed to a consistency enabling use of the blended mixture for dust suppression within the road.
6. A method as in claim 1 wherein in step a, the blended mixture is further mixed with asphalt cement to form an asphalt aggregate mixture and step b includes incorporating the asphalt aggregate mixture onto the top course of a road
7. A method as in any one of claims 1-5 wherein the blended mixture of hydrocarbon-contaminated drill cuttings to aggregate is 5-25% (w/w).
8. A method as in any one of claims 1-6 wherein step a further comprises mixing the hydrocarbon-contaminated drill cuttings with any one of or a combination of elastomeric materials, viscous hydrocarbons or waxes.
9. A method as in claim 8 wherein the elastomeric materials, viscous hydrocarbon or wax are selected from any one of or a combination of recycled rubber crumb and recycled asphalt shingles, gilsonite, mined asphalt, montan wax, ceresine wax, beeswax, candelilla wax, carnauba wax, castor wax, chinese wax, hydrogenated jojoba oil, jojoba wax, jojoba oil, jojoba esters, lanolin, lignoceric acid, ozokerite, ouricury wax, paraffin or shellac.
10. A method of disposal of hydrocarbon-contaminated drill cuttings in a road comprising the steps of:
a. mixing hydrocarbon-contaminated drill cuttings with any one of or a combination of an elastomeric material, viscous hydrocarbon or a wax to form a blended mixture of a desired consistency; and b. incorporating the blended mixture into the road.
a. mixing hydrocarbon-contaminated drill cuttings with any one of or a combination of an elastomeric material, viscous hydrocarbon or a wax to form a blended mixture of a desired consistency; and b. incorporating the blended mixture into the road.
11. A method as in claim 10 wherein the elastomeric materials, viscous hydrocarbon or wax are selected from any one of or a combination of recycled rubber crumb, recycled asphalt shingles, gilsonite, mined asphalt, montan wax, ceresine wax, beeswax, candelilla wax, carnauba wax, castor wax, chinese wax, hydrogenated jojoba oil, jojoba wax, jojoba oil, jojoba esters, lanolin, lignoceric acid, ozokerite, ouricury wax, paraffin or shellac.
12. The use of hydrocarbon contaminated drill cuttings for dust suppression in roads.
13. The use of hydrocarbon contaminated drill cuttings stabilized with any one of or a combination of elastomeric materials, viscous hydrocarbons or wax for dust suppression in roads.
14. The use as in claim 13 wherein the elastomeric materials, viscous hydrocarbons or wax are selected from any one of or a combination of recycled rubber crumb, recycled asphalt shingles, gilsonite, mined asphalt, montan wax, ceresine wax, beeswax, candelilla wax, carnauba wax, castor wax, chinese wax, hydrogenated jojoba oil, jojoba wax, jojoba oil, jojoba esters, lanolin, lignoceric acid, ozokerite, ouricury wax, paraffin or shellac.
15. A method of stabilizing hydrocarbon-contaminated drill cuttings comprising the step of mixing hydrocarbon-contaminated drill cuttings with blending materials to form a blended mixture of a desired consistency.
16. A method as in claim 15 wherein the blending materials are selected from any one of or a combination of recycled rubber crumb, recycled asphalt shingles, waxes and viscous hydrocarbons.
17. A method as in claim 16 wherein the waxes or viscous hydrocarbons are selected from any one of or a combination of montan wax, ceresine wax, beeswax, candelilla wax, carnauba wax, castor wax, chinese wax, hydrogenated jojoba oil, jojoba wax, jojoba oil, jojoba esters, lanolin, lignoceric acid, ozokerite, ouricury wax, paraffin or shellac.
18. A method of stabilizing hydrocarbon contaminated drill fluids comprising the step of mixing hydrocarbon-contaminated drill fluids with blending materials to form a blended mixture of a desired consistency.
19. A method as in claim 18 wherein the blending materials are selected from any one of or a combination of recycled rubber crumb, recycled asphalt shingles, waxes and viscous hydrocarbons.
20. A method as in claim 19 wherein the waxes or viscous hydrocarbons are selected from any one of or a combination of montan wax, ceresine wax, beeswax, candelilla wax, carnauba wax, castor wax, chinese wax, hydrogenated jojoba oil, jojoba wax, jojoba oil, jojoba esters, lanolin, lignoceric acid, ozokerite, ouricury wax, paraffin or shellac.
21. The use of a blended mixture in accordance with claim 15 or 18 as a fuel.
22. A method of stabilizing hydrocarbon contaminated drill cuttings or drill fluids comprising the step of mixing the hydrocarbon-contaminated drill cuttings or drill fluid with any one of or a combination of montan wax, ceresine wax, beeswax, candelilla wax, carnauba wax, castor wax, chinese wax, hydrogenated jojoba oil, jojoba wax, jojoba oil, jojoba esters, lanolin, lignoceric acid, ozokerite, ouricury wax, paraffin or shellac to form a blended mixture of a desired consistency.
Applications Claiming Priority (4)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| US80612406P | 2006-06-29 | 2006-06-29 | |
| US60/806,124 | 2006-06-29 | ||
| US82570706P | 2006-09-14 | 2006-09-14 | |
| US60/825,707 | 2006-09-14 |
Publications (2)
| Publication Number | Publication Date |
|---|---|
| CA2578318A1 CA2578318A1 (en) | 2007-05-30 |
| CA2578318C true CA2578318C (en) | 2009-05-26 |
Family
ID=38110582
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CA002578318A Expired - Fee Related CA2578318C (en) | 2006-06-29 | 2007-02-23 | Methods of stabilizing drill fluids and drill cuttings, compositions and uses thereof |
Country Status (3)
| Country | Link |
|---|---|
| US (1) | US20090238643A1 (en) |
| CA (1) | CA2578318C (en) |
| WO (1) | WO2008000087A1 (en) |
Families Citing this family (13)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CA2669487A1 (en) * | 2006-11-17 | 2008-05-22 | Engineered Drilling Solutions Inc. | Methods of utilizing recycled rubber |
| CA2787257A1 (en) * | 2010-01-15 | 2011-07-21 | Lbi, Llc | Organic absorbent product and method |
| US20120245401A1 (en) * | 2011-03-22 | 2012-09-27 | BioMaxx, Inc. | Processing mine tailings |
| EP2721248A2 (en) | 2011-06-15 | 2014-04-23 | Total Waste Management Alliance Limited | Process for utilising waste drill cuttings in plastics |
| WO2013106578A1 (en) * | 2012-01-10 | 2013-07-18 | Pronghorn Environmental Technologies LLC | Road material compositions, systems and methods of making |
| GB2503456A (en) * | 2012-06-25 | 2014-01-01 | Kracken Ltd | A method of processing contaminated geological material |
| BR102012019092B8 (en) | 2012-06-26 | 2023-01-17 | Manancial Projetos E Consultoria Ambiental Ltda | ENVIRONMENTAL RECOVERY PROCESS OF EXTINGUISHED OR EXHAUSTED MINING AREAS |
| RU2524708C1 (en) * | 2013-02-19 | 2014-08-10 | Юрий Яковлевич Эль | Method of bore mud processing |
| US10472280B1 (en) | 2014-05-21 | 2019-11-12 | D-Trace Investments, Llc | Drill cuttings with a drying agent |
| MX2016016117A (en) | 2014-06-06 | 2018-01-15 | Boldwater Usa Lp | Processes for remediation of a contaminated material. |
| US10161204B2 (en) | 2014-10-31 | 2018-12-25 | Canadian Energy Services L.P. | Treatment of heavy oil cuttings for disposal |
| WO2016122456A1 (en) | 2015-01-27 | 2016-08-04 | Halliburton Energy Services, Inc. | Using biodegradable oils for controlling dust from additive particles |
| WO2016182722A1 (en) * | 2015-05-12 | 2016-11-17 | Racional Energy & Environment Company | Roadway materials based on drill cuttings |
Family Cites Families (17)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US3338849A (en) * | 1964-08-14 | 1967-08-29 | Us Rubber Reclaiming Co | Incorporation of reclaimed rubber into asphalt |
| US3422053A (en) * | 1964-10-05 | 1969-01-14 | Neville Chemical Co | Paving compositions |
| US3567660A (en) * | 1970-02-02 | 1971-03-02 | Joseph Winkler | Method of conversion of oil-spills into improved,rubberized carbon-black and fiber fortified asphaltic materials |
| US4075853A (en) * | 1976-09-29 | 1978-02-28 | The International Synthetic Rubber Company, Ltd. | Soil injection machine |
| US4793729A (en) * | 1985-09-16 | 1988-12-27 | Bosich Joseph F | Process of making material for and constructing a road |
| US5242493A (en) * | 1990-03-20 | 1993-09-07 | American Reclamation Corporation | Asphaltic concrete product for the fixation of contaminated soils |
| US5173115A (en) * | 1990-03-20 | 1992-12-22 | American Reclamation Corporation | Asphaltic concrete product and a method for the fixation of contaminated soils in the asphaltic concrete |
| AU1416897A (en) * | 1995-12-12 | 1997-07-03 | Rubber Resources, L.L.C. | Rubber base asphalt emulsion additive and method |
| US6102617A (en) * | 1998-01-13 | 2000-08-15 | Vivian A. Hampton | Impoundment leak detection, location, and containment system and method with mobile sensor |
| US6322489B1 (en) * | 1999-01-19 | 2001-11-27 | M-I Llc | Drill cuttings solidification for wetlands restoration |
| US6689925B2 (en) * | 2001-05-11 | 2004-02-10 | Invifuel Ltd. | Conversion of drilling waste to fuel |
| US6706108B2 (en) * | 2001-06-19 | 2004-03-16 | David L. Polston | Method for making a road base material using treated oil and gas waste material |
| US20030116887A1 (en) * | 2001-08-10 | 2003-06-26 | Scott J. Blake | Incorporation of drilling cuttings into stable load-bearing structures |
| US6752273B2 (en) * | 2002-01-24 | 2004-06-22 | Baker Hughes Incorporated | Cuttings disposal method |
| US7597754B2 (en) * | 2005-06-21 | 2009-10-06 | Andrew L. Argenio | Asphaltic compositions and methods of their manufacture |
| JP4079446B2 (en) * | 2005-07-28 | 2008-04-23 | 株式会社コスモ総合研究所 | Modified asphalt composition for paving |
| US8276666B2 (en) * | 2007-08-08 | 2012-10-02 | Halliburton Energy Services Inc. | Sealant compositions and methods of use |
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2007
- 2007-02-23 CA CA002578318A patent/CA2578318C/en not_active Expired - Fee Related
- 2007-06-29 WO PCT/CA2007/001166 patent/WO2008000087A1/en active Application Filing
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2008
- 2008-12-29 US US12/345,268 patent/US20090238643A1/en not_active Abandoned
Also Published As
| Publication number | Publication date |
|---|---|
| CA2578318A1 (en) | 2007-05-30 |
| US20090238643A1 (en) | 2009-09-24 |
| WO2008000087A1 (en) | 2008-01-03 |
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