GB2351989A - Processing drilling cuttings - Google Patents

Processing drilling cuttings Download PDF

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Publication number
GB2351989A
GB2351989A GB0016380A GB0016380A GB2351989A GB 2351989 A GB2351989 A GB 2351989A GB 0016380 A GB0016380 A GB 0016380A GB 0016380 A GB0016380 A GB 0016380A GB 2351989 A GB2351989 A GB 2351989A
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GB
United Kingdom
Prior art keywords
flushing medium
entrained
drilled cuttings
reaction vessel
filler material
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Withdrawn
Application number
GB0016380A
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GB0016380D0 (en
Inventor
John Astleford
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Individual
Original Assignee
Individual
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Filing date
Publication date
Application filed by Individual filed Critical Individual
Publication of GB0016380D0 publication Critical patent/GB0016380D0/en
Publication of GB2351989A publication Critical patent/GB2351989A/en
Withdrawn legal-status Critical Current

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Classifications

    • EFIXED CONSTRUCTIONS
    • E21EARTH OR ROCK DRILLING; MINING
    • E21BEARTH OR ROCK DRILLING; OBTAINING OIL, GAS, WATER, SOLUBLE OR MELTABLE MATERIALS OR A SLURRY OF MINERALS FROM WELLS
    • E21B21/00Methods or apparatus for flushing boreholes, e.g. by use of exhaust air from motor
    • E21B21/06Arrangements for treating drilling fluids outside the borehole
    • E21B21/063Arrangements for treating drilling fluids outside the borehole by separating components
    • E21B21/065Separating solids from drilling fluids
    • E21B21/066Separating solids from drilling fluids with further treatment of the solids, e.g. for disposal

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  • Engineering & Computer Science (AREA)
  • Life Sciences & Earth Sciences (AREA)
  • Geology (AREA)
  • Mining & Mineral Resources (AREA)
  • Mechanical Engineering (AREA)
  • Physics & Mathematics (AREA)
  • Environmental & Geological Engineering (AREA)
  • Fluid Mechanics (AREA)
  • General Life Sciences & Earth Sciences (AREA)
  • Geochemistry & Mineralogy (AREA)
  • Processing Of Solid Wastes (AREA)

Abstract

A method for processing drilling cuttings which are entrained in flushing medium whereby the cuttings are homogenised for introduction to a reaction vessel and are burned, in the presence of a fuel, to produce a filler material suitable for the construction industry. The reaction vessel may include means for controlling the flow rates and volumes of material and fuel to the vessel and a heat recovery process may be put in place to recycle the excess heat created by the process. The emissions produced by the process may be collected, treated and tested in order to conform to the relevant safety standards.

Description

2351989 PROCESSING DRILLED CUTTINGS This invention relates to the
processing of drilled cuttings.
Drilled cuttings are fragments of rock generated by the rotary action of a drill bit against geological material. Drilled cuttings can range in size from 0.01mm to 50mm and in form from granular particles to lath like structures.
A situation in which large volumes of drilled cuttings are produced is in the construction of boreholes. As a borehole is lengthened hollow pipe is added behind the drill bit in order to continue cutting fresh rock further from the surface of the hole. A flushing medium is forced down the inside of the hollow pipe and out of the bit in order to wash the drilled cuttings up past the outside of the pipe and out of the borehole. The flushing medium can take many forms such as air, foam or liquid.
At surface the drilled cuttings are screened out of the flushing medium and disposed of. The flushing medium can be retumed to the borehole in order to recover more drilled cuttings.
In instances were the flushing medium used is of a foam or liquid nature, the drilled cuttings often become coated in the flushing medium. Even after several cleaning processes the drilled cuttings can still retain up to 10% weight for weight of the flushing medium. In these instances the entrained flushing medium is disposed of along with the drilled cuttings.
According to the present invention there is provided a process by which the drilled cuttings and any entrained flushing medium can be transformed in to a filler material for construction and engineering projects. A byproduct of certain instances of the invention would be the release of energy that could be harnessed in order to power other processes. A further advantage of the process would be the amelioration of any environmentally damaging constituents of the drilled cuttings and entrained flush material that may be I released through other methods of processing and or disposing of the drilled cuttings.
The process requires a means of testing the drilled cuttings and entrained flush material to ascertain that it is suitable, means for transporting the drilled cuttings and entrained flushing medium from the source to the processing plant, means by which the drilled cuttings and entrained flushing medium are stored and engineered in order to optimise the efficiency of the process, means by which the drilled cuttings and entrained flushing medium are introduced to a heated reaction vessel in which the drilled cuttings and entrained flushing medium are converted to filler material, means by which the rate of drilled cuttings and entrained flushing medium introduced to the reaction vessel are controllable, means by which a fuel can be introduced to the vessel along with the drilled cuttings and entrained flushing medium at a controlled rate, means by which the oxygen content of the reaction vessel can be controlled thus combustion of the fuel and any flammable content of the drilled cuttings and entrained flushing medium can be managed, means by which any gaseous, liquid or solid emissions which occur as the drilled cuttings and entrained flushing medium are converted to filler material through combustion are recovered or monitored, a means by which the filler material is collected, tested and used in engineering and construction projects, a means by which any energy produced by the conversion of the drilled cuttings and entrained flushing medium to filler material is captured and used to power other processes.
A specific embodiment of the invention will now be described by way of example with reference to the accompanying drawings in which: - Figure I shows a flow chart of the process: Figure 2 illustrates the required features of the reaction vessel.
The drilled cuttings and entrained flushing medium are tested to record the composition. Testing may include but would not be limited to:
I The percentage of entrained flushing medium in comparison with drilled cuttings.
The geological nature of the drilled cuttings collected.
The chemical composition of the drilled cutting and flushing medium, including but not limited to the concentrations of Chlorine, Fluorine, Lead, Cadmium, Nickel, Chromium, Copper, Vanadium.
The physical nature of the drilled cuttings and entrained flushing medium including but not limited to specific gravity, viscosity and calorific value.
Records would also be made of the total volumes of material that is to be processed.
If testing shows that the drilled cuttings and entrained flushing medium contains any one or combination of constituents found in greater concentrations than those prescribed below, then they will be found not suitable for processing by this method.
Chlorine >20 %, Fluorine >100 ppm, Lead >300 ppm, Cadmium > 25 ppm, Nickel >50 ppm, Chromium >75 ppm, Copper > 75 ppm, Vanadium >75 ppm.
Once it is ascertained that the drilled cuttings and entrained flushing medium is suitable for the process the drilled cuttings and entrained flushing medium are then containerised and transported to the processing plant.
From the results of the initial testing of the drilled cuttings and entrained flushing medium a decision is made on what engineering is required. Liquid flushing mediums have a range of rheological properties and it may be necessary to effect a change upon these properties in order to process the 3 drilled cuttings and entrained flushing medium mixture. For this reason a variety of engineering methods will need to be available.
The methods to achieve an effect upon the drilled cuttings and entrained flushing medium include but are not limited to, one or any combination of the following:
Grinding- if the drilled cuttings are too large it may be necessary to reduce them in size.
Slurrifying- if the drilled cuttings and entrained flushing medium are too viscous it may be necessary to blend in a fluid in order to produce a less viscous mixture.
Drying- if the drilled cuttings and entrained flushing medium are not viscous enough it may be necessary to remove some of the excess fluid by, but not limited to, centrifuging or filtering. This would help achieve a more viscous mixture. The liquid portion recovered from the drying of the drilled cuttings and entrained flushing medium could then be processed separately or stored for use in slurrifying material that is too viscous.
Separating- by means of but not limited to centrifuge and filters it may be necessary to separate the drilled cuttings and entrained flushing medium into two distinct streams. Both streams could then be processed separately.
Blending- the mixing of one or more materials or sources of drilled cuttings and flushing mediums may give optimal material characteristics for the process. For instance it may be desirable to mix the ddlied cuttings and entrained flushing medium as a small percentage (less than 20%) with a fuel such as coal and/or oil. This would facilitate combustion of the mixture in the reaction vessel.
Once the drilled cuttings and / or flushing medium are of the desired consistency they are introduced by, but not limited to pumping or screw conveying into the reaction vessel in which they will be transformed to a filler material. In instances were a free flowing mixture is desirable the material 4 may be injected into the reaction vessel by pumping or aerosol. In instances were the mixture is not free flowing it may be necessary to convey the material in to the reaction vessel by screw or belt.
The transformation of the drilled cuttings and entrained flushing medium to a filler material occurs as a result of exposure to temperatures of between 800 and 1800 degrees Celsius for a period of at least 3 seconds. The required residence time at this temperature will be a function of the properties of the drilled cuttings and entrained flushing medium. This temperature is achieved by the combustion of a fuel source such as but not limited to coal, oil and/or gas within the reaction vessel. At this temperature any flammable portion of the drilled cuttings and / or flushing medium is incinerated and the remaining material is fused into an inert filler material.
The reaction vessel in which the drilled cuttings and / or flushing medium are transformed to a filler material has the following features as shown in figure 2; The reaction vessel is capable of withstanding high temperatures 1 and has means by which the drilled cuttings and / or flushing medium can be added in a controlled manner 2. It has means by which a fuel such as but not limited to coal, oil or gas can be added in a controlled manner 3. It has a means by which the amount of oxygen available to aid combustion of the flammable material in the vessel is controllable and no more than 15% 4. The vessel also has a means for gases, liquids and solid particles produced in the conversion of the drilled cuttings and / or flushing medium to a filling material to be evacuated monitored and collected 5, 6. The vessel also has a means by which the energy produced through combustion is captured converted to another source of power for another process 7.
The overall design of the vessel is such that the drilled cuttings and / or flush material are introduced at the correct concentrations and rates in comparison with the fuel and oxygen content of the vessel and have a sufficient residence time at the prescribed temperature in order that it is wholly transformed to ash.
The drilled cuttings and entrained flushing medium should form no more than 15% of the total material within the reaction vessel at any one time. The drilled cuttings and entrained flushing medium should be resident in the hottest part of the reaction vessel for a minimum of 3 seconds. The reaction vessel should have sufficient oxygen content of no more than 15% in order to support controlled combustion.
Any emissions from the process are monitored and can be passed through washers that remove any harmful substances 8. Such washers would be, but not limited to flu gas desulphurisation plants and electronic precipitators.
Monitoring of the emissions 9 would include but would not be limited to dust, Carbon Monoxide, Carbon Dioxide, Hydrogen Sulphide, Hydrochloric and Hydrofluoric acid. From time to time the regulating authority will set the permissible limits of the varying components of any emissions. If emissions exceed the limits set by the regulating authority further cleaning of the flu gas will be undertaken. It may also be necessary to adjust the concentrations found in the accepted sourced drilled cuttings and flushing medium in order to achieve results within the range set.
Energy from the combustion of the fuel and any additional energy released by the combustion of the drilled cuttings and / or flushing medium are used to power the continuation of the process, excess energy is collected via a network of pipes 7 carrying water or steam through the reaction vessel. The water or steam is heated by the excess energy and can then be utilised in other processes such as but not limited to electricity generation via steam driven turbines.
The filler material produced by the process takes two forms, small airborne particulates and larger fused material. The small airborne particles are recovered from the reaction vessel by means of electrostatic precipitation 10 and are collected 11. The larger fused material collects at the bottom of the vessel and is removed from time to time and stored 11 6 The collected filler material mixed with any residue from the fuel combustion is tested to ensure it is inert and suitable for use in the engineering and construction industry. Tests carried out on the filler material will include but not be limited to the detection of levels of Arsenic, Cadmium, Chromium, Lead, Copper, Nickel, Zinc, Mercury, Selenium, Boron (water soluble), Phenols, Cyanide, Sulphide and Sulphates. The pH of the ash the calorific value and the size distribution of particles will also be noted. The regulating authority will set the permissible limits of the varying components of the filler material from time to time.
Once it is ascertained that the filler material is of sufficient quality it would be available for use in engineering and construction projects.
The range of engineering and construction projects in to which the ash can be used includes but is not limited to; cement filler, building (breeze) blocks, road fill and land fill capping.
7

Claims (16)

CLAIMS:
1. A process by which the drilled cuttings and associated entrained flushing medium, which are produced as a by-product of the drilling process are transformed in to a source of filler material for construction and engineering projects.
2. A method as in claim 1, by which in certain instances of the process energy will be produced.
3. A method as in claim 1, by which the drilled cuttings and associated entrained flushing medium are tested in order to ascertain their suitability for the process and are in step with environmental regulations.
4. A method as in claiml, by which through, but not limited to, any one or combination of grinding, slurrifying, drying, separating or blending the drilled cuttings and associated entrained flushing medium are homogenised in order to provide a material which can be further processed.
5. A method as in claim 1, by which a reaction vessel is used to transform the drilled cuttings and associated entrained flushing medium into a filler material.
6. A method as in claim 5, by which the reaction vessel is capable of withstanding reaction temperatures in the order of 1800 degrees Celsius.
7. A method as in claim 5, by which the introduction of drilled cuttings and entrained flushing medium is controlled.
9
8. A method as in claim 5, by which the introduction of a fuel is controlled.
9. A method as in claim 5, 7 and 8, by which the management of the feed rates and oxygen content of the reaction vessel controls the rate of combustion.
10. A method as in claims 5, 6 and 7, by which the design of the reaction vessel is such that the drilled cuttings and entrained flushing medium are exposed to the maximum temperature possible for at least 3 seconds.
11. A method as in claim 5 in which emissions from the reaction vessel are monitored and treated as is necessary in order to achieve targets set by regulatory bodies.
12. A method as in claim 11, in which the methods for treating emissions includes, but is not limited to electrostatic precipitators for fine particulates and flu gas desulphurisation for sulphurous material.
13. A method as in claims 1 and 5, in which water or steam filled pipes are used to capture excess energy created in the transformation of drilled cuttings and entrained flushing medium to a filler material.
14. A method as in claims 1, 5 and 13 in which the energy captured is utilised in other processes.
15. A method as in claim 1, by which the solid residues of the transformation process are recovered and sold as a filler material.
A
16. A method as in claims I and 15 in which the solid residues of the process are tested in order to ascertain that they are wholly inert and as such suitable for use as a filler material.
GB0016380A 1999-07-09 2000-07-05 Processing drilling cuttings Withdrawn GB2351989A (en)

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
GBGB9916036.8A GB9916036D0 (en) 1999-07-09 1999-07-09 Environmentally friendly method of disposal for oil coated drilled cuttings

Publications (2)

Publication Number Publication Date
GB0016380D0 GB0016380D0 (en) 2000-08-23
GB2351989A true GB2351989A (en) 2001-01-17

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GBGB9916036.8A Ceased GB9916036D0 (en) 1999-07-09 1999-07-09 Environmentally friendly method of disposal for oil coated drilled cuttings
GB0016380A Withdrawn GB2351989A (en) 1999-07-09 2000-07-05 Processing drilling cuttings

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GBGB9916036.8A Ceased GB9916036D0 (en) 1999-07-09 1999-07-09 Environmentally friendly method of disposal for oil coated drilled cuttings

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Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2003062592A1 (en) * 2002-01-24 2003-07-31 Baker Hughes Incorporated Cuttings disposal method

Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4181494A (en) * 1976-08-12 1980-01-01 West's Pyro Limited Process for treating drilling cuttings and mud
US4725362A (en) * 1985-11-18 1988-02-16 Dugat John W Treatment techniques for drill fluids, cuttings and other oil field wastes
US4726301A (en) * 1985-03-13 1988-02-23 Ormeaux Farrell P Des System for extracting contaminants and hydrocarbons from cuttings waste in oil well drilling
US4989522A (en) * 1989-08-11 1991-02-05 Sharpe Environmental Services Method and system for incineration and detoxification of semiliquid waste
WO1993015361A2 (en) * 1992-01-25 1993-08-05 Bp Chemicals Limited Removal of contaminants

Patent Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4181494A (en) * 1976-08-12 1980-01-01 West's Pyro Limited Process for treating drilling cuttings and mud
US4726301A (en) * 1985-03-13 1988-02-23 Ormeaux Farrell P Des System for extracting contaminants and hydrocarbons from cuttings waste in oil well drilling
US4725362A (en) * 1985-11-18 1988-02-16 Dugat John W Treatment techniques for drill fluids, cuttings and other oil field wastes
US4989522A (en) * 1989-08-11 1991-02-05 Sharpe Environmental Services Method and system for incineration and detoxification of semiliquid waste
WO1993015361A2 (en) * 1992-01-25 1993-08-05 Bp Chemicals Limited Removal of contaminants

Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2003062592A1 (en) * 2002-01-24 2003-07-31 Baker Hughes Incorporated Cuttings disposal method

Also Published As

Publication number Publication date
GB0016380D0 (en) 2000-08-23
GB9916036D0 (en) 1999-09-08

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