CASE STUDY

Baroid's Waste Management Service

Helps Operator Save $1.39M and Ensure
Environmental Compliance
BAROID DRILLING WASTE MANAGEMENT SERVICE HELPED OPERATOR NET
$1.39M IN BASE OIL REUSE SAVINGS AND ENSURE ENVIRONMENTAL
COMPLIANCE IN REMOTE LAND OPERATION
NORTHWEST KAZAKHSTAN

CHALLENGE CHALLENGE
» To improve drilling performance, To improve drilling performance, a major operator switched from water-based mud to a low-
far from the mud stockpoints toxicity oil-based system. However, the remote drill sites were located far from the mud stock
under harsh climatic conditions
points and harsh climatic conditions threatened to impede logistics. Most challenging of all
threatened to impede logistics.
» Deploy cuttings treatment was the need to deploy cuttings treatment technology that could keep pace with continuous
technology that could keep pace drilling operations on three rigs, each producing 1,000 m3 of oil-based cuttings per well. All
with continuous drilling operations cuttings had to meet the regulated specification of 1.0% (w/w) oil on cuttings at the end of
on three rigs, each producing 1,000 the process. Additionally, strict environmental regulations imposed by the Government of the
m3 of oil-based cuttings per well
Republic of Kazakhstan required deployment of Best Available Technology (BAT) for treatment
» All cuttings had to meet the
regulated specification of 1.0% of oil-based drill cuttings, making this an ideal application for the Baroid thermo-mechanical
(w/w) oil on cuttings at the end of Cuttings Cleaner (TCC).
the process
To address these challenges, the operator’s waste management strategy needed revision to
help ensure operations continued in a safe and environmentally acceptable manner. Major
SOLUTION objectives included making rig site modifications, optimizing transfer and transportation
practices, installing new mixing and storage capacity at the liquid mud plant and establishing
Baroid Drilling Waste Management
reliable methods for base oil recovery with 100% reuse.
service personnel provided a
comprehensive engineered solution:
» Baroid thermo-mechanical Cuttings SOLUTION
Cleaner (TCC)
Baroid Drilling Waste Management service personnel provided a comprehensive engineered
solution to expedite the change in mud systems safely and economically. Key components
RESULTS of the solution are shown below, with the thermo-mechanical Cuttings Cleaner as the
centerpiece of the operation.
» The recovery of 1,110 m3 base
oil resulted in total net profit to
» Detailed rig audits to identify needed modifications
operator of over $1,390,000 USD
» This volume of recovered oil » Waste management personnel on all rigs to ensure the transition from water-based to oil-
represents 16% of the overall base based fluid was accomplished smoothly
oil used in this project, significantly » New storage and mud reconditioning capabilities to manage cuttings and expedite reuse of
reducing the logistical issues recovered base oil
related to maintaining the oil-based
» Dedicated cuttings skips and trucks to prevent delays in handling that could slow or halt
system and maximizing drilling
effciencies in this remote location drilling operations
» Dedicated vacuum trucks for oil-based mud transport
» Engineered oily water treatment package to minimize pollution risk

Thermo-mechanical Cuttings Cleaner – A key factor in selecting the best cuttings treatment
technology is the Total Petroleum Hydrocarbon (TPH) level permitted to remain on the
cuttings. The goal is to produce oil-free (ultra-low TPH) solids for disposal through thermal
CASE STUDY

desorption. The oil and water is evaporated from the cuttings and the vapor is condensed in stages
recovering clean oil for reuse in drilling fluid.

The TCC system uses a process mill which contains a rotating shaker with a series of hammer
arms to generate friction. The use of friction efficiently generates heat directly in the cuttings bed
without the use of flame or indirect sources. The temperatures associated with the process (250°C
to 300°C) and short retention time (a few seconds) reduce the risk of fracturing the base oil, which
results in recovery of a consistent high quality oil comparable to the original product.

RESULT
Over a nine-month period, cuttings processed with the TCC unit have shown average TPH levels of
2,400 ppm. The permitted limit imposed by the Government of the Republic of Kazakhstan is 10,000
ppm. The TCC process allows the operator to carry out safe and compliant disposal of all treated
cuttings at the dedicated landfill site.

Since making the change to oil-based mud in mid-2008, the operation has recorded zero spills at the
rig site or during the transport of over 9,000 m3 of contaminated cuttings across the 75-km distance
to the central treatment site. A significant volume of base oil has been recovered for reuse, creating
savings in fluid and disposal costs.

Additionally, since the start of oil-based system implementation, all three rigs have sustained
continuous drilling operations with no downtime related to cuttings handling or oil-based mud
supply.

In nine months, Baroid Drilling Waste Management service personnel assigned to this project have
treated over 8,100 m3 of oil-based drill cuttings. The recovery of 1,110 m3 base oil resulted in total
net profit to operator of over $1,390,000 USD. This volume of recovered oil represents 16% of the
overall base oil used in this project, significantly reducing the logistical issues related to maintaining
the oil-based system and maximizing drilling efficiencies in this remote location.

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