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Aade-04-Df-Ho-25 Effect of Drilling Fluid Components on Composting and the Consequences for Mud Formulation 3

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Aade-04-Df-Ho-25 Effect of Drilling Fluid Components on Composting and the Consequences for Mud Formulation 3 AADE-04-DF-HO-25 Effect of Drilling Fluid Components on Composting and the Consequences for Mud Formulation. Karen McCosh, Jonathan Getliff, M-I SWACO This paper was prepared for presentation at the AADE 2004 Drilling Fluids Conference, held at the Radisson Astrodome in Houston, Texas, April 6-7, 2004. This conference was sponsored by the Houston Chapter of the American Association of Drilling Engineers. The information presented in this paper does not reflect any position, claim or endorsement made or implied by the American Association of Drilling Engineers, their officers or members. Questions concerning the content of this paper should be directed to the individuals listed as author/s of this work. Abstract such as composting are becoming increasingly important Composting is a well-established, biological as this allows the conversion of the waste into a useful technique in which bacteria and other microorganisms product. Such technologies allow recycling and reuse degrade and convert organic matter to humus and and sit near the top of the waste management hierarchy microbial biomass. Composting can also be utilized to (Figure 1) which is preferential when deciding on the degrade the oil component of drill cuttings, but the means of drill cuttings disposal. Bioremediation can be choice of drilling fluid coating these cuttings will affect adapted to co-compost drill cuttings with the microbial the quality and composition of the compost end product flora and fauna being able to utilize the hydrocarbon as well as reaction rates and the final concentrations of component of the drilling fluid as a carbon source for hazardous materials. Drilling fluid formulations can be growth. Through this process, the hydrocarbon content designed to optimize the composting rate and minimize of the drill cuttings is reduced in a natural process that hazardous residues, but the fluids technical converts the cuttings into a non-toxic and potentially performance, cost and availability are also critical. useful end product. This paper describes the results of laboratory investigations into the effect of drilling fluid chemistry Composting Mechanisms and Reactions and organic amendments on composting rate and end- Microbiological activity during the process of product quality together with the consequences for large- composting generates metabolic heat that divides the scale composting operations and their likely impact on composting process into four stages. drilling operations. During the mesophilic stage (1-2 days) indigenous Experiments have shown that the optimum cuttings: micro-organisms (bacteria and fungi) multiply rapidly and amendments ratio is 1:1, with a variety of organic the temperature increases from ambient to ~40°C.1 The amendments being suitable for use in the process. mesophilic bacteria break down the soluble, readily Hydrocarbon loading and hydrocarbon type affect degradable material2 and as organic acids are produced, reaction rate but all base fluids tested (linear paraffin’s the mass becomes increasingly acidic.1 are the fastest, diesel was the slowest) were degraded As temperatures increase above 40°C, the to less than 1% TEH in the “mature” compost. Little composting reaction enters the thermophilic stage which effect on composting efficiency was seen by changing can last a few days to several months. The indigenous the drilling fluid internal phase salt type or weighting mesophile population starts to decline and the agent type. thermophilic bacteria (particularly Bacillus and some fungi) take-over.2 During this stage, high temperatures Introduction accelerate the breakdown of proteins and fats and some Cuttings are pieces of formation rock produced by the of the more complex carbohydrates. The pH starts to drill bit that are returned up the annulus of the hole turn alkaline as ammonia is liberated.1 Thermophiles suspended in the drilling fluid. Solids-control equipment continue to grow increasing the temperature to ~60°C, (e.g. shakers, centrifuges) at the drill site remove the where fungi start to be deactivated. solids from the fluid and return the valuable drilling fluid Above 60°C, the composting is continued by back to the active system in a process that reduces the actinomycetes (slower growing than bacteria and fungi in waste at source. When drilling with oil- or synthetic- mesophilic stage)1 which play an important role in based drilling fluids (invert emulsions), the fluid coating degrading complex organics such as cellulose, lignin, the cuttings typically contains ~10% hydrocarbon. With chitin and proteins.3 Temperatures >60°C are also useful increasing environmental constraints on the discharge of in controlling thermo-sensitive pathogens to crops, oil- or synthetic-based drill cuttings, various treatment animals and man and in killing off weeds and seeds that options are available to reduce the hydrocarbon content will be detrimental for land use of the product. The and allow disposal or re-use. Bioremediation techniques reaction rate decreases as more resistant materials are 2 K. MCCOSH and J. GETLIFF AADE-04-DF-HO-25 encountered and a temperature maximum is reached 55°C would be an optimum temperature for composting1. when the rate of heat generation equals the rate of heat Cooling or insulation may be required to control loss.1 temperature. As heat generation decreases further the compost enters the cooling stage, where the compost is said to Composting Drill Cuttings have reached stability. The easily convertible material Successful composting of drill cuttings requires a has been decomposed, the major O2 demand has been source of bacteria and the blending of the cuttings with met and the production of odorous vapors has declined. organic materials to provide the correct carbon, nitrogen During this stage the pH drops slightly but remains and moisture ratios. alkaline. Thermophilic fungi re-invade the mass from the In order to ensure an efficient composting reaction cooler regions and with the actinomycetes attack the and degradation of the hydrocarbon component of the long chain polysaccharides, celluloses etc. and degrade cuttings as well as to ensure that the end-product meets them into simple sugars. The rate of energy release is all relevant legislation, the quality and composition of very small and the temperature of the mass falls to both the starting material and the end product need to be 1 th ambient. Compost is typically left to mature (the 4 controlled. stage) for several months, prior to use as a horticultural The addition of the drilling fluid and its chemical or agricultural growth medium, allowing complex constituents as well as large amounts of inert material (in chemical reactions to occur between lignin residues and the form of formation rock) will have consequences for proteins of dead microorganisms to produce humus. The the composting process. The choice of drilling fluid 1 final pH is slightly alkaline. chemistry not only will affect the quality and composition Many factors govern the rate and efficiency of the of the compost end product, but also influences reaction composting process. A summary of the optimum rates and final concentrations of the drilling wastes. conditions proposed for composting is given in Table 1. Drilling fluid formulations can be designed to optimize Composting is an aerobic process and adequate the composting rate and minimize hazardous residues, aeration will supply the oxygen essential for the aerobic but the fluids technical performance, cost and availability composting micro-organisms and also removes CO2, are also critical. moisture and heat (evaporative heat transfer) from the Oil-based or synthetic-based drilling fluids consist of compost heap. Adequate aeration can be achieved by a continuous phase of hydrocarbon whose chemical turning or more advanced engineered solutions. composition varies according to logistics, legislation and Optimization of the blend particle size can ensure a high environmental limits as well as fluid properties, e.g. surface area for microbiological attack yet prevent viscosity and flash point. The fluids used vary in compaction and allow diffusion of air into, and CO2 out composition and structure and may contain linear, of, the mass. branched, saturated, unsaturated and aromatic The requirements for C, N, P, K and trace elements hydrocarbons, covering a range of molecular weights. for the bacterial growth are normally met by the organic The precise nature of the hydrocarbon affects the material to be degraded. Only the C:N ratio and biodegradation potential. For molecules of the same 2 occasionally the P level require adjustment. An initial molecular weight, decreasing the degree of aromaticity C:N ratio of 25:1-30:1 has been suggested as optimum and branching causes the base fluid to become more but as the composting process proceeds the C:N ratio biodegradable and less toxic. For example, the paraffinic will fall to ~10:1 as CO2 is released and C is assimilated components of diesel will degrade quicker than the 2 in microbial cells. The required C:N ratio can be aromatic, branched and cyclic hydrocarbons present. achieved by the correct blending ratio for the raw Furthermore, lower molecular weight structures tend to ingredients. be easier to biodegrade, although in some The moisture content of the compost blend is crucial circumstances they can be more toxic. Regulations as water is the medium for chemical reactions and water concerning the quantities of organic contaminants is required for micro-organisms to move about. Optimal permitted in composts vary. Some legislation quote water content is 50-60% allowing optimum biological permitted quantities of specific organics, e.g. PCBs, reaction without saturating the air spaces of the compost PAHs, Dioxins, while others quote in addition a thereby preventing anaerobic conditions. This can be hydrocarbon loading. For example Austria permits 3000- achieved by correct blending of the raw ingredients and mg/kg hydrocarbons, 6-mg/kg PAH and 1-mg/kg PCB.4 supplemental addition of water throughout the The micro-organisms that can utilize these non-water composting reaction as required.
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