Drill Cuttings Reuse in Bituminous Roofing Materials
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Solution Overview
Problem
Drilling waste, contaminated with residual drilling mud, is typically discarded in landfills due to the inefficiency of existing separation technologies, posing environmental and economic challenges, and there is a need for effective recycling methods to reclaim and reuse this waste.
Innovation Solution
A process involving the collection of drilling waste solids of uniform particle size, mixing them with hot bituminous tar to create a viscous mixture, which can be used in roofing materials, either alone or blended with conventional fillers, to produce a hybrid filler phase adapted for roofing applications, thereby reusing contaminated drilling waste.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of substance
If mechanical separators (shale shakers, decanter centrifuges) are used to separate drill cuttings from drilling mud, then a substantial portion of drilling mud can be returned for reuse, but residual drilling mud remains in the cuttings making them contaminated and unsuitable for reuse
Solution Approach 1:
The patent applies thermal processing to change the physical state and properties of the drilling mud contaminants in drill cuttings. By heating the cuttings to temperatures sufficient to vaporize or decompose the drilling mud components, the contaminants are removed or transformed, converting contaminated solid waste into a clean, reusable filler material suitable for roofing applications.
Solution Approach 2:
The invention utilizes phase transitions of the drilling mud contaminants during thermal processing. The drilling mud components undergo phase changes from liquid to vapor through heating, separating them from the solid drill cuttings. This phase transition enables effective removal of contaminants that mechanical separation cannot eliminate, producing clean reusable material.
2Object-affected harmful factors
If drill cuttings are stabilized with bulking agents to prevent liquid leaching, then transport safety is improved, but the cuttings occupy more volume and require landfill storage
Solution Approach 1:
The patent converts the harmful contaminated drill cuttings into a beneficial reusable resource through thermal processing. By applying heat to remove or decompose the drilling mud contaminants, the previously harmful waste material is transformed into a clean, dry filler suitable for manufacturing roofing materials, thereby converting a waste disposal problem into an economic opportunity.
Solution Approach 2:
The invention recovers value from previously discarded drill cuttings by removing contaminants through thermal processing. Instead of discarding the contaminated cuttings to landfill, the process recovers the solid filler material by eliminating the harmful drilling mud components, enabling reuse in construction applications.
3Object-affected harmful factors
If contaminated drill cuttings are discarded in landfills, then environmental contamination is prevented, but production costs increase and environmental sustainability is reduced
Solution Approach 1:
The patent demonstrates that processed drill cuttings can serve multiple functions: they act as a filler material in roofing products, providing both structural functionality and waste diversion. This multi-functionality allows the material to replace traditional fillers while simultaneously addressing waste management concerns, creating economic and environmental benefits.
Solution Approach 2:
The invention converts the previously harmful contaminated drill cuttings into a beneficial reusable resource. Through thermal processing, the waste material is transformed into a valuable filler that reduces manufacturing costs and eliminates landfill disposal requirements, simultaneously achieving economic and environmental benefits.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This process effectively recycles drilling waste into a valuable roofing material, reducing landfill burden and lowering production costs by utilizing contaminated drilling waste as a filler in bituminous roofing materials, enhancing environmental sustainability and economic viability.
Implementation Method 1
mixing the drilling waste solids with hot bituminous tar to create a viscous hot bituminous tar liquids phase
Data Source
AI summary
A process for the reuse of oilfield drilling waste with an natural affinity for oil which has had at least a portion of the contaminants removed using a remediation technology. The drilling waste can be further refined to ensure the waste meets a desired particle size distribution and thereafter sent for reuse by mixing the drilling waste with hot bituminous tar and thereafter using the liquids phase in roofing materials. A method of mixing the drilling waste with conventional fillers is also described to create a blended mixture of drilling waste and conventional fillers to create a new hybrid filler which is mixed with hot bituminous tar for use in roofing materials.