Amanallah_CSIRO_v6 31/10/07 11:06 Page 68

Drilling & Well Technology

Environmentally Friendly Mud Additives for Superior Drilling-fluid Design to

Meet the Current and Future Technical and Environmental Challenges
a report by
Mohammed Amanullah
Commonwealth Scientific and Research Organisation (CSIRO) Petroleum

Drilling fluids introduced in 1887 and used in the period 1887–1901 Figure 1: Measured Membrane Efficiency of Several Mud Systems

were basic mixtures of clays and water that had no impact on the 80
surrounding environment. However, they have now become a 60
complex mixture of fluids, suspended or dissolved solids, polymers 40
and chemicals, and thus require an engineered design approach to 20
fulfil their technical performance without having any impact on the 0
Silicate mud Mud A Mud B Mud C
surrounding environment, ecosystems and habitats, as well as to Types of mud
ensure the occupational health and safety (OHS) of drilling-fluid Figure 2: Comparison of the Rheological Behaviour of Mineral- and
testing and handling staff. Environmental problems associated with Vegetable-oil-based Muds
complex drilling fluids in general, and oil-based mud (OBM) in 400
particular, are among the major concerns of world communities. For
Dial reading 300
this reason, the Environmental Protection Agency (EPA) and other
regulatory bodies are imposing increasingly stringent regulations to 200

ensure the use of environmentally friendly muds and mud additives. 1

100

0
Throughout the 1970s and 1980s, the EPA and other regulatory 0 100 200 300 400 500 600 700
Rotational speed (rpm)
bodies imposed environmental laws and regulations affecting all
VOM RYOM VOM+GSP
aspects of petroleum-related operations from exploration, MOM VOM+TP
production and refining to distribution.2 In particular, there has been
Figure 3: Comparison of the Rheological Behaviour of Mineral- and
increasing pressure on exploration companies to find Plant-oil-based Muds
environmentally acceptable alternatives to OBMs. This has been 400
reflected in the introduction of new legislation by government
300
agencies in almost every part of the world – including the US, the
Dial reading

North Sea, the Adriatic and the Commonwealth of Independent 200

States (CIS) – on the use of OBMs.3
100

Nearly three-quarters of the Earth is ocean, which provides huge
potential for hydrocarbon resources in addition to other valuable
marine resources. According to Liesman, 4 reserves at depths
approaching a mile or more now represent the biggest single new
oil resources for world communities. For this reason, industry
attention is focused on the vast offshore areas. This is reflected in
increasing drilling activities in the marine environment.1 Even though
Mohammed Amanullah is a Principal Research Scientist at
the Commonwealth Scientific and Research Organisation
(CSIRO) Petroleum in Australia. Prior to joining CSIRO, he
worked as a technical specialist (drilling fluid) in Nigeria
with Interdril Nigeria Ltd, having previously worked at
Bangladesh Oil, Gas and Mineral Corporation as an
Assistant Engineer. His major areas of research are novel
techniques and product development, shale-drilling mud
interactions, borehole instability, water- and oil- (synthetic
and plant/vegetable) based mud design, mudcake characterisation, membrane efficiency
measurement, mud- and production-related formation damage, water cut problems, water
management and environmentally friendly product development for oil field and other
industrial applications. He is the lead inventor of vegetable-oil-based dielectric fluid, has
published more than 60 papers and reports and also prepared the drilling fluid manual for
Interdril Nigeria Ltd. In 2005 he was one of the recipients of the Green Chemistry
Challenge Awards, awarded by the Royal Australian Chemical Institute. He completed his
PhD in petroleum engineering at Imperial College, London in 1993, having obtained an
MSc with first-class honours in mechanical engineering, with specialisation in oil and gas
field equipment, from Moscow Oil and Gas Institute in 1983.
0
0 100 200 300 400 500 600 700
Rotational speed (rpm)
PLOM – BP PLOM – AP MOM
the overall environmental impact of water-based muds (WBMs) is
minimal, due to the detrimental effect of some mud additives such
as potassium chloride, potassium sulphate, polyamine, etc., drilling
and operating companies have been forced to review their mud
additive selection guidelines to exclude or control the use of non-
environmentally friendly and low-toxic mud additives in the
formulation of WBMs.
Some of the WBM additives that were acceptable from an
environmental point of view decades ago are not acceptable for
current and future drilling operations in environmentally sensitive
areas. For this reason, the industry is dedicated to replacing some of
the low-toxic, less harmful and less pure WBM additives that may
not be tolerable in future due to the introduction of increasingly
strict environmental legislation to protect the global environment.
Moreover, some of the WBM additives that are considered
environmentally friendly on the basis of the evaluation of short-term
exposure effect may not be acceptable if they show long-
term exposure effect. This may lead to changes in WBM and mud
additives selection and disposal guidelines all over the world.

68 © TOUCH BRIEFINGS 2007

Amanallah_CSIRO_v6 31/10/07 11:06 Page 69

Environmentally Friendly Mud Additives for Superior Drilling-fluid Design

This paper provides a brief description of the muds and Figure 4: Comparison of the Fluid-loss Characteristics of Mineral- and
mud additives that were developed to meet the current and Vegetable-oil-based Muds

future technical and environmental challenges likely to be 40

Spurt and API fluid losses

encountered in the exploration and exploitation of international oil 30
and gas resources.

(cc)
20

10
High Membrane Efficiency Water-based Mud
OBM eliminates reactive shale and mudrock problems through the 0
VOM RVOM VOM+GSP MOM
formation of membrane at the borehole wall, which allows the Mud types
Spurt loss – BHR Spurt loss – AHR
removal of water from the shale formation. This concept was used API fluid loss – BHR API fluid loss – AHR
to develop several high-membrane-generating WBMs jointly with
Figure 5: Fluid-loss Characteristics of Plant-oil-based Muds in the
Halliburton Baroid. A novel test facility was built for accurate Presence of Different Fluid-loss Additives
assessment of the membrane-generating efficiency of different
40

Spurt and API fluid losses

WBMs. Figure 1 shows the membrane-generating capability of
several newly formulated WBM systems compared with the 30

(cc)
frequently used silicate-based mud. The data show that two of the 20
newly developed WBMs have higher membrane efficiency compared 10
with the widely used silicate-based mud, and thus are expected
0
Duratone Barablock Baranex Polyac CMC LV1
significantly to reduce mud-related borehole instability problems.
Fluid loss additive
Spurt loss API fluid loss
Vegetable- and Plant-oil-based Muds
Due to the poor environmental standing and biodegradation 2 and 3 show the rheological behaviour of the newly developed
characteristics of conventional oil-based muds, the Commonwealth vegetable- and plant-oil-based muds. The American Petroleum
Scientific and Research Organisation (CSIRO) conducted dedicated Industry (API) filtration test, however, indicates much higher API fluid-
research to develop plant- and vegetable-oil-based muds to replace loss properties (see Figures 4 and 5) for both the vegetable- and the
the toxic OBMs. Innovative processing and additive techniques led to plant-oil-based muds compared with mineral OBM. This problem can
the successful formulation of plant- and vegetable-oil-based muds easily be fixed by identifying or developing an appropriate fluid-loss
with rheological characteristics similar to conventional OBMs. Figures additive that is effective in vegetable- and plant-oil-based muds.

Only gas lift valve in the industry tested and

approved to the Rogaland test for gas lift barrier
valves - ISO 17078-2 and ISO 14310-V0
Amanallah_CSIRO_v6 31/10/07 11:07 Page 70

Environmentally Friendly Mud Additives for Superior Drilling-fluid Design

Figure 6: Comparison of the Dynamic Fluid-loss Behaviour of Novel thermo-mechanical gelatinisation with a twin screw extruder. The
Fluid-loss Additives with Respect to a Widely Used Modified Starch process produces no waste by-product, as no solvent is used in the
manufacturing process. Figures 7 and 8 show the static and dynamic
20
Dynamic fluid loss (cc)

fluid-loss characteristics of the novel fluid-loss additives compared

15
with those of a commonly used modified starch. The results show
10
similar or better performance for some of the newly developed
5 starch-based fluid-loss additives in both static and dynamic
0 conditions, along with a thermal stability of up to 150°C. Further
Bentonite Bentonite Bentonite Bentonite Bentonite Bentonite Bentonite
+DF-01 +DF-02 +DF-03 +DF-04 +PSMulti +MS mud information regarding the manufacturing process and the product’s
Types of mud characteristics can be found in Amanullah and Yu.7
Figure 7: Viscosity and Gel Strength Change of Bentonite Mud after
Hot Rolling at 150°C Thermal Inhibitor
Bentonite muds, which contain more than 90% water and usually
300
PV, YP and gel strength

Positive values indicate increase less than 10% bentonite, are environmentally friendly muds that have
change (%)

200 no impact on the surrounding environment, offshore and onshore

100 areas, sensitive habitats and ecosystems. However, the thermally
induced flocculation of this mud at temperatures above 120°C makes
0
10-second gel 10-minute gel PV YP it difficult to use for borehole environments with high temperatures.
Mud parameters

Dedicated research at CSIRO Petroleum has led to the development

Figure 8: Viscosity and Gel Strength Change of Bentonite plus
Geosynthetic Polymer Mud after Hot Rolling at 150°C of an environmentally friendly thermal inhibitor that can extend the
thermal stability of bentonite mud beyond 150°C. Figures 7 and 8
Hot-rolled GSP bentonite mud viscosity/gel change with respect to original GSP bentonite mud show the change in the viscosity, yield point and gel characteristics
75
PV, YP and gel strength

Positive values indicate increase

of the original bentonite and the geosynthetic-polymer (GSP)-
50
change (%)

containing bentonite muds after hot rolling. The dramatic change in

25
the rheological properties of original bentonite mud after hot rolling
0
demonstrates serious thermal degradation of the mud. Further
-25
Negative values indicate decrease information regarding the thermal inhibitor can be found in
-50
10-second gel 10-minute gel PV YP Amanullah and Richard.8
Mud parameters

Gel-based Lost Circulation Material and

These newly developed OBM systems have technical performance Strengthening Fluid
standards similar to conventional OBMs because of their lack Unconsolidated sand formations encountered during drilling create
of interaction with shale and mudrock. Their environmental standing different borehole problems, such as loss of circulation due to
is similar to that of WBMs due to their negligible toxicity effect high permeability, washout, hole enlargement and sanding due to
and highly biodegradable nature. Further information about poor mechanical strength. The sealing of the permeable pathways
vegetable- and plant-oil-based mud can be found in Amanullah and 5 and bonding of the unconsolidated particles are very important to
Amanullah et al.6 reduce mud loss and improve load-bearing capacity and resistance to
flow-induced failure of the unconsolidated sand formations. CSIRO
Highly Pure Corn-based Fluid-loss Additive has recently developed an environmentally friendly gel system
Conventional starch-based fluid-loss additive is manufactured by that can simultaneously cause blockage of permeable pathways
gelatinisation using a solvent that generates a huge amount of and binding of the loose particles together to reduce the scope of
waste water, which is an environmental liability. Furthermore, the mud loss and borehole washout.
product is not highly pure due to the use of a solvent in the
manufacturing process. Moreover, the common starch-based fluid- Conclusion
loss additives used by the industry have a thermal stability of less These novel environmentally friendly products are expected to
than 120°C. To extend the thermal stability as well as the purity of improve technical performance without causing any environmental
starch-based fluid-loss additives, CSIRO Petroleum, jointly with impact. Furthermore, they will maintain technical performance at the
CSIRO Manufacture and Infrastructure Technology (CMIT), same level without causing any impact to the surrounding
developed several highly pure corn-based starches using a process of environment, ecosystems or habitats. ■

1. Amanullah M, Yu L, Environment friendly fluid loss additives
to protect the marine environment from the detrimental effect
of mud additives, Journal of Petroleum Science and Engineering,
2005;48(3–4):199–208.
2. Amanullah M, Shale-drilling mud interactions, PhD thesis,
University of London, 1993;275.
3. Reid PI, Elliot GP, Milton RC, Burt DA, Reduced
environmental impact and improved drilling performance with
water-based muds containing glycols. SPE/EPA Exploration
and Production Environmental Conference, San Antonio,
Texas, 7–10 March 1993, SPE 25989, 453–63.
4. Liesman S, Big oil starts to tap vast reserves buried far below
the waves, Wall Street Journal, 3 July 2000.
5. Amanullah M, Physio-chemical characterisation of vegetable oils
and preliminary test results of vegetable oil-based muds.
SPE/IADC Middle East Drilling Technology Conference and
Exhibition, 12–14 September 2005, Dubai, UAE, SPE-97008-PP.
6. Amanullah M, Tan CP, Camilleri M, Rheological and filtration
properties of novel plant-oil-based invert emulsion muds,
CSIRO Confidential Report No. 00-025, 2000.
7. Amanullah M, Yu L, Dynamic and static fluid loss properties
of novel starches prepared using reactive extrusion technique,
Asia Pacific Oil and Gas Conference and Exhibition, 18–20
October 2004, Perth, Australia.
8. Amanullah M, Boyle R, An environment friendly and
economically attractive thermal degradation inhibitor for
bentonite mud, SPE Europec/EAGE Conference and Exhibition,
Vienna, Austria, 12–15 June 2006, SPE-99410.

70 EXPLORATION & PRODUCTION – OIL & GAS REVIEW 2007 – ISSUE II

Amanallah_CSIRO_v6 31/10/07 11:08 Page 71

Supporting New Developments in Drilling and Testing of High-pressure Offshore Wells

Supporting New Developments in Drilling and Testing of

High-pressure Offshore Wells
a report by
Energy Institute (EI)

The Energy Institute (EI) is the leading professional body for the energy industry, with over 13,000 individuals and 300 companies in membership
across 100 countries. At the heart of the EI lies its scientific and technical programme. Each year, the EI undertakes a focused technical work
programme comprising original independent research and investigations, technical responses to legislation and regulation and workshops and
seminars, providing the international energy industry with information and guidance on relevant technical matters related to health, safety,
environment, aviation, distribution and marketing, test methods and hydrocarbon management. It is supported by BP, Shell, ExxonMobil, Chevron,
ConocoPhillips, Maersk Oil, Talisman, ENI, Kuwait Aviation International, Total, Statoil, Murco, BG Group, Nexen, BHP Billiton and Saudi Aramco.

The EI technical programme covers the development of good practice guidance in support of offshore safety and integrity, which has of late
included work on high-pressure, high-temperature (HPHT) drilling. In response to developments in exploration and production, the EI is revising
the Institute of Petroleum (IP) Model Code of Safe Practice, Part 17: well control during the drilling and testing of high-pressure offshore wells.

This Code was developed for the safe practice for those concerned with well control during the drilling and testing of high-pressure offshore wells,
providing information and guidance on those well control activities associated with high-pressure wells that have an impact on safety offshore.
The Code is intended to be used in the UK Continental Shelf (UKCS) context, but the principles and recommendations have general relevance to
similar operations elsewhere. Each chapter covers an important aspect of well control and has an introduction that describes the part each activity
plays in the drilling and testing of high-pressure offshore wells. In 2006, the EI’s technical partners agreed to support these revisions and the EI is
working with consultants Think Well to provide the expertise needed. This work is being directed by a cross-industry steering group drawn from
the EI’s Aberdeen HPHT forum, and includes the Health and Safety Executive (HSE). The group is chaired by Bruce McEwan of Shell, with the EI
providing management and secretarial functions. To find out more, please visit www.energyinst.org.uk ■

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