Thermal Desorption TechnologiesC U T T I N G S T R E A T M E N T

� A P P L I C A T I O N S

Onshore and offshore projectswhere drilling waste solids fromoil-base mud operations need appropriate “end-point” disposal.

� P R O B L E M S

Untreated, oil-contaminated drill -ing waste creates environ mental liability and often is a source ofunrealized revenue.

� S O L U T I O N S

The project-specific, advancedThermal Desorption technologyoptions from M-I SWACO incor -porate efficient processes forreclaiming entrained hydrocar- bons, minimizing waste and preparing solids for disposal.

� E C O N O M I C S

M-I SWACO preproject analysishelps determine the optimum thermal desorption method(s) fora particular situation, allowing theoperator to optimize operationsand control the capital cost of theequipment required.

� E N V I R O N M E N T A L

Recovered synthetic, oil, diesel orlow-toxicity mineral oil can be rein-troduced to the active mud system,used as a supplemental fuel or soldfor reuse. Treated solids are containedand rigorously tested prior to disposal.

M-I SWACO offers three ThermalDesorption technologies, alldesigned to reduce the amountof produced waste at the source,reclaim valuable base oils and prepare solids for disposal:

• THERMAL PHASE SEPARATION* (TPS*)

• Hammermill (onshore and offshore systems)

• Rotary KilnAll three technologies are capa-

ble of producing dry, clean solidswith less than 1% and often lessthan 0.5% Total Petroleum Hydro -carbon (TPH) content — a major accom plishment for the petroleumindustry. Our THERMAL PHASE

SEPARATION, Hammermill, andRotary Kiln units are engineeredfor high mobility and have the flexibility to adapt to changingoperational requirements. Afterappropriate treatment, dischargematerial can often be used as a fundamental building material;for example, as a base materialin the construction of roads or building blocks.

An additional system enhance- ment — the FLUID OXIDIZER*(FOx*) unit — removes odors associated with thermally recovered oil and water.

Finding the best solutionThe best solutions are the result ofan in-depth understanding of theunique project situation and issuesthat can include:

• Project location

• Source of material

• Discharge or reuse

• Recovery

• Logistics

• Storage capacity

• Preprocessing preparation

• Separation of solids, oil and water

• Processor type and capacityAddressing each set of cir cum-

stances allows M-I SWACO toaddress the broad spectrum of cus-tomer needs, including removal ofcontaminants, safe solids disposal,reuse of hydrocarbons and water,cost control and safety.

Adapting technology tolocal needs worldwideM-I SWACO has commissioned,operated and completed desorptionprojects around the world, consis-tently improving the technologyand the results since 1999. We havecompleted projects in Australia,Central Asia, North and SouthAmerica, and the Middle East.

Our operations experience coversvastly different locations and climates from open steppe anddesert to elevated tropical jungleand even urban locations.

How it worksWhile each desorption technologyfrom M-I SWACO operates differ-ently from the others, many ofthe basic principles are the same.Hydrocarbons are volatized fromoily solids in a closed chamberusing carefully controlled heat.Temperature levels and retentiontime in the chamber are closelymonitored to ensure maximumphase separation without exceed-ing the fractionation point of thebase oil.

The desorbed vapors are removedand condensed. The condensate isthen divided into fractions using aspecially engineered oil/water sepa rator. Recovered base oil is col-lected, tested and recycled as basefluid and/or used as fuel. Water isrecovered and is also used to re-wettreated solids. Treated solids can besafely disposed of in many ways,depending on local regulations.

Eco-sensitive project realizes$1 million in savings A project site in Ecuador was completely isolated, accessibleonly by helicopter and too remotefor con tinual re-supply of drillingfluid or removal of spent mud andcontaminated cuttings.

The major multinational opera-tor needed an economical, effec-tive solution for managing the

synthetic-base drilling fluids andcontaminated cuttings in thisremote, ecologically sensitiveregion. Environmental consider -ations dictated complete reuseof recovered base oil without degradation or contamination,and treated solids were subjectto a limit of <1% residual oil.

The M-I SWACO TPS-2 THERMAL

PHASE SEPARATION system offeredthe operator two key advantages:compact design and ability to betransported by helicopter.

Savings exceeding $1 millionfrom the use of the M-I SWACOTPS-2 unit were reported earlyin the project. Averaging greaterthan 99% recovery/removal andallowing reuse of the high-valuesynthetic-base fluid, the TPS-2 system provided ecologicallysound recycling of spent mudsand treatment of contaminated cuttings. Gas chromatographicanaly sis indicated <1% base sedi-ment and water, demonstratingthat the recovered base oil metthe required specifications.

For more information aboutour portfolio of thermal desorp- tion technologies, contact yourM-I SWACO representative.

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Features and Benefits• Efficient base-oil recovery

and onsite treatment for immediate reuse

• Three desorption systemsto address project-specific requirements

• Consistently achieves <1%TPH on treated solids and<1% BS&W in recovered oil

• Effective odor removalto meet current environ -mental guidelines

• Modular desorption systemdesigns for minimal rig-up/rig-down time

• System enhancement topurify oil without creatinga waste stream

• Reduced emissions from minimized use of cranes,trucks and ship-to-shoreskips to transport cuttingsfor disposal

• Recycling of discharged,treated material

• Enhanced fluid-recovery rates

• Rigorous testing of solidsprior to disposal

Thermal Desorption: Hammermill OnshoreC U T T I N G S T R E A T M E N T

The Hammermill desorption pro -cess is based on direct mechanicalheating through the use of a pound-ing mill’s action on the cuttings. The combi nation of high mechanicalshear and in-situ heat generationcreates an environment that pro-motes flash evaporation of waterand hydrocarbons. There is no ignition source in this type of des-orption process, hence the term“friction.” This technology elimi-nates the need for large surfacesand complex systems for warmingand maintaining a heat-transfermedium, e.g., hot oil, steam orexhaust gas. It is fast, clean and efficient to run.

Due to the operating flexibilityof the mechanical approach to

desorption, Hammermill systemscan be designed as compact unitsthat meet the highest safety and explosion-proofing standards.

The drilling waste must bescreened for larger objects by a simple shaker screen on top of thefeed hopper. Double piston pumpshave proven to be the most reliablemethod of introducing the materialto the process mill. The efficientcrush ing of the solids results in sig -nificant amounts of ultra-fine parti-cles fol lowing the vapors from theprocess chamber. These particlesare efficiently removed by a cycloneand a special dust separator priorto the vapors moving throughthe condensers.

Specs Best recorded

Oil on cuttings (TPH) <1 0.02%

Flash point reduction of recovered oil, °C <5 0

Solids in recovered oil, ppm <1 <0.5

Oil in recovered water, ppm <1,000 <50

Hammermill Performance

Features• ATEX approved

• CE marked

• Small footprint

• Low manpower requirements

• Operates very cleanly and quietly

• Ability to operate offshore

Benefits• Limited process temperature

• Very short retention timerequired for complete removalof oil in the solids

• Good condition of the recovered oil

• Efficient, intense agitationto break up solid particles, inducing efficient thermal desorption

Drilling waste

Cooling water

Feed hopper

Vapours

Hydraulic Feed pump

Oil condenser

Cyclone

TCC process mill

Feedhopper

Drive- unit

Screw conveyors

Mixer

Cooling air

Combustion air

Diesel from tank

Exhaust

El. supply

N2 supply

Compr.air supply

Cooling air for water and oil

Water supply

Cooling air return

Steam condenser

Recoveredwater

Recovered oil

Recovered solids

Non-condensible gas

Screening device

Transport device

Thermal Desorption: Hammermill Offshore

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Now the Hammermill unit is specif-ically designed for offshore, capableof being installed in the space thatwould have been used for the skipspreviously used to collect and trans-port cuttings to shore. Through theintegration of the proven CLEANCUT

cuttings transfer and storage tech -nology with an M-I SWACO Thermo -mechanical Cuttings Cleaner (TCC)modular design, we provide thetotal offshore solution, including:

• Pneumatic transfer of drilled cuttings offshore to a thermal system

• Complete enclosed system

• CLEANCUT and Hammermill PLC-controlled for reduced manpower requirements

• Cross-trained CLEANCUT

and TCC engineers

• Modular DNV 2-7.1approved modules

• Minimal rig-up/rig-down time– Plug and socket on cabling to

reduce rig-up/rig-down time

• Best available technology fordrive module featuring the newCAT C32 low emissions engine(less than Tier 2)

• ATEX Approved

• Rated for Zone 2 use

• Hammermill technology utilizingfriction to generate heat withinthe cuttings that separates thebase oil without damaging itsmolecular structure

• Offshore rigs and other installa-tions where space is at a pre- mium and where base oils mustbe recovered from drilled cuttings,both for the recovery of the baseoil and for preparing the cuttingsfor disposal or reuse

• Reduced manpower on the rig

• Reduced crane lifts for lifting cuttings containers (skips) —reduced manpower — removalof additional deck hands on therig to handle the skips

• Reduced emissions – Diesel crane emissions —

unloading the cuttings containers from the rig

– Ship to shore of skips onsupply boat — fewer boats,reduced emissions

– Reduced emissions from dieselcranes onshore to unload the cuttings containers from the supply boat

– Reduced emissions from thetrucks to transport the cuttingscontainers to the onshore thermal process facility

– Reduced emissions to unloadthe cuttings containers fromthe truck at the onshorethermal treatment facility

– Reduced emissions from fork- lift trucks to empty the cuttingscontainers into the onshore thermal treatment facility

– Reduced cost of container rental

Features• ATEX approved

• CE marked

• Small footprint

• Low manpower requirements

• Operates very cleanly and quietly

• Ability to operate offshore

Benefits• Limited process temperature

• Very short retention timerequired for complete removalof oil in the solids

• Good condition of the recovered oil

• Efficient, intense agitationto break up solid particles,inducing efficient thermaldesorption