Green Drilling Fluid Additives For A Sustainable Hole Cleaning Performance: A Comprehensive Review
Green Drilling Fluid Additives For A Sustainable Hole Cleaning Performance: A Comprehensive Review
https://doi.org/10.1007/s42247-023-00524-w
REVIEW
Received: 25 March 2023 / Accepted: 9 June 2023 / Published online: 20 July 2023
© The Author(s) 2023
Abstract
Drilling fluids are the core of drilling operations, and they are responsible for many roles, such as lubricating drill string,
cooling down drilling equipment, maintaining wellbore integrity, and transporting cuttings to the surface. High-energy
demands have caused the oil and gas production rates to increase by orders of magnitude, which is accompanied by increased
usage of different drilling fluids, including oil-based muds (OBM) and water-based muds (WBM). Large amounts of fluids
used without caution can cause severe consequences to the environment if not well monitored. Therefore, the field has been
exploring the utilization of biodegradable and environmentally friendly additives (green). These green formulations can
promote a safer alternative to the currently available commercial additives, meet sophisticated drilling requirements, and
ensure resource sustainability. A comprehensive overview of the literature has been conducted in this review, starting with
a background on oil and gas reservoir types and cuttings transportation mechanisms, followed by a discussion on various
recent green fluids or additives emerging in the field. In addition, an economic comparison has been conducted to assess the
feasibility of the reviewed green formulations. Finally, the review ends with a summary and future prospective on the topic.
In conclusion, this review suggests the development of multifunctional drilling fluids with good hole-cleaning properties,
utilizing additives studied for different functions (e.g., filtration). Enhancement of rheological properties achieved through
the addition of these additives indicates their suitability for hole-cleaning applications, which must be confirmed through
additional studies. Consequently, filling the existing gap in the literature is by triggering research topics in this area.
Keywords Drilling fluids · Green additives · Rheology · Hole cleaning · Cuttings transportation
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used in 15% of drilled wells worldwide, while around 80% out of the reservoir due to pressure within the wellbore. On
of the wells are currently being drilled using WBM [9]. the other hand, conventional reservoirs require sophisti-
OBMs have been extensively used in many drilling opera- cated techniques to withdraw the oil/gas from the ground
tions; characteristics such as good thermal stability, effective since the flow pressure in these formations is inadequate.
cuttings transportation, good lubricity, salt-resistance, and Hydraulic fracturing, among many unconventional reser-
stability in shale formation nominate them as the superior voir techniques, utilizes water to propagate pre-made cracks
option [10–13]. Nowadays, global communities prioritize throughout the wellbore, enabling oil or natural gas to flow
sustainability and protection of the environment over oil/ [29, 30]. Major unconventional resources include coal bed
gas exploration and production [14]. Many studies in the methane (CBM), tight gas, shale gas, and natural gas hydrate
literature have addressed the toxicity and severe effects of (NGH) [31, 32].
OBMs on the environment and human health [10, 15]–[20]; Porosity and permeability are among many important
thus, the use of OBMs is restricted and faces many govern- properties of oil and gas reservoirs. Rock porosity is defined
mental and non-governmental regulations and challenges. as the ratio of pore volume to bulk rock volume (Eq. (1)),
These concerns have redirected the drilling industry toward and permeability refers to rock formation ability to transfer
the utilization and exploration of eco-friendly drilling flu- fluid (gas or oil); the connection of pores within the forma-
ids. WBMs are considered inexpensive and environmentally tion increases the reservoir permeability [29, 30]. Figure 1
friendly drilling fluids [16, 21, 22]. Nevertheless, WBMs illustrates the geological properties of various types of oil
encounter instability issues in shale formation or under and gas reservoirs. Formations such as sandstone are of high
extreme wellbore conditions, and they lack suspension permeability as they are formed of huge-well-connected
properties that facilitate cuttings transportation. Therefore, pores. Shale and siltstones are of lower permeability, with a
improvement of WBM characteristics is crucial to replace reduced and lesser number of interconnected pores.
the toxic OBM with a viable alternative and consequently
Vpore
achieving environmental sustainability. Incongruous drill- ∅= (1)
ing fluid usage can jeopardize the whole drilling process, Vbulk
reducing the penetration rate, increasing fluid filtration,
higher risk of stuck pipe, or even catastrophic downhole
blowout [23, 24]. Therefore, the development and enhance- 1.3 Types of drilling muds (WB‑emulsions‑OB)
ment of environmentally friendly drilling fluids are crucial
for sustainable oil and gas exploration and production. A Drilling fluids come in a variety of varieties and are used
review article was published addressing nanoparticle addi- frequently. Certain wells call for the use of various types
tives used in WBM [25]; moreover, some reviews focused at various depths in the hole or the combination of various
on bio-lubricants or biodegradable synthetic drilling fluid types. The different kinds of fluid can be broadly divided
[26, 27]. Those reviews either focus on fluid filtration or into a few groups. Drilling fluids is classified into three types
lubrication, and none addresses fluid properties from a hole according to their base material: water-based, oil-based, and
cleaning prospective. To the best of our knowledge, there is water–oil-based (emulsions). Of all the mud systems, water-
no comprehensive review on green WBM/OBM additives based drilling fluids are the most often used. They are typi-
reported in the literature. Consequently, the ultimate goal cally less expensive, easier to maintain, and, in some unique
of this review is to provide a background and highlight the types of systems, almost as shale inhibitive as oil muds. The
current green drilling muds or additives used in both OBM most fundamental water-based mud systems start with water,
and WBM in the literature up to year 2023. which is then combined with clays and other chemicals to
produce a homogeneous mixture that resembles a cross
1.2 Types of reservoirs between chocolate milk and malt (depending on viscosity).
Water is the continuous phase of the fluid, which is mud.
Natural gas and oil reservoirs have many classifications Oil-based mud is mud that uses petroleum products, like
and categorizations. The Petroleum Resources Manage- diesel fuel, as the basis fluid. Oil-based muds are helpful
ment System (PRMS) classification splits reservoirs into for numerous reasons, including boosting lubricity, improv-
two main types, conventional and unconventional [28]. The ing shale inhibition, having superior cleaning powers with
conventional reservoirs are defined as easy to reach and do less viscosity, and withstanding higher temperatures without
not require advanced technologies to recover their storage. degrading. Oil-based muds come in two varieties: pseudo-
The unconventional terms account for reservoirs of distinct oil-based muds and invert emulsion oil muds. If the water
storage locations, extraction methods, origin, and properties. content is greater than 5%, it will transform into an inverted
The conventional oil drilling processes are less expensive or water-in-oil emulsion. A mud that has synthetic oil as its
than unconventional methods; since the oil/gas fluid flows base fluid is known as synthetic-based fluid. Because it has
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Emergent Materials (2024) 7:387–402 389
the same qualities as an oil-based mud but is less harmful accordingly, the bed moves either in moving bed dunes or
than an oil-based fluid; this is most frequently utilized in separate dunes. Higher flow velocities will cause further
offshore rigs. Oil-based fluid and synthetic-based fluid both deformation of the dunes into smaller bodies and suspended
provide environmental and analytical challenges. particles, which move or creep in the flow direction [34,
37, 38].
1.4 Cuttings transportation patterns Fluid flow velocity is a detrimental factor for cuttings
transportation in a specific pattern. Minimum transport
Drill bit interaction with formation generates solid parti- velocity (MTV) is the minimum velocity required to move
cles (cuttings). The generated cuttings blend into the fluid cuttings particles; reducing the fluid velocity below the
medium resulting in a two-phase flow system. The distribu- MTV causes cuttings deposition (bed formation) on the
tion of cuttings in the annulus depends on the hydrodynamic low side of the wellbore. Alternatively, increasing the fluid
interaction of cuttings and drilling fluid. Also, cuttings trans- velocity above the MTV — in the presence of a stationary
portation is contingent upon fluid (e.g., flow rate) and cut- bed — applies non-uniform shear and pressure on the cutting
tings (e.g., size and density) properties. Experimental inves- surface. These uneven forces cause particle re-suspension
tigations have shown that cuttings flow in pipes is grouped into the fluid medium [40, 41]. The complexity of field con-
into suspended symmetric, suspended asymmetric, moving ditions usually leads the cuttings transportation to follow the
bed, and stationary bed [34, 35]. Other reports have further three layers model: stationary bottom bed, middle moving
sub-classified the flow patterns to include suspension/salta- bed, and suspend moving particles [40].
tion and cutting clusters [36]. Small particles present in the
slurry (solid/liquid) mixture have slow settling velocities
in the horizontal configuration. In such cases, the turbulent 2 Environmentally friendly additives
mixing is higher, causing the particles to be well mixed in
the solution (homogenous). Particle diameter larger than 2.1 Green fluids and global standards
10 μm has various settling rates, and a vertical concentra-
tion gradient is observed (heterogeneous). In cases where the In the light of the global recognition of drilling fluids’
particle settling rate is higher than fluid washing, a packed impacts on the environment, in 2000, the United States
bed is formed (Fig. 2). (US) has spent $7.8 billion on environmental protection
The fluid flow velocity has four classifications in packed [42]. Nevertheless, terms such as “green” or “environ-
bed flow: low, moderate, moderate-high, or high flow. The ment friendly” are not well defined or standardized, and
low-velocity flow leads to bed accumulation, which will start the criteria for the evaluation of green fluid are diverted.
pressure build-up within the pipe. Moderate and moderate- Subsequently, the absence of a clear definition makes
high flow rates will cause deformation to the packed bed; these terms very subjective and further complicates
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System
Country Relevant Standards Symbol Ref.
(year)
85% of oil formulation must be from renewable
sources
Nordiac Oil degradability (70%) should compile with
Nordic [47],
Swan OECDb 301 B or F or other equivalent methods.
Countriesa [48]
(1989) Aquatic toxicity must be measured in
accordance with OECD 201 and 202 or
equivalent methods.
90% minimum biodegradability of vegetable oil-
based, or 60% biodegradability if tested by
Ecomark OECD test methods. [47],
India
(1991) Must be free from halogens compounds (PCTs, [49]
and PCBs)c and nitrates.
Must be non-toxic to marine life.
Biodegradability must be 60% within 28 days if
Ecomark tested following OECD test Guidelines or
Japan [50]
(1989) ASTMd methods.
a
Geographical region in Northern Europe and the North Atlantic; it consists of Sweden, Norway, Finland, Denmark, and Iceland. OECD Organi-
zation for Economic Co-operation and Development, PCBs polychlorinated biphenyls, PCTs polychlorinated terphenyls, ASTM American Soci-
ety for Testing and Materials.
Table 2 Drilling fluid discharge RegionStandards North America South America Asia–Pacific Europe Africa Middle East
[55]
Prohibited USA Brazil Thailand Russia Angola Saudi Arabia
Canada Venezuela China Norway Oman
Not prohibited Argentina Australia UK Nigeria Kuwait
Egypt
increase in apparent viscosity and gel strength with date In addition to food waste, plant-based additives are also
seed concentration. Although MPP, PPP, and DS studies utilized in the formulation of eco-fluids. Ghaderi et al. [63]
have shown their ability to improve the rheological proper- conducted a comprehensive study on saffron purple petals
ties of WBM, they failed to address additives’ feasibility (SPP). SEM images showed SPP powder structure is shape-
from an economic aspect. In addition, no pilot-scale or less with a wide variety of size distributions. Major ele-
field tests were performed. Some additives were used in ments identified by EDX analysis were carbon (60.8 wt%),
simple mud mixtures that exhibit no chemical interactions oxygen (35.5 wt%), and trace mineral elements, including
with other commonly used additives, overlooking physi- Zn, P, Ca, and S. The addition of 1–3 wt% of SPP to base
cal and chemical interactions that are essential for fluid mud significantly increased shear stress by 26–151%. SPP
properties. muds had an excellent fitting to rheological models, and they
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Mandarin peel powder (MPP) 1–4 wt% Food waste • MPP had a slight effect on mud weight due [61]
to foam formation
• Addition of 3–4% MPP increased the YP
and PV of mud
• MPP addition increased filtration proper-
ties
Potato peel powder (PPP) 1–4 wt% Food waste PPP can be used as a multifunctional bio- [62]
enhancer additive
• PPP additions reduced gel strength, YP,
and pH
• Further increase of PPP concentration
(1–4%) had an insignificant impact on mud
weight, YP, pH, or gel strength
• Filtration volume decreased by 30%
Date seeds 0.25–2 ppb Food waste • PV and YP rheological properties were [14]
improved following the addition of date
seeds
• Filtration decreased by 20%
Pistachio shell powder (PSP) 1.4–2.57 wt% Food waste Formulations were tested at ambient and [72]
extreme field conditions at lab and field-
scale
• Improved the rheological properties
• It reduced fluid loss (30%) and filter cake
thickness
Saffron purple petals 1–3 wt% Flower petals • 3% of SPP improved filtration performance [63]
by 45%
• SPP increased PV and rheological proper-
ties
• SPP presence decreased the corrosion rates
of mild steel
Henna 4.5 wt% Plant leaf • Henna leaf enhanced the fluid thermal [64]
aging resistivity for most rheological
properties
Tree trunk fibers 10 and 30 ppb Deceased tree • Organic fibers have outperformed the com- [65]
mercial LCM fibers
Grass 0.25–1 ppb Horticultural waste Grass powder of different sizes [67]
• Increased the PV and AV values of drilling
fluid
• The grass was able to reduce filtrate vol-
ume by 25%
• Finally, grass containing solutions had
lower pH values
Grass 0.5–1.5 wt% Horticultural waste • At LTLP and HTHP conditions, grass [68]
decreased the filtration by 48% and 26%,
respectively
Averrhoa carambola L. (Kian) 0.5–3 ppb Fruit • Kian fruit showed similar rheological prop- [69]
erties to PAC-R additive at 25 and 65 °C
Carrageenans 0.1–2 wt% Extracted from red seaweeds • Carageenan solutions treated with NaOH [71]
solution were able to reduce the filtration
properties by 37%
• Different concentrations had different
rheological behaviors. High concentration
exhibited shear thinning behavior, while
low concentration revealed shear thicken-
ing behavior
• • Nevertheless, 1.2% concentration and
beyond demonstrated Newtonian flow
behavior
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Emergent Materials (2024) 7:387–402 393
Table 3 (continued)
Additive Type Findings Reference
Tamarind gum 0.05–0.25 wt% Seed extracts • Rheological properties such as PV and [70, 73]
YP slightly increased, and filtration was
reduced to some extent
Okra mucilage 10–20 wt% Vegetable • Shale swelling inhibitor [74, 75]
• Reduce the bentonite swelling
• Rheological properties such as PV and YP
were improved, and filtration and friction
coefficient were reduced to some extent
Novel starch 2 wt% Modified natural polymer • High-performance fluid loss additives [76]
• Improve the filtration capacity of the fluid
• Salt resistance
• Excellent high temperature resistance
Wild Jujube pit powder (WJPP) Seed extracts • Increase the viscosity and yield point [77]
• Reduce the filtration rate and the lubrica-
tion coefficient
• Enhance the shear thinning and thixotropy
• Decreasing the particle size or increasing
the density of WJPP lead to significant
enhancement in WJPP effects
Acorn shell powder Seed extract • Rheological properties such as PV and [78]
YP slightly increased, and filtration was
reduced to some extent
• Displayed filtration controlling efficiency
comparable to that of the traditional addi-
tives
Lignin nanoparticles Extracted from plant • Increase the rheological properties such as [79]
PV and AV by 500% and 600%, respec-
tively for SSBM
Basil seed powder (BSP) Seed extract • Combination of BSP into bentonite suspen- [80]
sion improves the rheological and filtration
properties effectively after 120 °C thermal
aging
• Hydrate the surface to reduce friction
• Superior to bentonite particles and able to
reduce filtering on their own
• Inhibiting shale dispersion, BSP is more
effective than XC and KCl and is compara-
ble to PHPAh
• Drop in lubricity coefficient of about 60%
is after the addition of 1% BSP
Aloe vera Plant leaf • Rheological properties such as PV and [81]
YP slightly increased, and filtration was
reduced to some extent
Peanut shell powder (PSP) Food waste • Use large quantities without harming the [82]
density of the drilling fluid
• Utilized to minimize the problems of bit
nozzles plugging due to its fine size
• Can withstand up to 79 °C and 30 h of
aged time
Low-rank coals (leonardite and lignite) Fossil fuel • Run the Herschel-Buckley model in all [83]
shear rate and temperature ranges
• The injection of both low-rank coals
increases the yield stress and yield point
build-up with temperature increase and
keeps them within acceptable ranges
African oil bean husk (AOBH) 63, 125, and Seed husk • Filter cake thickness (2.1–2.28 mm) [84]
250 µm • Filtrate loss (2.0–3.4 ml)
• pH (8.5–8.69)
• Marsh funnel test (44.35–45.57 s)
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394 Emergent Materials (2024) 7:387–402
Table 3 (continued)
Additive Type Findings Reference
Natural deep eutectic solvent (NADES) 3 Ascorbic acid and glycerine (AA:Gly) • Improve (YP/PV) ratio [85]
wt% • 77.77% shale inhibition and 87% shale
recovery
YP yield point, PV plastic viscosity, AV apparent viscosity, LPLT, low-pressure and low-temperature, HPHT, high-pressure and high-tempera-
ture, SSBM, saturated salt-based mud, XC xanthan gum, PHPA partially hydrolyzed polyacrylamide
displayed non-Newtonian shear thinning behavior. Hydroxyl point), and Kian resilience to temperature was similar to
and other functional groups found in SPP-containing muds polyanionic cellulose (PAC); consequently, it is promoted as
have the ability to form H-bonds (high water uptake). These an organic-economical substitute. Similarly, tamarind gum
bonds form structured physical 3D bulk networks that influ- (TG) is extracted from the tamarind tree seeds as a thickener
ence solution shear viscosity. Moreover, SPP powder dem- [70]. TG is widely used in the drilling field for its cheapness.
onstrated robust inhibition to mild steel corrosion with 96% Carrageenan is a linear sulfated polysaccharide additive; it
efficiency and a 0.004 mm year−1 corrosion rate. Morpho- can be extracted from red seaweeds [71] Solution with a
logical results displayed the formation of SPP inhibitive lay- high concentration of carrageenan exhibited shear thinning
ers on mild steel surface, hindering the anodic and cathodic behavior, while low concentration revealed shear thickening
reactions. Powdered henna leaf [64] has also shown consid- behavior. The presence of sulfate groups in the carrageenan
erable results in improving WBM rheological and hydraulic structure promotes its viscoelastic and filtration properties.
characteristics. Flow loop hole-cleaning experiments were Moreover, carrageenan additives have shown good resistiv-
carried on using henna (4 wt%) containing fluids. Cuttings ity to salt contamination; thus, it is suggested for high salin-
transport efficiency test showed the dominance of henna ity drilling regions.
fluids at all hole-angles, compared to bentonite and pure
water fluids. Henna-WBM, on average, had higher transpor- 2.3 OBM additives
tation efficiency by 5.43 and 9.94% than bentonite-WBM
and pure WBM, respectively, at all angles. Furthermore, the High-pressure and high-temperature wellbore conditions
thermal heating of henna-WBM has slightly decreased the are very challenging for the drilling industry. Such condi-
mud plastic viscosity by 1.5%. Lawsone presence — identi- tions cause drilling fluids to destabilize, resulting in well-
fied by FTIR analysis conduct on henna leaf powder — in bore instability, severe control problems, and well loss [86].
henna makes it resilient to temperature changes. Ramasamy Despite the current advancement of WBMs, OBMs are still
and Amanullah [65] assessed the efficacy of fibers gener- the preferable choice for harsh HPHT drilling conditions,
ated from deceased trees as loss circulation materials. Pore and WBM does not entirely replace them [87]. Therefore,
plugging tests were performed on tree fibers and compared the development of less environmentally harmful OBMs are
to commercial fibers. Results revealed the superior perfor- necessary [86] Vegetable-based oils, including palm oil, corn
mance of organic tree-fibers used as loss circulation material oil, and rice bran oil were classified as non-toxic to aquatic
(LCM). Nevertheless, the study has ignored formation-fluid life with 80% biodegradability in less than 30 days [88–90].
interaction, which is very detrimental in field applications Oseh et al. [91] were able to utilize non-edible almond seeds.
[66]. Almond-based mud was found to have comparable rheologi-
Some researchers have driven the development of horti- cal, filtration, and swelling properties to commercial diesel
cultural waste as organic additives [67, 68]. Formulations’ oils. Moreover, the mud thermal and electrical stabilities
high-pressure and high-temperature filtration loss was were similar to diesel oils, while the biodegradation was sig-
reduced by 22% on average. In contrast, low-pressure and nificantly higher. The high biodegradability is attributed to
low-temperature conditions had a 42% reduction in filtration the absence of aromatic compounds and the low branching
loss. Noticeable increases in rheological properties such as degree of the almond oil. According to Jinsheng et al. [92],
viscosity and gel strength were observed. Grass elemental OBM fluids can be used without the addition of organo-
analysis displayed high calcium content (54%), followed by clays. The organoclay-free OBM can be modified with: (1) a
potassium (19.83) and chlorine (16%). Therefore, it can be rheological modifier to replace the organoclay (treated with
used as a pH controller to fluid alkalinity that peaks during amide solution), (2) primary emulsifier produced from fatty
operations. According to Ekeinde et al. [69], Kian fruit in acid and maleic anhydride reaction, (3) fatty acid amide as
its powdered form can be used as fluid viscosifiers. Kian a secondary emulsifier, (4) and a waterborne acrylic acting
containing fluids tested at 25 and 65 °C has enhanced the as filtrate reducer. The selection of #5 white oil as a base
fluid rheological properties (e.g., plastic viscosity and yield for the mud was very detrimental to the fluid environmental
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Emergent Materials (2024) 7:387–402 395
WRa)
Palm methyl ester (85:15 O Palm oil-biofuel derivative Palm methyl ester (PME) fluids can be used as a [89]
bio alternative to synthetic oil or diesel oils
• 2022In terms of rheological and filtration
properties, PME fluids outperformed commercial
mineral oil (S147)
Modified rectorite (1.2 wt.%) in biodiesel (70:30 Biodiesel additive Modified rectorite containing fluid compared to [93]
OWR) commercial bentonite
• had similar viscosity readings and higher yield
point measurements
• The rectorite fluids showed high-temperature
resistivity
Biodiesel (80:20 OWR) Waste cooking oil con- Compared to conventional OBM, biodiesel has [90]
verted into biodiesel • Similar rheological properties
• Acceptable filtration properties
Biodiesel (80:20 OWR) Sweet almond seed • Almond-based biodiesel had excellent rheo- [91]
logical properties and can be utilized for HTHP
conditions
• The filtration properties of the biodiesel were
very similar to commercial OBM (type #2)
Organoclay-free OBM (85:15 OWR) Industrial oil (#5) • Organoclay-free OBM was developed with four [92]
key additives
• A fatty acid modifier was able to replace the
organoclay with good rheological, filtration, and
temp. resistivity properties
Jatropha oil Jatropha plant Comparison with diesel oil has shown that Jat- [94]
(10:90–30:70 OWR) ropha oil has:
• Similar rheological properties
• Better filtration, lubrication, and emulsion in
water properties
Pharmaceutical waste Pharmaceutical waste • The rheology and filtration characteristics are [95]
comparable to or superior to those of all the
examined oil/water ratios (80/20, 75/25, and
70/30)
• After hot rolling (16 h at 250 °F and 300 pres-
sure), the mud has the requisite compatibility and
thermal stability
• Excellent control over HPHT fluid loss
Graphene oxide (GO) Polymer-grafted graphene • Increase in yield point (YP) [96]
• Low Shear yield point (LSYP)
• Enhance particulate suspension capabilities
African oil bean husk (AOBH) 63, 125, and Seed husk • Filter cake thickness (2.3–2.9 mm) [84]
250 µm • Filtrate loss (2.3–3.3 ml)
• pH (8.5–8.69)
• Marsh Funnel test (44.35–45.57 s)
a
OWR oil–water ratio
suitability. Table 4 summarizes the reviewed green OBM and drilling fluid comprise the second-largest volume of left-
and some additives which can enhance their properties. overs made by the E&P industry [97]. Oil-based fluids (OBF)
and water-based drilling fluids (WBF) are both employed in
2.4 (WBM and OBM) environmental aspects drilling operations [98]. Drilling fluids carries out several
crucial tasks in the drilling of wells. While drilling an oil
The oil exploration and production (E&P) sector provides well, they are repeatedly circulated between the well and the
an essential energy source for the entire world. However, the platform. Spent drilling fluid contaminated with oil returns to
environmental effects of E&P activities are a source of con- the surface when drilling reaches the reservoir phase [99]. If
cern for people worldwide. One of the drilling wastes the oil improperly disposed of, the resulting residue can pose risks
and gas sector produces used drilling fluids. Drill cuttings to terrestrial, aquatic, and aerial environments by decreasing
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396 Emergent Materials (2024) 7:387–402
Table 5 Comparison between WBM and OBM considering environ- total cost; consequently, any change in the drilling fluid
mental aspects [97, 102–106] additives cost strongly impacts the total cost. Therefore,
WBM OBM there is a great motive for utilizing eco-friendly drilling
fluid additives. The unit cost of each material per kilogram
• Environmentally friendly • Environmentally non-friendly
is obtained for the literature and represented in the US dol-
• Low initial cost • High initial cost
• Easy discharge • Difficult discharge lar ($). Table 6 shows the cost of raw additives; it compares
• No fire hazard • Potential fire hazard the cost of the most extensively used additives with new
• No critical health risk • Posing health risk to workers emerging additives, which can be utilized for hole cleaning.
• No damaging to rubber parts • Damaging to rubber parts of the
Costs are ranked from highest to lowest, with xanthan gum
of the circulation system circulation system
• Easy cutting separation • Difficult cuttings separation having the greatest cost and pistachio shell having the least
reported cost. Few additives were reported as having almost
zero cost, yet it was not precisely specified.
Evaluation of green additives based only on cost per kg
soil fertility, harming flora and fauna, and posing health risks can be misleading without accounting for a performance fac-
due to the volatilization of hazardous oil components like tor. An additive of a very low-cost ($) could have very poor
benzene, toluene, ethylbenzene, and xylene into the atmos- performance (filtration loss reduction); thus, large quanti-
phere. In this regard, officials have decided that drilling fluids ties of this cheap additive are needed to attain an adequate
made of non-water and water that contains free oil may not performance. On the contrary, a relatively higher-cost addi-
be disposed of in quantities greater than 1% [100]. Therefore, tive could perform better, revealing the need for small addi-
treating oily waste produced during E&P activities is a cru- tive quantities. Figure 3 compares each additive’s cost and
cial challenge. Drilling waste management solutions include relates this cost to a performance factor (e.g., reduction in
discharge, down-hole injection, and on-land disposal. Certain fluid filtration loss per gram). Data extracted from different
drilling fluids and drill cuttings may be dumped into the sea sources [62, 67, 72, 108, 109, 111–115] with average cost
in various parts of the world, if they adhere to specified envi- data (Table 6) are used to construct Fig. 3.
ronmental standards. Regulations prohibiting hydrocarbon Based on the previous analogy, pistachio shell powder has
losses and site closure following drilling without treatment the lowest cost (0.11 $/kg), with a 5% reduction in filtration
have existed since the early 1990s [101]. Dewatering, distil- per gram. Resinex has a higher price (2.9 $/kg) and 17% fil-
lation, solvent extraction, cuttings reinjection, fixation, land tration reduction per gram. Assuming that the fluid filtration
farming, and (bio) remediation are examples of remediation reduces linearly with additive addition (g), it would cost 3 kg
technologies. All impact how acceptable drilling activities of pistachio powder to reach 17% filtration reduction, equiva-
are on the economy and the environment [99]. Table 5 sum- lent to $ 0.374. This cost-performance comparison promotes
marizes the comparison between WBM and OBM, consider- pistachio powder against Resinex for filtration loss reduction
ing the most important environmental aspects. as an eco-green additive. Consequently, the selection of addi-
tives must be based on the cost-performance analysis. Never-
2.5 Economic comparison theless, the assumption of linearity between additive amount
and performance is never valid, and a plateau is always faced
Drilling operation cost varies from 5.4 to 11 million dol- at very early concentrations. Therefore, extensive experimen-
lars [61]. On average, drilling fluid cost weighs 20% of the tal work is required for fair and complete economic analysis.
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Emergent Materials (2024) 7:387–402 397
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398 Emergent Materials (2024) 7:387–402
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dashed line represents a conventional fluid yield point represents a conventional thickening ratio
13
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