Methods for treating spent drilling muds and drill cuttings

The purpose of the study is to examine the pressing issue of drilling waste treatment – namely, spent drilling muds and drilling cuttings – as well as to analyze the shortcomings of the traditional disposal method in sludge storage ponds, which include low environmental reliability and inefficient use of land resources. The study involves a review and comparative analysis of modern treatment methods: physicochemical neutralization, phase separation, thermal treatment, washing, and curing. Based on the comparison of technological, environmental, and economic criteria, it is substantiated that the curing method using mineral and fast-setting binders is the most preferable. Special attention is paid to formulations based on Portland cement, phosphogypsum, and magnesia cement, the use of which at a dosage of 40% or more makes it possible to form a durable, water‑insoluble matrix that almost completely prevents the migration of petroleum products and heavy metals into the environment. The article also examines current trends in technological development, including the combination of mechanical dewatering, chemical modification, and biological remediation, which provides a synergistic effect and reduces specific costs. The potential for producing man-made soils from recycled cuttings, suitable for construction backfill and reclamation of disturbed lands, is analyzed. It is noted that cured soils allow backfilling of pits and site grading using standard construction equipment, which simplifies the implementation of the technology.

1. Zhukov T.N., Glushankova I.S. Research the processes of neutralization and recycling of waste drilling fluids. Ehkologiya i nauchno-tekhnicheskii progress. Urbanistika. 2015;1:120-128. (In Russ.). EDN: VUYZYP.

2. Bal A.S., Stewart R., Schliephake K. A review of the current options for the treatment and safe disposal of drill cuttings. Waste Management & Research. 2012;30(5):457-473. DOI: 10.1177/0734242X11419892.

3. Gaevaya E.V. Geo-ecological state of the soil cover in the influence zone of the sludge pit at an oil field. Environmental protection in the oil and gas complex. 2023;5:42-48. (In Russ.). DOI: 10.33285/2411-7013-2023-5(314)-42-48. EDN: UJHVRB.

4. Bu J., Zhang X., Yan H., Li B., Guo X., Han C., et al. Application of a cationic polymer flocculant for the treatment and recycling of spent oil-based drilling fluids. ACS Omega. 2026;11(11):17511-17520. DOI: 10.1021/acsomega.5c11043.

5. Zahran A., Reyad M., Ibrahim A., Salim M., Atiah M., Gamal H. Sustainable drilling mud recycling: engineering solutions for waste minimization and cost optimization. Kuwait Oil & Gas Show. 3–5 February 2026, Kuwait. Kuwait; 2026, p. SPE-230969-MS. DOI: 10.2118/230969-MS.

6. Kompasenko E.I., Kadyrov O.R., Mazlova E.A., Ostakh O.S. Improvement of the drilling waste management system when constructing wells on land. Environmental protection in the oil and gas complex. 2023;1:33-41. (In Russ.). DOI: 10.33285/2411-7013-2023-1(310)-33-41. EDN: POOLKB.

7. Zimnukhova A.E., Gaevaya E.V. The effect of iron-containing powders on the physical-mechanical properties of drilling cuttings when producing environmentally friendly materials. Environmental protection in the oil and gas complex. 2025;4:16-22. (In Russ.). EDN: VIZLYY.

8. Maslov V.V., Telkov V.P., Semyantseva P.K. Geoecological risks in strategic planning of development of hydrocarbon potential of Paleozoic complex of arctic shelf deposits of the Russian Federation. Proceedings of Gubkin University. 2024;2:40-50. (In Russ.). EDN: EVLSKW.

9. Reyes-Urrutia A., Fernandez A., Torres-Sciancalepore R., Zalazar-García D., Venier C., Rozas-Formandoy C., et al. Sustainable hazardous mitigation and resource recovery from oil-based drill cuttings through slow pyrolysis: a kinetic and product analysis. Sustainability. 2026;18(2):969. DOI: 10.3390/su18020969.

10. Mazlova E.A., Smirnova T.S., Vishnevskiy V.D., Sidorenko M.S. The efficiency of a combined method of disposal of oil-containing waste. Ecology and Industry of Russia. 2026;30(1):10-15. (In Russ.). DOI: 10.18412/1816-0395-2026-1-10-15. EDN: MCSOGI.

11. Gaevaya E.V., Rudakova L.V. Development of geoecological safety measures for the technological process of drilling mud disposal. Industrial Ecology. 2025;4:2-10. (In Russ.). DOI: 10.52190/2073-2589_2025_4_2. EDN: GZIIXA.

12. Shevchenko A. Russian scientists have developed a technology for recycling drill cuttings. But its effectiveness is unclear. Neftegaz.ru. Available from: https://neftegaz.ru/news/standarts/914865-rossiyskie-uchenye-razrabotali-tekhnologiyu-utilizatsii-burovykh-shlamov/ [Accessed 16th March 2026]. (In Russ.).

13. Pugin K.G. Utilization of drilling cuttings in the technological process of asphalt-concrete mixture production. Ecology and Industry of Russia. 2025;29(5):34-39. (In Russ.). DOI: 10.18412/1816-0395-2025-5-34-39. EDN: NSQAHN.

14. Vlasov A.S., Pugin K.G., Tyuryukhanov K.Yu., Rudakova L.V., Glushankova I.S., Surkov A.A. Development of a method for producing geoecologically safe road building materials based on drill cuttings. Ecology and Industry of Russia. 2020;24(11):19-23. (In Russ.). DOI: 10.18412/1816-0395-2020-11-19-23. EDN: JXAABU.

15. Perevoshchikova A.A., Perevoshchikov R.D., Surkov A.A., Rudakova L.V. Methods of restoring lands disturbed by drill cuttings disposal: current approaches review. Theoretical and Applied Ecology. 2025;4:18-27. (In Russ.). DOI: 10.25750/1995-4301-2025-4-018-027. EDN: CRPJJI.

16. Tarasova S.S., Gaevaya E.V. Effect of water-soluble salt content in drilling mud on the mortality of hydrobionts (Daphnia magna Straus and Chlorella vulgaris Beijer). Natural and technical sciences. 2021;7:81-84. (In Russ.). EDN: VKAIRW.

17. Babkina V.A., Zagorskaya A.A., Pimneva L.A. Prospects for treatment of drilling waste liquid fraction by electrocoagulation. Vestnik molodogo uchenogo UGNTU. 2022;S3:39-43. (In Russ.). EDN: UYUHAG.

18. Kosach A.F., Memyachkin K.A., Kurbanova R.B., Pedun G.A. Application of drill sludge in the composition of cement-sludge binders in the construction of oil and gas wells. Architectural, construction and road transport complexes: problems, prospects, innovations: collected materials of the 6th International scientific and practical conference. 25–26 November 2021, Omsk. Omsk: Siberian State Automobile and Highway University; 2021, p. 395-398. (In Russ.). EDN: GFWPWT.

19. Zimnukhova A.E., Gaevaya E.V. Research of physical and mechanical properties of drilling sludges during its hightemperature neutralization. RUDN Journal of Ecology and Life Safety. 2024;32(2):155-162. (In Russ.). DOI: 10.22363/2313-2310-2024-32-2-155-162. EDN: WQYTZY.

20. Gaevaya E.V. Integrated geo-ecological assessment of drill cuttings and approaches to their disposal. RUDN Journal of Ecology and Life Safety. 2025;33(2):219-230. (In Russ.). DOI: 10.22363/2313-2310-2025-33-2-219-230. EDN: IGMWYJ.

21. Gaevaya E.V., Rudakova L.V. Study of patterns of changes in salt compositiondrill cuttings in the process of their disposal. Theoretical and Applied Ecology. 2024;2:125-134. (In Russ.). DOI: 10.25750/1995-4301-2024-2-125-134. EDN: AKHBSG.

22. Gaevaya E.V. Justification of geoecological parameters of technogenic soils in the process of recycling drill. Industrial Ecology. 2024;2:2-7. (In Russ.). DOI: 10.52190/2073-2589_2024_2_2. EDN: BEHDFA.

23. Gayevaya E.V., Tarasova S.S., Solonina V.A. Application of drill cuttings recovery technology with the production of building material on the example of a deposit in Western Siberia. Ecology and Industry of Russia. 2023;27(4):34-39. (In Russ.). DOI: 10.18412/1816-0395-2023-4-34-39. EDN: ORUIZV.

24. Smirnova T.S., Vishnevskii V.D., Alekseev A.A. Recycling of production and consumption waste in remote oil and gas fields of the Russian Arctic. Industrial Ecology. 2024;4:2-11. (In Russ.). DOI: 10.52190/2073-2589_2024_4_2. EDN: XCUHLY.

25. Jalalov V.Z. Analysis of modern methods of waste drilling muds and cuttings recycling. Zashchita okruzhayushchei sredy v neftegazovom komplekse. 2011;9:29-35. (In Russ.). EDN: OCBXPT.

26. Yagafarova G.G., Rakhmatullin D.V., Insapov A.N., Kuznetsova G.M., Mirsaitov N.R. Modern methods of drilling waste recycling. Petroleum Engineering. 2018;16(2):123-129. (In Russ.). DOI: 10.17122/ngdelo-2018-2-123-129. EDN: XODFZB.

27. Shtripling L.O., Tokarev V.V., Gerzhberg Yu.M., Kraus Yu.A., Logunova Yu.V. Processing and disposal of oil sludge and oil-contaminated materials generated at the sites of extraction, transportation, and processing of hydrocarbon raw materials. Novosibirsk: Siberian Branch of the Russian Academy of Sciences; 2013, 176 p. (In Russ.). EDN: RVAYEN.

28. Povarova L.V. Determination of optimal methods for the neutralize and dispose of drill cuttings. Bulatovskie chteniya. 2020;5:218-226. (In Russ.). EDN: CKTPLZ.

29. Wang X., Jin W., Li Y., Liu S., Xu J., Liu J., et al. Treatment advances of hazardous solid waste from oil and gas drilling and production processes. Chemical Engineering Journal. 2024;497:154182. DOI: 10.1016/j.cej.2024.154182.

30. Hrachanika A.V., Kauchur A.S., Manak P.I. Inorganic sludge from chemical water treatment of combined heat and power plants as an additive to general construction materials. Safe and comfortable city: Proceedings of the 6th International scientific and practical conference. 21–23 March 2023, Oryol. Oryol: Orel State University named after I.S. Turgenev; 2020, p. 407-413. (In Russ.). EDN: CIEQCJ.